Operation and Maintenance

Instructions Manual

PDFP SERIES ENGINES

FOR
FIRE PUMP APPLICATIONS

This manual covers Perkins 1000 Series engines

prepared by Clarke DD-A
for fire pump service

LISTED FM APPROVED LISTED

Printed in U.S.A. C13196 MP-5 1/98

 ABBREVIATIONS

AC Alternating Current

AEC Automatic Engine Controller

API American Petroleum Institute

CDD-A Clarke Detroit Diesel-Allison

DC Direct Current

DDC Detroit Diesel Corporation

PDFP Perkins Diesel Engines approved for Fire Pump Service

as certified by FM/UL/ULC for Clarke Detroit Diesel-Allison

FM Factory Mutual Research

ID Identification

IP Instrument Panel

Y 1000 Series, Perkins Engine

N Naturally Aspirated

NA Naturally Aspirated

NFPA National Fire Protection Association

P/N Part Number

PSI Pounds Per Square Inch

PTO Power Take Off

RPM Revolutions Per Minute

SAE Society of Automotive Engineers

S/N Serial Number

T Turbocharged

W Turbocharged and Intercooled

UL Underwriters Laboratories Inc.

ULC Underwriters Laboratories of Canada

LISTED FM APPROVED LISTED

 TABLE OF CONTENTS
SUBJECT PAGE

ABBREVIATIONS........................................................................................................................................ Inside Front Cover

DESCRIPTION — Section 1
Principles of Diesel Engine Operation ............................................................................................................................ 1
General Description .......................................................................................................................................................... 2
Introduction .............................................................................................................................................................. 2
Model and Serial Number Identifications ................................................................................................................ 2
FM/UL/ULC Certification Nameplate ...................................................................................................................... 3
Standard Engine Equipment ............................................................................................................................................ 5

GENERAL INSTRUCTIONS — Section 2

Engine Storage .......................................................................................................................................................... 6
Preparing New Engine For Start-Up.......................................................................................................................... 6
Normal Running ...................................................................................................................................................... 7
Normal Maintenance Checks .......................................................................................................................................... 8
Fuel System .............................................................................................................................................................. 8
Drive Belts ................................................................................................................................................................ 8
Battery ...................................................................................................................................................................... 8
Oil Pressure .............................................................................................................................................................. 8
Coolant Temperature & Level .................................................................................................................................. 8
Crankcase .................................................................................................................................................................. 8
Running Inspection .................................................................................................................................................. 8
Preventative Maintenance Schedule ........................................................................................................................ 9

ENGINE SYSTEMS — Section 3

Fuel System — Section 3.1 .............................................................................................................................................. 10
Operation.................................................................................................................................................................... 10
Diesel Fuel Recommendations .................................................................................................................................. 11
Maintenance Procedures ............................................................................................................................................ 12
Service Procedures .................................................................................................................................................... 13
Fuel System Priming ................................................................................................................................................ 15

Air Intake and Exhaust System — Section 3.2 ................................................................................................................ 17

Air System Operation ................................................................................................................................................ 17
Air Cleaner ................................................................................................................................................................ 17
Crankcase Ventilation .............................................................................................................................................. 19
Exhaust Operation...................................................................................................................................................... 19
Maintenance & Service Procedures .......................................................................................................................... 20

Lubrication System — Section 3.3 .................................................................................................................................. 21

Operation.................................................................................................................................................................... 21
Lubricating System Schematics ................................................................................................................................ 22
Oil Cooler ................................................................................................................................................................ 23
Lube Oil Fill ............................................................................................................................................................ 23
Oil Level Dipstick .................................................................................................................................................... 23
Lube Oil Filter .......................................................................................................................................................... 23
Lubricating Oil Requirements .................................................................................................................................. 24
Changing The Lubricating Oil .................................................................................................................................. 24
Lubricating Oil Analysis .......................................................................................................................................... 25
Changing The Lubricating Oil Filter ........................................................................................................................ 26
Maintenance Procedures ............................................................................................................................................ 26
 TABLE OF CONTENTS
SUBJECT PAGE

Cooling System — Section 3.4 ........................................................................................................................................ 27

