M0108133-05 (en-us)

March 2022

Operation and
Maintenance
Manual
904D-E28T and 904D-E36TA Industrial
Engine
FT (Engine)
FE (Engine)
 Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions correctly.
Incorrect 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. You must not use
this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of
the product in the location of use, including site-specific rules and precautions applicable to the
worksite. 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 you are authorized to perform this work, and that the product will not
be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.

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 prema-
ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
M0108133-05 3
Table of Contents

Table of Contents Maintenance Section

Refill Capacities............................................... 55
Foreword ........................................................... 4
Maintenance Recommendations .................... 72
Safety Section
Maintenance Interval Schedule....................... 75
Safety Messages............................................... 6

General Hazard Information............................ 10

Warranty Section

Warranty Information..................................... 102

Burn Prevention............................................... 13

Fire Prevention and Explosion Prevention...... 15 Reference Information Section

Crushing Prevention and Cutting Prevention.. 17 Reference Materials ...................................... 103

Mounting and Dismounting ............................. 17 Index Section

High Pressure Fuel Lines ................................ 17 Index.............................................................. 105

Before Starting Engine .................................... 19

Engine Starting................................................ 19

Engine Stopping .............................................. 20

Electrical System............................................. 20

Engine Electronics........................................... 21

Product Information Section

General Information ........................................ 23

Product Identification Information ................... 31

Operation Section

Lifting and Storage .......................................... 33

Features and Controls..................................... 35

Engine Diagnostics ......................................... 41

Engine Starting................................................ 43

Engine Operation ............................................ 47

Cold Weather Operation ................................. 49

Engine Stopping .............................................. 53

4 M0108133-05
Foreword

Foreword Some photographs or illustrations in this manual

show details or attachments that may be different
from your engine. Guards and covers may have been
California Proposition 65 Warning removed for illustrative purposes. Continuing
improvement and advancement of product design
Diesel engine exhaust and some of its may have caused changes to your engine which are
not included in this manual. Whenever a question
constituents are known to the State of arises regarding your engine, or this manual, please
California to cause cancer, birth defects, consult with your Perkins dealer or your Perkins
and other reproductive harm. distributor for the latest available information.

WARNING – This product can Safety

expose you to chemicals
including ethylene glycol, which This safety section lists basic safety precautions. In
is known to the State of California to addition, this section identifies hazardous, warning
cause birth defects or other reproductive situations. Read and understand the basic
precautions listed in the safety section before
harm. For more information go to: operating or performing lubrication, maintenance,
and repair on this product.
www.P65Warnings.ca.gov
Do not ingest this chemical. Wash hands Operation
after handling to avoid incidental Operating techniques outlined in this manual are
ingestion. basic. The operating techniques assist with
developing the skills and techniques required to
WARNING – This product can operate the engine more efficiently and economically.
expose you to chemicals Skill and techniques develop as the operator gains
including lead and lead knowledge of the engine and the capabilities of the
compounds, which are known to the engine.
State of California to cause cancer, birth The operation section is a reference for operators.
defects, or other reproductive harm. For Photographs and illustrations guide the operator
more information go to: through procedures of inspecting, starting, operating,
and stopping the engine. This section also includes a
www.P65Warnings.ca.gov discussion of electronic diagnostic information.

Wash hands after handling components Maintenance

that may contain lead.
The maintenance section is a guide to engine care.
Literature Information The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
This manual contains safety, operation instructions, intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
lubrication, and maintenance information. This
manual should be stored in or near the engine area in Recommended service should be performed at the
a literature holder or literature storage area. Read, appropriate intervals as indicated in the Maintenance
study, and keep the manual with the literature and Interval Schedule. The actual operating environment
engine information. of the engine also governs the Maintenance Interval
Schedule. Therefore, under severe, dusty, wet, or
English is the primary language for all Perkins freezing cold operating conditions, more frequent
publications. The English used facilitates translation lubrication, and maintenance than is specified in the
and consistency. Maintenance Interval Schedule may be necessary.
M0108133-05 5
Foreword

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. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation, and application. Perkins recommends that
the maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
Perkins also recommends that a maintenance record
be maintained as part of the permanent record of the
engine.
Your authorized Perkins dealer or your Perkins
distributor can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.

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 are best left to trained personnel or an
authorized Perkins distributor or dealer. Your Perkins
dealer or your Perkins distributor offers various
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.
6 M0108133-05
Safety Section
Safety Messages

Safety Section
i08185619

Safety Messages

There may be several specific warning signs on your

engine. The exact location and a description of the
warning signs are reviewed in this section. Ensure
that you are familiar with all warning signs.
Ensure that all the warning signs are legible. Clean
the warning signs or replace the warning signs if the
words cannot be read or if the illustrations are not
visible. Use a cloth, water, and soap to clean the
warning signs. Do not use solvents, gasoline, or
other harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
warning signs. The warning signs that are loosened
could drop off the engine.
Replace any warning sign that is damaged or
missing. If a warning sign is attached to a part of the
engine that is replaced, install a new warning sign on
the replacement part. Your Perkins dealer or your
Perkins distributor can provide new warning signs.
M0108133-05 7
Safety Section
Safety Messages

904D-E36TA Industrial Engine

Illustration 1 g06504861
Typical example
(1) Universal Warning label (2) Hand (High Pressure) Warning label
8 M0108133-05
Safety Section
Safety Messages

904D-E28T Industrial Engine

Illustration 2 g06536564
Typical example
(1) Universal Warning label (2) Hand (High Pressure) Warning label

Universal Warning 1

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 3 g01154807
Typical example
M0108133-05 9
Safety Section
Safety Messages

The universal warning labels are located in two

positions. One label is on the front over the engine,
the other label is on the right side of the engine.

Hand (High Pressure) 2

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.

Illustration 4 g02382677
Typical example

The hand high-pressure label is on the high-pressure

fuel line between pump and manifold, on the right
side of the engine.

Ether Warning

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
personal injury.

Illustration 5 g01154809
Typical example
10 M0108133-05
Safety Section
General Hazard Information

The ether warning label is installed on the air cleaner • Ensure that all protective guards and all covers
close to the intake. The location will depend on the are secured in place on the engine.
application. In some applications, the ether label will
be supplied loose for fitting by the engine installer. • Never put maintenance fluids into glass
containers. Glass containers can break.
i08355700
• Use all cleaning solutions with care.
General Hazard Information • Report all necessary repairs.
Unless other instructions are provided, perform the
maintenance under the following conditions:
• The engine is stopped. Ensure that the engine
cannot be started.
• The protective locks or the controls are in the
applied position.

• Engage the secondary brakes or parking brakes.

• Block the vehicle or restrain the vehicle before
maintenance or repairs are performed.
• After the Electronic Control Module (ECM) has
powered down, disconnect the batteries when
maintenance is performed or when the electrical
Illustration 6 g00104545 system is serviced. Disconnect the battery ground
leads. Tape the leads to help prevent sparks.
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls • If equipped, disconnect the connectors for the unit
before the engine is serviced or before the engine is injectors that are on the valve cover base. This
repaired. Attach the warning tags to the engine and action will help prevent personal injury from the
to each operator control station. When appropriate, high voltage to the unit injectors. Do not come in
disconnect the starting controls. contact with the unit injector terminals while the
engine is operating.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being • Do not attempt any repairs or any adjustments to
serviced. the engine while the engine is operating.
• Tampering with the engine installation or • Do not attempt any repairs that are not
tampering with the OEM supplied wiring can be understood. Use the proper tools. Replace any
dangerous. Personal injury, death and/or engine equipment that is damaged or repair the
damage could result. equipment.
• Vent the engine exhaust to the outside when the • For initial start-up of a new engine or for starting
engine is operated in an enclosed area. an engine that has been serviced, make
provisions to stop the engine if an overspeed
• If the engine is not running, do not release the
occurs. The stopping of the engine may be
secondary brake or the parking brake systems
accomplished by shutting off the fuel supply and/
unless the vehicle is blocked or unless the vehicle
or the air supply to the engine. Ensure that only
is restrained.
the fuel supply line is shut off. Ensure that the fuel
• Wear a hard hat, protective glasses, and other return line is open.
protective equipment, as required.
• Start the engine from the operators station (cab).
• When working around an engine, the engine must Never short across the starting motor terminals or
not be in operation. You may only be near a the batteries. This action could bypass the engine
running engine to carry out maintenance neutral start system and/or the electrical system
procedures that require the engine to be in could be damaged.
operation.
• Do not wear loose clothing or jewelry that can
snag on controls or on other parts of the engine.
M0108133-05 11
Safety Section
General Hazard Information

Engine exhaust contains products of combustion • Report all necessary repairs.

which may be harmful to your health. Always start the
engine and operate the engine in a well-ventilated Unless other instructions are provided, perform
area. If the engine is in an enclosed area, vent the the maintenance under the following conditions:
engine exhaust to the outside.
• The engine is stopped. Ensure that the engine
To help prevent spraying or splashing of pressurized cannot be started.
fluids, hold a rag over the part that is being removed.
• Disconnect the batteries when maintenance is
Remove the following parts with caution. performed or when the electrical system is
serviced. Disconnect the battery ground leads.
• Filler caps Tape the leads to help prevent sparks.
• Grease fittings • Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
• Pressure taps
equipment that is damaged or repair the
• Breathers equipment.

• Drain plugs Pressurized Air and Water

Use caution when cover plates are removed. Pressurized air and/or water can cause debris and/or
Gradually loosen, but do not remove the last two hot water to be blown out. This action could result in
bolts or nuts that are at opposite ends of the cover personal injury.
plate or the device. Before removing the last two
bolts or nuts, pry the cover loose to relieve any spring When pressurized air and/or pressurized water is
pressure or other pressure. 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 fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved
correctly.
Illustration 7 g00702020 Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
• Wear a hard hat, protective glasses, and other may occur. Do not disassemble any hydraulic
protective equipment, as required. components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
• Perkins recommend that you do not stand next to information for any procedures that are required to
an exposed running engine unless it is necessary relieve the hydraulic pressure.
when carrying out daily checks or maintenance
procedures. The appropriate Personal Protective
Equipment (PPE) must be worn when standing
next to an exposed running engine.
• Do not wear loose clothing or jewelry that can
snag on controls or on other parts of the engine.

• Ensure that all protective guards and all covers

are secured in place on the engine.

• Never put maintenance fluids into glass

containers. Glass containers can break.
• Use all cleaning solutions with care.
12 M0108133-05
Safety Section
General Hazard Information

Avoid static electricity risk when fueling. Ultra-

low sulfur diesel fuel (ULSD fuel) poses a greater
static ignition hazard than earlier diesel formula-
tions with a higher sulfur contents. Avoid death
or serious injury from fire or explosion. Consult
with your fuel or fuel system supplier to ensure
the delivery system is in compliance with fueling
standards for proper grounding and bonding
practices.

Inhalation
Illustration 8 g00687600

Always use a board or cardboard when you check for

a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.

Containing Fluid Spillage

Care must be taken to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting, and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or Illustration 9 g00702022
disassembling any component containing fluids.
Exhaust
Dispose of all fluids according to local regulations
and mandates. Use caution. Exhaust fumes can be hazardous to
health. If you operate the equipment in an enclosed
Static Electricity Hazard when area, adequate ventilation is necessary.
Fueling with Ultra-low Sulfur Diesel Hexavalent Chromium
Fuel
Perkins equipment and replacement parts comply
The removal of sulfur and other compounds in ultra- with applicable regulations and requirements where
low sulfur diesel fuel (ULSD fuel) decreases the originally sold. Perkins recommends the use of only
conductivity of ULSD and increases the ability of genuine Perkins replacement parts.
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive. Hexavalent chromium has occasionally been
Many factors can reduce the effectiveness of the detected on exhaust and heat shield systems on
additive over time. Static charges can build up in Perkins engines. Although laboratory testing is the
ULSD fuel while the fuel is flowing through fuel only accurate way to know if hexavalent chromium is,
delivery systems. Static electricity discharge when in fact, present, the presence of a yellow deposit in
combustible vapors are present could result in a fire areas of high heat (for example, exhaust system
or explosion. Ensure that the entire system used to components or exhaust insulation) may be an
refuel your machine (fuel supply tank, transfer pump, indication of the presence of hexavalent chromium.
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel Use caution if you suspect the presence of
system supplier to ensure that the delivery system hexavalent chromium. Avoid skin contact when
handling items that you suspect may contain
complies with fueling standards for proper grounding hexavalent chromium, and avoid inhalation of any
and bonding. dust in the suspect area. Inhalation of, or skin contact
with, hexavalent chromium dust may be hazardous to
your health.
M0108133-05 13
Safety Section
Burn Prevention

If such yellow deposits are found on the engine, • Use exhaust ventilation on permanent machining
engine component parts, or associated equipment or jobs.
packages, Perkins recommends following local
health and safety regulations and guidelines, utilizing • Wear an approved respirator if there is no other
good hygiene, and adhering to safe work practices way to control the dust.
when handling the equipment or parts. Perkins also
recommends the following: • Comply with applicable rules and regulations for
the work place. In the United States, use
• Wear appropriate Personal Protective Equipment Occupational Safety and Health Administration
(PPE) (OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Wash your hands and face with soap and water
prior to eating, drinking, or smoking, and also • Obey environmental regulations for the disposal of
during rest room breaks, to prevent ingestion of asbestos.
any yellow powder
• Stay away from areas that might have asbestos
• Never use compressed air for cleaning areas particles in the air.
suspected of containing hexavalent chromium

• Avoid brushing, grinding, or cutting materials Dispose of Waste Properly

suspected of containing hexavalent chromium

• Obey environmental regulations for the disposal of

all materials that may contain or have come into
contact with hexavalent chromium

• Stay away from areas that might have hexavalent

chromium particles in the air.

Asbestos Information
Perkins equipment and replacement parts that are
shipped from Perkins engine company limited are
asbestos free. Perkins recommends the use of only
genuine Perkins replacement parts. Use the following
guidelines when you handle any replacement parts
that contain asbestos or when you handle asbestos Illustration 10 g00706404
debris.
Use caution. Avoid inhaling dust that might be Improperly disposing of waste can threaten the
generated when you handle components that contain environment. Potentially harmful fluids should be
asbestos fibers. Inhaling this dust can be hazardous disposed of in accordance with local regulations.
to your health. The components that may contain Always use leakproof containers when you drain
asbestos fibers are brake pads, brake bands, lining fluids. Do not pour waste onto the ground, down a
material, clutch plates, and some gaskets. The
drain, or into any source of water.
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that i07794119
contains asbestos is generated.
Burn Prevention
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning. Do not touch any part of an operating engine system.
The engine and the exhaust system can exceed
• Avoid brushing materials that contain asbestos. 650° C (1202° F) under normal operating conditions.

• Avoid grinding materials that contain asbestos. Allow the engine system to cool before any
maintenance is performed. Relieve all pressure in the
• Use a wet method to clean up asbestos materials. air system, hydraulic system, lubrication system, fuel
system, and the cooling system before the related
• A vacuum cleaner that is equipped with a high items are disconnected.
efficiency particulate air filter (HEPA) can also be
used.
14 M0108133-05
Safety Section
Burn Prevention

Cooling system conditioner contains alkali. Alkali can

cause personal injury. Do not allow alkali to contact
Contact with high pressure fuel may cause fluid the skin, the eyes, or the mouth.
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow Oils
these inspection, maintenance and service in-
structions may cause personal injury or death. Skin may be irritated following repeated or prolonged
exposure to mineral and synthetic base oils. Refer to
your suppliers Material Safety Data Sheets for
After the engine has stopped, wait for 10 minutes to detailed information. Hot oil and lubricating
allow the fuel pressure to be purged from the high- components can cause personal injury. Do not allow
pressure fuel lines before any service or repair is hot oil to contact the skin. Appropriate personal
performed on the engine fuel lines. The 10 minute protective equipment should be used.
wait will also allow static charge to dissipate from the
low-pressure fuel system. Diesel Fuel
Allow the pressure to be purged in the air system, in
the hydraulic system, in the lubrication system, or in Diesel engines have high-pressure fuel systems and
the cooling system before any lines, fittings, or the fuel can reach temperatures of over 100° C
related items are disconnected. (212° F). Ensure that the fuel has cooled before any
service or repairs are performed.
Induction System

Sulfuric Acid Burn Hazard may cause serious

personal injury or death.
The exhaust gas cooler may contain a small
amount of sulfuric acid. The use of fuel with sul-
fur levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid
may spill from the cooler during service of the en-
gine. The sulfuric acid will burn the eyes, skin
and clothing on contact. Always wear the appro-
priate personal protective equipment (PPE) that
is noted on a material safety data sheet (MSDS)
for sulfuric acid. Always follow the directions for
first aid that are noted on a material safety data
sheet (MSDS) for sulfuric acid.

Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters, or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly to
relieve pressure.
M0108133-05 15
Safety Section
Fire Prevention and Explosion Prevention

Diesel may be irritating to the eyes, respiratory Determine whether the engine will be operated in an
system, and skin. Prolonged exposure to diesel may environment that allows combustible gases to be
cause various skin conditions. Appropriate personal drawn into the air inlet system. These gases could
protective equipment should be used. Refer to cause the engine to overspeed. Personal injury,
supplier Material safety Data sheets for detailed property damage, or engine damage could result.
information.
If the application involves the presence of
combustible gases, consult your Perkins dealer and/
Batteries or your Perkins distributor for additional information
about suitable protection devices.
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or Remove all flammable combustible materials or
the eyes. Always wear protective glasses for conductive materials such as fuel, oil, and debris
servicing batteries. Wash hands after touching the from the engine. Do not allow any flammable
batteries and connectors. Use of gloves is combustible materials or conductive materials to
recommended. accumulate on the engine.
Store fuels and lubricants in correctly marked
Engine containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
Do not touch any part of an operating engine . Allow containers. Do not smoke in areas that are used for
the engine to cool before any maintenance is storing flammable materials.
performed on the engine. Relieve all pressure in the
appropriate system before any lines, fittings, or Do not expose the engine to any flame.
related items are disconnected.
Exhaust shields (if equipped) protect hot exhaust
i07817010 components from oil or fuel spray if there was a line,
a tube, or a seal failure. Exhaust shields must be
installed correctly.
Fire Prevention and Explosion
Prevention Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Ensure that all
electrical wires are correctly installed 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 fire. Secure
connections, recommended wiring, and correctly
maintained battery cables will help to prevent arcing
Illustration 11 g00704000 or sparking.
All fuels, most lubricants, and some coolant mixtures
are flammable.
Flammable fluids that are leaking or spilled onto hot Contact with high pressure fuel may cause fluid
surfaces or onto electrical components can cause a penetration and burn hazards. High pressure fuel
fire. Fire may cause personal injury and property spray may cause a fire hazard. Failure to follow
damage. these inspection, maintenance and service in-
structions may cause personal injury or death.
After the emergency stop button is operated, ensure
that you allow 15 minutes, before the engine covers
are removed.
16 M0108133-05
Safety Section
Fire Prevention and Explosion Prevention

After the engine has stopped, you must wait for 10

minutes to allow the fuel pressure to be purged from
the high-pressure fuel lines before any service or
repair is performed on the engine fuel lines. The 10
minute wait will also allow static charge to dissipate
from the low-pressure fuel system.
Ensure that the engine is stopped. Inspect all lines
and hoses for wear or for deterioration. Ensure that
the hoses are correctly routed. The lines and hoses
must have adequate support and secure clamps. If
any fuel lines or fuel hoses become kinked, the fuel
line or fuel hose must be replaced. Refer to the
Disassembly and Assembly manual for more
information.
Oil filters and fuel filters must be correctly installed.
The filter housings must be tightened to the correct
torque. Refer to the Disassembly and Assembly
manual for more information.

Illustration 13 g00704135

Gases from a battery can explode. Keep any open

flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a
hydrometer.
Incorrect jumper cable connections can cause an
explosion that can result in injury. Refer to the
Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. A frozen battery may
cause an explosion.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
Illustration 12 g00704059
recommended cables, connections, and battery box
covers when the engine is operated.
Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not Fire Extinguisher
refuel an engine near open flames or sparks. Always
stop the engine before refueling. Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Avoid static electricity risk when fueling. Ultra-low Inspect the fire extinguisher and service the fire
Sulfur Diesel fuel (ULSD fuel) poses a greater static extinguisher regularly. Obey the recommendations
ignition hazard than earlier diesel formulations with a on the instruction plate.
higher sulfur content. Avoid death or serious injury
from fire or explosion. Consult your fuel or fuel
system supplier to ensure that the delivery system is Ether
in compliance with fueling standards for proper
grounding and bonding practices.

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
personal injury.
Ether is flammable and poisonous.
M0108133-05 17
Safety Section
Crushing Prevention and Cutting Prevention

Do not smoke while you are replacing an ether When objects are struck, wear protective glasses in
cylinder. order to avoid injury to the eyes.
Do not store ether cylinders in living areas or in the Chips or other debris may fly off objects when objects
engine compartment. Do not store ether cylinders in are struck. Before objects are struck, ensure that no
direct sunlight or in temperatures above 49° C one will be injured by flying debris.
(120° F). Keep ether cylinders away from open
flames or sparks. i07926237

Lines, Tubes, and Hoses Mounting and Dismounting

Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are
damaged. Do not climb on the engine or radiator assembly. The
engine and the radiator assembly have not been
Leaks can cause fires. Consult your Perkins dealer or designed with mounting or dismounting locations.
your Perkins distributor for replacement parts.
Refer to the Original Equipment Manufacturer (OEM)
Replace the parts if any of the following conditions for the location of foot and hand holds for your
are present: specific application.

• High-pressure fuel line or lines are removed. i07366423

• End fittings are damaged or leaking. High Pressure Fuel Lines

• Outer coverings are chafed or cut.
• Wires are exposed.

• Outer coverings are ballooning.

Contact with high pressure fuel may cause fluid
• Flexible parts of the hoses are kinked. penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
• Outer covers have embedded armoring. these inspection, maintenance and service in-
structions may cause personal injury or death.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation,
correct installation will help to prevent vibration,
rubbing against other parts, and excessive heat.

i02143194

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.
18 M0108133-05
Safety Section
High Pressure Fuel Lines

Illustration 14 g06334696

(1) High-pressure line (4) High-pressure line (7) High-pressure line

(2) High-pressure line (5) Fuel transfer line that is high pressure (8) High-pressure fuel manifold (rail)
(3) High-pressure line (6) High-pressure pump

The high-pressure fuel lines are the fuel lines that are Do not check the high-pressure fuel lines with the
between the high-pressure fuel pump and the high- engine or the starting motor in operation. After the
pressure fuel manifold and the fuel lines that are engine has stopped, you must wait for 10 minutes to
between the fuel manifold and electronic unit allow the fuel pressure to be purged from the high-
injectors. These fuel lines are different from fuel lines pressure fuel lines before any service or repair is
on other fuel systems. performed on the engine fuel lines. The 10 minute
wait will also allow static charge to dissipate from the
The fuel lines are different because of the following low-pressure fuel system.
items:
Do not loosen the high-pressure fuel lines to remove
• The high-pressure fuel lines are constantly air from the fuel system. This procedure is not
charged with high pressure. required.
• The internal pressures of the high-pressure fuel Visually inspect the high-pressure fuel lines before
lines are higher than other types of fuel system. the engine is started. This inspection should be each
day.
• The high-pressure fuel lines are formed to shape
and then strengthened by a special process. If you inspect the engine in operation, always use the
proper inspection procedure to avoid a fluid
Do not step on the high-pressure fuel lines. Do not penetration hazard. Refer to Operation and
deflect the high-pressure fuel lines. Do not bend or Maintenance Manual, “General hazard Information”.
strike the high-pressure fuel lines. Deformation or
damage of the high-pressure fuel lines may cause a • Inspect the high-pressure fuel lines for damage,
point of weakness and potential failure. deformation, a nick, a cut, a crease, or a dent.
M0108133-05 19
Safety Section
Before Starting Engine

• Do not operate the engine with a fuel leak. If there All protective guards and all protective covers must
is a leak, do not tighten the connection, to stop the be installed if the engine must be started to perform
leak. The connection must only be tightened to the service procedures. To help prevent an accident that
recommended torque. Refer to Disassembly and is caused by parts in rotation, work around the parts
Assembly, “Fuel injection lines - Remove and Fuel carefully.
injection lines - Install”.
Do not bypass the automatic shutoff circuits. Do not
• If the high-pressure fuel lines are torqued correctly disable the automatic shutoff circuits. The circuits are
provided to help prevent personal injury. The circuits
and the high-pressure fuel lines are leaking, the are also provided to help prevent engine damage.
high-pressure fuel lines must be replaced.
Before starting the engine, ensure that the drive belt
• Ensure that all clips on the high-pressure fuel lines is securely in place. The coolant pump is operated by
are in place. Do not operate the engine with clips the drive belt.
that are damaged, missing, or loose.
See the Service Manual for repairs and for
• Do not attach any other item to the high-pressure adjustments.
fuel lines.
i08185623
• Loosened high-pressure fuel lines must be
replaced. Also removed high-pressure fuel lines Engine Starting
must be replaced. Refer to Disassembly and
assembly manual, “Fuel Injection Lines - Install”.

i07728672

Before Starting Engine Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.

NOTICE If a warning tag is attached to the engine start switch,

For initial start-up of a new or rebuilt engine, and for or to the controls DO NOT start the engine or move
start-up of an engine that has been serviced, make the controls. Consult with the person that attached
provision to shut the engine off should an overspeed the warning tag before the engine is started.
occur. This may be accomplished by shutting off the
All protective guards and all protective covers must
air and/or fuel supply to the engine.
be installed if the engine must be started to perform
service procedures. To help prevent an accident that
is caused by parts in rotation, work around the parts
carefully.

Engine exhaust contains products of combustion Start the engine from the operator's compartment or
which may be harmful to your health. Always from the engine start switch.
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust Always start the engine according to the procedure
to the outside. described in the Operation and Maintenance Manual,
“Engine Starting” topic in the Operation Section.
Inspect the engine for potential hazards. Knowing the correct procedure will help to prevent
major damage to the engine components. Knowing
Do not start the engine or move any of the controls if the procedure will also help to prevent personal
there is a “DO NOT OPERATE” warning tag or similar injury.
warning tag attached to the start switch or to the
controls. To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
Before starting the engine, ensure that no one is on, correctly, check the water temperature gauge. Also,
underneath, or close to the engine. Ensure that the check the oil temperature gauge during the heater
area is free of personnel. operation.
If equipped, ensure that the lighting system for the Engine exhaust contains products of combustion
engine is suitable for the conditions. Ensure that all which can be harmful to health. Always start the
lights work properly, if equipped. 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.
20 M0108133-05
Safety Section
Engine Stopping

Note: The engine is equipped with a device for cold Check the electrical wires daily for wires that are
starting. If the engine will be operated in very cold loose or frayed. Tighten all loose electrical
conditions, an extra cold starting aid may be connections before the engine is started. Repair all
required. Normally, the engine will be equipped with frayed electrical wires before the engine is started.
the correct type of starting aid for the region of See the Operation and Maintenance Manual for
operation. specific starting instructions.

These engines are equipped with a glow plug starting Grounding Practices
aid in each cylinder which heats the intake air to
improve starting. Some Perkins engines may have a
cold starting system that is controlled by the ECM
which allows a controlled flow of ether into the
engine. The ECM will disconnect the glow plugs
before the ether is introduced. This system would be
installed at the factory.

i02234873

Engine Stopping

Stop the engine according to the procedure in the

Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
the engine components.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an
engine that has been overhauled.
To stop an electronically controlled engine, cut the
power to the engine and/or shutting off the air supply Illustration 15 g06579667
to the engine. Typical example
(1) Ground to battery
i08186804 (2) Ground to starting motor
(3) Starting motor to engine block
Electrical System

Never disconnect any charging unit circuit or battery

circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” cable should be connected last from the
external power source to the primary position for
grounding.
M0108133-05 21
Safety Section
Engine Electronics

To ensure that the engine and the engine electrical

systems function correctly, an engine-to-frame
ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct
engine ground to the frame.
The connections for the grounds should be tight and
free of corrosion. The engine alternator must be
grounded to the negative “-” battery terminal. The
wire used must be adequate to handle the full
charging current of the alternator.
The power supply connection for the engine
electronics should always be from the isolator to the
battery. It is the decision of the OEM which polarity
the isolator is connected to.

i08146550

Engine Electronics

Tampering with the electronic system installation

or the OEM wiring installation can be dangerous
and could result in personal injury or death and/
or engine damage.
Illustration 16 g06579672
Typical example
(4) Ground to the battery
(5) Ground to the engine block
(6) Primary position for grounding Electrical Shock Hazard. The electronic unit injec-
tors use DC voltage. The ECM sends this voltage
to the electronic unit injectors. Do not come in
NOTICE contact with the harness connector for the elec-
For 904D-E36TA industrial engines, ensure that a 12 tronic unit injectors while the engine is operating.
VDC or 24 VDC battery source is used to start the en- Failure to follow this instruction could result in
gine. For 904D-E28T industrial engines, use a 12 personal injury or death.
VDC battery source to start the engine. Never at-
tempt to start an engine from an external power This engine has a comprehensive, programmable
source such as electric welding equipment, which Engine Monitoring System. The Electronic Control
has a voltage that is unsuitable for engine starting Module (ECM) monitors the engine operating
and will damage the electrical system. conditions. If any of the engine parameters extend
outside an allowable range, the ECM will initiate an
Correct grounding for the engine electrical system is immediate action.
necessary for optimum engine performance and
reliability. Incorrect grounding will result in The following actions are available for engine
uncontrolled electrical circuit paths and in unreliable monitoring control:
electrical circuit paths.
• Warning: A warning light could be illuminated or a
Uncontrolled electrical circuit paths can result in sound warning could be activated (horn)
damage to the crankshaft bearing journal surfaces
and to aluminum components. • Derate: The engine power could be reduced by 50
percent
Engines that are installed without engine-to-frame
ground straps can be damaged by electrical • Shutdown: The engine could be shut down or only
discharge. operate at low idle
The following monitored engine operating conditions
and components can limit engine speed and/or the
engine power:
• Engine Coolant Temperature
22 M0108133-05
Safety Section
Engine Electronics

• Engine Oil Pressure

• Intake Manifold Air Temperature

• Intake Manifold Air Pressure

• Engine Speed Sensors

• Fuel Temperature
• Electronic Unit Injectors

• Wastegate Actuator
• Throttle Valve
• Supply Voltage to Sensors

• Fuel Pressure in Manifold (Rail)

• NOx Reduction System (NRS)
The Engine Monitoring package can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.

Note: Many of the engine control systems and

display modules that are available for Perkins
engines will work in unison with the Engine
Monitoring System. Together, the two controls will
provide the engine monitoring function for the specific
engine application. Refer to the Troubleshooting for
more information on the Engine Monitoring System.
M0108133-05 23
Product Information Section
General Information

Product Information
Section

General Information
i08131199

Model View Illustrations

The following model views show typical features of

the engine. Due to individual applications, your
engine may appear different from the illustrations.
24 M0108133-05
Product Information Section
Model View Illustrations

904D-E28T Industrial Engine Views

Illustration 17 g06561996
Typical example
(1) Engine harness interface (5) Oil filter assembly (9) Starting motor
(2) NOx Reduction System (NRS) valve (6) Oil filler (lower) (10) High-pressure fuel pump
(3) Air intake from air charge cooler (7) Oil gauge (Dipstick)
(4) Alternator (8) Oil drain tap
M0108133-05 25
Product Information Section
Model View Illustrations

Illustration 18 g06559846
Typical example
(11) Rear lifting eyes (15) Electronic Control Module (ECM), (19) Fan drive pulley
(12) Actuator for turbocharger location for transportation only (20) Drive belt
(13) Turbocharger (16) Adjuster for drive belt (21) Coolant outlet
(14) Air intake from air cleaner (17) Coolant pump pulley (22) Front lifting eye
(18) Coolant intake (23) Top oil filler
26 M0108133-05
Product Information Section
Model View Illustrations

904D-E36TA Industrial Engine Views

Illustration 19 g06480143
Typical example
(1) Engine harness interface (5) Oil filter assembly (9) Starting motor
(2) NOx Reduction System (NRS) valve (6) Oil filler (lower) (10) High-pressure fuel pump
(3) Air intake from air charge cooler (7) Oil gauge (Dipstick)
(4) Alternator (8) Oil drain tap
M0108133-05 27
Product Information Section
Model View Illustrations

Illustration 20 g06480156
Typical example
(11) Front lifting eye (16) Electronic Control Module (ECM), (20) Fan drive pulley
(12) Rear lifting eyes location for transportation only (21) Drive belt
(13) Actuator for turbocharger (17) Adjuster for drive belt (22) Coolant outlet
(14) Turbocharger (18) Coolant pump pulley (23) Top oil filler
(15) Air intake from air cleaner (19) Coolant intake
28 M0108133-05
Product Information Section
Product Description

Loose or Off Engine Components

Illustration 21 g06481343
Typical example
(1) Primary fuel filter, combined with electric (2) If equipped, secondary fuel filter (5) Link harness
fuel priming pump and Water-In-Fuel (3) Electric control module (6) Inlet temperature sensor
(WIF) sensor (4) Low-pressure fuel line (7) Exhaust assembly

i08185938

Product Description

904D-E28T Industrial Engine

The Perkins 904D-E28T industrial engine is a single
turbocharged engine with an engine prefix of FE.
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right
sides of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder.
M0108133-05 29
Product Information Section
Product Description

Illustration 22 g06297997 Illustration 23 g06297997

Typical example Typical example
(A) Inlet valves (A) Inlet valves
(B) Exhaust valves (B) Exhaust valves

Table 1 Table 2
904D-E28T Engine Specifications 904D-E36TA Engine Specifications

Operating Range (rpm) 800 to 2400 (1) Operating Range (rpm) 800 to 2400 (1)

Number of Cylinders 4 In-Line Number of Cylinders 4 In-Line

Bore 90 mm (3.54 inch) Bore 98 mm (3.858 inch)

Stroke 110 mm (4.33 inch) Stroke 120 mm (4.724 inch)

Power rating 50 kW to 55.4 kW Power (Model FT) 55 to 90 kW (73.7 to 120.7 hp)

(67.05 hp to 74.29 hp)
Aspiration Turbocharged charge cooled
Aspiration Turbocharged and Turbo-
charged charge cooled Compression Ratio 17:1

Compression Ratio 17:1 Displacement 3.621 L (220.966 cubic inch)

Displacement 2.8 L (170.87 cubic inch) Firing Order 1-3 -4-2

Firing Order 1-3 -4-2 Valves per cylinder 4

Valves per cylinder 4 Rotation (flywheel end) Counterclockwise

(1) The operating rpm depends on the engine rating, the applica-
Rotation (flywheel end) Counterclockwise
tion, and the configuration of the throttle.
(1) The operating rpm depends on the engine rating, the applica-
tion, and the configuration of the throttle.
Electronic Engine Features
904D-E36TA Engine The engine operating conditions are monitored. The
Electronic Control Module (ECM) controls the
The Perkins 904D-E36TA industrial engine is a single response of the engine to these conditions and to the
turbocharged, air to air charge cooled engine with an demands of the operator. These conditions and
engine prefix of FT. operator demands determine the precise control of
fuel injection by the ECM. The electronic engine
The configuration will depend on the power output of control system provides the following features:
the engine.
• Engine monitoring
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right • Engine speed governing
sides of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder. • Control of the injection pressure

• Cold start strategy

• Automatic air/fuel ratio control
30 M0108133-05
Product Information Section
Product Description

• Torque rise shaping Engine efficiency, efficiency of emission controls, and

engine performance depend on adherence to proper
• Injection timing control operation and maintenance recommendations.
Engine performance and efficiency also depend on
• System diagnostics the use of recommended fuels, lubrication oils, and
coolants. Refer to this Operation and Maintenance
• NOx reduction system control Manual, “Maintenance Interval Schedule” for more
information on maintenance items.
The ECM provides an electronic governor that
controls the injector output to maintain the desired Engine Service Life
engine speed.
For more information on electronic engine features, Engine efficiency and maximum utilization of engine
refer to the Operation and Maintenance Manual, performance depend on the adherence to proper
“Features and Controls” topic (Operation Section). operation and maintenance recommendations. In
addition, use recommended fuels, coolants, and
lubricants. Use the Operation and Maintenance
Engine Diagnostics Manual as a guide for required engine maintenance.

The engine has built-in diagnostics to ensure that the Expected engine life is generally predicted by the
engine systems are functioning correctly. The average power that is demanded. The average
operator will be alerted to the condition by a “Stop or power that is demanded is based on fuel
Warning” lamp. Under certain conditions, the engine consumption of the engine over time. Reduced hours
horsepower and the vehicle speed may be limited. of operation at full throttle and/or operating at
The electronic service tool may be used to display reduced throttle settings result in a lower average
the diagnostic codes. power demand. Reduced hours of operation will
increase the length of operating time before an
There are three types of diagnostic codes: active, engine overhaul is required. For more information,
logged, and event. refer to the Operation and Maintenance Manual,
“Overhaul Considerations” topic (Maintenance
Most of the diagnostic codes are logged and stored in Section).
the ECM. For additional information, refer to the
Operation and Maintenance Manual, “Engine
Diagnostics” topic (Operation Section). Aftermarket Products and Perkins
Engines
Engine Cooling and Lubrication
Perkins does not warrant the quality or performance
The cooling system and lubrication system consists of non-Perkins fluids and filters.
of the following components:
When auxiliary devices, accessories, or
• Belt driven water pump consumables (filters, additives, catalysts) which are
made by other manufacturers are used on Perkins
• Water temperature regulator which regulates the products, the Perkins warranty is not affected simply
engine coolant temperature because of such use.
However, failures that result from the installation
• Gear-driven gerotor type oil pump or use of other manufacturers devices,
accessories, or consumables are NOT Perkins
• Oil cooler defects. Therefore, the defects are NOT covered
under the Perkins warranty.
The engine lubricating oil is supplied by a gerotor
type oil pump. The engine lubricating oil is cooled
and the engine lubricating oil is filtered. The bypass
valve can provide unrestricted flow of lubrication oil to
the engine if the oil filter element should become
plugged.
M0108133-05 31
Product Information Section
Product Identification Information

Product Identification Serial Number Plate

Information The engine serial number plate is on the right side of
the cylinder block to the rear of the front engine
mounting.
i08146560

Plate Locations and Film

Locations

Illustration 25 g06298094
Serial number plate

i08043623

Emissions Certification Film

Illustration 24 g06505322
Typical example
(1) Engine serial number plate location

Perkins engines are identified by an engine serial

number.
An example of an engine number is
FT*****U000001D.
***** The list number for the engine
FT Type of engine
U Built in the United Kingdom
000001 Engine Serial Number
D Year of Manufacture
Perkins dealers or Perkins distributors need all these
numbers to determine the components that were
included with the engine. This information permits
accurate identification of replacement part numbers.
The numbers for fuel setting information for electronic
engines are stored within the flash file. These Illustration 26 g06522161
numbers can be read by using the electronic service
tool. Typical location of the engine emission label
32 M0108133-05
Product Information Section
Reference Information

The engine emission label is typically installed on the

flywheel housing at Position (X). An extra engine
emission label may be supplied loose.

i07989955

Reference Information

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 Element
Secondary Fuel Filter Element
Lubrication Oil Filter Element
Auxiliary Oil Filter Element
Total Lubrication System Capacity
Total Cooling System Capacity
Air Cleaner Element
Drive Belt
M0108133-05 33
Operation Section
Lifting and Storage

Operation Section 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
Lifting and Storage be perpendicular to the top of the object that is being
lifted.
i08153778 To obtain the correct balance for lifting an application,
adjust the chain lengths.
Product Lifting Lifting eyes are designed and installed for the
specific engine arrangement. Alterations to the lifting
eyes and/or the engine, make the lifting eyes and the
lifting fixtures obsolete. If alterations are made,
NOTICE
Always inspect lifting eyebolts and all other lifting ensure that correct lifting devices are provided.
equipment for damage before performing any lifting.
There are several different designs of lifting eyes.
Never bend the eyebolts and the brackets. Never
The following sections give examples of lifting eyes
perform product lifting if components are damaged.
on the engine.
Only load the eyebolts and the brackets under ten-
sion. Remember that the capacity of an eyebolt is Consult your Perkins dealer for information regarding
less as the angle between the supporting members fixtures for correct engine lifting.
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 correctly rated
for the weight.
Read all the information within product lifting before
any lifting is attempted. Ensure that the correct set of
lifting eyes for the assembly to be lifted have been
selected.

Illustration 28 g06505346
Typical example
(1) Lifting eyes

Use both lifting eyes when lifting an engine assembly.

Illustration 27 g01097527
Perpendicular engine lifting
34 M0108133-05
Operation Section
Product Storage

Perkins recommends that model-specific cradles are 3. The engine oil will not need to be drained in order
used to store and transport engines. Supporting to store the engine. Provided the correct
engines on the sump/oil pan is not recommended specification of engine oil is used the engine can
under any circumstances. This action is for both be stored for up to 6 months. For the correct
safety and quality reasons.
specification of engine oil refer to this Operation
and Maintenance Manual, “Fluid
i04151489
recommendations”.
Product Storage 4. Remove the drive belt from the engine.

Sealed Coolant System

Perkins are not responsible for damage which may
occur when an engine is in storage after a period in Ensure that the cooling system is filled with Perkins
service. ELC, or an antifreeze that meets “ASTM D6210”
specification.
Your Perkins dealer or your Perkins distributor can
assist in preparing the engine for extended storage Open Cooling System
periods.
Ensure that all cooling drain plugs have been
opened. Allow the coolant to drain. Install the drain
Condition for Storage plugs. Place a vapor phase inhibitor into the system.
The coolant system must be sealed once the vapor
The engine must be stored in a water proof building. phase inhibitor has been introduced. The effect of the
The building must be kept at a constant temperature. vapor phase inhibitor will be lost if the cooling system
Engines that are filled with Perkins ELC will have is open to the atmosphere.
coolant protection to an ambient temperature of
−36° C (−32.8° F). The engine must not be subjected For maintenance procedures refer to this Operation
to extreme variations in temperature and humidity. and Maintenance Manual.

Storage Period Monthly Checks

An engine can be stored for up to 6 months provided The crankshaft must be rotated in order to change
all the recommendation are adhered to. the spring loading on the valve train. Rotate the
crankshaft more than 180 degrees. Visibly check for
Storage Procedure damage or corrosion to the engine.

Keep a record of the procedure that has been Ensure that the engine is covered completely before
completed on the engine. storage. Log the procedure in the record for the
engine.
Note: Do not store an engine that has biodiesel in the
fuel system.

1. Ensure that the engine is clean and dry.

a. If the engine has been operated using
biodiesel, the system must be drained and new
filters installed. The fuel tank will require
flushing.
b. Fill the fuel system with an acceptable fuel. For
more information on acceptable fuels refer to
this Operation and Maintenance Manual, “Fluid
recommendations”. Operate the engine for 15
minutes in order to remove all biodiesel from
the system.
2. Drain any water from the primary filter water
separator. Ensure that the fuel tank is full.
M0108133-05 35
Operation Section
Features and Controls

Features and Controls Intake manifold pressure – The intake manifold

pressure sensor checks the rated pressure in the
engine manifold.
i07797317
Fuel rail pressure – The fuel rail pressure sensor
Alarms and Shutoffs measures the high pressure or low pressure in the
fuel rail. The ECM will Check the pressure.
Engine oil pressure – The engine oil pressure
switch indicates when oil pressure drops below rated
Shutoffs system pressure, at a set engine speed.
The shutoffs are electrically operated or mechanically Engine overspeed – If the engine rpm exceeds the
operated. The electrically operated shutoffs are overspeed setting, the alarm will be activated.
controlled by the ECM.
Air filter restriction – The switch checks the air filter
Shutoffs are set at critical levels for the following when the engine is operating.
items:
User-defined switch – This switch can shut down
• Operating temperature the engine remotely.
Water in fuel switch – This switch checks for water
• Operating pressure in the primary fuel filter when the engine is operating.
• Operating level Fuel temperature – The fuel temperature sensor
monitors the pressurized fuel in the high-pressure
• Operating rpm fuel pump.
The particular shutoff may need to be reset before
the engine will start. NRS absolute pressure and NRS delta pressure –
A combined pressure sensor across the NRS valve.
NOTICE
Always determine the cause of the engine shutdown.
Note: The sensing element of the coolant
Make necessary repairs before attempting to restart
the engine. temperature sensor must be submerged in coolant to
operate.

Be familiar with the following items: Engines may be equipped with alarms to alert the
operator when undesirable operating conditions
• Types and locations of shutoff occur.

• Conditions which cause each shutoff to function NOTICE

When an alarm is activated, corrective measures
• The resetting procedure that is required to restart must be taken before the situation becomes an emer-
the engine gency in order to avoid possible engine damage.

Alarms If corrective measures are not taken within a

reasonable time, engine damage could result. The
The alarms are electrically operated. The operations alarm will continue until the condition is corrected.
of the alarms are controlled by the ECM. The alarm may need to be reset.

The alarm is operated by a sensor or by a switch. Note: If installed, the coolant level switch and the oil
When the sensor or the switch is activated, a signal is level switch are indicators. Both switches operate
sent to the ECM. An event code is created by the when the application is on level ground and the
ECM. The ECM will send a signal to illuminate the engine RPM at zero.
lamp.
Your engine may be equipped with the following Testing
sensors or switches:
Turning the keyswitch to the ON position will check
Coolant temperature – The coolant temperature the indicator lights on the control panel. All the
sensor indicates high jacket water coolant indicator lights will be illuminated for 2 seconds after
temperature. the keyswitch is operated. Replace suspect bulbs
immediately.
Intake manifold air temperature – The intake
manifold air temperature sensor indicates high intake
air temperature.
36 M0108133-05
Operation Section
Gauges and Indicators

Refer to Troubleshooting for more information. Jacket Water Coolant Temperature –

Typical temperature range is 82° to 96°C
i08153798 (147.6° to 172.8°F). The maximum
allowable temperature with the pressurized
Gauges and Indicators cooling system at 90 kPa (13 psi) is 112° C
(233.6° F). Higher temperatures may occur under
certain conditions. The water temperature
reading may vary according to load. The reading
Your engine may not have the same gauges or all the should never exceed the boiling point for the
gauges that are described. For more information
about the gauge package, see the OEM information. pressurized system that is being used.

Gauges provide indications of engine performance. The coolant temperature is measured at the outlet for
the water temperature regulator. The engine coolant
Ensure that the gauges are in good working order.
temperature is monitored by the engine sensors and
Determine the normal operating range by observing
the gauges over a period. the engine ECM. This programming cannot be
altered. Derates can occur if the maximum engine
Noticeable changes in gauge readings indicate coolant temperature is exceeded.
potential gauge or engine problems. Problems may
also be indicated by gauge readings that change If the engine is operating above the normal range,
even if the readings are within specifications. reduce the engine load. If high coolant temperatures
Determine and correct the cause of any significant are a frequent event, perform the following
change in the readings. Consult your Perkins dealer procedures:
or your Perkins distributor for assistance. 1. Reduce the load on the engine.
Some engine applications are equipped with 2. Determine if the engine must be shut down
Indicator Lamps. Indicator lamps can be used as a immediately or if the engine can be cooled by
diagnostic aid. There are two lamps. One lamp has reducing the load.
an orange lens and the other lamp has a red lens.
3. Inspect the cooling system for leaks. If necessary,
These indicator lamps can be used in two ways:
consult your Perkins dealer or your Perkins
• The indicator lamps can be used to identify the distributor for assistance.
current operational status of the engine. The
indicator lamps can also indicate that the engine Tachometer – This gauge indicates
has a fault. This system is automatically operated engine speed (rpm). When the throttle
via the ignition switch. control lever is moved to the full throttle
position without load, the engine is running at
• The indicator lamps can be used to identify active high idle. The engine is running at the full load
diagnostic codes. This system is activated by rpm when the throttle control lever is at the full
pressing the Flash Code button. throttle position with maximum rated load.

Refer to the Troubleshooting Guide, “Indicator NOTICE

Lamps” for further information. To help prevent engine damage, never exceed the
high idle rpm. Overspeeding can result in serious
NOTICE damage to the engine. Operation at speeds exceed-
If no oil pressure is indicated, STOP the engine. If ing high idle rpm should be kept to a minimum.
maximum coolant temperature is exceeded, STOP
the engine. Engine damage can result.
Ammeter – This gauge indicates the
amount of charge or discharge in the
Engine Oil Pressure – The oil pressure battery charging circuit. Operation of
should be greatest after a cold engine is the indicator should be to the “ +”” side of “ 0””
started. The typical engine oil pressure (zero).
with SAE10W30 is 207 kPa to 413 kPa
(30 psi to 60 psi) at rated rpm. Fuel Level – This gauge indicates the
fuel level in the fuel tank. The fuel level
A lower oil pressure is normal at low idle. If the gauge operates when the “ START/STOP””
engine speed and load are stable and the gauge switch is in the “ on”” position.
reading changes, perform the following procedure:
1. Remove the load. Service Hour Meter – The gauge
indicates total operating hours of the
2. Stop the engine. engine.
3. Check and maintain the oil level.
M0108133-05 37
Operation Section
Sensors and Electrical Components

Indicator Lamps
• Shutdown lamp
• Warning lamp

• Low oil pressure lamp

• Wait to start lamp (Glow plug warning lamp)
For information, refer to this manual, “Monitoring
System (Table for the Indicator Lamps)” for the
sequence of operation of the shutdown lamp and the
warning lamp.
The function of the wait to start lamp is automatically
controlled at engine start-up.
The function of the low oil pressure lamp is controlled
by the engine ECM. If low oil pressure is detected,
the lamp will be illuminated. The reason for the
illumination of the low-pressure lamp should be
investigated immediately.
The glow plug warning lamp will flash to show that
the engine is being held at low speed. This function
will be performed at engine starting and the duration
will depend on ambient temperature and engine
temperature.
The lamps will illuminate for 2 seconds to check that
the lamps are functioning when the keyswitch is
turned to the ON position. If any of the lamps stay
illuminated, or a lamp fails to be illuminated the
reason should be investigated immediately.

i08083277

Sensors and Electrical

Components

The illustrations within the following sections are

typical location of the sensors or electrical
components for an industrial engine. Specific
engines may appear different due to differences in
applications.
NRS – NOx Reduction System
ECM – Electronic Control Module
38 M0108133-05
Operation Section
Sensors and Electrical Components

Illustration 29 g06538268
Typical example
(1) Engine 47-pin interface connector (5) Control valve for high-pressure fuel (8) Camshaft speed/timing sensor
(2) Air inlet temp sensor pump (9) Pre-NRS temperature sensor
(3) Coolant temperature sensor (6) Fuel temperature sensor (10) Inlet manifold temperature sensor
(4) Alternator (7) Starting motor (11) Inlet Manifold temperature sensor
M0108133-05 39
Operation Section
Sensors and Electrical Components

Illustration 30 g06538269
Typical example
(12) NRS valve (14) Crankshaft speed/timing sensor (16) Fuel rail pressure sensor
(13) Injector 1, 2, 3 and injector 4 (15) Engine oil pressure switch
40 M0108133-05
Operation Section
Sensors and Electrical Components

Off Engine Sensors and Electrical

Components

Illustration 31 g06481423
Typical example
(1) ECM (2) If equipped, Air intake temperature (3) Priming pump
sensor (Air Cleaner) (4) Water in fuel switch
M0108133-05 41
Operation Section
Engine Diagnostics

Engine Diagnostics 1. Move the keyswitch from the on/off two times
within 3 seconds.
i05194988 2. The shutdown warning lamp will flash once.
3. A flashing YELLOW lamp indicates a 3-digit
Self-Diagnostics diagnostic code for the engine. The sequence of
flashes represents the system diagnostic
message. Count the first sequence of flashes in
Perkins Electronic Engines have the capability to
perform a self-diagnostics test. When the system order to determine the first digit of the flash code.
detects an active problem, a diagnostic lamp is After a two second pause, the second sequence of
activated. Diagnostic codes will be stored in flashes will identify the second digit of the flash
permanent memory in the Electronic Control Module code. After the second pause, the third sequence
(ECM). The diagnostic codes can be retrieved by of flashes will identify the flash code.
using Perkins electronic service tools.
4. After the diagnostic codes have been displayed,
Some installations have electronic displays that the shutdown lamp will flash twice and the
provide direct readouts of the engine diagnostic indicator lamp will start to flash the logged
codes. Refer to the manual that is provided by the
OEM for more information on retrieving engine diagnostic codes.
diagnostic codes. 5. After the logged diagnostic codes have been
Active codes represent problems that currently exist. displayed, the shutdown lamp will flash three times
These problems should be investigated first. in order to indication that the code sequences
have finished.
Logged codes represent the following items:
Note: If there are no diagnostic codes or logged
• Intermittent problems diagnostic codes, the system will flash the code 551.
• Recorded events
i07506447

• Performance history
Fault Logging
The problems may have been repaired since the
logging of the code. These codes do not indicate that
a repair is needed. The codes are guides or signals The system provides the capability of Fault Logging.
when a situation exists. Codes may be helpful to When the Electronic Control Module (ECM)
troubleshoot problems. generates an active diagnostic code, the code will be
When the problems have been corrected, the logged in the memory of the ECM. The codes that
corresponding logged fault codes should be cleared. have been logged by the ECM can be identified by
the electronic service tool. The active codes that
have been logged will be cleared when the fault has
i03554520 been rectified or the fault is no longer active. The
following logged faults cannot be cleared from the
Diagnostic Lamp memory of the ECM without using a factory
password: Overspeed, low engine oil pressure, and
high engine coolant temperature codes.
A diagnostic lamp is used to indicate the existence of
an active fault. A fault diagnostic code will remain i03554534
active until the problem is repaired. The diagnostic
code may be retrieved by using the electronic service Engine Operation with Active
tool.
Diagnostic Codes
i04907245

Diagnostic Flash Code If a diagnostic lamp illuminates during normal engine

operation, the system has identified a situation that is
Retrieval not within the specification. Use electronic service
tools to check the active diagnostic codes.