Operation.................................................................................................................................................................... 27
Engine Coolant ........................................................................................................................................................ 28
Water ........................................................................................................................................................................ 28
Antifreeze .................................................................................................................................................................. 28
Coolant Inhibitor ...................................................................................................................................................... 28
Procedure For Filling Engine .................................................................................................................................. 29
Pressure Cap ............................................................................................................................................................ 29
Thermostat ................................................................................................................................................................ 30
Engine Coolant Heater .............................................................................................................................................. 30
Heat Exchanger Cooling .......................................................................................................................................... 31
Raw Water System (Cooling Loop) .......................................................................................................................... 31
Zinc Electrode .......................................................................................................................................................... 32
Maintenance & Service Procedures .......................................................................................................................... 32
Electrical System — Section 3.5 ...................................................................................................................................... 33
Engine Operating System .......................................................................................................................................... 33
Manual Starting Instructions .................................................................................................................................... 33
Fuel Injection Pump Solenoid .................................................................................................................................. 34
Instrumentation And Controls .................................................................................................................................. 34
Speed Switch ............................................................................................................................................................ 35
Battery Charging Alternator .................................................................................................................................... 36
Starters ...................................................................................................................................................................... 36
Alarms ...................................................................................................................................................................... 36
Batteries .................................................................................................................................................................... 36
Battery Cables .......................................................................................................................................................... 36
DC Wiring Diagram .................................................................................................................................................. 37
Engine Heater AC Wiring Diagram .......................................................................................................................... 38
Maintenance & Service Procedures .......................................................................................................................... 39

Falk Drive Coupling Instructions — Section 3.6 ...................................................................................................... 40-45

Installation Procedures ...................................................................................................................................... 40-45

ENGINE TUNE-UP — Section 4

Tune Up ............................................................................................................................................................................ 46
Speed Adjustments .......................................................................................................................................................... 47

TECHNICAL DATA — Section 5 .......................................................................................................................................... 48

PARTS INFORMATION — Section 6

Basic Engine Parts ............................................................................................................................................................ 49
Option Parts ...................................................................................................................................................................... 50

OWNER ASSISTANCE — Section 7 .................................................................................................................................. 51

WARRANTY — Section 8 .............................................................................................................................................. 53-54

ALPHABETICAL INDEX — Section 9 ........................................................................................................................ 55-56

SECTION 1 PDFP

PRINCIPLES OF DIESEL ENGINE OPERATION

4 CYCLE

INTAKE COMPRESSION POWER EXHAUST

Fig. 1 - The Four Stroke Cycle

gasoline engines.
A reciprocating engine is an internal combustion power unit,
in which the heat of burning fuel is converted into work in The intake charge consists of air only with no fuel mixture.
the cylinder of the engine. In the diesel engine, air is com-
pressed in the cylinder; then, after the air has been com-
pressed, a charge of fuel is sprayed into the cylinder and Compression Stroke:
ignition is accomplished by the heat of compression. The At the end of the intake stroke, the intake valve closes and
resulting expanding gas provides the force to turn the crank- the piston starts upward on the compression stroke. The
shaft. exhaust valve remains closed.

At the end of the compression stroke, the air in the combus-

THE FOUR CYCLE PRINCIPLE tion chamber has been compressed by the piston to occupy
The four piston strokes of the cycle occur in the following a space about one-sixteenth in volume as it occupied at the
order: Intake, Compression, Power and Exhaust. beginning of the stroke. Thus, the compression ratio is 16:1.

Intake Stroke: Compressing the air into a small space causes the tempera-
During the intake stroke, the piston travels downward, the ture of that air to rise. Near the end of the compression
intake valve is open, and the exhaust valve is closed. stroke, the pressure of the air above the piston is approxi-
mately 470 to 585 psi (3240 to 4034 kPa) and the tempera-
The downstroke of the piston permits air from outside to ture of that air is approximately 1000˚ F (538˚ C).
enter the cylinder through the open intake valve port. The
turbocharger (when fitted) increases air pressure in the During the last part of the compression stroke and the early
engine intake manifold and forces it into the cylinder. The part of the power stroke, a small metered charge of fuel is
intake of air is never restricted by carburetion or mixing injected in the combustion chamber.
valves such as those used on spark-ignited, automotive-type

Page 1
SECTION 1 PDFP

Almost immediately after the fuel charge is injected into the Exhaust Stroke:
combustion chamber, the fuel is ignited by the hot air and During the exhaust stroke, the intake valve is closed, the
starts to burn. exhaust valve is open, and the piston is on its upstroke.

By the time the piston reaches the end of the compression Burned gases are forced out of the combustion chamber
stroke, the burning fuel causes a further increase in the pres- through the open exhaust valve port by the upward travel of
sure above the piston. As the more fuel is added and burns the piston.
the gases get hotter, the pressure increases, pushing the pis-
ton downward and adds impetus to crankshaft rotation. From the preceding description of the Diesel Cycle, it is
apparent that the proper operation of the engine depends
upon the two separate functions - first compression for igni-
Power Stroke: tion, and, second, that fuel be measured and injected into the
During the power stroke, the piston travels downward and compressed air in the cylinder in the proper quantity and at
torque power is translated to the rotating crankshaft thru the proper time.
connecting rods. Both intake and exhaust valves are closed.

GENERAL DESCRIPTION

Introduction
Model Numbering & Identification
FM/UL/ULC Certification Name Plate

Introduction
Exchanger End) of the engine to determine the rotation of
NFPA 20 states "The compression ignition diesel engine has the output shaft. Also cylinder designation is made from the
proven to be the most dependable of the internal combustion front to rear of the engine in ascending sequence starting
engines for driving fire pumps." The diesel engine will oper- with one. All other engine references, (right or left) are
ate under emergency power conditions where loss of utility made from a rear view of the engine, looking at the rear face
or stand-by electric power renders electric motor driven of the flywheel.
pumps useless. The diesel driven fire pump system is pre-
ferred by most insurance companies. All PDFP engines are Underwriters Laboratories (UL) list-
ed, Underwriters Laboratories of Canada (ULC) listed
This manual covers Perkins diesel engines as marketed thru and/or Factory Mutual (FM) approved and meet the require-
Detroit Diesel Corporation. These engines have been manu- ments of the National Fire Protection Association (NFPA)
factured with specific options to function integrally with an 20.
automatic engine controller for stand-by fire protection ser-
vice and to meet NFPA-20 requirements. These systems are
designed to function under emergency conditions and to Model Numbering & Identification
assist in holding fire damage to a minimum. Complete under-
standing of the operation and maintenance of this fire protec- There are two model numbers associated with this product.
tion system is essential to achieve this objective. First is the Clarke FM/UL/ULC approved model number
showing the prefix PDFP. Figure 2 explains the identifica-
A separate manual covers the operation and maintenance of tion system on PDFP units. Second is the Perkins basic
the Automatic Engine Controller (AEC). engine model number. Figure 3 provides details for under-
standing this number.
The four-cycle engines covered in this manual are of the
four and six cylinder inline arrangement. The engines are The Clarke model number appears on the FM/UL/ULC tag
either naturally aspirated (N) or turbocharged (T) and some attached to the left rear engine mount. Perkins doesn't attach
units are turbocharged and intercooled (W). their model number to the engine.

The engines are clockwise (CW) rotating engines. The Perkins serial number is stamped on a label which is
Rotational reference is made from a front view (Heat fastened to the left side of the cylinder block (Fig. 5) just
under the cylinder head.
Page 2
SECTION 1 PDFP

P D F P — L 6YT 1 0 0 6 — 6TW

N Naturally Aspirated
T Turbocharged
W Turbocharged & Innercooled
N Naturally Aspirated
T Turbocharged
TW Turbocharged & Intercooled
Y 1000 Series, Perkins Engine

(X) Number of Cylinders

(X) Engine liter
O Basic Build Level
L Reduced Output Build
1004 1000 Series Perkins Engine, 4 Cylinder
1006 1000 Series Perkins Engine, 6 Cylinder

Perkins Diesel Engines

Prepared by Clarke and
Certified by FM/UL/ULC for
Fire Pump Service

Figure 2 - Clarke FM/UL/ULC Model Figure 3 - Perkins Basic Engine Model

FM/UL/ULC Certification Name Plate

The standard nameplate (Fig. 6) contains the following in- the power rating of these engines at an intermediate speed,
formation: FM/UL certified model number; Clarke specifi- use a linear interpolation. Interpolation must be made by
cation number; production date; basic engine serial number; consulting the power curves from the two ratings listed.
a rated horsepower range; and the associated full load en- Power curves are also available from Clarke. Speed adjust-
gine speed range. The name plate is located on the left rear ment is described in Section 4, Page 42 of this manual.
engine mount (Fig. 4).
When requested, a ULC nameplate is provided in addition to
All PDFP models are certified at a horsepower and speed the FM & UL nameplate. This plate is mounted separately
range. These engines can be adjusted to a desired speed on the engine.
within the range listed on the FM/UL nameplate. To obtain

Page 3
SECTION 1 PDFP

Figure 4 - Clarke FM/UL Name Plate Location Figure 5 - Perkins Serial Number Location

Figure 6 - Name Plate Dwg

Page 4
SECTION 1 PDFP

PDFP STANDARD ENGINE EQUIPMENT LIST

—Air cleaner, oiled gauze type for protected —Low oil pressure switch
environment.