Use the following procedure to retrieve the flash

codes if the engine is equipped with a
“DIAGNOSTIC” lamp:
42 M0108133-05
Operation Section
Engine Operation with Intermittent Diagnostic Codes

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

there is a low oil pressure condition, the Electronic
Control Module (ECM) will limit the engine power
until the problem is corrected. If the oil pressure is
within the normal range, the engine may be operated
at the rated speed and load. However, maintenance
should be performed as soon as possible.
The active diagnostic code should be investigated.
The cause of the problem should be corrected as
soon as possible. If the cause of the active diagnostic
code is repaired and there is only one active
diagnostic code, the diagnostic lamp will turn off.
Operation of the engine and performance of the
engine can be limited as a result of the active
diagnostic code that is generated. Acceleration rates
may be significantly slower. Refer to the
Troubleshooting Guide for more information on the
relationship between these active diagnostic codes
and engine performance.

i01797063

Engine Operation with

Intermittent Diagnostic Codes

If a diagnostic lamp illuminates during normal engine

operation and the diagnostic lamp shuts off, an
intermittent fault may have occurred. If a fault has
occurred, the fault will be logged into the memory of
the Electronic Control Module (ECM).
In most cases, it is not necessary to stop the engine
because of an intermittent code. However, the
operator should retrieve the logged fault codes and
the operator should reference the appropriate
information in order to identify the nature of the event.
The operator should log any observation that could
have caused the lamp to light.

• Low power
• Limits of the engine speed

• Excessive smoke, etc

This information can be useful to help troubleshoot
the situation. The information can also be used for
future reference. For more information on diagnostic
codes, refer to the Troubleshooting Guide for this
engine.
M0108133-05 43
Operation Section
Engine Starting

Engine Starting i08165229

i08158794
Cold Weather Starting
Before Starting Engine

Perform the required daily maintenance and other Do not use aerosol types of starting aids such as
periodic maintenance before the engine is started. ether. Such use could result in an explosion and
Inspect the engine compartment. This inspection can personal injury.
help prevent major repairs later. Refer to the
Operation and Maintenance Manual, “Maintenance The ability to start the engine will be improved at
Interval Schedule” for more information. temperatures below −18 °C (0 °F) from the use of a
jacket water heater or extra battery capacity.
• Ensure that the engine has an adequate fuel
The following items provide a means of minimizing
supply. starting problems and fuel problems in cold weather:
• Open the fuel supply valve (if equipped). Engine oil pan heaters, jacket water heaters, fuel
heaters, and fuel line insulation.
• Drain the water separators. Use the procedure that follows for cold weather
starting.
NOTICE
All valves in the fuel return line must be open and fuel Note: Do not adjust the engine speed control during
supply lines must be open. Damage to the fuel sys- start-up. The electronic control module (ECM) will
tem can occur if fuel lines are closed with the engine control the engine speed during start-up.
in operation.
1. Disengage any driven equipment.
If the engine has not been started for several weeks, Note: During key ON, the indicator lamps will be
fuel may have drained from the fuel system. Air may illuminated for 2 seconds to check the lamp
have entered the filter housing. Also, when fuel filters operation. If any of the indicator lamps do not
have been changed, some air pockets will be trapped illuminate check the bulb. If any indicator lamps stay
in the engine. In these instances, prime the fuel illuminated or flash, refer to Troubleshooting,
system. Refer to the Operation and Maintenance “Indicator Lamp Circuit - Test”.
Manual, “Fuel System - Prime” for more information
on priming the fuel system. Also, check that the fuel
2. Turn the keyswitch to the RUN position. Leave the
specification is correct and that the fuel condition is
correct. Refer to the Operation and Maintenance keyswitch in the RUN position until the warning
Manual, “Fuel Recommendations”. light for the glow plugs is extinguished.
3. When the warning light for the glow plugs is
extinguished, turn the keyswitch to the START
position to engage the electric starting motor and
Engine exhaust contains products of combustion
crank the engine.
which may be harmful to your health. Always
start and operate the engine in a well ventilated Note: The operating period of the warning light for
area and, if in an enclosed area, vent the exhaust
to the outside. the glow plugs will change due to the ambient air
temperature.

• Do not start the engine or move any of the controls NOTICE

if there is a “DO NOT OPERATE” warning tag or Do not engage the starting motor when flywheel is
similar warning tag attached to the start switch or turning. Do not start the engine under load.
to the controls.
If the engine fails to start within 30 seconds, release
• Reset all the shutoffs or alarm components. the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
• Ensure that any driven equipment has been start the engine again.
disengaged. Minimize electrical loads or remove
any electrical loads. 4. Allow the keyswitch to return to the RUN position
after the engine starts.
44 M0108133-05
Operation Section
Starting the Engine

5. Repeat step 2 through step 4 if the engine fails to 3. When the warning light for the glow plugs is
start. extinguished, turn the keyswitch to the START
position to engage the electric starting motor and
Note: After starting, the engine may be held at low crank the engine.
speed for a duration between 1 and 60 seconds to
allow engine systems to stabilize. The duration will Note: The operating period of the warning light for
depend on ambient temperature, time since last run the glow plugs will change due to the temperature of
and other factors. The glow plug warning lamp will the engine.
flash to indicate that the engine has been held at low
speed.
NOTICE
Do not engage the starting motor when flywheel is
6. The engine should not be raced to speed up the turning. Do not start the engine under load.
warm-up process. Allow the engine to idle for 3 to
5 minutes, or allow the engine to idle until the If the engine fails to start within 30 seconds, release
water temperature indicator begins to rise. When the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
idling after the engine has started in cold weather,
start the engine again.
increase the engine rpm from low idle to 1200 rpm.
This operation will warm up the engine more
quickly. 4. Allow the keyswitch to return to the RUN position
after the engine starts.
7. Operate the engine at low load until all systems
reach operating temperature. Check the gauges 5. Repeat step 2 through step 4 if the engine fails to
during the warm-up period. start.

Following a cold start, white vapor can be seen from 6. After starting, the engine may be held at low speed
the tailpipe. This vapor is normal and caused by for a duration between 1 and 60 seconds to allow
condensation leaving the exhaust system after engine systems to stabilize. The duration will
warming up. The white vapor should clear following depend on ambient temperature, time since last
working of the engine. run and other factors. The glow plug warning light
will flash to indicate that the engine is being held at
i08165241 low speed in some applications.
Starting the Engine i08717337

Starting with Jump Start

Note: Do not adjust the engine speed control during
start-up. The electronic control module (ECM) will Cables
control the engine speed during start-up. (Do Not Use This Procedure in
Starting the Engine Hazardous Locations that have
Explosive Atmospheres)
1. Disengage any equipment that is driven by the
engine.
2. Turn the keyswitch to the RUN position. Leave the
keyswitch in the RUN position until the warning
light for the glow plugs is extinguished. The connection of battery cables to a battery and
the disconnection of battery cables from a battery
Note: If the keyswitch has been left in the RUN may cause an explosion which may result in in-
position for a long period of time without engaging the jury or death. The connection and the disconnec-
electric starting motor, turn the keyswitch from the tion of other electrical equipment may also cause
RUN position to the OFF position and then back to an explosion which may result in injury or death.
the RUN position to reactivate the glow plug preheat The procedures for the connection and the dis-
stage. connection of battery cables and other electrical
equipment should only be performed in a nonex-
Note: During the key on, the indicator lamps will be plosive atmosphere.
illuminated for 2 seconds to check lamp operation. If
any of the lamps do not illuminate, check the bulb. If
any indicator lamps stay illuminated or flash, refer to
Troubleshooting, “Indicator Lamp Circuit - Test”.
M0108133-05 45
Operation Section
After Starting Engine

3. Connect one negative end of the jump-start cable

to the negative cable terminal of the electrical
Improper jump start cable connections can cause source. Connect the other negative end of the
an explosion resulting in personal injury. jump-start cable to the engine block or to the
chassis ground. This procedure helps to prevent
Prevent sparks near the batteries. Sparks could potential sparks from igniting the combustible
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine. gases that are produced by some batteries.
Note: The engine ECM must be powered before the
Note: If possible, first diagnose the reason for the starting motor is operated or damage can occur.
starting failure. Refer to Troubleshooting, “Engine
Will Not Crank and Engine Cranks But Will Not Start” 4. Start the engine in the normal operating
for further information. Make any necessary repairs. procedure. Refer to this Operation and
If the engine will not start only due to the condition of Maintenance Manual, “Starting the Engine”.
the battery, either charge the battery, or start the 5. Immediately after the engine is started, disconnect
engine by using another battery with jump-start
the jump-start cables in reverse order.
cables. The condition of the battery can be
rechecked after the engine has been switched OFF. After jump starting, the alternator may not be able to
recharge fully batteries that are severely discharged.
NOTICE The batteries must be replaced or charged to the
Never attempt to start an engine from an external proper voltage with a battery charger after the engine
power source such as electric welding equipment, is stopped. Many batteries which are considered
which has a voltage that is unsuitable for engine unusable are still rechargeable. Refer to Operation
starting and will damage the electrical system. and Maintenance Manual, “Battery - Replace” and
Testing and Adjusting Manual, “Battery - Test”.
For 904D-E28T industrial engines, use a 12 VDC bat-
tery source to start the engine. i08165244

For 904D-E36TA industrial engines, ensure that a 12

VDC or 24 VDC battery source is used to start the After Starting Engine
engine.

After starting, the engine may be held at low speed

NOTICE for a duration between 1 and 60 seconds to allow
Using a battery source with the same voltage as the engine systems to stabilize. Holding the engine
electric starting motor. Use ONLY equal voltage for speed low is controlled by the Electronic Control
jump starting. The use of higher voltage will damage Module (ECM). The duration will depend on ambient
the electrical system. temperature, time since last run and other factors.
Do not reverse the battery cables. The alternator can Note: In ambient temperatures from 15° to 20°C
be damaged. Attach ground cable last and remove (59° to 68°F), the warm-up time is approximately 20
first. to 30 minutes. In temperatures below 15°C (59°F),
additional warm-up time may be required. In
Turn all electrical accessories OFF before attaching
the jump start cables. temperatures greater than 20° C (68° F), warm-up
time may be less.
Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en- When the engine idles during warm-up, observe the
gine being started. following conditions:
Do not check the high-pressure fuel lines with the
1. Turn the start switch on the stalled engine to the engine or the starting motor in operation. If you
OFF position. Turn off all the engines accessories. inspect the engine in operation, always use the
correct inspection procedure to avoid a fluid
2. Connect one positive end of the jump-start cable to penetration hazard. Refer to Operation and
the positive cable terminal of the discharged Maintenance Manual, “General hazard Information”.
battery. Connect the other positive end of the • Check for any fluid or air leaks at idle rpm and at
jump-start cable to the positive cable terminal of one-half full rpm (no load on the engine), before
the electrical source. operating the engine under load. This check may
not be possible in some applications.
46 M0108133-05
Operation Section
After Starting Engine

• Allow the engine to idle for 3 to 5 minutes, or allow

the engine to idle until the water temperature
indicator begins to rise. Check all gauges during
the warm-up period.
Constant speed engines should be allowed to
operate at low idle for 3 minutes before used at
operational speed. If the low idle option is not
available, then operate the engine at operational
speed with no load for 2 minutes.
Note: Gauge readings should be observed and the
data should be recorded frequently while the engine
is operating. Comparing the data over time will help
to determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
M0108133-05 47
Operation Section
Engine Operation

Engine Operation For the 904D-E36TA engine, 726.73 g/kWh was

determined to be the CO2 value during the EU type
approval process.
i08185450
The value was recorded in EU type approval
Engine Operation certificate. This CO2 measurement results from
testing over a fixed test cycle, under laboratory
conditions, with a(n) (parent) engine representative
of the engine type (engine family). This value shall
Correct operation and maintenance are key factors in not imply, or express any guarantee of the
obtaining the maximum life and economy of the performance of a particular engine.
engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be i01646335
minimised and engine service life can be maximised.
The time that is needed for the engine to reach Engaging the Driven
normal operating temperature can be less than the
time taken for a walk-around inspection of the
Equipment
engine.
The engine can be operated at the rated rpm after 1. Operate the engine at one-half of the rated rpm,
the engine is started and after the engine reaches
operating temperature. The engine will reach normal when possible.
operating temperature sooner during a low engine 2. Engage the driven equipment without a load on the
speed (rpm) and during a low-power demand. This equipment, when possible.
procedure is more effective than idling the engine at
no load. The engine should reach operating Interrupted starts put excessive stress on the drive
temperature in a few minutes. train. Interrupted starts also waste fuel. To get the
Avoid excess idling. Excessive idling causes carbon driven equipment in motion, engage the clutch
build-up and engine slobber, these issues are smoothly with no load on the equipment. This
harmful to the engine. method should produce a start that is smooth and
easy. The engine rpm should not increase and the
Gauge readings should be observed and the data clutch should not slip.
should be recorded frequently while the engine is
operating. Comparing the data over time will help to 3. Ensure that the ranges of the gauges are normal
determine normal readings for each gauge. when the engine is operating at one-half of the
Comparing data over time will also help detect
rated rpm. Ensure that all gauges operate
abnormal operating developments. Significant
changes in the readings should be investigated. properly.
4. Increase the engine rpm to the rated rpm. Always
NOTICE increase the engine rpm to the rated rpm before
The engine and emissions control system shall be
operated, used, and maintained in accordance with the load is applied.
the instructions provided. Failure to follow the instruc- 5. Apply the load. Begin operating the engine at low
tions could result in emissions performance that does
not meet the requirements applicable to the category load. Check the gauges and equipment for proper
of the engine. No deliberate tampering with, or mis- operation. After normal oil pressure is reached and
use of the engine emissions control system should the temperature gauge begins to move, the engine
take place. Prompt action is critical to rectify any in- may be operated at full load. Check the gauges
correct operation, use, or maintenance of the emis- and equipment frequently when the engine is
sions control system. operated under load.
Extended operation at low idle or at reduced load
Carbon Dioxide (CO2) Emissions may cause increased oil consumption and carbon
buildup in the cylinders. This carbon buildup
Statement results in a loss of power and/or poor
Emissions regulations require that the value of the performance.
CO2 emissions be reported to the end user.
For the 904D-E28T engine, 831.2 g/kWh was
determined to be the CO2 value during the EU type
approval process.
48 M0108133-05
Operation Section
Fuel Conservation Practices

i07677865

Fuel Conservation Practices

The efficiency of the engine can affect the fuel

economy. Perkins design and technology in
manufacturing provides maximum fuel efficiency in
all applications. Follow the recommended procedures
to attain optimum performance for the life of the
engine.

• Avoid spilling fuel.

Fuel expands when it is warmed up. The fuel may
overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.

• Be aware of the properties of different fuels. Use

only the recommended fuels. Refer to the
Operations and Maintenance Manual, “Fuel
Recommendations” for further information.
• Avoid unnecessary idling.
Shut off the engine rather than allowing the engine to
idle for long periods of time.

• Observe the service indicator frequently. Keep the

air cleaner elements clean.

• Ensure that the turbocharger is operating

correctly. For more information refer to this
Operation and Maintenance Manual,
“Turbocharger - Inspect”
• Maintain a good electrical system.
One faulty battery cell will overwork the alternator.
This fault will consume excess power and excess
fuel.
• The belt should be in good condition. Refer to the
Systems Operation, Testing and Adjusting, “V-Belt
Test” for further information.
• Ensure that all the connections of the hoses are
tight. The connections should not leak.
• Ensure that the driven equipment is in good
working order.

• Cold engines consume excess fuel. Utilize heat

from the jacket water system and the exhaust
system, when possible. Keep cooling system
components clean and keep cooling system
components in good repair. Never operate the
engine without water temperature regulators. All
these items will help maintain operating
temperatures.
M0108133-05 49
Operation Section
Cold Weather Operation

Cold Weather Operation • Achieving operating temperature will help prevent

the intake valves and exhaust valves from
sticking.
i08165245
• The cooling system and the lubrication system for
Cold Weather Operation 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 retained heat
Perkins Diesel Engines can operate effectively in within the engine will allow the engine to readily
cold weather. During cold weather, the starting and start.
the operation of the diesel engine depends on the
following items: • Install the correct specification of engine lubricant
before the beginning of cold weather. Refer to this
• The type of fuel that is used Operation and Maintenance Manual, “Fluid
Recommendations” for the recommended
• The viscosity of the engine oil viscosity of oil.
• The operation of the glow plugs • Check all rubber parts (hoses, fan drive belts)
weekly.
• Optional Cold starting aid
• Check all electrical wiring and connections for any
• Battery condition fraying or damaged insulation.
• Ambient air temperature and altitude • Keep all batteries fully charged and warm by
ensuring that the engine is allowed to operate at
• Parasitic load of the application normal operating temperature.
• Application hydraulic and transmission oil • Fill the fuel tank at the end of each shift.
viscosities
This section will cover the following information: • Check the air cleaners and the air intake daily.
Check the air intake more often when you operate
• Potential problems that are caused by cold- in snow.
weather operation
• Ensure that the glow plugs are in working order.
• Suggest steps which can be taken to minimize Refer to Troubleshooting, “Glow Plug Starting Aid-
starting problems and operating problems when Test”.
the ambient air temperature is between
0° to −40 °C (32° to -40 °F).
The operation and maintenance of an engine in Personal injury or property damage can result
freezing temperatures is complex . This complexity is from alcohol or starting fluids.
because of the following conditions:
Alcohol or starting fluids are highly flammable
• Weather conditions and toxic and if improperly stored could result in
injury or property damage.
• 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 Do not use aerosol types of starting aids such as
operation. ether. Such use could result in an explosion and
personal injury.
Hints for Cold-Weather Operation
• After starting the engine, the engine speed will be
governed for up to a maximum of 60 seconds.
After this period, the engine should be operated at
low loads until a minimum operating temperature
of 80° C (176° F) is achieved.
50 M0108133-05
Operation Section
Cold Weather Operation

• For jump starting with cables in cold weather, refer While the engine is idling, the application of a light
to the Operation and Maintenance Manual, load (parasitic load) will help in achieving the
“Starting with Jump-Start Cables.” for instructions. minimum operating temperature. The minimum
operating temperature is 80° C (176° F).
Viscosity of the Engine Lubrication
Oil Recommendations for Coolant
Warm Up
Correct engine oil viscosity is essential. Oil viscosity
affects lubrication properties and wear protection that Warm up an engine that has cooled below normal
the oil provides for the engine. Refer to this Operation operating temperatures due to inactivity. This warm
and Maintenance Manual, “Fluid Recommendations” -up should be performed before the engine is
for the recommended viscosity of oil. returned to full operation. During operation in very
cold temperature conditions, damage to engine valve
At temperatures below −10° C (14° F) damage to mechanisms can result from engine operation for
engine components can occur if the engine is short intervals. This damage can happen if the
allowed to operate at high load and speed engine is started and the engine is stopped many
immediately after starting. times without being operated to warm up completely.

Recommendations for the Coolant When the engine is operated below normal operating
temperatures, fuel and oil are not burned completely
Provide cooling system protection for the lowest in the combustion chamber. This fuel and oil causes
expected outside temperature. Refer to this soft carbon deposits to form on the valve stems.
Operation and Maintenance Manual, “Fluid Generally, the deposits do not cause problems and
Recommendations” for the recommended coolant the deposits are burned off during operation at
mixture. normal engine operating temperatures.
In cold weather, check the coolant often for the When starting and stopping an engine many times
correct glycol concentration to ensure adequate without being operated to warm up completely, the
freeze protection. carbon deposits become thicker. This starting and
stopping can cause the following problems:
Engine Block Heaters
• Free operation of the valves is prevented.
Engine block heaters (if equipped) heat the engine
jacket water that surrounds the combustion • Valves become stuck.
chambers. This heat provides the following functions:
• Pushrods may become bent.
• Startability is improved.
• Other damage to valve train components can
• Warm up time is reduced. result.

An electric block heater can be activated once the For these reasons, when the engine is started, the
engine is stopped. A block heater can be 120 V ac engine must be operated until the coolant
600W or 220 V ac 550W. Consult your Perkins dealer temperature is 80° C (176° F) minimum. Carbon
or your Perkins distributor for more information. deposit on the valve stems will be kept at a minimum.
The free operation of the valves and the valve
components will be maintained.
Idling the Engine
The engine must be warmed thoroughly to keep
After starting the engine, the engine speed will be other engine parts in better condition. The service life
governed for a maximum period of 60 seconds. of the engine will be generally extended. Lubrication
When idling after the engine is started in cold will be improved. There will be less acid and less
weather, increase the engine rpm from 1000 to 1200 sludge in the oil. This condition will provide longer
rpm. This idling will warm up the engine more quickly. service life for the engine bearings, the piston rings,
Maintaining an elevated low idle speed for extended and other parts. However, limit unnecessary idle time
periods will be easier with the installation of a hand to 10 minutes to reduce wear and unnecessary fuel
throttle. The engine should not be “raced” to speed consumption.
up thewarm-up process.
M0108133-05 51
Operation Section
Radiator Restrictions

The Water Temperature Regulator and If an airflow restriction device must be used, the
device should have a permanent opening directly in
Insulated Heater Lines line with the fan hub. The device must have a
minimum opening dimension of at least 770 cm2
The engine is equipped with a water temperature (120 in2).
regulator. When the engine coolant is below the
correct operating temperature, jacket water circulates A centered opening that is directly in line with the fan
through the engine cylinder block and into the engine hub is specified to prevent an interrupted airflow on
cylinder head. The coolant then returns to the the fan blades. Interrupted airflow on the fan blades
cylinder block via an internal passage that bypasses could cause a fan failure.
the valve of the coolant temperature regulator. This
return ensures that coolant flows around the engine Perkins recommends a warning device for the inlet
under cold operating conditions. The water manifold temperature and/or the installation of an
temperature regulator begins to open when the inlet air temperature gauge. The warning device for
engine jacket water has reached the correct the inlet manifold temperature should be set at 75 °C
minimum operating temperature. As the jacket water (167 °F). The inlet manifold air temperature should
coolant temperature rises above the minimum not exceed 75 °C (167 °F). Temperatures that
operating temperature, the water temperature exceed this limit can cause power loss and potential
regulator opens further allowing more coolant engine damage.
through the radiator to dissipate excess heat.
i07818744
The progressive opening of the water temperature
regulator operates the progressive closing of the
bypass passage between the cylinder block and Fuel and the Effect from Cold
head. This action ensures maximum coolant flow to Weather
the radiator to achieve maximum heat dissipation.
Note: Do not restrict the air flow. Restriction of the air
flow can damage the fuel system. Perkins Note: Only use grades of fuel that are recommended
discourages the use of all air flow restriction devices by Perkins. Refer to this Operation and Maintenance
such as radiator shutters. Restriction of the air flow Manual, “Fluid Recommendations”.
can result in the following: high exhaust
temperatures, power loss, excessive fan usage, and Properties of the diesel fuel can have a significant
reduction in fuel economy. effect on the engine cold start capability. It is critical
that the low temperature properties of diesel fuel are
A cab heater is beneficial in very cold weather. The acceptable for the minimum ambient temperature the
feed from the engine and the return lines from the engine is expected to see in operation.
cab should be insulated to reduce heat loss to the
outside air. Following properties are used to define fuels low
temperature capability:
i07926238
• Cloud point
Radiator Restrictions • Pour point
• Cold Filter Plugging Point (CFPP)
Perkins discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow The cloud point of the fuel is the temperature at
restriction can cause the following conditions: which waxes naturally found in the diesel fuel begin
to form crystals. The cloud point of the fuel must be
• High exhaust temperatures below lowest ambient temperature to prevent filters
from plugging.
• Power loss
Pour point is the last temperature before the fuel flow
• Excessive fan usage stops and waxing of the fuel will start.