—Manual over-ride of automatic operations

—Battery charging alternator (12V-DC) negative ground Instruction plate on instru-
ment panel

—Engine coolant heater with AC power cord

(120V-AC S/P) —Mode selector switch for automatic or manual operation

—Engine DC junction included in instrument panel —Manual start crank switches - two provided on engine
instrument panel

—Electric starting motors (two) (12V-DC)

—Oil cooler

—Exhaust manifold insulation

—Oil filter(s) full flow with by-pass

—Falk coupling direct mounted (engine half only),

or drive plate for drive shaft —Overspeed control with reset switch on instrument
panel face

—Fuel filters - Primary and Secondary

—Solenoid Run/Stop control-energized to run

—Governor speed regulation

(10% Maximum No Load to Full Load) —Tamper proof throttle control-factory preset

—Heat Exchanger with pressure cap —Warning indicator for mode selection in "manual" posi-
tion

—High water temperature switch

—Wiring harness on engine for DC control

—Instrument panel with water temperature gauge, oil

pressure gauge, two battery voltmeters, and tachometer
with integral hourmeter

Page 5
SECTION 2 PDFP

GENERAL INSTRUCTIONS
Engine Storage
Preparing New Engine For Start-Up
Normal Running

Engine Storage NOTE: Do not allow exhaust system plumbing to stress

on engine.
Storing engines requires special attention. Clarke PDFP en-
gines, as prepared for shipment, may be stored for a maxi-
mum of six months. During this period, they should be C. Install all of the drain cocks or plugs in the cooling sys-
stored indoors in a dry environment. Protective coverings tem (drain cocks are removed for shipping engines dry).
are recommended provided they are arranged to allow for
air circulation. The stored engine should be inspected peri-
D. Fill engine cooling system with PRE-MIXED 50 percent
odically for obvious conditions such as standing water, part
water and 50 percent permanent type antifreeze solution.
theft, excess dirt buildup or any other condition that may be
Fill to bottom of neck in heat exchanger tank.
detrimental to the engine or components. Any such condi-
tions found must be corrected immediately.
NOTE: DO NOT USE 100% ANTIFREEZE.
Failure to premix antifreeze and water during
If a situation arises that extended storage is unavoidable
initial fill may result in heater damage.
(beyond six months), contact your local Distributor/Dealer
for assistance. Do not store engines beyond this time with-
out proper protection.
E. Connect fuel supply line and fuel return line to supply
tank. Bleed fuel system of all air.

NOTE: Do not use galvanized material for any compo-

nent of a diesel fuel system. The fuel will chem-
ically react with the zinc coating.
Preparing New Engine For Start-Up

Before starting a new or overhauled engine for the first time, F. Fill fuel tank with No. 2 diesel fuel.
carefully read and follow the check list below. Attempting to
NOTE: No. 2 diesel fuel is the only recommended fuel,
run the engine before studying these instructions may result
low engine power or damage could result by
in serious damage to the engine.
using any other type. (See Page 11 for fuel
recommendations.)
A. Make all raw water connections to heat exchanger tank.
Discharge line should be one size larger than supply line.
Discharge water is to be piped to an open waste cone.
G. Fill engine crankcase with SAE 15W-40 weight oil per
NOTE: Do not allow raw water plumbing to stress on oil recommendations of Section 3. Oil filler locations will be
engine heat exchanger. found on the engine valve cover.

NOTE: All heat exchanger plumbing to be securely fas- H. Pre-lubricate engine to a minimum 25 psi (172 KPA) to
tened to limit movement caused by engine vi- insure an immediate flow of oil to all bearings at the initial
bration. engine start-up. Contact the authorized Distributor/Dealer if
you require assistance with this item.

B. Install exhaust system. A vertical flexible exhaust outlet I. Unbox and inspect air cleaner element for damage or de-
connection is furnished for customer/contractor installation. terioration. Install air cleaner element on engine.

NOTE: Do not exceed exhaust back pressure limits. See J. Make all electrical (DC) connections between engine
Section 5 for details for each engine model. (DC) instrument panel and engine controller.

Page 6
SECTION 2 PDFP

K. Install batteries, battery cables and service batteries as Normal Running

required by manufacturer. See battery recommendation
Fire pump engines are run periodically to assure proper
under Section 3.
operation. Units may be run automatically as programmed
within the AEC for systems evaulation or they may be run
If any problems or questions develop in performing the manually.
above procedures, advise the authorized Distributor/Dealer
of details when making arrangements for the installation in- NOTE: For specific operating instructions, see Section
spection. 3 - Electrical System.

NOTE: Only one initial start-up inspection is provided

at no charge for an installation review. Be sure
to cover items A-K thoroughly before calling
the authorized Distributor/Dealer.