• Reduction in fuel economy Cold Filter Plugging Point (CFPP) is a temperature at

which a particular fuel will pass through a
Reducing air flow over components will also affect standardized filtration device. This CFPP gives an
under hood temperatures. Reducing air flow can estimate of the lower operability temperature of fuel
increase surface temperatures and could affect
component reliability.
52 M0108133-05
Operation Section
Fuel Related Components in Cold Weather

Be aware of these properties when diesel fuel is Drain the water and sediment from any fuel storage
purchased. Consider the average ambient air tank at the following intervals: weekly, service
temperature for the engines application. Engines that intervals and refueling of the fuel tank. Draining will
are fueled in one climate may not operate well if the help prevent water and/or sediment from being
engines are shipped to colder climate. Problems can pumped from the fuel storage tank and into the
result due to changes in temperature. engine fuel tank.
Before troubleshooting for low power or for poor
performance in the winter, check the fuel for waxing Fuel Filters
The following components can provide a means of After you change the fuel filter, always prime the fuel
minimizing fuel waxing problems in cold weather: system to remove air bubbles from the fuel system.
Refer to the Operation and Maintenance Manual in
• Fuel heaters, which may be an OEM option the Maintenance Section for more information on
priming the fuel system.
• Fuel line insulation, which may be an OEM option
The micron rating and the location of a primary fuel
Winter and arctic grades of diesel fuel are available in filter is important in cold-weather operation. The
the countries and territories with severe winters. For primary fuel filter, and the fuel supply line are the
more information refer to the Operation and most common components that are affected by cold
Maintenance Manual, “Fuel For Cold-Weather fuel.
Operation”
Another important fuel property which can affect cold
Fuel Heaters
start and operation of diesel engine is Cetane
number. Detail and requirements of this property are Note: The OEM may equip the application with fuel
given in this Operation and Maintenance Manual, heaters. If so, the temperature of the fuel must not
“Fluid Recommendations”. exceed 80° C (176° F) at the fuel transfer pump. The
fuel heater should be installed before the electric lift
i07486546
pump.
For more information about fuel heaters (if equipped),
Fuel Related Components in refer to the OEM information.
Cold Weather

Fuel Tanks
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after you operate the engine.
Fuel tanks should contain some provision for draining
water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe.
Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.
M0108133-05 53
Operation Section
Engine Stopping

Engine Stopping i07797387

i07797382
After Stopping Engine
Stopping the Engine Note: Before you check the engine oil, do not
operate the engine. Wait for at least 30 minutes after
the engine has stopped to allow the engine oil to
NOTICE return to the oil pan.
Stopping the engine immediately after the engine has
been working under load, can result in overheating
and accelerated wear of the engine components.
Contact with high pressure fuel may cause fluid
Avoid accelerating the engine prior to shutting down
penetration and burn hazards. High pressure fuel
the engine.
spray may cause a fire hazard. Failure to follow
Avoiding hot engine shutdowns will maximize turbo- these inspection, maintenance and service in-
charger shaft and bearing life. Also, selective cata- structions may cause personal injury or death.
lytic reduction component life.
• After the engine has stopped, you must wait for 10
Note: Individual applications will have different minutes to allow the fuel pressure to be purged
control systems. Ensure that the shutoff procedures from the high-pressure fuel lines before any
are understood. Use the following general guidelines service or repair is performed on the engine fuel
to stop the engine. lines. If necessary, perform minor adjustments.
Repair any leaks from the low-pressure fuel
1. Remove the load from the engine. Reduce the system and from the cooling, lubrication, or air
engine speed to low idle. Allow the engine to idle systems. Replace any high-pressure fuel line that
for 5 minutes to cool the engine. has leaked. Refer to Disassembly and Assembly
Manual, “Fuel Injection Lines - Install”.
2. Stop the engine after the cool down period
according to the shutoff system on the engine and • Check the crankcase oil level. Maintain the oil
turn the ignition keyswitch to the OFF position. If level between the “MIN” mark and the “MAX” mark
on the engine oil level gauge.
necessary, refer to the instructions that are
provided by the OEM. • If the engine is equipped with a service hour
meter, note the reading. Perform the maintenance
Note: In some applications the engine will continue that is in the Operation and Maintenance Manual,
to operate after the keyswitch is turned to the OFF “Maintenance Interval Schedule”.
position. The engine will operate for a short time to
allow engine components to cool. • Fill the fuel tank, to help prevent accumulation of
moisture in the fuel. Do not overfill the fuel tank.
i05195199

NOTICE
Emergency Stopping Only use antifreeze/coolant mixtures recommended
in this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” topic or in this
Operation and Maintenance Manual, “Fluid Recom-
NOTICE mendations” topic. Failure to do so can cause engine
Emergency shutoff controls are for EMERGENCY damage.
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
Pressurized System: Hot coolant can cause seri-
the emergency stop button, refer to the OEM
ous burns. To open the cooling system filler cap,
information. stop the engine and wait until the cooling system
Ensure that any components for the external system components are cool. Loosen the cooling system
that support the engine operation are secured after pressure cap slowly in order to relieve the
the engine is stopped. pressure.
54 M0108133-05
Operation Section
After Stopping Engine

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

• Check the coolant for correct antifreeze protection
and the correct corrosion protection. Add the
correct coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all
driven equipment. This maintenance is outlined in
the instructions from the OEM.
M0108133-05 55
Maintenance Section
Refill Capacities

Maintenance Section Table 5

904D-E28T Industrial Engine
Refill Capacities
Refill Capacities Compartment or System Capacity
Engine Only 3.9 L (1.03038 US gal)
i08791218
External System Per OEM(1)
Refill Capacities (1) The External System includes a radiator or an expansion tank
with the following components: heat exchanger and piping. Re-
fer to the OEM specifications. Enter the value for the capacity
of the External System in this row.
Lubrication System
Table 6
OEM – Original Equipment Manufacturer 904D-E36TA Industrial Engine
Refill Capacities
The refill capacities for the engine crankcase reflect
the approximate capacity of the crankcase or sump Compartment or System Capacity
plus standard oil filters. Auxiliary oil filter systems will
require extra oil. Refer to the OEM specifications for Engine Only 4.3 L (1.136 US gal)
the capacity of the auxiliary oil filter. Refer to the External System Per OEM(1)
Operation and Maintenance Manual, “Maintenance
Section” for more information on Lubricant (1) The External System includes a radiator or an expansion tank
Specifications. with the following components: heat exchanger and piping. Re-
fer to the OEM specifications. Enter the value for the capacity
Table 3
of the External System in this row.
904D-E28T Industrial Engine
Refill Capacities i07794074

Compartment or System Capacity

Fluid Recommendations
Crankcase Oil Sump(1) 7.5 to 8.8 L
(1.98150 to 2.32496 US gal) (General Fuel Information)
(1) These values are the approximate capacities for the crankcase
oil sump which includes the standard factory installed oil filters.
Engines with auxiliary oil filters will require extra oil. Refer to • Glossary
the OEM specifications for the capacity of the auxiliary oil filter.
The design of the oil pan can change the oil capacity of the oil • ISO International Standards Organization
pan.
• ASTM American Society for Testing and Materials
Table 4
904D-E36TA Industrial Engine • HFRR High Frequency Reciprocating Rig for
Refill Capacities Lubricity testing of diesel fuels
Compartment or System Capacity • FAME Fatty Acid Methyl Esters
9.1 to 10.6 L
Crankcase Oil Sump(1) • CFR Co-ordinating Fuel Research
(2.40422 to 2.80052 US gal)
(1) These values are the approximate capacities for the crankcase • LSD Low Sulfur Diesel
oil sump which includes the standard factory installed oil filters.
Engines with auxiliary oil filters will require extra oil. Refer to • ULSD Ultra Low Sulfur Diesel
the OEM specifications for the capacity of the auxiliary oil filter.
The design of the oil pan can change the oil capacity of the oil • RME Rape Methyl Ester
pan.
• SME Soy Methyl Ester
Cooling System
• EPA Environmental Protection Agency of the
Refer to the OEM specifications for the External United States
System capacity. This capacity information will be
needed to determine the amount of coolant/
antifreeze that is required for the Total Cooling
System.
56 M0108133-05
Maintenance Section
General Fuel Information

General Information
NOTICE
Every attempt is made to provide accurate, up-to-
date information. By use of this document you agree
that Perkins Engines Company Limited is not respon-
sible for errors or omissions.

NOTICE
These recommendations are subject to change with-
out notice. Contact your local Perkins distributor for
the most up-to-date recommendations.

Diesel Fuel Requirements

Perkins is not in a position to evaluate continuously
and monitor all worldwide distillate diesel fuel
specifications that are published by governments and
technological societies.
Perkins Specification for Distillate Diesel Fuel in table
7 provides a known reliable baseline to judge the
expected performance of distillate diesel fuels that
are derived from conventional sources.
Satisfactory engine performance depends on the use
of a good quality fuel. The use of a good quality fuel
will give the following results: long engine life and
acceptable exhaust emissions levels. The fuel must
meet the minimum requirements that are stated in
table 7 .

NOTICE
The footnotes are a key part of the Perkins Specifica-
tion for Distillate Diesel Fuel Table. Read ALL of the
footnotes.

Table 7
Perkins Specification for Distillate Diesel Fuel

Property UNITS Requirements “ASTM Test” “ISO Test”

Aromatics %Volume 35% maximum “D1319” “ISO 3837”

Ash %Weight 0.01% maximum “D482” “ISO 6245”

Carbon Residue on 10% %Weight 0.30% maximum “D524” “ISO 4262”

Bottoms
Cetane Number (1) - 40 minimum “D613 or D6890” “ISO 5165”

Cloud Point °C The cloud point must not ex- “D2500” “ISO 3015”
ceed the lowest expected
ambient temperature.

Copper Strip Corrosion - No. 3 maximum “D130” “ISO 2160”

(continued)
M0108133-05 57
Maintenance Section
General Fuel Information

(Table 7, contd)
Distillation °C 10% at 282 °C (539.6 °F) “D86” “ISO 3405”
maximum
90% at 360 °C (680 °F)
maximum
Density at 15 °C (59 °F) Kg / M3 800 minimum and 860 No equivalent test “ISO 3675” or “ISO 12185”
(2) maximum

Flash Point °C legal limit “D93” “ISO 2719”

Thermal Stability Minimum of 80% reflec- “D6468” No equivalent test

- tance after aging for 180 mi-
nutes at 150 °C (302 °F)

Pour Point °C 6 °C (10°F) “D97” “ISO 3016”

Minimum below ambient
temperature

Sulfur %mass (3) “D5453 or /D2622” “ISO 20846” or “ISO 20884”

Kinematic Viscosity (4) “MM2/S (cSt)” The viscosity of the fuel that “D445” “ISO 3405”
is delivered to the fuel injec-
tion pump. “1.4 minimum
and /4.5 maximum”
Water and sediment % weight 0.05% maximum “D1796” “ISO 3734”

Water % weight 0.02% maximum “D1744” No equivalent test

Sediment % weight 0.05% maximum “D473” “ISO 3735”

Gums and Resins (5) mg/100mL 10 mg per 100 mL “D381” “ISO 6246”
maximum
Lubricity corrected wear mm 0.52 maximum “D6079” “ISO 12156-1”
scar diameter at 60 °C
(140 °F). (6)

Fuel cleanliness (7) - “ISO”18/16/13 “7619” “ISO 4406”

3
Oxidation Stability g/m Maximum 25 “D2274” “ISO 12205”

Hours (8) Minimum 20 - “EN 15751”

(1) In order to insure minimum cetane number of 40 a distillate diesel fuel should have minimum cetane index of 44 when ASTM D4737 test
method is used. A fuel with a higher cetane number is recommended to operate at a higher altitude or in cold weather.
(2) Density range allowed includes summer and winter diesel fuel grades. Fuel density varies depending on the sulfur level where high sulfur
fuels have higher densities. Some unblended alternative fuels have lower densities which are acceptable, if all the other properties meet this
specification.
(3) Regional regulations, national regulations, or international regulations can require a fuel with a specific sulfur limit. Consult all applicable reg-
ulations before selecting a fuel for a given engine application. LSD fuel with less than 0.05 percent (≤ 500 ppm (mg/kg)) sulfur is recom-
mended for use in these engine models. Diesel fuel with more than 0.05 percent (≥ 500 ppm (mg/kg)) sulfur can be used only where allowed
by legislation. Fuel sulfur levels affect exhaust emissions. High sulfur fuels also increase the potential for corrosion of internal components.
Fuel sulfur levels above 0.05% may significantly shorten the oil change interval. For additional information, refer to General lubricant
Information.
(4) The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscos-
ity requirement and the fuel should meet the maximum viscosity requirements at 40° C (104° F) of either the "ASTM D445" test method or
the "ISO 3104" test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain 1.4 cSt or greater viscosity at
the fuel injection pump. Fuels with a high viscosity might require fuel heaters to lower the viscosity to 4.5 cSt at the fuel injection pump.
(5) Follow the test conditions and procedures for gasoline (motor).
(6) The lubricity of a fuel is a concern with low sulfur and ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1 or ASTM
D6079 High Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel
supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in
the fuel system.
(7) Recommended cleanliness level for fuel as dispensed into machine or engine fuel tank is "ISO 18/16/13 or cleaner as per ISO 4406. Refer to
the "Contamination Control Recommendations for Fuels" in this chapter.
(8) Additional limit for fuel containing FAME. Fuel containing more than 2%v/v FAME must meet both tests.
58 M0108133-05
Maintenance Section
General Fuel Information

The viscosity of the fuel is significant because fuel

NOTICE serves as a lubricant for the fuel system components.
Operating with fuels that do not meet the Perkins rec-
ommendations can cause the following effects: Start- Fuel must have sufficient viscosity to lubricate the
ing difficulty, poor combustion, deposits in the fuel fuel system in both cold temperatures and hot
injectors, reduced service life of the fuel system, de- temperatures. If the kinematic viscosity of the fuel is
posits in the combustion chamber and reduced serv- lower than 1.4 cSt at the fuel injection pump, damage
ice life of the engine. to the fuel injection pump can occur. This damage
can be excessive scuffing and seizure. Low viscosity
Engines that are manufactured by Perkins are certi- may lead to difficult hot restarting, stalling, and loss of
fied with the fuel that is prescribed by the United performance. High viscosity may result in seizure of
States Environmental Protection Agency. Engines the pump.
that are manufactured by Perkins are certified with
the fuel that is prescribed by the European Certifica- Perkins recommends kinematic viscosities of 1.4 and
4.5 cSt that is delivered to the fuel injection pump. If a
tion and other regulatory agencies. Perkins does not fuel with a low viscosity is used, cooling of the fuel
certify diesel engines on any other fuel. may be required to maintain 1.4 cSt or greater
viscosity at the fuel injection pump. Fuels with a high
viscosity might require fuel heaters to lower the
Note: The owner and the operator of the engine has viscosity to 4.5 cSt at the fuel injection pump.
the responsibility of using the fuel that is prescribed
by the Environmental Protection Agency (EPA) and
other appropriate regulatory agencies.
Density
Density is the mass of the fuel per unit volume at a
Diesel Fuel Characteristics specific temperature. This parameter has a direct
influence on engine performance and a direct
Perkins Recommendations influence on emissions. This influence determines
the heat output from a given injected volume of fuel.
Cetane Number This parameter is quoted in the following kg/m3 at
15 °C (59 °F).
Fuel that has a high cetane number will give a shorter
ignition delay. A high cetane number will produce a Perkins recommends a value of density of 841 kg/m3
better ignition quality. Cetane numbers are derived to obtain the correct power output. Lighter fuels are
for fuels against proportions of cetane and acceptable but these fuels will not produce the rated
heptamethylnonane in the standard CFR engine. power.
Refer to “ISO 5165” for the test method.
Sulfur
Cetane numbers more than 45 are normally expected
from current diesel fuel. However, a cetane number Sulfur levels in the fuel affect the durability of engine
of 40 may be experienced in some territories. The components and also affect engine exhaust
United States of America is one of the territories that emissions. The level of sulfur is governed by
can have a low cetane value. A minimum cetane emissions legislations. Regional regulation, national
value of 40 is required during average starting
regulations, or international regulations can require a
conditions. A higher cetane value may be required for
fuel with a specific sulfur limit. The sulfur content of
operations at high altitudes or in cold-weather
the fuel and the fuel quality must comply with all
operations.
existing local regulations for emissions.
Fuel with a low cetane number can be the root cause
of problems during cold start. Low sulfur diesel (LSD) fuel with less than 0.05
percent (≤ 500 ppm (mg/kg)) sulfur is recommended
for use in these engine models
Viscosity
ULSD less than 0.0015% (≤15 PPM (mg/Kg)) sulfur
Viscosity is the property of a liquid of offering is acceptable to use in these engine models. The
resistance to shear or flow. Viscosity decreases with lubricity of these fuels must not exceed wear scar
increasing temperature. This decrease in viscosity diameter of 0.52 mm (0.02047 inch) as per “ISO
follows a logarithmic relationship for normal fossil 12156-1”. Refer to “Lubricity” for more information.
fuel. The common reference is to kinematic viscosity.
Kinematic viscosity is the quotient of the dynamic
viscosity that is divided by the density. The
determination of kinematic viscosity is normally by
readings from gravity flow viscometers at standard
temperatures. Refer to “ISO 3104” for the test
method.
M0108133-05 59
Maintenance Section
General Fuel Information

Fuels with sulfur content higher than 0.05 percent Group 1: Preferred Fuels
(500 PPM) can only be used where allowed by
legislation and in countries that do not regulate The following fuel specifications are considered
emissions. High sulfur fuel will have a negative acceptable.
impact on emissions of particulates. High sulfur fuels
increase potential for corrosion and wear of internal • Fuels that meet the requirements that are listed in
component and may significantly shorten the oil the table 7 .
change interval. Oil sampling analysis is very strongly
recommended to determine oil drain intervals when • “EN590 - Grades A to F and class 0 to 4”
using fuel with sulfur levels above 0.05% (500 ppm).
• “ASTM D975 Grade No. 1-D and 2-D”
Lubricity
• “JIS K2204 Grades 1, 2 & 3 & Special Grade 3”
Lubricity is the capability of the fuel to prevent pump acceptable provided lubricity ware scar diameter
wear. The lubricity of the fluid describes the ability of does not exceed of 0.52 mm (0.02047 inch) as
the fluid to reduce the friction between surfaces that per “ISO 12156-1” .
are under load. This ability reduces the damage that
is caused by friction. Fuel injection systems rely on • “BS2869 - Class A2 Off Highway Gas Oil, Red
the lubricating properties of the fuel. Until fuel sulfur Diesel”
limits were mandated, the lubricity of the fuel was
believed to be a function of fuel viscosity. Note: The lubricity of these fuels must not exceed
wear scar diameter of 0.52 mm (0.02047 inch) as
The lubricity has particular significance to the current per “ISO 12156-1” . Refer to “Lubricity”.
low viscosity fuel, low sulfur fuel, and low aromatic
fossil fuel. These fuels are made to meet stringent Group 2: Aviation Kerosene Fuels
exhaust emissions.
The lubricity of these fuels must not exceed wear Following kerosene and jet fuel specifications are
scar diameter of 0.52 mm (0.02047 inch). The fuel acceptable alternative fuels, and may be used on a
lubricity test must be performed on an HFRR, contingency base for emergency or continuous use,
operated at 60 °C (140 °F). Refer to “ISO 12156-1”. where standard diesel fuel is not available and where
legislation allows their use:
NOTICE • “MIL-DTL-83133 NATO F34 (JP-8)”
The fuels system has been qualified with fuel having
lubricity up to 0.52 mm (0.02047 inch) wear scar di- • “MIL-DTL-83133 NATO F35”
ameter as tested by “ISO 12156-1”. Fuel with higher
wear scar diameter than 0.52 mm (0.02047 inch) will • “MIL-DTL-5624 NATO F44 (JP-5)”
lead to reduced service life and premature failure of
the fuel system. • “MIL-DTL-38219 (USAF) (JP7)”

• “NATO XF63”
In the fuels which do not meet specified lubricity
requirement appropriate lubricity additive can be • “ASTM D1655 JET A”
used to enhance the lubricity of the fuel.
• “ASTM D1655 JET A1”
Contact your fuel supplier for those circumstances
when fuel additives are required. Your fuel supplier
can make recommendations for additives to use and NOTICE
for the proper level of treatment. These fuels are only acceptable when used with ap-
propriate lubricity additive and must meet minimum
Distillation requirements that are listed in table 7 . The lubricity
of these fuels must not exceed wear scar diameter of
Distillation will give an indication of the mixture of 0.52 mm (0.02047 inch) as per “ISO 12156-1” . Refer
different hydrocarbons in the fuel. A high ratio of to “Lubricity”.
lightweight hydrocarbons can affect the
characteristics of combustion.
Note: Minimum cetane number of 40 is
recommended otherwise cold starting problems or
Classification of the Fuels light load misfire might occur. Since jet fuel
Diesel engines have an ability to burn wide variety of specifications do not mention cetane requirements,
fuels. Below is a list of typically encountered fuel Perkins recommends that a fuel sample is taken to
specifications that have been assessed as to their determine the cetane number.
acceptability and are divided into following
categories:
60 M0108133-05
Maintenance Section
General Fuel Information

Note: Fuels must have minimum viscosity of 1.4 cSt Note: Engines that are manufactured by Perkins are
delivered to the fuel injection pump. Cooling of the certified by use of the prescribed Environmental
fuel may be required to maintain 1.4 cSt or greater Protection Agency (EPA) and European Certification
viscosity at the fuel injection pump. Perkins fuels. Perkins does not certify engines on any other
recommends that the actual viscosity of the fuel, be fuel. The user of the engine has the responsibility of
measured to determine if a fuel cooler is needed. using the correct fuel that is recommended by the
Refer to “Viscosity”. manufacturer and allowed by the EPA and other
appropriate regulatory agencies.
Note: Rated power loss of up to 10 percent is
possible due to lower density and lower viscosity of Specification Requirements
jet fuels compared to diesel fuels.
These engine models have been approved to
Biodiesel Fuel operate with biodiesel blends up to B20. Where
specifically mandated blends up to B30 may be used.
Biodiesel is a fuel that can be defined as mono-alkyl
esters of fatty acids. Biodiesel is a fuel that can be To be acceptable for blending, the biodiesel
made from various feedstock. The most commonly constituent must conform to the latest edition of
available biodiesel in Europe is Rape Methyl Ester “EN14214” or “ASTM D6751”.
(REM). This biodiesel is derived from rapeseed oil. The distillate diesel fuel acceptable for blending with
Soy Methyl Ester (SME) is the most common biodiesel must meet requirements of “Perkins
biodiesel in the United States. This biodiesel is Specification for Distillate Diesel Fuel” the listed in
derived from soybean oil. Soybean oil or rapeseed oil table 7 or the latest edition of “EN590” and “ASTM D
are the primary feedstocks. These fuels are together 975” commercial standards.
known as Fatty Acid Methyl Esters (FAME).
Biodiesel blends of B6 to B20 must meet the
Raw pressed vegetable oils are NOT acceptable for requirements listed in the latest edition of “ASTM
use as a fuel in any concentration in compression D7467”and must be of an API gravity of 30-45 or
engines. Without esterification, these oils may gel in latest edition of the “EN 16709” Table 1 specification
the crankcase and the fuel tank. These fuels may not for B20 blends.
be compatible with many of the elastomers that are
used in engines that are manufactured today. In Where mandated, biodiesel blends of B30 must meet
original forms, these oils are not suitable for use as a the regional requirements and “EN 16709” Table 2
fuel in compression engines. Alternate base stocks specification for B30 blends.
for biodiesel may include animal tallow, waste In North America biodiesel and biodiesel blends must
cooking oils, or various other feedstocks. To use any be purchased from the BQ-9000 accredited
of the products that are listed as fuel, the oil must be producers and BQ-9000 certified distributors.
esterified.
In other areas of the world, the use of biodiesel that is
Fuel made of 100 percent FAME is normally referred BQ-9000 accredited and certified, or that is
to as B100 biodiesel or neat biodiesel. accredited and certified by a comparable biodiesel
quality body to meet similar biodiesel quality
Biodiesel can be blended with distillate diesel fuel. standards is required.
The blends can be used as fuel. The most commonly
available biodiesel blends are B5, which is 5 percent Engine Service Requirements with B20
biodiesel and 95 percent distillate diesel fuel. B20,
which is 20 percent biodiesel and 80 percent distillate
diesel fuel. Aggressive properties of biodiesel fuel may cause
debris in the fuel tank and fuel lines. The aggressive
Biodiesel blends are denoted as “BXX” with “XX” properties of biodiesel will clean the fuel tank and fuel
representing the content of neat biodiesel contained lines. This cleaning of the fuel system can
in the blend with mineral diesel fuel (for example B5, prematurely block of the fuel filters. Perkins
B10, B20). recommends that after the initial usage of B20
biodiesel blended fuel the fuel filters must be
Note: The percentages given are volume-based. The replaced at 50 hours.
U.S. distillate diesel fuel specification “ASTM D975-
09a” includes up to B5 (5 percent) biodiesel. Glycerides present in biodiesel fuel will also cause
fuel filters to become blocked more quickly. Therefore
European distillate diesel fuel specification the regular service interval should be reduced to 250
“EN590:2010” includes up B7 (7 percent) biodiesel. hours.
M0108133-05 61
Maintenance Section
General Fuel Information

When biodiesel fuel is used, crank case oil may be For standby generator sets and emergency vehicles
influenced. This influence is due to the chemical that cannot avoid use of biodiesel blends fuel quality
composition and characteristics of biodiesel fuel, in the engine fuel tank must be sampled and checked
such as density and volatility, and to chemical monthly. Test should include acid number
contaminants that can be present in this fuel, such as (“EN14104”), oxidation stability (“EN15751”
alkali and alkaline metals (sodium, potassium, commonly know as the Rancimant test), and
calcium, and magnesium). sediment (“ISO12937”). For standby generator sets
oxidation stability of biodiesel blend must be 20 hours
• Crankcase oil fuel dilution can be higher when or more as per EN 15751. If the test shows that the
biodiesel or biodiesel blends are used. This fuel has degraded, fuel tank must be drained and
increased level of fuel dilution when using engine flashed by running with the fresh high-quality
biodiesel or biodiesel blends is related to the diesel fuel.
typically lower volatility of biodiesel. In cylinder
emissions control strategies utilized in many of the For standby generator sets and emergency vehicles
industrial latest engine designs may lead to a that cannot avoid use of biodiesel blends fuel quality
higher level of biodiesel concentration in the in the engine fuel tank must be sampled and checked
monthly. Test should include acid number
engine oil pan. The long-term effect of biodiesel (“EN14104”), oxidation stability (“EN15751”
concentration in crankcase oil is unknown. commonly know as the Rancimant test), and
sediment (“ISO12937”). For standby generator sets
• Perkins recommends the use of oil analysis to
oxidation stability of biodiesel blend must be 20 hours
check the quality of the engine oil if biodiesel fuel or more as per “EN15751”. If the test shows that the
is used. Ensure that the level of biodiesel in the fuel has degraded, fuel tank must be drained and
fuel is noted when the oil sample is taken. engine flashed by running with fresh high-quality
diesel fuel.
Performance Related Issues with B20
Perkins strongly recommends that seasonally
Due to the lower energy content than the standard operated engines have the fuel systems, including
distillate fuel B20 will cause a power loss in order of 2 fuel tanks, flashed with conventional diesel fuel
to 4 percent. In addition, over time the power may before prolonged shutdown periods. An example of
deteriorate further due to deposits in the fuel an application that should seasonally flush the fuel
injectors. system is a combine harvester.
Biodiesel and biodiesel blends are known to cause Microbial contamination and growth can cause
an increase in fuel system deposits, most significant corrosion in the fuel system and premature plugging
of which are deposits within the fuel injector. of the fuel filter. Consult your supplier of fuel for
assistance in selecting appropriate antimicrobial
Perkins Diesel Fuel Cleaner T400012 is most additive.
effective in cleaning and preventing the formation of
deposits. Refer to section, Perkins Diesel Fuel Water accelerates microbial contamination and
System Cleaner for more information. Therefore the growth. When biodiesel is compared to distillate
use of Perkins Diesel Fuel Cleaner is recommended fuels, water is naturally more likely to exist in the
when running biodiesel blends, especially B20. biodiesel. Frequent checks are therefore essential
and if necessary, drain the water separator.
General Requirements
Materials such as brass, bronze, copper, led, tin, and
Biodiesel has poor oxidation stability, which can zinc accelerate the oxidation process of the biodiesel
result in long-term problems in the storage of fuel. The oxidation process can cause deposits
biodiesel. Biodiesel fuel should be used within 6 formation therefore these materials must not be used
months of manufacture. Equipment should not be for fuel tanks and fuel lines.
stored with the B20 biodiesel blends in the fuel
system for longer than 3 months. Fuel for Cold-Weather Operation
Due to poor oxidation stability and other potential
issues, Perkins recommends that engines with The European standard “EN590” contains climate
limited operational time either do not use biodiesel dependant requirements and a range of options. The
blends or, while accepting some risk, limit biodiesel options can be applied differently in each country.
blend to a maximum of B5. Examples of applications There are five classes that are given to arctic
that should limit the use of biodiesel are the following: climates and severe winter climates. 0, 1, 2, 3 and 4.
Standby generator sets and certain emergency Fuel that complies with “EN590” CLASS 4 can be
vehicles. used at temperatures as low as −44 °C (−47.2 °F).
Refer to “EN590” fora detailed discretion of the
physical properties of the fuel.
62 M0108133-05
Maintenance Section
General Fuel Information

The diesel fuel “ASTM D975 1-D” used in the United Perkins Diesel Fuel System Cleaner
States of America may be used in cold temperatures
that are below −18 °C (−0.4 °F). Perkins T400012 Fuel Cleaner is the only fuel
cleaner that is recommended by Perkins.
In extreme cold ambient conditions, you may use the
aviation kerosene fuels that are specified in Group 2. Perkins Diesel Fuel Cleaner (part number T400012)
These fuels are intended to be used in temperatures is the only fuel cleaner that is recommended by
that can be as low as −54 °C (−65.2 °F). Refer to Perkins.
Group 2 for detail and conditions of use of the
aviation kerosene fuels. If biodiesel or biodiesel blends of fuel are to be used,
Perkins require the use of Perkins fuel cleaner. For
more information on the use of biodiesel and
biodiesel blends refer to “Biodiesel Fuel”.
Mixing alcohol or gasoline with diesel fuel can Perkins fuel cleaner will remove deposits that can
produce an explosive mixture in the engine form in the fuel system with the use of biodiesel and
crankcase or the fuel tank. Alcohol or gasoline biodiesel blends. These deposits can create a loss of
must not be used in order to dilute diesel fuel. power and engine performance.
Failure to follow this instruction may result in
death or personal injury. Once the fuel cleaner has been added to the fuel, the
deposits within the fuel system are removed after 30
hours of engine operation. For maximum results,
There are many other diesel fuel specifications that continue to use the fuel cleaner for up to 80 hours.
are published by governments and by technological Perkins fuel cleaner can be used on an on-going
societies. Usually, those specifications do not review basis with no adverse impact on engine or fuel
all the requirements that are addressed in table 7 . To system durability.
ensure optimum engine performance, a complete
fuel analysis should be obtained before engine Detailed instructions on the rate of which the fuel
operation. The fuel analysis should include all the cleaner must be used, are on the container.
properties that are stated in the table 7 .
Contamination Control
Aftermarket Fuel Additives
Recommendations for Fuels
NOTICE Fuels of “ISO 18/16/13” cleanliness level or cleaner
Perkins does not warrant the quality or performance as dispensed into the engine or application fuel tank
of non-Perkins fluids and filters. should be used. This will reduce risk of power loss,
fuel system failures, and related down time of
When auxiliary devices, accessories, or consum- engines. This cleanliness level is important for new
ables (filters, additives) which are made by other fuel system designs such as common rail injection
manufacturers are used on Perkins products, the systems and unit injectors. These fuels systems
Perkins warranty is not affected simply because of utilize higher fuel injection pressures and have tight
such use. clearances between moving parts to meet required
stringent emissions regulations. Peak injection
However, failures that result from the installation pressures in current fuel injection systems may
or use of other manufacturers devices, accesso-
ries, or consumables are NOT Perkins defects. exceed 2000 bar (29000 psi). Clearances in these
Therefore, the defects are NOT covered under the systems are less than 5 μm. As a result, particle
Perkins warranty. contaminants as small as 4 μm can cause scoring
and scratching of internal pump and injector surfaces
Supplemental diesel fuel additives are not generally and of injector nozzles.
recommended, This recommendation is due to
potential damage to the fuel system or the engine. Water in the fuel causes cavitation, corrosion of fuel
system parts, and provides an environment where
Perkins recognizes the fact that additives may be microbial growth in the fuel can flourish. Other
required in some special circumstances. Fuel sources of fuel contamination are soaps, gels, or
additives must be used with caution. Contact your other compounds that may result from undesirable
fuel supplier for those circumstances when fuel chemical interactions in the fuels, particularly in
additives are required. Your fuel supplier can ULSD. Gels and other compounds can also form in
recommend the appropriate fuel additive and the biodiesel fuel at low temperatures or if biodiesel is
correct level of treatment. stored for extended periods. The best indication of
microbial contamination, fuel additives, or cold
Note: For the best results, your fuel supplier should temperature gel is rapid filter plugging of bulk fuel
treat the fuel when additives are required. The filters or application fuel filters.
treated fuel must meet the requirements that are
stated in table 7 . To reduce downtime due to contamination, follow
these fuel maintenance guidelines.
M0108133-05 63
Maintenance Section
Fluid Recommendations

• Use high-quality fuels per recommended and Consult your local Perkins distributor for additional
required specifications information on Perkins designed and produced
filtration products.
• Fill fuel tanks with fuels of “ISO 18/16/13”
cleanliness level or cleaner, in particular for Renewable and Alternative Fuels
engines with common rail and unit injection
systems. When you refuel the tank, filter the fuel Perkins supports development and use of renewable
through a 4 µm absolute filter (Beta 4 = 75 up to fuels through sustainability initiatives. In recent years
200) in order to reach the recommended various forms of renewable and alternative
cleanliness level. This filtration should be located (synthetic) diesel fuels have started to emerge.
at the device that dispenses the fuel to the fuel
tank. In addition, filtration at the dispensing point Synthetic diesel fuels are produced by gasification of
should remove water to ensure that fuel is various feedstock and then synthesis to liquid to
obtain paraffinic diesel fuel. Based on the feedstock
dispensed at 500 ppm water or less. used these fuels are commonly referred to as
• Perkins recommends the use of bulk fuel filter / Biomass to liquid (BTL), Gas to liquid (GTL) and Coal
to liquid (CTL). Hydrotreating of vegetable oils and
coalescer units which clean the fuel of both
animal fats is another emerging process for
particulate contamination and water in a single production of bio based diesel fuel called
pass. Hydrotreated Vegetable Oil (HVO).
• Ensure that you use Perkins Advanced Efficiency BTL and HVO fuels are considered to be low carbon
Fuel Filters. Change your fuel filters per fuels, as they reduce carbon foot print compared to
recommended service requirements or as needed. fossil fuels and are commonly referred to as
renewable fuels. These fuels must not be confused
• Drain your water separators daily. with biodiesel FAME which is fundamentally different
fuel and is discussed in a separate section in this
• Drain your fuel tanks of sediment and water per manual.
the Operation and Maintenance Manual
instructions. These paraffinic fuels have virtually no sulfur or
aromatics and have very high cetane numbers which
• Install and maintain a properly designed bulk filter enable very clean burning and efficient engine
/ coalescer filtration system. Continuous bulk operation. Chemically these fuels are similar to diesel
filtration systems may be required to ensure that fuel derived from petroleum and are therefore
suitable to use in diesel engines as a replacement or
dispensed fuel meets the cleanliness target.
blend stock with conventional diesel fuel. To be
Consult your Perkins distributor for availability of acceptable renewable and alternative fuels must
bulk filtration products. meet latest edition of the paraffinic diesel fuel
specification “CENTS 15940”. The fuel should also
• Centrifugal filters may need to be used as a pre- meet requirements described in table 7 , Perkins
filter with fuel that is severely contaminated with Specification for Distillate Diesel Fuel, EN590, or
gross amounts of water and/or large particulate latest ASTM D975 specification.
contaminants. Centrifugal filters can effectively
remove large contaminants. Centrifugal filters may Ensure that the fuel has got appropriate cold flow
not be able to remove the small abrasive particles properties (cloud point and CFPP) for the minimum
required to achieve the recommended “ISO” statistical ambient temperature the engine is
cleanliness level. Bulk filter / coalescers are expected to see in the operation. The Fuel must also
necessary as a final filter to achieve the meet lubricity requirements as specified in the
recommended cleanliness level. lubricity section of the “Operation and Maintenance
Manual” Fluid Recommendations
• Install desiccant type breathers of 4 µm or less
absolute efficiency with the ability to remove water i07911111
on bulk storage tanks.
Fluid Recommendations
• Follow proper practices of fuel transportation.
Filtration from the storage tank to the application
promotes the delivery of clean fuel. Fuel filtration
can be installed at each transport stage to keep General Coolant Information
the fuel clean.
• Cover, protect, and ensure cleanliness of all NOTICE
Never add coolant to an overheated engine. Engine
connection hoses, fittings, and dispensing
damage could result. Allow the engine to cool first.
nozzles.
64 M0108133-05
Maintenance Section
Fluid Recommendations

Table 8
NOTICE
If the engine is to be stored in, or shipped to an area Acceptable Water
with below freezing temperatures, the cooling system
must be either protected to the lowest outside tem- Property Maximum Limit
perature or drained completely to prevent damage.
Chloride (Cl) 40 mg/L

Sulfate (SO4) 100 mg/L

NOTICE
Frequently check the specific gravity of the coolant Total Hardness 170 mg/L
for proper freeze protection or for anti-boil protection. 340 mg/L
Total Solids
Clean the cooling system for the following reasons: Acidity pH of 5.5 to 9.0

• Contamination of the cooling system

For a water analysis, consult one of the following
• Overheating of the engine sources:

• Foaming of the coolant • Local water utility company

• Agricultural agent
NOTICE
Never operate an engine without water temperature • Independent laboratory
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob-
Additives
lems can develop without water temperature Additives help to protect the metal surfaces of the
regulators. cooling system. A lack of coolant additives or
insufficient amounts of additives enable the following
Many engine failures are related to the cooling conditions to occur:
system. The following problems are related to cooling
system failures: Overheating, leakage of the water • Corrosion
pump and plugged radiators or heat exchangers.
• Formation of mineral deposits
These failures can be avoided with correct cooling
system maintenance. Cooling system maintenance is • Rust
as important as maintenance of the fuel system and
• Scale
the lubrication system. Quality of the coolant is as
important as the quality of the fuel and the lubricating • Foaming of the coolant
oil.
Coolant is normally composed of three elements: Many additives are depleted during engine operation.
Water, additives, and glycol. These additives must be replaced periodically.
Additives must be added at the correct concentration.
Water Over concentration of additives can cause the
inhibitors to drop out-of-solution. The deposits can
enable the following problems to occur:
NOTICE
Never use water alone as coolant. Water alone is cor- • Formation of gel compounds
rosive and does not provide any protection against
boiling or freezing. • Reduction of heat transfer
Water is used in the cooling system to transfer heat. • Leakage of the water pump seal
Distilled water or deionized water is • Plugging of radiators, coolers, and small passages
recommended for use in engine cooling systems.
DO NOT use the following types of water in cooling Glycol
systems: Hard water, softened water that has been
conditioned with salt and sea water. Glycol in the coolant helps to provide protection
against the following conditions:
If distilled water or deionized water is not available,
use water with the properties that are listed in Table 8 • Boiling
.
• Freezing
M0108133-05 65
Maintenance Section
Fluid Recommendations

• Cavitation of the water pump • SCA Supplement Coolant Additive,

concentrated inorganic inhibitor package
For optimum performance, Perkins recommends a
50 percent by volume of glycol in the finished coolant • ASTM American Society for Testing and
(also referred to as 1:1 mixture). Materials
Note: Use a mixture that will provide protection • Conventional Coolant a coolant that relies
against the lowest ambient temperature. on inorganic inhibitors for corrosion and cavitation
protection
Note: 100 percent pure glycol will freeze at a
temperature of −13 °C (8.6 °F). • Hybrid Coolant a coolant in which the
corrosion and cavitation protection is based on a
Most conventional antifreezes use ethylene glycol. mixture of organic and inorganic inhibitors.
Propylene glycol may also be used. In a 1:1 mixture
with distilled or deionized water, ethylene and • Extender concentrated organic inhibitor
propylene glycol provide similar protection against package
freezing and boiling. Refer to Table 9 and refer to
table 10 .
Table 9
Coolant Recommendations
Ethylene Glycol The following three glycol-based coolants are
recommended for use in Perkins diesel engines:
Concentration Freeze Protection
−36 °C (−33 °F)
Preferred – Perkins ELC
50 Percent

60 Percent −51 °C (−60 °F)

Acceptable – A commercial heavy-duty antifreeze
that meets “ASTM D6210” specifications. Must be
replaced after 2 years.
NOTICE
Do not use propylene glycol in concentrations that
exceed 50 percent glycol because of the reduced Adequate – A commercial heavy-duty antifreeze that
heat transfer capability of propylene glycol. Use ethyl- meets “ASTM D4985” specifications. Must be
ene glycol in conditions that require additional protec- replaced after 1 year.
tion against boiling or freezing.

Table 10 NOTICE
The Perkins industrial engines must be operated
Propylene Glycol with a 1:1 (50 Percent) mixture of distilled or de-
ionized water and glycol. This concentration al-
Concentration Freeze Protection lows the NOx reduction system to operate
50 Percent −29 °C (−20 °F) correctly at high ambient temperatures.

Some commercially available coolants are based on

alternative fluids, such as 1, 3-propanediol (beta- NOTICE
Do not use a commercial coolant/antifreeze that only
propylene glycol, PDO), glycerin (glycerol), or meets the ASTM D3306 specification. This type of
mixtures of these alternatives with ethylene/ coolant/antifreeze is made for light automotive
propylene glycols. At the time of publication of this applications.
document no industry standard exists for coolants
based on these chemicals. Until such standard/
specifications are published and evaluated, use of
PDO, glycerine, or other alternative coolants are not NOTICE
recommended in Perkins engines. A commercial heavy-duty antifreeze that meets
“ASTM D4985” specification requires a treatment
To check the concentration of glycol in the coolant, with an SCA at the initial fill. Read the label or the in-
measure the specific gravity of the coolant. structions that are provided by the manufacturer of
the product.
Coolant Terminology
• ELC Extended Life Coolant. A coolant that NOTICE
A commercial heavy-duty antifreeze that meets either
relies on organic inhibitors for corrosion and “ASTM D4985” or “ASTM D6210” specification re-
cavitation protection. Also known as Organic Acid quires the SCA concentration to be checked at 500-
Technology (OAT) coolant. hour service intervals.
• ELI Extended Life Inhibitor
66 M0108133-05
Maintenance Section
Fluid Recommendations

Perkins recommends a 50 percent volume glycol and Containers of several sizes are available. Consult
distilled or deionized water of the correct your Perkins distributor for the part numbers.
specification. This mixture will provide optimum
performance as a coolant/antifreeze. ELC Cooling System Maintenance
Distilled or deionized water is preferred. Water which
has the recommended properties may be used. Correct additions to the Extended Life
Table 11 Coolant
Coolant Service Life
Required NOTICE
Coolant Type Service Life (1) Mixing Extended Life Coolant with other products re-
Maintenance
duces the Extended Life Coolant service life. Failure
Commercial to follow the recommendations can reduce cooling
Heavy-Duty Anti- 3000 Service Hours SCA at maintenance system components life unless appropriate corrective
freeze that meets or Two Years intervals action is performed.
“ASTM D6210”
Commercial
To maintain the correct balance between the
SCA at initial fill and antifreeze and the additives, you must maintain the
Heavy-Duty Anti- 3000 Service Hours
SCA at maintenance recommended concentration of ELC. Lowering the
freeze that meets or One Year
intervals proportion of antifreeze lowers the proportion of
“ASTM D4985”
additive. Lowering the ability of the coolant to protect
6,000 Service Hours the system will form pitting, from cavitation, from
Perkins ELC -
or Three Years erosion, and from deposits.
(1) Use the interval that occurs first. The cooling system must also
be flushed out at this time. These service lives can only be met NOTICE
if regular coolant sampling, analysis, and proper maintenance Do not use a conventional coolant to top-off a cooling
are carried out, with the engine in normal service. system that is filled with Extended Life Coolant
(ELC).
ELC
Do not use Supplemental Coolant Additive (SCA).
Perkins provides ELC for use in the following
applications: Do not use ELC in systems with SCA filters. When
switching from conventional coolant to ELC in a sys-
• Heavy-duty spark ignited gas engines tem equipped with SCA filter, remove the filter from
the system to prevent ELC contamination and filter
• Heavy-duty diesel engines corrosion and leaks.

• Automotive applications
ELC Cooling System Cleaning
The anti-corrosion package for ELC is different from
the anti-corrosion package for other coolants. ELC is Note: If the cooling system is already using ELC,
an ethylene glycol base coolant. However, ELC cleaning agents are not required to be used at the
contains organic corrosion inhibitors and antifoam specified coolant change interval. Cleaning agents
agents with low amounts of nitrite. Perkins ELC has are only required if the system has been
been formulated with the correct amount of these
additives to provide superior corrosion protection for contaminated by the addition of some other type of
all metals in engine cooling systems. coolant or by cooling system damage.

ELC is available in a premixed cooling solution with Distilled or deionized water is the only cleaning agent
distilled water. ELC is a 50 percent by volume of that is required when ELC is drained from the cooling
glycol mixture. The Premixed ELC provides freeze system.
protection to −36 °C (−33 °F). The Premixed ELC is
recommended for the initial fill of the cooling system. Before the cooling system is filled, the heater control
The Premixed ELC is also recommended for topping (if equipped) must be set to the HOT position. Refer
off the cooling system. to the OEM to set the heater control. After the cooling
system is drained and the cooling system is refilled,
operate the engine until the coolant level reaches the
normal operating temperature and until the coolant
level stabilizes. As needed, add the coolant mixture
to fill the system to the specified level.

Changing to Perkins ELC

To change from heavy-duty antifreeze to the Perkins
ELC, perform the following steps:
M0108133-05 67
Maintenance Section
Fluid Recommendations

9. Fill the cooling system with the Perkins Premixed

NOTICE
Care must be taken to ensure that all fluids are con- ELC.
tained during performance of inspection, mainte-
nance, testing, adjusting and the repair of the ELC Cooling System Contamination
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or disas-
sembling any component containing fluids. NOTICE
Mixing ELC with other products reduces the effective-
Dispose of all fluids according to local regulations ness of the ELC and shortens the ELC service life.
and mandates. Failure to follow these recommendations can result in
shortened cooling system component life.

1. Drain the coolant into a suitable container. Do not mix types and specifications of coolant.

2. Dispose of the coolant according to local Do not mix types and specifications of SCAs.
regulations.
ELC cooling systems can withstand contamination to
3. Flush the system with distilled or deionized water a maximum of 10 percent of conventional heavy-duty
to remove any debris. antifreeze or SCA. If the contamination exceeds 10
percent of the total system capacity, perform ONE of
4. Use an appropriate cleaner to clean the system. the following procedures:
Follow the instruction on the label.
• Drain the cooling system into a suitable container.
5. Drain the cleaner into a suitable container. Flush Dispose of the coolant according to local
the cooling system with distilled or deionized regulations. Flush the system with a 5 to 10
water. percent solution of Perkins ELC. Fill the system
with the Perkins ELC.
6. Fill the cooling system with distilled or deionized
water and operate the engine until the engine is • Maintain the system as a conventional Heavy-
warmed to 49° to 66°C (120° to 150°F). Duty Coolant. Treat the system with an SCA.
Change the coolant at the interval that is
NOTICE recommended for the conventional Heavy-Duty
Incorrect or incomplete flushing of the cooling system Coolant.
can result in damage to copper and other metal
components. Commercial Heavy-Duty Antifreeze and
To avoid damage to the cooling system, make sure
SCA
that the cooling system is completely flushed with dis-
tilled or deionized water. Continue to flush the system NOTICE
until all signs of the cleaning agent are gone. Commercial Heavy-Duty Coolant which contains
Amines as part of the corrosion protection system
Most commercial cooling system cleaning agents are must not be used.
corrosive and their use is not recommended by Per-
kins. If these agents have to be used to remove
heavy deposits, then they should not be left in the NOTICE
system any longer then recommended by the agent Never operate an engine without water temperature
manufacturer and engine temperature should not ex- regulators in the cooling system. Water temperature
ceed 30 oC. The system must be thoroughly flushed regulators help to maintain the engine coolant at the
with distilled or deionized water after use of these correct operating temperature. Cooling system prob-
cleaning agents. lems can develop without water temperature
regulators.
7. Drain the cooling system into a suitable container
Check the antifreeze (glycol concentration) to ensure
and flush the cooling system with distilled or adequate protection against boiling or freezing.
deionized water. Perkins recommends the use of a refractometer for
checking the glycol concentration. Do not use a
Note: The cooling system cleaner must be hydrometer.
thoroughly flushed from the cooling system. Cooling
system cleaner that is left in the system will
contaminate the coolant. The cleaner may also
corrode the cooling system.

8. Repeat Steps 6 and repeat steps 7 until the

system is completely clean.
68 M0108133-05
Maintenance Section
Fluid Recommendations

Table 14
NOTICE
Do not mix types and specifications of coolant. Equation for Adding the SCA to the Commercial Heavy-Duty
Coolant for Maintenance
Do not mix types and specifications of SCAs.
V × 0.023 = X
Do not mix SCAs and Extenders. V is the total volume of the cooling system.
Only use SCAs or Extender approved by coolant X is the amount of SCA that is required.
manufacturer and are compatible with coolant.
Table 15 is an example for using the equation that is
Perkins engine cooling systems should be tested at in Table 14 .
250 hour intervals for the concentration of SCA. Table 15

Additions of SCA are based on the results of the test. Example of the Equation for Adding the SCA to the Commer-
SCA that is liquid may be needed at 250 hour cial Heavy-Duty Coolant for Maintenance
intervals.
Total Volume of the Multiplication Amount of SCA
Cooling System (V) Factor that is Required
Adding the SCA to Heavy-Duty Coolant (X)
at the Initial Fill
15 L (4 US gal) × 0.023 0.35 L (11.7 oz)
Use the equation that is in Table 12 to determine the
amount of SCA that is required when the cooling
system is initially filled. Cleaning the System of Heavy-Duty
Antifreeze
Coolants that conform to “ASTM D4985” and do not
conform to “ASTM D6210” will require addition of Clean the cooling system for the following conditions.
SCA at initial fill.
Table 12 • Clean the cooling system after used coolant is
Equation For Adding The SCA To The Heavy-Duty Coolant At drained or before the cooling system is filled with
The Initial Fill new coolant
V × 0.07 = X • Clean the cooling system whenever the coolant is
V is the total volume of the cooling system. contaminated or whenever the coolant is foaming
X is the amount of SCA that is required. • The cooling system must be free from rust, scale,
and any deposits, before corrosion inhibitors can
Table 13 is an example for using the equation that is be effective
in Table 12 . To clean the cooling system of heavy-duty antifreeze,
Table 13 perform the following steps:
Example Of The Equation For Adding The SCA To The Heavy-
Duty Coolant At The Initial Fill
1. Drain the cooling system.