Page 7
SECTION 2 PDFP

NORMAL MAINTENANCE CHECKS

Fuel System
Drive Belts
Battery
Oil Pressure
Coolant Temperature & Level
Crankcase
Running Inspection

Fuel System Coolant Temperature & Level

Periodically check fuel tank to assure it is full. Keep the fuel When the engine is not running, the jacket water heater
tank filled to reduce condensation to a minimum and to maintains the coolant between 120 -140 degrees F (49-60˚
assure full running time during emergency operation. Per C). When running, engine coolant temperature should regis-
NFPA 25 specifications the fuel level should never be below ter between 160-200 degrees F (71-93˚ C).
67% of tank capacity. Engine fuel filter should be changed
annually or when fouled with contaminations. If contami- Coolant levels should be checked weekly by assuring that
nated, locate the source and correct. Check the gauze strain- the level is filled to the bottom of the heat exchanger fill
er of the fuel pump and clean if necessary. Refer to Page 13 neck. If the level is not there, check for the reason then refill
for procedures to clean the pump strainer and change fuel system.
filter.

Drive Belts Crankcase

All drive belts should be checked every six months. Belts The oil level should be maintained between the Full mark
can be inspected by pressing down the belt with the thumb and Low mark. Check the oil level weekly prior to normal
at the center of the longest free length and check the deflec- exercise. Do not check oil level when the engine is running.
tion. With moderate thumb pressure (10 lbs./70kPa) the If the engine crankcase was refilled, stop the engine after
deflection of the belt should be 3/8" (10mm). normal operating temperature has been reached, allow the
oil to drain back into the crankcase (approximately 10 min-
utes) and check the oil level. Add oil, if necessary, to bring
it to the proper level on the dipstick.
Battery
NOTE: DO NOT OVER-FILL CRANKCASE.
Check the batteries to insure they are clean and dry, the ter-
minals tight and protected, and the electrolyte must be at the Use only the recommended lubricating oil specified under
proper level. They should be tested weekly to determine the Section 3 - Lubricating Oil.
condition of cells, and the state of charge.

Running Inspection
Oil Pressure
While the engine is running at operating temperature, check
Normal engine operating oil pressure is 40-60 psi (276-414 for coolant, fuel or lubricating oil leaks. If any leaks are
kPa). If operating pressure falls below 40 psi (276 kPa), stop observed shut the engine off by consulting Page 9 "Impor-
engine and investigate cause. tant". Correct problem as necessary and re-run engine to
verify problem is corrected.

Page 8
 SECTION 2 PDFP

PREVENTIVE MAINTENANCE SCHEDULE

Item Inspection Interval

Weekly 6 Months 1 Year 2 Year

1. Run Engine
(per NFPA 25) X
2. General Inspection X
3. Lubricating Oil X R
4. Fuel Tank X
5. Fuel Lines X
6. Cooling System X R
7. Coolant Inhibitor X
8. Coolant Hoses X R
9. Battery X C R
10. Air Cleaner - Oil Gauze X X C
11. Belts X
12. Speed Control X
13. Fuel & Oil Filters R
14. Exhaust System X X
15. Battery Charging Alternator X
16. Warning Light X
17. Operating Gauges X
18. Crankcase Vent System X
19. Heat Exchanger Electrode X
20. Governor Run-Stop Control X
21. Jacket Water Heater X
22. Wiring System X
23. Remove Water From Fuel Filters X
24. Clean Fuel Lift Pump Strainer X

C – CLEAN R – REPLACE X – CHECK

NOTE: Refer to Section 3 for Maintenance Procedure.

IMPORTANT: Set AEC to "off" while servicing engine. the event that the AEC is connected by silent alarm to head-
Before turning the AEC to the "off" position, check with the quarters. When servicing is complete, return AEC selector to
maintenance and security supervisors to verify that all de- "Automatic" position and the manual operating lever to
partments concerned will be alerted of the temporary inter- AUTO - OFF position. Advise the appropriate personnel the
ruption of their fire protection equipment for normal main- engine has been returned to the "Automatic Mode".
tenance or testing. Also, alert the local fire department in

Page 9
SECTION 3 PDFP

ENGINE SYSTEMS

Section 3.1 Fuel System

Section 3.2 Air Intake & Exhaust System
Section 3.3 Lubrication System
Section 3.4 Cooling System
Section 3.5 Electrical System
Section 3.6 Falk Coupling

In this Engine Systems section that follows, data is pre- model being operated, make special note of the certified
sented in a generalized way for a description of system engine operating speed (RPM). Much of the data varies by
operation. For specific operational data and system limits, operating RPM - check the FM/UL/ULC certification tag on
refer to Section 5. In addition to knowing the specific PDFP the left rear engine mount for this information.

Section 3.1

FUEL SYSTEM

Operation
Diesel Fuel Recommendations
Maintenance Procedures
Service Procedures
Fuel System Priming

OPERATION

Fuel is drawn from the supply tank through the primary fuel fuel injection pump. The fuel injection pump raises the fuel
filter with a transparent water separator bowl, then enters the pressure forcing the fuel through each injector and into the
fuel lift pump. Upon leaving the fuel lift pump under pressure, combustion chamber. A leak-off fuel line from the injectors
the fuel is forced through the secondary fuel filter and into the and fuel injection pump returns fuel back to the fuel tank.