Total Volume of the Multiplication Amount of SCA 2. Fill the system with suitable distilled or deionized
Cooling System (V) Factor that is Required water.
(X)
NOTICE
15 L (4 US gal) × 0.07 1.05 L (35.5 oz) Most commercial cooling system cleaning agents are
corrosive and their use is not recommended by Per-
kins. If these cleaning agents have to be used to
Adding SCA to the Commercial Heavy- clean heavy deposits, then they should not be left in
Duty Coolant for Maintenance the system any longer then recommended by manu-
facturers. Also the engine temperature should not ex-
Heavy-duty antifreezes of all types require periodic ceed 30° C (86° F).
additions of SCA.
The system must be thoroughly flushed with distilled
Test the antifreeze periodically for the concentration or deionized water after use of cleaning agents.
of SCA.
Additions of SCA are based on the results of the test.
The size of the cooling system determines the
amount of SCA that is needed.
Use the equation that is in Table 14 to determine the
amount of SCA that is required, if necessary:
M0108133-05 69
Maintenance Section
Fluid Recommendations

NOTICE
Cleaning agents for industrial cooling system must
not be used. These cleaning agents are very aggres-
sive and cause damage to cooling system
components.

3. Dissolve a suitable cleaning agent in water: use

non-foaming detergent to clean oil contamination
or a cooling system cleaner to clean deposits.
Consult your Perkins dealer for suitable product.
4. Run the engine for approximately 30 minutes,
leave the engine to cool down, and drain the
system.
Illustration 32 g03580218
5. Take a sample of the solution from the system.
Typical API symbol
Allow the sample to sit for at least 30 minutes and
check for signs of oil or deposits. If contaminant is
still present repeat step 1 to step 4.
Terminology
6. Flush the system with distilled or deionized water. Certain abbreviations follow the nomenclature of
“SAE J754”. Some classifications follow “SAE J183”
7. Fill the system with new coolant. abbreviations, and some classifications follow the
“EMA Recommended Guideline on Diesel Engine
Oil”. In addition to Perkins definitions, there are other
i08153799 definitions that will be of assistance in purchasing
lubricants. Recommended oil viscosities can be
Fluid Recommendations found in this publication, “Fluid Recommendations/
Engine Oil Specification” topic (Maintenance
(Engine Oil Specification) Section).

Engine Oil
General Lubricant Information
Commercial Oils
Because of government regulations regarding the
certification of exhaust emissions from the engine,
the lubricant recommendations must be followed. NOTICE
Perkins require the use of the following specifica-
• API American Petroleum Institute tion of engine oil. Failure to use the appropriate
specification of engine oil will reduce the life of
• SAE Society Of Automotive Engineers Inc. your engine.

• ECF Engine Crankcase Fluid Table 16

Minimum Oil Specification for 904D-E28T and 904D-E36TA In-
Licensing dustrial Engine

The Engine Oil Licensing and Certification System by Minimum Oil API CH-4
specification ECF 1
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 Engines Operating on Biodiesel
authorized by API.
Refer to this Manual Fluid Recommendations, “Fuel
Specification” for the required service interval for
operating with biodiesel.
70 M0108133-05
Maintenance Section
Engine Oil Specification

Lubricant Viscosity Recommendations Aftermarket Oil Additives

for Direct Injection (DI) Diesel Engines Perkins does not recommend the use of aftermarket
additives in oil. It is not necessary to use aftermarket
The correct SAE viscosity grade of oil is determined additives to achieve the engines maximum service
by the minimum ambient temperature during cold life or rated performance. Fully formulated, finished
engine start-up, and the maximum ambient oils consist of base oils and of commercial additive
temperature during engine operation. packages. These additive packages are blended into
the base oils at precise percentages to help provide
Refer to illustration 33 (minimum temperature) to finished oils with performance characteristics that
determine the required oil viscosity for starting a cold meet industry standards.
engine.
There are no industry standard tests that evaluate
Refer to illustration 33 (maximum temperature) to the performance or the compatibility of aftermarket
select the oil viscosity for engine operation at the additives in finished oil. Aftermarket additives may
highest ambient temperature that is anticipated. not be compatible with the finished oils additive
package, which could lower the performance of the
Generally, use the highest oil viscosity that is finished oil. The aftermarket additive could fail to mix
available to meet the requirement for the temperature with the finished oil. This failure could produce sludge
at start-up. in the crankcase. Perkins discourages the use of
aftermarket additives in finished oils.
To achieve the best performance from a Perkins
engine, conform to the following guidelines:
• See the appropriate “Lubricant Viscosities”. Refer
to the illustration 33 to find the correct oil viscosity
grade for your engine.
• At the specified interval, service the engine. Use
new oil and install a new oil filter.
• Perform maintenance at the intervals that are
specified in the Operation and Maintenance
Manual, “Maintenance Interval Schedule or Fluid
Recommendations Fuel Specification”.

Oil analysis
Some engines may be equipped with an oil sampling
valve. If oil analysis is required, the oil sampling valve
is used to obtain samples of the engine oil. The oil
Illustration 33 g03347115 analysis will complement the preventive maintenance
program.
Lubricant Viscosities
Supplemental heat is recommended for cold soaked The oil analysis is a diagnostic tool that is used to
starts below the minimum ambient temperature. determine oil performance and component wear
Supplemental heat may be required for cold soaked rates. Contamination can be identified and measured
starts that are above the minimum temperature that by using oil analysis. The oil analysis includes the
is stated, depending on the parasitic load and other following tests:
factors. Cold soaked starts occur when the engine
has not been operated for aperiod of time. This • The Wear Rate Analysis monitors the wear of the
interval will allow the oil to become more viscous due engines metals. The amount of wear metal and
to cooler ambient temperatures. type of wear metal that is in the oil is analyzed.
The increase in the rate of engine wear metal in
the oil is as important as the quantity of engine
wear metal in the oil.
• Tests are conducted to detect contamination of the
oil by water, glycol, or fuel.
M0108133-05 71
Maintenance Section
Engine Oil Specification

• The Oil Condition Analysis determines the loss of

the oils lubricating properties. An infrared analysis
is used to compare the properties of new oil to the
properties of the used oil sample. This analysis
allows technicians to determine the amount of
deterioration of the oil during use. This analysis
also allows technicians to verify the performance
of the oil according to the specification during the
entire oil change interval.
72 M0108133-05
Maintenance Section
Maintenance Recommendations

Maintenance • The high-pressure fuel lines are constantly

charged with high pressure.
Recommendations • The internal pressures of the high-pressure fuel
lines are higher than other types of fuel system.
i07819420
Before any service or repair is performed on the
System Pressure Release engine fuel lines, perform the following tasks:
1. Stop the engine.
2. Wait for 10 minutes.
Coolant System
Do not loosen the high-pressure fuel lines to remove
air from the fuel system.

Pressurized system: Hot coolant can cause seri- Engine Oil

ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve To relieve pressure from the lubricating system, turn
the pressure. off the engine.

i07797442

Welding on Engines with

When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid person- Electronic Controls
al injury, always remain clear of the the engine
when the engine is in the AUTOMATIC mode.

The engine can have the ability to auto start. Ensure NOTICE
that the power supply is isolated before any service Because the strength of the frame may decrease,
or repair is performed. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your Perkins dealer regarding welding on a
off the engine. Allow the cooling system pressure cap chassis frame or rail.
to cool. Remove the cooling system pressure cap
slowly to relieve pressure. Correct welding procedures are necessary to avoid
damage to the engines ECM, sensors, and
associated components. When possible, remove the
Fuel System component from the unit and then weld the
component. If removal of the component is not
To relieve the pressure from the fuel system, turn off possible, the following procedure must be followed
the engine. when you weld on a unit equipped with an Electronic
Engine. The following procedure is considered to be
High-Pressure Fuel Lines the safest procedure to weld on a component. This
procedure should provide a minimum risk of damage
to electronic components.

NOTICE
Contact with high pressure fuel may cause fluid Do not ground the welder to electrical components
penetration and burn hazards. High pressure fuel such as the ECM or sensors. Improper grounding
spray may cause a fire hazard. Failure to follow can cause damage to the drive train bearings, hy-
these inspection, maintenance and service in- draulic components, electrical components, and oth-
structions may cause personal injury or death. er components.
The high-pressure fuel lines are the fuel lines that are Clamp the ground cable from the welder to the com-
between the high-pressure fuel pump and the high- ponent that will be welded. Place the clamp as close
pressure fuel manifold and the fuel lines that are as possible to the weld. This will help reduce the pos-
between the fuel manifold and the fuel injectors. sibility of damage.
The high-pressure fuel lines are different from fuel
lines on other fuel systems, the differences are as Note: Perform the welding in areas that are free from
follows: explosive hazards.
M0108133-05 73
Maintenance Section
Welding on Engines with Electronic Controls

1. Stop the engine. Turn the switched power to the

OFF position.
2. Ensure that the fuel supply to the engine is turned
off.
3. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
open the switch.
4. Disconnect all electronic components from the
wiring harnesses. Include the following
components:

• Electronic components for the driven

equipment

• ECM

• Sensors

• Electric operated fuel pump

Illustration 34 g06482096
• Electronically controlled valves
Use the example above. The current flow from the
• Relays welder to the ground clamp of the welder will not
damage any associated components.
(1) Engine
NOTICE (2) Welding electrode
Do not use electrical components (ECM or ECM sen- (3) Keyswitch in the OFF position
sors) or electronic component grounding points for (4) Battery disconnect switch in the open position
grounding the welder. (5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) The component that is being welded
(9) Current path of the welder
(10) Ground clamp for the welder

5. Connect the welding ground cable directly to the

part that will be welded. Place the ground cable as
close as possible to the weld to reduce the
possibility of welding current damage to the
following components. Bearings, hydraulic
components, electrical components, and ground
straps.
Note: If electrical/electronic components are used as
a ground for the welder, or electrical/electronic
components are located between the welder ground
and the weld, current flow from the welder could
severely damage the component.

6. Protect the wiring harness from welding debris and

spatter.
7. Use standard welding practices to weld the
materials.
74 M0108133-05
Maintenance Section
Severe Service Application

i07014325 Maintenance can be very difficult. The buildup can

contain corrosive chemicals.
Severe Service Application Buildup – Compounds, elements, corrosive
chemicals, and salt can damage some components.

Severe service is the application of an engine that Altitude – Problems can arise when the engine is
either exceeds the current published standards for operated at altitudes that are higher than the
that engine range. Or results in the engine being intended settings for that application. Necessary
used at the extremes of certain operating conditions. adjustments should be made.

• Performance such as power range, speed range,

and fuel consumption Incorrect Operating Procedures
• Fuel quality • Extended operation at low idle
• Operational Altitude • Frequent hot shutdowns
• Maintenance intervals • Operating at excessive loads
• Oil selection and maintenance • Operating at excessive speeds
• Coolant type and maintenance • Operating outside the intended application
• Environmental qualities
Incorrect Maintenance Procedures
• Installation
• Extending the maintenance intervals
• The temperature of the fluid in the engine
• Failure to use recommended fuel, lubricants, and
Refer to the standards for the engine or consult your coolant/antifreeze
Perkins distributor to determine if the engine is
operating within the defined parameters.
Severe service operation can accelerate component
wear. Engines that operate under severe conditions
may need more frequent maintenance intervals to
ensure maximum reliability and retention of full
service life.
Due to individual applications, identification is not
possible for all the factors which can contribute to
severe service operation. Consult your Perkins
distributor for the unique maintenance that is
necessary for the engine.
The operating environment, incorrect operating
procedures, and incorrect maintenance procedures
can be factors which contribute to a severe service
application.

Environmental Factors
Ambient temperatures – The engine may be
exposed to extended operation in extremely cold
environments or hot environments. Valve
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
cold temperatures. Extremely hot intake air reduces
engine performance.
Quality of the air – The engine may be exposed to
extended operation in an environment that is dirty or
dusty, unless the equipment is cleaned regularly.
Mud, dirt, and dust can encase components.
M0108133-05 75
Maintenance Section
Maintenance Interval Schedule

i08159141 “ Water Pump - Inspect“. . . . . . . . . . . . . . . . . . . . . 101

Maintenance Interval Schedule Every 2000 Service Hours

“ Aftercooler Core - Inspect“ . . . . . . . . . . . . . . . . . . 76
When Required “ Alternator - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . 76

“ Battery - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 76 “ Engine Mounts - Inspect“ . . . . . . . . . . . . . . . . . . . 87

“ Battery or Battery Cable - Disconnect“ . . . . . . . . . 77 “ Starting Motor - Inspect“ . . . . . . . . . . . . . . . . . . . . 99

“ Engine - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Every 3000 Service Hours

“ Engine Air Cleaner Element - Replace“ . . . . . . . . 85
“ Alternator and Fan Belts - Replace“ . . . . . . . . . . . 76
“ Engine Oil Sample - Obtain“ . . . . . . . . . . . . . . . . . 89
Every 3000 Service Hours or 2
“ Fuel System - Prime“ . . . . . . . . . . . . . . . . . . . . . . . 93
Years
Daily “ Coolant (Commercial Heavy-Duty) - Change“ . . . 79
“ Coolant Level - Check“ . . . . . . . . . . . . . . . . . . . . . 84
Every 4000 Service Hours
“ Driven Equipment - Check“ . . . . . . . . . . . . . . . . . . 84
“ Aftercooler Core - Clean/Test“ . . . . . . . . . . . . . . . 76
“ Engine Air Cleaner Service Indicator - Inspect“ . . 86
“ Engine Air Precleaner - Check/Clean“ . . . . . . . . . 87 Every 4500 Service Hours
“ Engine Oil Level - Check“ . . . . . . . . . . . . . . . . . . . 87 “ Turbocharger - Inspect“ . . . . . . . . . . . . . . . . . . . . . 99
“ Fuel System Primary Filter/Water Separator -
Drain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Every 6000 Service Hours or 3
Years
“ Walk-Around Inspection“ . . . . . . . . . . . . . . . . . . . 100
“ Coolant (ELC) - Change“. . . . . . . . . . . . . . . . . . . . 82
Every Week
“ Hoses and Clamps - Inspect/Replace“. . . . . . . . . 98

Every 50 Service Hours

“ Fuel Tank Water and Sediment - Drain“ . . . . . . . . 97

Every 500 Service Hours or 1 Year

“ Battery Electrolyte Level - Check“ . . . . . . . . . . . . 77
“ Engine Air Cleaner Element - Replace“ . . . . . . . . 85
“ Engine Oil and Filter - Change“. . . . . . . . . . . . . . . 89
“ Fuel System Primary Filter (Water Separator)
Element - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 94
“ Fuel System Secondary Filter - Replace“. . . . . . . 96

Every 1000 Service Hours

“ Belt - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
“ Belt Tensioner - Check“ . . . . . . . . . . . . . . . . . . . . . 78
76 M0108133-05
Maintenance Section
Aftercooler Core - Clean/Test

i01807350 i02322311

Aftercooler Core - Clean/Test Alternator - Inspect

(Air-To-Air Aftercooler)
Perkins recommends a scheduled inspection of the
alternator. Inspect the alternator for loose
The air-to-air aftercooler is OEM installed in many connections and correct battery charging. Check the
applications. Please refer to the OEM specifications ammeter (if equipped) during engine operation in
for information that is related to the aftercooler. order to ensure correct battery performance and/or
correct performance of the electrical system. Make
i02322295 repairs, as required.

Aftercooler Core - Inspect Check the alternator and the battery charger for
correct operation. If the batteries are correctly
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
Note: Adjust the frequency of cleaning according to batteries should be kept warm because temperature
the effects of the operating environment. affects the cranking power. If the battery is too cold,
the battery will not crank the engine. When the
Inspect the aftercooler for these items: damaged fins, engine is not run for long periods of time or if the
corrosion, dirt, grease, insects, leaves, oil and other engine is run for short periods, the batteries may not
debris. Clean the aftercooler, if necessary. fully charge. A battery with a low charge will freeze
more easily than a battery with a full charge.
For air-to-air aftercoolers, use the same methods that
are used for cleaning radiators.
i02680137

Alternator and Fan Belts -

Personal injury can result from air pressure. Replace
Personal injury can result without following prop-
er procedure. When using pressure air, wear a
Refer to Disassembly and Assembly Manual , “
protective face shield and protective clothing.
Alternator Belt - Remove and Install”.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes. i07926258

After cleaning, start the engine and accelerate the

Battery - Replace
engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine. Use
a light bulb behind the core in order to inspect the
core for cleanliness. Repeat the cleaning, if
necessary.
Batteries give off combustible gases which can
Inspect the fins for damage. Bent fins may be opened explode. A spark can cause the combustible
with a “comb”. gases to ignite. This can result in severe personal
injury or death.
Note: If parts of the aftercooler system are repaired
or replaced, a leak test is highly recommended. Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
Inspect these items for good condition: Welds, der to help prevent electrical arcs and/or sparks
mounting brackets, air lines, connections, clamps near batteries. Do not smoke when batteries are
serviced.
and seals. Make repairs, if necessary.
M0108133-05 77
Maintenance Section
Battery Electrolyte Level - Check

The battery cables or the batteries should not be All lead-acid batteries contain sulfuric acid which
removed with the battery cover in place. The bat- can burn the skin and clothing. Always wear a
tery cover should be removed before any servic- face shield and protective clothing when working
ing is attempted. on or near batteries.

Removing the battery cables or the batteries with

the cover in place may cause a battery explosion 1. Remove the filler caps. Maintain the electrolyte
resulting in personal injury. level to the “FULL” mark on the battery.
If the addition of water is necessary, use distilled
1. Switch the engine to the OFF position. Remove all water. If distilled water is not available use clean
electrical loads. water that is low in minerals. Do not use artificially
softened water.
2. Turn off any battery chargers. Disconnect any
battery chargers. 2. Check the condition of the electrolyte with a
suitable battery tester.
3. Ensure that the battery disconnect switch is in the
OFF position. 3. Install the caps.
4. Disconnect the NEGATIVE “-” cable from the 4. Keep the batteries clean.
NEGATIVE “-” battery terminal.
Clean the battery case with one of the following
5. Disconnect the POSITIVE “+” cable from the cleaning solutions:
POSITIVE “+” battery terminal.
• Use a solution of 0.1 kg (0.2 lb) baking soda
Note: Always recycle a battery. Never discard a and 1 L (1 qt) of clean water.
battery. Dispose of used batteries to an appropriate
recycling facility. • Use a solution of ammonium hydroxide.

6. Remove the used battery. Thoroughly rinse the battery case with clean
water.
7. Install the new battery.
Note: Before the cables are connected, ensure that i07926262
the battery disconnect switch is in the OFF position.
Battery or Battery Cable -
8. Connect the POSITIVE “+” cable to the POSITIVE
“+” battery terminal.
Disconnect
9. Connect the NEGATIVE “-” cable to the
NEGATIVE “-” battery terminal.
10. Turn the battery disconnect switch to the ON
position. The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
i02747977
ing is attempted.
Battery Electrolyte Level - Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
Check resulting in personal injury.

When the engine is not run for long periods of time or 1. Turn the start switch to the OFF position. Turn the
when the engine is run for short periods, the batteries ignition switch (if equipped) to the OFF position
may not fully recharge. Ensure a full charge in order and remove the key and all electrical loads.
to help prevent the battery from freezing. If batteries
are correctly charged, the ammeter reading should 2. Disconnect the negative battery terminal. Ensure
be very near zero, when the engine is in operation. that the cable cannot contact the terminal. When
four 12 V batteries are involved, 2 negative
connections must be disconnected.
3. Remove the positive connection.
78 M0108133-05
Maintenance Section
Belt - Inspect

4. Clean all disconnected connection and battery • More than one section of the belt is displaced in
terminals. one rib of a maximum length of 50.8 mm (2 inch).
5. Use a fine grade of sandpaper to clean the To replace the belt, refer to Disassembly and
terminals and the cable clamps. Clean the items Assembly, “Alternator Belt - Remove and Install”. If
until the surfaces are bright or shiny. DO NOT necessary, replace the belt tensioner. Refer to
remove material excessively. Excessive removal Disassembly and Assembly, “Alternator Belt -
Remove and Install” for the correct procedure.
of material can cause the clamps to fit incorrectly.
Coat the clamps and the terminals with a suitable
i07382084
silicone lubricant or petroleum jelly.
6. Tape the cable connections to help prevent Belt Tensioner - Check
accidental starting.
7. Proceed with necessary system repairs.
8. When connecting the battery, connect the positive
connection before the negative connector.

i07380538

Belt - Inspect

Illustration 36 g06302365
Typical example

1. Remove the belt. Refer to Disassembly and

Assembly, “Alternator Belt - Remove and Install”.
2. Ensure that the belt tensioner (2) is securely
installed. Visually inspect the belt tensioner for
damage. Check that the pulley on the tensioner
Illustration 35 g06301080 rotates freely and that the bearing is not loose.
Typical example 3. Some engines have an idler pulley (2). Ensure that
the idler pulley is securely installed. Visually
To maximize the engine performance, inspect the inspect the idler pulley for damage. Ensure that
belt (1) for wear and for cracking. Replace the belt if
the belt is worn or damaged. the idler pulley can rotate freely and that the
bearing is not loose.
• Inspect the belt for cracks, splits, glazing, grease,
displacement of the cord and evidence of fluid
contamination.
The belt must be replaced if the following conditions
are present.

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

M0108133-05 79
Maintenance Section
Coolant (Commercial Heavy-Duty) - Change

• The fuel has entered the cooling system and the

coolant is contaminated.

NOTICE
When any servicing or repair of the engine cooling
system is performed, the procedure must be per-
formed with the engine on level ground. Level ground
will allow you to check accurately the coolant level.
This procedure will also help in avoiding the risk of in-
troducing an air lock into the coolant system.

Note: Inspect the water pump and the water

temperature regulator after the cooling system has
been drained. This inspection is a good opportunity
to replace the water pump, the water temperature
regulator, and the hoses, if necessary.

Drain

Illustration 37 g06302436
Pressurized System: Hot coolant can cause seri-
Typical example ous burns. To open the cooling system filler cap,
(A) Tensioner stop stop the engine and wait until the cooling system
(3) Tensioner body stop components are cool. Loosen the cooling system
(B) Tensioner stop pressure cap slowly in order to relieve the
pressure.
4. Ensure that the tensioner has full movement of
travel from stop (A) the other stop (B). Using a
1. Stop the engine and allow the engine to cool.
constant force the tensioner should move
Loosen the cooling system filler cap slowly to
smoothly between the tensioner stop and the
relieve any pressure. Remove the cooling system
tensioner body stop.
filler cap.
5. If necessary, replace damaged components.
Note: Refer to Operation and Maintenance Manual,
Install the belt. Refer to Disassembly and Assembly, “General Hazard Information” for information on
“Alternator Belt - Remove and Install”. Containing Fluid Spillage.

i07383167

Coolant (Commercial Heavy-

Duty) - Change

Note: This procedure is for coolants that meets a

commercial heavy-duty coolant specification of
“ASTM D6210” .
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and the

coolant is contaminated.
80 M0108133-05
Maintenance Section
Coolant (Commercial Heavy-Duty) - Change

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

of 30 minutes. The coolant temperature should be
at least 82 °C (180 °F).

NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal
components.
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water.
Continue to flush the system until all signs of the
cleaning agent are gone.

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

Loosen the cooling system filler cap slowly to
relieve any pressure. Remove the cooling system
filler cap. Remove the connection hose or remove
the cooling system drain plugs. Allow the water to
drain. Flush the cooling system with clean water.
Install the connection hose.
Illustration 38 g06302798
6. Install the drain plugs and tighten securely.
Typical example

2. Remove drain plug (1) on the engine. Open the Fill

drain cock or remove the drain plug on the
radiator. NOTICE
Do not fill the cooling system faster than 5 L
Allow the coolant to drain into a suitable container. (1.3 US gal) per minute to avoid air locks.
3. Properly dispose of the drained material. Obey Cooling system air locks may result in engine
local regulations for the disposal of the material. damage.

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

Refer to this Operation and Maintenance Manual,
NOTICE “Refill Capacities and Recommendations” topic
Cleaning agents for an industrial cooling system must (Maintenance Section) for more information on
not be used. These cleaning agents are very aggres-
sive and cause damage to the cooling system cooling system specifications. Do not install the
components. cooling system filler cap.
2. Start and run the engine at low idle. Increase the
1. Flush the cooling system with clean water and a engine rpm to high idle. Operate the engine to
suitable cleaning agent to remove any debris. open the engine thermostat. This operation will
Refer to your Perkins dealer or distributor for allow any air in the system to be purged. Decrease
suitable cleaning agents. the engine speed to low idle. Stop the engine.
2. Clean the drain plugs. Install the drain plugs. 3. Maintain the coolant level at the maximum mark
Tighten drain plug securely. that is correct for your application.
4. Clean the cooling system filler cap. Inspect the
NOTICE
Do not fill the cooling system faster than 5 L gasket that is on the cooling system filler cap. If
(1.3 US gal) per minute to avoid air locks. the gasket that is on the cooling system filler cap is
damaged, discard the old cooling system filler cap
Cooling system air locks may result in engine and install a new cooling system filler cap. If the
damage. gasket that is on the cooling system filler cap is not
damaged, perform a pressure test. If the cooling
3. Fill the cooling system with clean water and install system filler cap does not retain the correct
the cooling system filler cap. pressure, install a new cooling system filler cap.
M0108133-05 81
Maintenance Section
Coolant (Commercial Heavy-Duty) - Change

5. Start the engine. Inspect the cooling system for Note: Refer to Operation and Maintenance Manual,
leaks and for the correct operating temperature. “General Hazard Information” for information on
Containing Fluid Spillage.
i07676418

Coolant (Commercial Heavy-

Duty) - Change

Note: This procedure is for coolants that meets a

commercial heavy-duty coolant specification of
“ASTM D4985” .
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• The oil has entered the cooling system and the

coolant is contaminated.