A. PRIMARY FILTER AND WATER TRAP B. FUEL LIFT PUMP

The primary fuel filter and water separator bowl, located The fuel lift pump is designed to circulate the fuel from the
between tank and lift pump, is designed to remove the larg- tank through the primary fuel filter, the secondary fuel filter
er dirt particles from the fuel and to collect water, which and into the fuel injection pump. This pump is also equipped
should be drained weekly from the bowl. with a manual hand pump used for priming the system.

Page 10
SECTION 3.1 PDFP
C. SECONDARY FUEL FILTER A manual over-ride switch on the instrument panel, placed
in the manual position, allows manual operation should the
The secondary filter is a higher performance type which is AEC malfunction. Should this be necessary, please refer to
located between the lift pump and the fuel injector pump. the manual operational steps on the instrument panel.
This filter removes the smaller contaminants and any
remaining fine water droplets. Important: Always leave the instrument panel switch in
the auto position when the unit is unattended.
The mode selector light will stay on while the
switch is in manual. The AEC can start the
D. FUEL INJECTION PUMP engine when the switch is in the manual posi-
tion but the engine AEC will be unable to stop
The PDFP fuel injection pumps are described as an opposed the engine and damage may result.
plunger, inlet metered, positive displacement, distributor
type pump. The function of the fuel injection pump is to
pressurize, distribute the clean fuel received from the fuel
filters equally, in the correct quantities and at the correct F. INJECTORS
time to the injectors.
The injectors receive high pressure fuel via the high pressure
The fuel pump injection timing, governor setting and fuel pipes from the fuel injection pump, and inject the fuel into
delivery levels are accurately set before the engine leaves the the combustion chamber in the form of a very fine spray.
manufacturer, and should not be altered.

G. FUEL LEAK-OFF
E. ENGINE MECHANICAL GOVERNOR
Surplus fuel delivered to the injectors is carried away by
A variable speed mechanical governor provides speed con- return lines connected to each injector. The pipe then con-
trol of the engine. The certified engine speed, shown on the nects with the fuel filter overflow pipe, which takes the sur-
FM/UL/ULC label, has been preset at the factory. Speed ad- plus fuel out of the filter via the fuel injection pump over-
justments can be made in the field to meet specific installa- flow and delivers this fuel back through a fuel return line
tion conditions. See Page 42 for Speed Adjustment and into the fuel tank.
Procedure.

DIESEL FUEL RECOMMENDATIONS

The quality and grade of fuel used is a very important factor ommended #2-D Diesel Fuel. Refer to the Diesel Fuel Spec-
in obtaining satisfactory engine performance, long engine ifications chart Fig. 1 for verification of fuel properties. Fuel
life and acceptable exhaust emission levels. Certified engine System specifics are found in technical data Section 5.
ratings are based at standard SAE conditions using the rec-

Cetane No., min. Viscosity Density Sulphur Distillation

cSt at 40˚ C kg/litre % mass, max.

45 2.5 - 4.5 0.835 - 0.855 0.5 85% recov.

at 350˚ C

Figure 1 - Diesel Fuel Specification Chart

Page 11
SECTION 3.1 PDFP

MAINTENANCE PROCEDURES

Weekly 6 Months
1). Fuel Tank: Keep the fuel tank filled to reduce conden- Check condition of fuel lines for fraying, leaks or poor con-
sation to a minimum. Open drain at the bottom of the dition. Replace if necessary.
fuel tank once a week to drain off any possible water
and/or sediment. Fill tank after each test run. Yearly
NOTE: Per NFPA 25 standards, the fuel tank level must 1). Change primary and secondary fuel filters. Refer to
never be less than 67% of its capacity. Section 6 for recommended part numbers.
2). Fuel Filters: Both fuel filters have a drain located at the
bottom of their body (Fig. 2), these filters should be 2). Clean the gauze strainer of the fuel lift pump.
drained each week to relieve built up water.

See Fig. 4 for detail.

Figure 2 - Filtration System & Filter Drain

Page 12
SECTION 3.1 PDFP

Figure 3 - Screen Strainer of the Fuel Lift Pump Figure 4 - Hand Priming Pump

SERVICE PROCEDURE:

A. How To Clean The Screen Strainer Of The Fuel

Lift Pump:

1.) Remove the cover and seal from the top of the lift
pump. (Fig. 3) Remove screen strainer. On 6T and 6TW 3.) Reinstall screen being careful to align the hole.
engines it will be necessary to remove the small tur-
bocharger heat shield which is mounted above the 4.) Install cover and seal making sure it is seated properly,
pump. if not leaks will occur and pump will not function. Do
not over tighten cover screw. On 6T and 6TW engines
Caution: This shield must be replaced when finished. reinstall the heat shield.

5.) Operate the hand priming pump to aid in purging air

2.) Carefully wash the screen and lift pump body. from the system. (Fig. 4)

Page 13
SECTION 3.1 PDFP

B. Fuel Filter Change:

MOUNTING
BASE FRONT OF Each PDFP engine has two fuel filters, for the purpose of
HEADER identity, the primary filter incorporates the transparent water
Separator. (Fig. 5)

AIR VENT VALVE Primary Filters:

1.) Using waste oil or fuel collector, open the drain valve
on the bottom of the transparent water separator bowl.
Drain until fuel can no longer be seen in the bowl.

2.) Unscrew the bowl and bowl header from the filter ele-
MASTER KEY MASTER KEY ment.
TRACK

3.) Turn the quick change ring of the filter element left
until loose.
CUSTOMER
LOGO 4.) Grasp the filter element and pull straight down until dis-
lodged from filter base. Notice the six embossments on
the side of the filter cap. These are used for alignment
purposes.

5.) Fill new element with fuel making sure grommet is

lubricated. Align and install by pushing element in
place. Do not force into position.

QUICK 6.) Install the quick change ring by turning right approxi-
CHANGE mately 1/3 turn until it clicks into position. To verify its
RING locked in position, the outside of the ring has two sets
of arrows, one set will be located directly under the air
vent in the filter base.
O-Ring Seal
7.) Screw the bowl and bowl header back onto the bottom
of the new element.
Bowl Header

8.) Tighten drain valve.

O-Ring Seal
9.) Prime the filter by operating the hand priming pump. If
priming pump does not function, turn the engine crank-
shaft one full turn clockwise, then try priming pump
Water
again. To verify the filter is fully primed. Open the air
Separator Bowl vent valve on the filter base while priming until fuel is
observed coming from the vent, when full, close vent.

O-Ring Seal

Draw Bolt

Drain Valve and Seal

Figure 5 - Primary Fuel Filter

Page 14
SECTION 3.1 PDFP

C. Secondary Filter: mary filter section. To verify filter is primed loosen the
cap ring on top of filter base, operate priming pump
1.) Using a waste oil or fuel collector, open the drain valve until fuel is observed around cap. Re-tighten cap ring.
on bottom of filter element. Drain until fuel stops run-
ning. Note: Both fuel filters can be primed by top filling,
after installation of new element. To do so, remove the
2.) Follow steps 2 thru 6 as described in the primary filter cap insert, O-ring and Cap seal located on the top of the
section. filter. Remove the internal white plastic rod plug. Pour
clean #2-D fuel into the filter base center hole until full.
3.) Tighten drain valve. Reinstall plastic plug, O-ring, cap insert and cap nut.
Start engine using manual start method.
4.) Operate priming pump as described in step 9 of the pri-

FUEL SYSTEM PRIMING:

If air enters the fuel system, it must be eliminated prior to the vent, operate the hand primer until fuel is observed
putting engine in service. coming from vent. If this cannot be accomplished, there
is an obstruction between the filter and tank which
Air can enter system if: includes the lift pump. Locate and repair before any
—The fuel supply tank is emptied thru normal operation. attempt to proceed.
—Any low-pressure fuel lines are disconnected.
—Any component of the low-pressure system leaks during 4) Once fuel is observed at the air vent reclose.
operation.
5) Continue to operate hand primer but loosen the cap nut
on top of secondary fuel filter. Once the filter is full,
To Remove Entrapped Air Proceed As Follows: fuel should be observed coming out around the ring. If
not remove cap nut, cap insert and O-ring. Remove the
1) Make certain the condition that caused air has been cor- white plastic volume plug in the center of the filter.
rected. Do not attempt to loosen fuel injector lines to With an external fuel source fill the filter down thru the
eliminate air. center hole until full. Reinstall volume plug, O-ring,
cap insert and cap nut. Tighten nut making sure O-ring
2) Operate the hand priming pump located on the bottom seated properly.
of the fuel lift pump on the engines' right side.
6) Start engine by manual crank Sw-#1 or Sw-#2, manual
Note: If the priming pump does not function it is pos- start instructions on instrument panel.
sible the cam lift lobe is up. Turn the engines crankshaft
one full turn clockwise. Retry priming pump. 7) If engine fails to start or does start but runs erratic,
recheck all fuel lines, connections and filters for some-
thing obvious. If a simple solution cannot be located it
3) Locate the air vent valve (black plastic valve with screw may be necessary to contact your local Distributor /
driver slot) in the primary fuel filter base. Slightly open Dealer for service assistance.