• The fuel has entered the cooling system and the

coolant is contaminated. Illustration 39 g06302798
Typical example
NOTICE
When any servicing or repair of the engine cooling
system is performed, the procedure must be per- 2. Remove drain plug (1) on the engine. Open the
formed with the engine on level ground. Level ground drain cock or remove the drain plug on the
will allow you to check accurately the coolant level. radiator.
This procedure will also help in avoiding the risk of in-
troducing an air lock into the coolant system. Allow the coolant to drain into a suitable container.
3. Properly dispose of the drained material. Obey
Note: Inspect the water pump and the water local regulations for the disposal of the material.
temperature regulator after the cooling system has
been drained. This inspection is a good opportunity Flush
to replace the water pump, the water temperature
regulator, and the hoses, if necessary. NOTICE
Cleaning agents for an industrial cooling system must
Drain not be used. These cleaning agents are very aggres-
sive and cause damage to the cooling system
components.

Pressurized System: Hot coolant can cause seri- 1. Flush the cooling system with clean water and a
ous burns. To open the cooling system filler cap, suitable cleaning agent to remove any debris.
stop the engine and wait until the cooling system Refer to your Perkins dealer or distributor for
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the suitable cleaning agents.
pressure. 2. Clean the drain plugs. Install the drain plugs.
Tighten drain plug securely.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly to NOTICE
relieve any pressure. Remove the cooling system Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
filler cap.
Cooling system air locks may result in engine
damage.
82 M0108133-05
Maintenance Section
Coolant (ELC) - Change

3. Fill the cooling system with clean water and install 4. Clean the cooling system filler cap. Inspect the
the cooling system filler cap. gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap is
4. Start and run the engine at low idle for a minimum
damaged, discard the old cooling system filler cap
of 30 minutes. The coolant temperature should be
and install a new cooling system filler cap. If the
at least 82 °C (180 °F).
gasket that is on the cooling system filler cap is not
damaged, perform a pressure test. If the cooling
NOTICE
Improper or incomplete rinsing of the cooling system system filler cap does not retain the correct
can result in damage to copper and other metal pressure, install a new cooling system filler cap.
components.
5. Start the engine. Inspect the cooling system for
To avoid damage to the cooling system, make sure to leaks and for the correct operating temperature.
completely flush the cooling system with clear water.
Continue to flush the system until all signs of the i07383181
cleaning agent are gone.
Coolant (ELC) - Change
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly to
relieve any pressure. Remove the cooling system Clean the cooling system and flush the cooling
filler cap. Remove the connection hose or remove system before the recommended maintenance
the cooling system drain plugs. Allow the water to interval if the following conditions exist:
drain. Flush the cooling system with clean water. • The engine overheats frequently.
Install the connection hose.
• Foaming is observed.
6. Install the drain plugs and tighten securely.
• The oil has entered the cooling system and the
Fill coolant is contaminated.
• The fuel has entered the cooling system and the
NOTICE coolant is contaminated.
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks. Note: Use non-foaming detergent to clean oil or fuel
Cooling system air locks may result in engine contamination.
damage.
Note: When the cooling system is cleaned, only
clean water is needed when the ELC is drained and
1. Fill the cooling system with the coolant/antifreeze. replaced.
Refer to this Operation and Maintenance Manual,
Note: Inspect the water pump and the water
“Refill Capacities and Recommendations” topic
temperature regulator after the cooling system has
(Maintenance Section) for more information on been drained. Replace the water pump, the water
cooling system specifications. Do not install the temperature regulator, and the hoses, if necessary.
cooling system filler cap.
2. Start and run the engine at low idle. Increase the NOTICE
engine rpm to high idle. Operate the engine to Service or repair of the engine cooling system must
be performed on level ground. The engine must be
open the engine thermostat. This operation will level to check the coolant level. The engine must be
allow any air in the system to be purged. Decrease level to avoid the risk of introducing an air lock into
the engine speed to low idle. Stop the engine. the coolant system.
3. Maintain the coolant level at the maximum mark
that is correct for your application.
M0108133-05 83
Maintenance Section
Coolant (ELC) - Change

Drain 2. Install the connection hose. Clean the drain plugs

and install the drain plugs. Tighten the drain plugs
securely.

Pressurized System: Hot coolant can cause seri- NOTICE

ous burns. To open the cooling system filler cap, Do not fill the cooling system faster than 5 L
stop the engine and wait until the cooling system (1.3 US gal) per minute to avoid air locks.
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the Cooling system air locks may result in engine
pressure. damage.

1. Stop the engine and allow the engine to cool. 3. Fill the cooling system with distilled or deionized
Loosen the cooling system filler cap slowly to water. Install the cooling system filler cap.
relieve any pressure. Remove the cooling system 4. Start and run the engine at low idle until the
filler cap. temperature reaches 50° to 70°C (122° to 158°F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly to
relieve any pressure. Remove the cooling system
filler cap. Remove the connection hose and
remove the cooling system drain plugs. Allow the
water to drain. Flush the cooling system with clean
water. Install the connection hose.
6. Install the drain plugs and securely.

Fill
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Cooling system air locks may result in engine
damage.

1. Fill the cooling system with Extended Life Coolant

Illustration 40 g06302798 (ELC). Refer to this Operation and Maintenance
Typical example Manual, “Refill Capacities” topic (Maintenance
Section) for more information on cooling system
2. Remove drain plug (1) on the engine. Open the specifications. Do not install the cooling system
drain cock or remove the drain plug on the radiator filler cap.
and allow the coolant to drain. 2. Start and run the engine at low idle. Increase the
For information regarding the disposal and the engine rpm to high idle. Operate the engine to
recycling of used coolant, consult your Perkins dealer open the engine thermostat. An open thermostat
or Perkins distributor. will allow any air in the system to be purged.
Decrease the engine speed to low idle. Stop the
Flush engine.
3. Maintain the coolant level at the maximum mark
NOTICE that is correct for your application.
Cleaning agents for an industrial cooling system must
not be used. These cleaning agents are very aggres-
sive and cause damage to the cooling system
components.

1. Flush the cooling system with distilled or deionized

water to remove any debris.
84 M0108133-05
Maintenance Section
Coolant Level - Check

4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap is
damaged, discard the old cooling system filler cap
and install a new cooling system filler cap. If the
gasket that is on the cooling system filler cap is not
damaged, pressure test the cooling system filler
cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
cooling system filler cap.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.

i07925186

Coolant Level - Check

Illustration 41 g02590196
Typical filler cap gaskets

Pressurized System: Hot coolant can cause seri- 3. Clean the cooling system filler cap and check the
ous burns. To open the cooling system filler cap, condition of the filler cap gaskets. Replace the
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system cooling system filler cap if the filler cap gaskets are
pressure cap slowly in order to relieve the damaged. Reinstall the cooling system filler cap.
pressure.
4. Inspect the cooling system for leaks.
Check the coolant level when the engine is stopped
and cool. i02151646

NOTICE Driven Equipment - Check

When any servicing or repair of the engine cooling
system is performed, the procedure must be per-
formed with the engine on level ground. This proce-
dure will allow you to check accurately the coolant Refer to the OEM specifications for more information
level. This procedure will also help in avoiding the risk on the following maintenance recommendations for
of introducing an air lock into the coolant system. the driven equipment:
• Inspection
1. Remove the cooling system filler cap slowly to
• Adjustment
relieve pressure.
2. Maintain the coolant level at the maximum mark • Lubrication
that is correct for your application. If the engine is • Other maintenance recommendations
equipped with a sight glass, maintain the coolant
level to the correct level in the sight glass. Perform any maintenance for the driven equipment
which is recommended by the OEM.
M0108133-05 85
Maintenance Section
Engine - Clean

i07926240 i08154921

Engine - Clean Engine Air Cleaner Element -

Replace

Personal injury or death can result from high NOTICE

voltage. Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
Moisture can create paths of electrical cleaner element. Do not use air cleaner elements
conductivity. with damaged pleats, gaskets or seals. Dirt entering
the engine causes premature wear and damage to
Make sure that the electrical system is OFF. Lock engine components. Air cleaner elements help to pre-
out the starting controls and tag the controls “ DO vent airborne debris from entering the air inlet.
NOT OPERATE”” .

NOTICE
NOTICE Never service the air cleaner element with the engine
Accumulated grease and oil on an engine is a fire running since this will allow dirt to enter the engine.
hazard. Keep the engine clean. Remove debris and
fluid spills whenever a significant quantity accumu-
lates on the engine. Servicing the Air Cleaner Elements
Periodic cleaning of the engine is recommended. Note: The air filter system may not have been
Steam cleaning the engine will remove accumulated
provided by Perkins. The procedure that follows, is
oil and grease. A clean engine provides the following
benefits: for a typical air filter system. Refer to the OEM
information for the correct procedure.
• Easy detection of fluid leaks
If the air cleaner element becomes plugged, the air
• Maximum heat transfer characteristics can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal
• Ease of maintenance engine wear. Refer to the OEM information for the
correct air cleaner elements for your application.
Note: Caution must be used to prevent electrical
components from being damaged by excessive water • Check the pre-cleaner (if equipped) and the dust
when the engine is cleaned. Pressure washers and bowl daily for accumulation of dirt and debris.
steam cleaners should not be directed at any Remove any dirt and debris, as needed.
electrical connectors or the junction of cables into the • Operating in dirty conditions may require more
rear of the connectors. Avoid electrical components frequent service of the air cleaner element.
such as the alternator, the starter, and the ECM.
Protect the fuel injection pump from fluids to wash the • The air cleaner element should be replaced at
engine. least one time per year.
Ensure that care is taken that the safety labels, Replace the dirty air cleaner elements with clean air
emission label, and all other information labels are cleaner elements. Before installation, the new air
not removed during engine cleaning. cleaner elements should be thoroughly checked for
tears and/or holes in the filter material. Inspect the
gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner
elements for replacement purposes.

Air Cleaners
Some application can have dual elements. The dual
air cleaner contains a primary air cleaner element
and a secondary air cleaner element. Both element
must be replaced at the same time.
Do not replace the air cleaner filter elements in a dirty
environment, as dirt can enter the air system when
the elements are removed.
86 M0108133-05
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect

6. Install end cover (4) to air cleaner body (2) and

secure end cover. If necessary, reset the air
service indicator, refer to this Operation and
Maintenance Manual, Engine Air Cleaner Service
Indicator - Inspect for more information.

i02335405

Engine Air Cleaner Service

Indicator - Inspect

Some engines may be equipped with a different

service indicator.
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner element or in a remote location.
Illustration 42 g06217098
Typical example
(1) Top Cover
(2) Air Cleaner Body
(3) Primary Air Filter Element
(4) End Cover
(5) Vacuum Valve

1. Ensure that the outer body of the air cleaner to be

serviced is clean and free from dirt.
2. Inspect the top cover (1) and if necessary remove
top cover to clean cover. Ensure that dirt cannot
enter the air cleaner system with top cover
removed. If necessary, clean top cover and install.
Illustration 43 g00103777
3. Remove end cover (4) from air cleaner body (2). If
Typical service indicator
necessary, clean end cover and ensure that the
vacuum valve (5) is clean and free from dirt. Observe the service indicator. The air cleaner
Check the vacuum valve (5) for wear or damage, element should be cleaned or the air cleaner element
replace if necessary. should be replaced when one of the following
conditions occur:
4. Remove primary air filter element (3) and if
equipped, remove the secondary air filter element • The yellow diaphragm enters the red zone.
(Not Shown). Discard all old air filter elements.
• The red piston locks in the visible position.
5. If equipped, install new secondary air filter element
(Not Shown) and install new primary air filter Test the Service Indicator
element (3).
Service indicators are important instruments.

• Check for ease of resetting. The service indicator

should reset in less than three pushes.
M0108133-05 87
Maintenance Section
Engine Air Precleaner - Check/Clean

• Check the movement of the yellow core when the i07819538

engine is accelerated to the engine rated speed.
The yellow core should latch at the greatest Engine Mounts - Inspect
vacuum that is attained.
If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum, Note: The engine mounts may not have been
the service indicator should be replaced. If the new supplied by Perkins. Refer to the Original Equipment
service indicator will not reset, the hole for the service Manufacturer (OEM) information for further details on
indicator may be restricted. the engine mounts and the correct bolt torque.
The service indicator may need to be replaced Inspect the engine mounts for deterioration and for
frequently in environments that are severely dusty. correct bolt torque. Excessive engine vibration can
be caused by the following conditions:
i07819526
• Incorrect mounting of the engine
Engine Air Precleaner - Check/ • Deterioration of the engine mounts
Clean
• Loose engine mounts
Any engine mount that shows deterioration should be
replaced. Refer to the OEM information for the
recommended torques.
When the engine mounts are supplied by Perkins the
maintenance procedure will be supplied in the
Disassembly and Assembly manual for your engine.

i08055063

Engine Oil Level - Check

Illustration 44 g01453058 Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
Typical engine air precleaner contact the skin.
(1) Wing nut
(2) Cover
(3) Body
NOTICE
Remove wing nut (1) and cover (2). Check for an Perform this maintenance with the engine stopped.
accumulation of dirt and debris in body (3). Clean the
body, if necessary.
Note: Ensure that the engine is either level or that
After cleaning the precleaner, install cover (2) and the engine is in the normal operating position to
wing nut (1). obtain a true level indication.

Note: When the engine is operated in dusty NOTICE

conditions, more frequent cleaning is required. Do not overfill the crankcase. Engine damage can
result.
Do not tap or strike the air cleaner element.
88 M0108133-05
Maintenance Section
Engine Oil Level - Check

Before Operating the Engine 4. If necessary, drain a small quantity of oil from the
crankcase to reduce the oil level. The oil level
needs to be between the mark (L) and the mark
(H) before operating the engine. Refer to the
“Operation and Maintenance Manual”, Engine Oil
and Filter – Change, “Drain the Engine Lubricating
Oil” for more information.

After Operating the Engine

Illustration 45 g06525971
Note: Before checking the oil level, the engine must
Typical example of type 2 oil level gauge (dipstick) have been switched off for a minimum of 30 minutes
(L) Low to allow the oil to drain down to the crankcase.
(H) High
(A) Crosshatched area
(B) Warning symbol

Illustration 47 g06553532
Typical example of type 2 oil level gauge (dipstick)
Illustration 46 g06551003 (L) Low
(H) High
Typical example of type 1 oil level gauge (dipstick)
(L) Low
(H) High

1. Maintain the oil level between the mark (L) and the
mark (H) on the engine oil level gauge (dipstick).
Do not fill the crankcase above the (H).

NOTICE
The oil level checked that falls in the crosshatched (
Illustration 48 g06551003
Position “A” ) area between the (H) and below the
warning triangle ( Position “B” ) is safe for engine Typical example of type 1 oil level gauge (dipstick)
operation. (L) Low
(H) High
Operating your engine when the oil level is the in
warning triangle area ( Position “B” ) above cross- 1. Check the oil level and maintain the oil level
hatched section ( Position “A” ) could cause your
crankshaft to dip into the oil. The air bubbles created between the mark (L) and the mark (H) on the
from the crankshaft dipping into the oil reduces the engine oil level gauge (dipstick). Do not fill the
oils lubricating characteristics and could result in the crankcase above the mark (H).
loss of power.
2. If necessary, remove the oil filler cap and add oil.

2. Remove the oil filler cap and add oil, if necessary. Note: When the oil level is shown to be at the (L)
mark, 1 L (0.3 US gal) of oil added will bring up the
3. Clean the oil filler cap. Install the oil filler cap. oil level within the (L) and (H) marks.

3. Clean the oil filler cap and install the oil filler cap.
M0108133-05 89
Maintenance Section
Engine Oil Sample - Obtain

If an increase in the oil level is noticed, refer to The sample can be checked for the following: the
Troubleshooting, “Oil Contains Fuel”. quality of the oil, the existence of any coolant in the
oil, the existence of any ferrous metal particles in the
i01907674 oil and the existence of any nonferrous metal
particles in the oil.
Engine Oil Sample - Obtain
i08154951

The condition of the engine lubricating oil may be Engine Oil and Filter - Change
checked at regular intervals as part of a preventive
maintenance program. Perkins include an oil
sampling valve as an option. The oil sampling valve
(if equipped) is included in order to regularly sample
the engine lubricating oil. The oil sampling valve is
positioned on the oil filter head or the oil sampling Hot oil and hot components can cause personal
valve is positioned on the cylinder block. injury. Do not allow hot oil or hot components to
contact the skin.
Perkins recommends using a sampling valve in order
to obtain oil samples. The quality and the consistency
of the samples are better when a sampling valve is NOTICE
used. The location of the sampling valve allows oil Care must be taken to ensure that fluids are con-
that is flowing under pressure to be obtained during tained during performance of inspection, mainte-
normal engine operation. nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
Obtain the Sample and the bling any component containing fluids.
Analysis
Dispose of all fluids according to local regulations
and mandates.

Hot oil and hot components can cause personal NOTICE

injury. Do not allow hot oil or hot components to Keep all parts clean from contaminants.
contact the skin.
Contaminants may cause rapid wear and shortened
In order to help obtain the most accurate analysis, component life.
record the following information before an oil sample
is taken: Do not drain the engine lubricating oil when the
engine is cold. As the engine lubricating oil cools,
• The date of the sample suspended waste particles settle on the bottom of the
oil pan. The waste particles are not removed with
• Engine model draining cold oil. Allow 30 minutes after the engine is
stopped, before draining the oil pan. Drain the oil pan
• Engine number with the oil warm. This draining method allows the
waste particles that are suspended in the oil to be
• Service hours on the engine drained properly.
• The number of hours that have accumulated since Failure to follow this recommended procedure will
the last oil change cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
• The amount of oil that has been added since the
last oil change
Oil and Filter Change Intervals
Ensure that the container for the sample is clean and
dry. Also ensure that the container for the sample is The standard engine oil and filter change period is
clearly labelled. 500 hours or 1 year, whichever occurs sooner. There
are several other factors that can alter the standard
To ensure that the sample is representative of the oil engine oil and filter change of 500 hours.
in the crankcase, obtain a warm, well mixed oil
sample. • If the engine is using engine oil analysis to
determine oil and filter change period.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil • The engine is working in a severe service
samples must be clean. environment/Load Factor
90 M0108133-05
Maintenance Section
Engine Oil and Filter - Change

• Infrequent operation of the engine 4. Tighten oil drain plug (1) to a torque of 24 N·m
(212 lb in). Remove the container below oil drain
Refer to this Operation and Maintenance Manual, plug (1) and discard waste oil in accordance with
“Severe Service Application” for more information on
reducing the engine oil and filter change period. For local regulations.
severe service applications the recommended oil and
filter change period is 250 hours. Note: A drain valve may be installed. Tighten the
drain valve to a torque of 24 N·m (212 lb in).
If the engine is operated in severe service conditions,
Perkins recommends the use of engine oil sampling. Draining the Engine Lubricating Oil
Refer to this Operation and Maintenance Manual,
Engine Oil sample - Obtain for more information. From an Oil Pan Equipped With a
If the engine is operated infrequently less than 500
Balancer
hours in a 12-month period, then the engine oil and
filter change should be conducted yearly. Note: Ensure that the vessel that will be used is large
enough to collect the waste oil.
Draining the Engine Lubricating Oil After the engine has been run at the normal
operating temperature, stop the engine. Use the
From a Standard Oil Pan following method to drain the engine oil pan:
Note: Ensure that the vessel that will be used is large
enough to collect the waste oil.
After the engine has been run at the normal
operating temperature, stop the engine. Use the
following method to drain the engine oil pan:

Illustration 49 g06512019
Typical example of a nonmetallic oil pan.

1. Place container below oil drain plug (1). Remove

the oil drain plug and allow the oil to drain into the
container for storage or disposal.
2. Remove drain plug seal (2) from the drain plug.
Discard the drain plug seal.
3. Clean oil drain plug (1) and install new drain plug
seal (2). Install oil drain plug (1) into oil pan (3).
M0108133-05 91
Maintenance Section
Engine Oil and Filter - Change

Illustration 50 g06511911
Typical example of an engine oil pan with a balancer

1. Place a suitable container below oil drain plug (1)

and oil drain plug (5).
2. Remove oil drain plug (1) and oil drain plug (5)
from engine oil pan (3) and allow the oil to drain
into the container for storage or disposal.
3. Remove drain plug seal (2) and drain plug seal (4).
Discard the seals.
4. Clean the oil drain plugs and install new drain plug
seal (2) and new drain plug seal (4). Install oil
drain plug (1) and oil drain plug (5) into oil pan (3).
92 M0108133-05
Maintenance Section
Engine Oil and Filter - Change

5. Tighten oil drain plug (1) and oil drain plug (5) to a 5. Tighten cap (1) to a torque of 24 N·m (212 lb in)
torque of 24 N·m (212 lb in). Remove container
below oil drain plug (1) and oil drain plug (5). Fill the Oil Pan
Discard waste oil in accordance with local
regulations.

Replace the Oil Filter Element

Illustration 52 g06304141
Typical example
(1) Top mounted filler cap
(2) Side-mounted filler cap

Illustration 51 g06304150
Typical example

1. Remove cap (1) from filter body (4).The filter

element (3) will be attached to cap (1). Remove
filter element (3) from cap (1). Discard old filter
element.
2. Remove O ring seal (2) from cap (1). Discard O
ring seal.
3. Ensure that cap and filter body are clean and free
from dirt or damage. Inspect new filter element for
damage before installing.
4. Install new O ring seal (2) onto cap (1). Install new
filter element (3) into cap (1). Install new filter Illustration 53 g06512039
element (3) and cap (1) to filter body (4). Typical example of engines equipped with a balancer
(3) Oil pan-mounted filler

1. Refer to this Operation and Maintenance Manual,

“Fluid Recommendations” for more information on
suitable oils.
M0108133-05 93
Maintenance Section
Fuel System - Prime

2. Fill the oil pan with the correct amount of new Electric Fuel Priming Pump
engine lubricating oil. Refer to this Operation and
Maintenance Manual, “Refill Capacities” for more Use the following procedure to remove air from the
information on refill capacities. fuel system:
1. Ensure that the fuel system is in working order.
Note: If the oil is filled through the top mounted filler
cap (1), allow the oil to drain down to the oil pan for a Check that the fuel supply valve (if equipped) is in
minimum of 30 minutes before starting the engine. the “ON” position.
2. Turn the keyswitch to the “RUN” position.
3. After installing the oil filler cap, start the engine and
run the engine at “LOW IDLE” for 2 minutes. 3. The keyswitch will allow the electric priming pump
Perform this procedure to ensure that the to operate. Operate the electric priming pump. The
lubrication system has oil and that the oil filter is ECM will stop the pump after 2 minutes.
filled. Inspect the oil filter for oil leaks.
4. Turn the keyswitch to the “OFF” position. The fuel
4. Stop the engine and allow the oil to drain back to system should now be primed and the engine
the oil pan for a minimum of 30 minutes. should be able to start.
5. Remove the engine oil level gauge to check the oil 5. Operate the engine starter and crank the engine.
level. Maintain the oil level between “L” and “H” After the engine has started, operate the engine at
marks on the engine oil level gauge. Do not fill the low idle for a minimum of 5 minutes. Ensure that
crankcase above the “H” mark. the fuel system is free from leaks.

Note: For more information on accurate oil level Note: Operating the engine for this period will help
check, refer to this Operation and Maintenance ensure that the fuel system is free of air.DO NOT
Manual, “Engine Oil Level - Check”. loosen the high-pressure fuel lines to purge air
from the fuel system. This procedure is not
i07989866 required.
After the engine has stopped, you must wait for 10
Fuel System - Prime minutes to allow the fuel pressure to be purged from
the high-pressure fuel lines before any service or
repair is performed on the engine fuel lines. The 10
Note: Refer to Systems Operation, Testing, and minute wait will also allow static charge to dissipate
Adjusting, “Cleanliness of Fuel System from the low-pressure fuel system. If necessary,
Components” for detailed information on the perform minor adjustments. Repair any leaks from
standards of cleanliness that must be observed the low-pressure fuel system and from the cooling,
lubrication, or air systems. Replace any high-
during ALL work on the fuel system. pressure fuel line that has leaked. Refer to
Ensure that all adjustments and repairs are Disassembly and Assembly Manual, “Fuel Injection
performed by authorized personnel that have had the Lines - Install”.
correct training. If you inspect the engine in operation, always use the
proper inspection procedure to avoid a fluid
NOTICE penetration hazard. Refer to Operation and
Do not crank the engine continuously for more than Maintenance Manual, “General hazard Information”.
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

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

from the fuel system before the engine can be
started. Air can enter the fuel system when the
following events occur:

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

partially drained.
• The low-pressure fuel lines are disconnected.

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

• The fuel filter has been replaced.
94 M0108133-05
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

If the engine will not start, refer to Troubleshooting,

“Engine Cranks but will not Start”.

i07989873

Fuel System Primary Filter

(Water Separator) Element -
Replace

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

Note: Refer to Systems Operation, Testing, and

Adjusting, “Cleanliness of Fuel System Illustration 54 g06304505
Components” for detailed information on the Typical example
standards of cleanliness that must be observed
during ALL work on the fuel system. 3. Install a suitable tube onto drain (2). Open the
drain valve (1). Rotate the drain valve fully
NOTICE counterclockwise. Two full turns are required.
Ensure that the engine is stopped before any servic-
ing or repair is performed. 4. Allow the fuel to drain into the container.
5. Remove the tube from the drain (2).
Fuel System Primary Filter (Water 6. Remove the wiring harness from connection (3).
Separator) Element for Electric 7. Rotate filter bowl (5) counterclockwise and remove
Fuel Priming Pump the filter bowl from assembly.
Note: If a strap wrench is required to loosen the filter
Remove the Element bowl (5), ensure that the strap is positioned in the
middle of the ribbed section. To avoid damage or
1. Turn the fuel supply valve (if equipped) to the OFF mechanical failure, do not position the strap around
position before performing this maintenance. the clear area. Do not apply loads to the clear plastic
2. Place a suitable container under the water bowl and the joint of the black plastic section of the
lower bowl.
separator to catch any fuel that might spill. Clean
up any spilled fuel. Clean the outside body of the
filter assembly.
M0108133-05 95
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

1. After repositioning the self-venting drain up, locate

the thread in the new filter element (6) onto the
thread (7). Spin on the filter element and tighten
the drain valve (2) securely.
2. Lubricate the lip (Position (X) ) with clean engine
oil. Do NOT fill the bowl with fuel before the
assembly is installed.

Note: Do not use a tool to install the filter assembly.

3. Align the filter bowl (5) to the assembly. Rotate the

filter bowl (5) clockwise by hand. Rotate the filter
bowl (5) until there is no visible gap between the
element and the filter bowl and the assembly.
4. Remove the container and dispose of the fuel in a
safe place.
5. Install the wiring harness to connection (3).
6. The secondary filter element (if equipped) must be
replaced at the same time as the primary filter
Illustration 55 g06304508
element. Refer to the Operation and Maintenance
Typical example
Manual, “Fuel System Secondary Filter - Replace”.
8. Remove the filter element (4). Clean the filter bowl.
i08158885

Install the New Filter Element

Fuel System Primary Filter/
Water Separator - Drain

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.

NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.

NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the
fuel system.

Drain Procedure
1. Place a suitable container under the water
separator to catch any fluid that might spill. Clean
Illustration 56 g06304524
up any spilled fluid.
Typical example
96 M0108133-05
Maintenance Section
Fuel System Secondary Filter - Replace

2. Ensure that the outer body of the filter assembly is Refer to Systems Operation, Testing, and
clean and free from dirt. Adjusting, “Cleanliness of Fuel System
Components” for detailed information on the
standards of cleanliness that must be observed
during ALL work on the fuel system.

Remove the Element

1. Turn the fuel supply valve (if equipped) to the OFF
position before performing this maintenance.
2. Place a suitable container under the fuel filter to
catch any fuel that might spill. Clean up any spilled
fuel. Clean the outside body of the filter assembly.

Illustration 57 g06304526
Typical example

3. Install a suitable tube onto drain (2). Open the

drain valve (1). Rotate the drain valve fully
counterclockwise. Two full turns are required.
4. Visually check that the fluid will drain. Allow the
fluid to drain into the container.
5. When fluid free from water comes from the primary
fuel filter, tighten the drain valve clockwise by hand
only. Remove the tube and remove the container. Illustration 58 g03088718

i07694301 3. Install a suitable tube onto drain (4). Open the

drain valve (3). Rotate the drain valve
Fuel System Secondary Filter - counterclockwise. Two full turns are required.
Loosen vent screw (1).
Replace
4. Allow the fuel to drain into the container and
remove the tube.
5. Tighten the vent screw (1) to a torque of 2.5 N·m
(22 lb in).
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent 6. Remove the filter bowl (2). Rotate the filter
possible injury, turn the start switch off when assembly counterclockwise to remove the
changing fuel filters or water separator elements. assembly.
Clean up fuel spills immediately.

NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
M0108133-05 97
Maintenance Section
Fuel Tank Water and Sediment - Drain

3. Do not use a tool to install the filter assembly.

Tighten the assembly by hand. Install the filter
bowl (2). Turn the filter bowl clockwise until the
filter bowl locks into position against the stops.
4. Turn the fuel supply valve to the ON position.
5. The primary and secondary fuel filters must be
replaced at the same time. Refer to the Operation
and Maintenance Manual, “Fuel System Primary
Filter (Water Separator) Element - Replace”.
6. Prime the fuel system. Refer to the Operation and
Maintenance Manual, “Fuel System - Prime” for
more information.

i02348492

Fuel Tank Water and Sediment

- Drain
Illustration 59 g02546456

7. Rotate the filter element (5) counterclockwise and NOTICE

Care must be taken to ensure that fluids are con-
remove the filter element. Clean the filter bowl. tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Install the Element Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.

Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system.
Water can be introduced into the fuel tank when the
fuel tank is being filled.
Condensation occurs during the heating and cooling
of fuel. The condensation occurs as the fuel passes
through the fuel system and the fuel returns to the
fuel tank. This causes water to accumulate in fuel
tanks. Draining the fuel tank regularly and obtaining
fuel from reliable sources can help to eliminate water
in the fuel.

Illustration 60 g03088837
Drain the Water and the Sediment
Fuel tanks should contain some provision for draining
1. Locate the thread (7) in the filter element onto the water and draining sediment from the bottom of the
threads (8). Spin on the element and tighten the fuel tanks.
drain valve (3) by hand.
Open the drain valve on the bottom of the fuel tank in
2. Lubricate the O ring seal (6) with clean engine oil. order to drain the water and the sediment. Close the
Do NOT fill the filter bowl (2) with fuel before the drain valve.
filter assembly is installed.
98 M0108133-05
Maintenance Section
Hoses and Clamps - Inspect/Replace

Check the fuel daily. Allow five minutes after the fuel • Cracking
tank has been filled before draining water and
sediment from the fuel tank. • Softness
Fill the fuel tank after operating the engine in order to • Loose clamps
drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The fuel Replace hoses that are cracked or soft. Tighten any
expands as the fuel gets warm. The tank may loose clamps.
overflow.
Check for the following conditions:
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel • End fittings that are damaged or leaking
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If the • Outer covering that is chafed or cut
engine is equipped with this system, regular
maintenance of the fuel system filter is important. • Exposed wire that is used for reinforcement

Fuel Storage Tanks • Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed

Drain the water and the sediment from the fuel
storage tank at the following intervals: • Armoring that is embedded in the outer covering
• Weekly A constant torque hose clamp can be used in place
of any standard hose clamp. Ensure that the constant
• Service intervals torque hose clamp is the same size as the standard
clamp.
• Refill of the tank
This will help prevent water or sediment from being Due to extreme temperature changes, the hose will
pumped from the storage tank into the engine fuel harden. Hardening of the hoses will cause hose
tank. clamps to loosen. This can result in leaks. A constant
torque hose clamp will help to prevent loose hose
If a bulk storage tank has been refilled or moved clamps.
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal Each installation application can be different. The
baffles in the bulk storage tank will also help trap differences depend on the following factors:
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel. • Type of hose
When possible, water separators should be used. • Type of fitting material
i07819616 • Anticipated expansion and contraction of the hose

Hoses and Clamps - Inspect/ • Anticipated expansion and contraction of the

fittings
Replace
Replace the Hoses and the Clamps
Refer to the OEM information for further information
on removing and replacing fuel hoses (if equipped).
Contact with high pressure fuel may cause fluid The following text describes a typical method of
penetration and burn hazards. High pressure fuel replacing coolant hoses. Refer to the OEM
spray may cause a fire hazard. Failure to follow information for further information on the coolant
these inspection, maintenance and service in- system and the hoses for the coolant system.
structions may cause personal injury or death.
If you inspect the engine in operation, always use the
proper inspection procedure to avoid a fluid
penetration hazard. Refer to Operation and Pressurized System: Hot coolant can cause seri-
Maintenance Manual, “General hazard Information” ous burns. To open the cooling system filler cap,
and Operation and Maintenance Manual, “High stop the engine and wait until the cooling system
Pressure Fuel Lines” for the correct procedures. components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
Inspect all hoses for leaks that are caused by the pressure.
following conditions:
M0108133-05 99
Maintenance Section
Starting Motor - Inspect

1. Stop the engine. Allow the engine to cool. i08134393

2. Loosen the cooling system filler cap slowly to

relieve any pressure. Remove the cooling system
Turbocharger - Inspect
filler cap.
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
Hot engine components can cause injury from
3. Drain the coolant from the cooling system to a burns. Before performing maintenance on the en-
level that is below the hose that is being replaced. gine, allow the engine and the components to
cool.
4. Remove the hose clamps.
5. Disconnect the old hose.
NOTICE
6. Replace the old hose with a new hose. Turbocharger bearing failures can cause large quan-
tities of oil to enter the air intake and exhaust sys-
7. Install the hose clamps with a torque wrench. tems. Loss of engine lubricant can result in serious
engine damage.
Note: For the correct coolant, see this Operation and
Maintenance Manual, “Fluid Recommendations”. Minor leakage of oil into a turbocharger under ex-
tended low idle operation should not cause problems
8. Refill the cooling system. Refer to the OEM as long as a turbocharger bearing failure has not
information for further information on refilling the occured.
cooling system.
When a turbocharger bearing failure is accompanied
9. Clean the cooling system filler cap. Inspect the by a significant engine performance loss (exhaust
cooling system filler cap's seals. Replace the smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is renewed.
cooling system filler cap if the seals are damaged.
Install the cooling system filler cap. A visual inspection of the turbocharger or
turbochargers can minimize unscheduled downtime.
10. Start the engine. Inspect the cooling system for
A visual inspection of the turbocharger or
leaks. turbochargers can also reduce the chance for
potential damage to other engine parts. Do not
i07888480 inspect the engine with the engine in operation.

Starting Motor - Inspect

Perkins recommends a scheduled inspection of the

starting motor. If the starting motor fails, the engine
may not start in an emergency situation.
Check the starting motor for correct operation. Check
the electrical connections and clean the electrical
connections. Refer to the Systems Operation, Testing
and Adjusting Manual, “Electric Starting System -
Test” for more information on the checking procedure
and for specifications consult your Perkins dealer or
your Perkins distributor for assistance.

Illustration 61 g06536519
Typical example of 904D-E28T Industrial Engine
100 M0108133-05
Maintenance Section
Walk-Around Inspection

i07926235

Walk-Around Inspection

Inspect the Engine for Leaks and

for Loose Connections
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
For maximum engine service life, make a thorough
inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or
coolant leaks, loose bolts, worn belts, loose
connections, and trash buildup. Make repairs, as
needed:

• The guards must be in the correct place. Repair

damaged guards or replace missing guards.
Illustration 62 g06304904
• Wipe all caps and plugs before the engine is
Typical example of 904D-E36TA Industrial Engine serviced to reduce the chance of system
contamination.
1. Ensure that the turbocharger is clean and free from
dirt before removing components for inspection. NOTICE
2. Remove the pipe from the turbocharger exhaust For any type of leak (coolant, lube, or fuel) clean up
the fluid. If leaking is observed, find the source and
outlet and remove the air intake pipe (1). Visually correct the leak. If leaking is suspected, check the flu-
inspect the piping for the presence of oil. Clean the id levels more often than recommended until the leak
interior of the pipes to prevent dirt from entering is found or fixed, or until the suspicion of a leak is
during reassembly. proved to be unwarranted.

3. Check for obvious heat discoloration of the

turbocharger. Check for any loose bolts or any NOTICE
missing bolts. Check for damage to the oil supply Accumulated grease and/or oil on an engine is a fire
line and the oil drain line. Check for cracks in the hazard. Remove the accumulated grease and oil. Re-
housing of the turbocharger. Ensure that the fer to this Operation and Maintenance Manual, “En-
gine - Clean” for more information.
compressor wheel can rotate freely.
4. Check for the presence of oil. If oil is leaking from
• Ensure that the cooling system hoses are correctly
the back side of the compressor wheel, there is a
clamped and that the cooling system hoses are
possibility of a failed turbocharger oil seal. tight. Check for leaks. Check the condition of all
The presence of oil may be the result of extended pipes.
engine operation at low idle. The presence of oil
• Inspect the water pump for coolant leaks.
may also be the result of a restriction of the line for
the intake air (clogged air filters), which causes the Excessive coolant leakage may indicate the need to
turbocharger to slobber. replace the water pump. Remove the water pump.
Refer to Disassembly and Assembly, “Water Pump -
5. Install the air intake pipe and the exhaust outlet Remove and Install”.
pipe to the turbocharger housing. Ensure that all
clamps are installed correctly and that all clamps • Inspect the lubrication system for leaks at the front
are tightened securely. For more information, refer crankshaft seal, the rear crankshaft seal, the oil
to Systems Operation, Testing, and Adjusting, pan, the oil filters, and the rocker cover.
“Turbocharger - Inspect”. • Inspect the piping for the air intake system and the
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses.
M0108133-05 101
Maintenance Section
Water Pump - Inspect

• Ensure that the areas around the rotating parts are • Disconnect any battery chargers that are not
clear. protected against the current drain of the starting
motor. Check the condition and the electrolyte
• Inspect the alternator belts and any accessory level of the batteries, unless the engine is
drive belts for cracks, breaks, or other damage. equipped with a maintenance free battery.
• Inspect the wiring harness for damage. • Check the condition of the gauges. Replace any
gauges that are cracked. Replace any gauge that
Belts for multiple groove pulleys must be replaced as cannot be calibrated.
matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on i07385598
the new belt could cause the belt to break.
Water Pump - Inspect
High-Pressure Fuel Lines
A failed water pump may cause severe engine
overheating problems that could result in the
following conditions:
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel • Cracks in the cylinder head
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in- • A piston seizure
structions may cause personal injury or death.
• Other potential damage to the engine
After the engine has stopped, wait 10 minutes to
allow the fuel pressure to be purged from the high-
pressure fuel lines before any service or repair is
performed. The 10 minute wait will also allow static
charge to dissipate from the low-pressure fuel
system. If necessary, perform minor adjustments.
Repair any leaks from the low-pressure fuel system
and from the cooling, lubrication, or air systems.
Replace any high-pressure fuel line that has leaked.
Refer to Disassembly and Assembly Manual, “Fuel
Injection Lines - Install”.
If you inspect the engine in operation, always use the
proper inspection procedure to avoid a fluid
penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”.
Visually inspect the high-pressure fuel lines for
damage or signs of fuel leakage. Replace any
damaged high-pressure fuel lines or high-pressure
fuel lines that have leaked.
Ensure that all clips on the high-pressure fuel lines
are in place and that the clips are not loose.
Illustration 63 g06304598
• Inspect the rest of the fuel system for leaks. Look
for loose fuel line clamps.
Visually inspect the water pump for leaks between
• Drain the water and the sediment from the fuel water pump pulley (1) and water pump body (2).
tank daily. The water pump is not a serviceable item. To install a
new water pump, refer to Disassembly and
• Inspect the wiring and the wiring harnesses for Assembly, “Water Pump - Remove” and Disassembly
loose connections and for worn wires or frayed and Assembly, “Water Pump - Install”.
wires. Check for any loose tie-wraps or missing
tie-wraps.

• Inspect the ground strap for a good connection

and for good condition.
102 M0108133-05
Warranty Section
Warranty Information

Warranty Section

Warranty Information
i05341027

Emissions Warranty
Information

This engine may be certified to comply with exhaust

emission standards and gaseous emission standards
that are prescribed by the law at the time of
manufacture. This engine may be covered by an
Emissions Warranty.
For a full warranty statement contact your Perkins
dealer or your Perkins distributor. For customers that
have a valid user name and password, for perkins.
com. Login then go to TIPSS, and the warranty
information can be accessed.
M0108133-05 103
Reference Information Section
Reference Materials

Reference Information
Section

Reference Materials
i05204675

Maintenance Log

Table 17
Engine Model Customer Identifier

Serial Number Arrangement Number

Service Quantity Of
Service Item Date Authorization
Hours Fuel

(continued)
104 M0108133-05
Reference Information Section
Reference Material

(Table 17, contd)

i07677995 To purchase an Extended Service Contract, is quick

and simple! Contact your local Perkins Distributor
Reference Material now and the distributor can provide you with a quote
in minutes. You can locate your nearest Perkins
(Extended Service Contract) Distributor by visiting:

www.perkins.com
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protected for years. NOTICE
Dependant upon engine type and application.
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Why buy an Extended Service Contract?
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Flexible coverage provides the right level of
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You can buy an ESC at any time during standard
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M0108133-05 105
Index Section

Index
A D
After Starting Engine ....................................... 45 Diagnostic Flash Code Retrieval..................... 41
After Stopping Engine ..................................... 53 Diagnostic Lamp.............................................. 41
Aftercooler Core - Clean/Test (Air-To-Air Driven Equipment - Check .............................. 84
Aftercooler) .................................................... 76
Aftercooler Core - Inspect ............................... 76 E
Alarms and Shutoffs ........................................ 35
Alarms.......................................................... 35 Electrical System............................................. 20
Shutoffs........................................................ 35 Grounding Practices .................................... 20
Testing ......................................................... 35 Emergency Stopping....................................... 53
Alternator - Inspect .......................................... 76 Emissions Certification Film ............................ 31
Alternator and Fan Belts - Replace ................. 76 Emissions Warranty Information ................... 102
Engaging the Driven Equipment ..................... 47
Engine - Clean................................................. 85
B
Engine Air Cleaner Element - Replace ........... 85
Battery - Replace............................................. 76 Servicing the Air Cleaner Elements............. 85
Battery Electrolyte Level - Check .................... 77 Engine Air Cleaner Service Indicator -
Battery or Battery Cable - Disconnect............. 77 Inspect ........................................................... 86
Before Starting Engine .............................. 19, 43 Test the Service Indicator ............................ 86
Belt - Inspect.................................................... 78 Engine Air Precleaner - Check/Clean ............. 87
Belt Tensioner - Check .................................... 78 Engine Diagnostics ......................................... 41
Burn Prevention............................................... 13 Engine Electronics........................................... 21
Batteries....................................................... 15 Engine Mounts - Inspect.................................. 87
Coolant ........................................................ 14 Engine Oil and Filter - Change ........................ 89
Diesel Fuel ................................................... 14 Draining the Engine Lubricating Oil From a
Engine.......................................................... 15 Standard Oil Pan........................................ 90
Induction System ......................................... 14 Draining the Engine Lubricating Oil From an
Oils............................................................... 14 Oil Pan Equipped With a Balancer ............ 90
Fill the Oil Pan.............................................. 92
C Oil and Filter Change Intervals .................... 89
Replace the Oil Filter Element..................... 92
Cold Weather Operation ................................. 49 Engine Oil Level - Check................................. 87
Hints for Cold-Weather Operation ............... 49 After Operating the Engine .......................... 88
Idling the Engine .......................................... 50 Before Operating the Engine ....................... 88
Recommendations for Coolant Warm Up.... 50 Engine Oil Sample - Obtain............................. 89
Recommendations for the Coolant.............. 50 Obtain the Sample and the Analysis ........... 89
Viscosity of the Engine Lubrication Oil ........ 50 Engine Operation ............................................ 47
Cold Weather Starting ..................................... 43 Carbon Dioxide (CO2) Emissions
Coolant (Commercial Heavy-Duty) - Statement................................................... 47
Change .................................................... 79, 81 Engine Operation with Active Diagnostic
Drain ...................................................... 79, 81 Codes ............................................................ 41
Fill .......................................................... 80, 82 Engine Operation with Intermittent
Flush ...................................................... 80–81 Diagnostic Codes .......................................... 42
Coolant (ELC) - Change.................................. 82 Engine Starting.......................................... 19, 43
Drain ............................................................ 83 Engine Stopping ........................................ 20, 53
Fill ................................................................ 83
Flush ............................................................ 83
F
Coolant Level - Check ..................................... 84
Crushing Prevention and Cutting Prevention.. 17 Fault Logging................................................... 41
106 M0108133-05
Index Section

Features and Controls..................................... 35 G

Fire Prevention and Explosion Prevention...... 15
Gauges and Indicators .................................... 36
Ether ............................................................ 16
Indicator Lamps ........................................... 37
Fire Extinguisher.......................................... 16
General Hazard Information............................ 10
Lines, Tubes, and Hoses ............................. 17
Containing Fluid Spillage............................. 12
Fluid Recommendations ................................. 63
Dispose of Waste Properly .......................... 13
ELC Cooling System Maintenance.............. 66
Fluid Penetration ..........................................11
General Coolant Information ....................... 63
Inhalation ..................................................... 12
Fluid Recommendations (Engine Oil
Pressurized Air and Water............................11
Specification) ................................................. 69
Static Electricity Hazard when Fueling with
Engine Oil .................................................... 69
Ultra-low Sulfur Diesel Fuel ....................... 12
General Lubricant Information..................... 69
General Information ........................................ 23
Fluid Recommendations (General Fuel
Information) ................................................... 55
Contamination Control Recommendations for H
Fuels .......................................................... 62 High Pressure Fuel Lines ................................ 17
Diesel Fuel Characteristics.......................... 58 Hoses and Clamps - Inspect/Replace............. 98
Diesel Fuel Requirements ........................... 56 Replace the Hoses and the Clamps ............ 98
General Information..................................... 56
Renewable and Alternative Fuels................ 63
I
Foreword ........................................................... 4
California Proposition 65 Warning ................. 4 Important Safety Information............................. 2
Literature Information .................................... 4
Maintenance .................................................. 4 L
Maintenance Intervals ................................... 5
Operation ....................................................... 4 Lifting and Storage .......................................... 33
Overhaul ........................................................ 5
Safety............................................................. 4 M
Fuel and the Effect from Cold Weather ........... 51 Maintenance Interval Schedule....................... 75
Fuel Conservation Practices ........................... 48 Daily ............................................................. 75
Fuel Related Components in Cold Weather ... 52 Every 1000 Service Hours........................... 75
Fuel Filters ................................................... 52 Every 2000 Service Hours........................... 75
Fuel Heaters ................................................ 52 Every 3000 Service Hours........................... 75
Fuel Tanks ................................................... 52 Every 3000 Service Hours or 2 Years ......... 75
Fuel System - Prime ........................................ 93 Every 4000 Service Hours........................... 75
Electric Fuel Priming Pump ......................... 93 Every 4500 Service Hours........................... 75
Fuel System Primary Filter (Water Every 50 Service Hours ............................... 75
Separator) Element - Replace....................... 94 Every 500 Service Hours or 1 Year ............. 75
Fuel System Primary Filter (Water Separator) Every 6000 Service Hours or 3 Years ......... 75
Element for Electric Fuel Priming Pump.... 94 Every Week ................................................. 75
Fuel System Primary Filter/Water When Required............................................ 75
Separator - Drain ........................................... 95 Maintenance Log........................................... 103
Drain Procedure........................................... 95 Maintenance Recommendations .................... 72
Fuel System Secondary Filter - Replace ........ 96 Maintenance Section....................................... 55
Install the Element ....................................... 97 Model View Illustrations .................................. 23
Remove the Element ................................... 96 904D-E28T Industrial Engine Views............ 24
Fuel Tank Water and Sediment - Drain ........... 97 904D-E36TA Industrial Engine Views ......... 26
Drain the Water and the Sediment .............. 97 Loose or Off Engine Components ............... 28
Fuel Storage Tanks...................................... 98 Mounting and Dismounting ............................. 17
Fuel Tank ..................................................... 97
M0108133-05 107
Index Section

O Starting Motor - Inspect ................................... 99

Starting the Engine.......................................... 44
Operation Section............................................ 33
Starting the Engine ...................................... 44
Starting with Jump Start Cables (Do Not
P Use This Procedure in Hazardous
Plate Locations and Film Locations ................ 31 Locations that have Explosive
Serial Number Plate..................................... 31 Atmospheres) ................................................ 44
Product Description ......................................... 28 Stopping the Engine ........................................ 53
904D-E28T Industrial Engine ...................... 28 System Pressure Release............................... 72
904D-E36TA Engine.................................... 29 Coolant System ........................................... 72
Aftermarket Products and Perkins Engine Oil .................................................... 72
Engines ...................................................... 30 Fuel System................................................. 72
Electronic Engine Features ......................... 29
Engine Cooling and Lubrication .................. 30 T
Engine Diagnostics...................................... 30
Table of Contents .............................................. 3
Engine Service Life...................................... 30
Turbocharger - Inspect .................................... 99
Product Identification Information ................... 31
Product Information Section............................ 23
Product Lifting ................................................. 33 W
Product Storage .............................................. 34 Walk-Around Inspection ................................ 100
Condition for Storage................................... 34 High-Pressure Fuel Lines .......................... 101
Inspect the Engine for Leaks and for Loose
R Connections ............................................. 100
Warranty Information..................................... 102
Radiator Restrictions....................................... 51
Warranty Section ........................................... 102
Reference Information..................................... 32
Water Pump - Inspect.................................... 101
Record for Reference .................................. 32
Welding on Engines with Electronic
Reference Information Section ..................... 103
Controls ......................................................... 72
Reference Material (Extended Service
Contract)...................................................... 104
Reference Materials ...................................... 103
Refill Capacities............................................... 55
Cooling System............................................ 55
Lubrication System ...................................... 55

S
Safety Messages............................................... 6
904D-E28T Industrial Engine ........................ 8
904D-E36TA Industrial Engine ...................... 7
Ether Warning ................................................ 9
Hand (High Pressure) 2 ................................. 9
Universal Warning 1 ...................................... 8
Safety Section ................................................... 6
Self-Diagnostics .............................................. 41
Sensors and Electrical Components............... 37
Off Engine Sensors and Electrical
Components .............................................. 40
Severe Service Application ............................. 74
Environmental Factors................................. 74
Incorrect Maintenance Procedures ............. 74
Incorrect Operating Procedures .................. 74
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
M0108133
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All Rights Reserved

110 March 2022