Page 15
 SECTION 3.1 PDFP

Figure 7 - Fuel System

Speed Adjustment Primary Filter

Fuel Injection Pump Secondary Filter

Page 16
SECTION 3.2 PDFP

AIR INTAKE AND EXHAUST SYSTEM

Air Intake Operation
Air Cleaner
Crankcase Ventilation
Exhaust Operation
Maintenance And Service Procedures

AIR INTAKE OPERATION

During the intake stroke, the piston travels downward, the On some engines a turbocharger is introduced in the air sys-
intake valve is open, and the exhaust valve is closed. The tem. Power to drive the turbocharger is extracted from the
downstroke of the piston permits air to enter the cylinder waste energy in the engine exhaust gas. The expanding
that has been drawn from the air cleaner through the open exhaust gases turn a single stage turbo wheel which drives
intake valve. The intake air is never restricted by any con- an impeller thus supplying air under pressure to the cylin-
trolling valve or mixing devices. The intake charge consists ders.
of fresh, clean air which provides for efficient combustion.

AIR CLEANER

The air cleaner is designed to remove foreign matter from

the air, pass the required volume of air for proper combus- CAUTION: Do not attempt to remove the air cleaner
tion, and maintain efficient operation for a reasonable peri- while an engine is running nor run the engine
od of time before requiring service. while the air cleaner is off. Exposed compo-
nents could cause severe injury to personnel
The importance of keeping foreign matter out of the engine and major internal engine damage could
cannot be over-emphasized, since clean air is essential to occur should any foreign matter be drawn
satisfactory engine operation and long engine life. Should into the engine.
dust in the air supply enter the engine it would be carried
into the cylinders and due to its abrasive properties, cause The air cleaner manufacturer recommends the following:
premature wear of the moving parts. Dirt, which is allowed
to build-up in the air cleaner passages, will eventually 1. The pre-oiled reusable elements are serviced with a spe-
restrict the air supply to the engine and result in heavy car- cial oil. The elements can be serviced or replaced.
bon deposits on the valves and pistons due to incomplete
combustion. 2. Figure 1 shows the air filter Service Instructions.

The air cleaner used on PDFP engines is a reusable type. 3. When servicing the element is not practical, you can im-
Should a situation occur where the air cleaner becomes prove filter efficiency by re-spraying with oil.
plugged with dirt (starving the engine of air), low power and
heavy black smoke will result; the air cleaner should be ser-
NOTE: Do not attempt this while engine is running.
viced immediately.

NOTE: Do not over oil.

Page 17
SECTION 3.2 PDFP

AIR FILTER SERVICE INSTRUCTIONS

Figure 1 - Air Filter Service Instructions

Page 18
SECTION 3.2 PDFP

CRANKCASE VENTILATION

Vapors which may form within the engine are removed from compartment. This crankcase pressure and resulting ventila-
the crankcase and gear train compartment by a continuous, tion is accomplished by the air seepage past the piston rings
pressurized ventilation system. sweeping up through the cylinder block and into the rocker
arm compartment. Here it is expelled through a vent pipe
A slight pressure is maintained within the engine crankcase attached to the rocker cover breather element (Fig. 2).

Figure 2 - Crankcase Ventilation

EXHAUST OPERATION

Internal combustion engines convert fuel energy into both exhaust piping elbows and outlet. In addition to providing
useful work and wasted heat. The useful work is the fly- engine exhaust data and back-pressure limitations, Clarke
wheel rotation that drives the pump. The wasted heat offers a service to installers, through the local Pump OEM
involves the engine water cooling system, radiated heat and Dealer, for making recommendations on exhaust system siz-
the exhaust gases. Approximmately 2/3 of the fuel energy is ing for specific installations.
wasted. Critical review must be made of these systems to
assure that the engine delivers the useful power required and If the exhaust system should become restricted, the hot ex-
maintains the engine within the operating parameters estab- haust gases cannot escape from the engine. This condition
lished by the engine manufacturer. would cause a loss of power, extreme internal engine heat,
and very high exhaust gas temperatures. These conditions
Some engines are turbocharged (T). Turbochargers increase can and will cause internal engine damage and a reduction
the air flow into the engine cylinder and permit increased of engine life.
horsepower by burning more fuel than is possible in a natu-
rally aspirated (N) engine. Turbochargers enhance the effi- Should any exhaust manifold studs or bolts break or come
ciencies of engines and add power to a similar displacement loose, engine exhaust gases can start leaking into the pump
(N) engine. Turbochargers are maintenance free. room. Under these conditions, the engine should be attend-
ed to immediately. Indications of an exhaust leak would be
The exhaust system is critical to the proper engine perfor- the smell of diesel exhaust, possible eye irritation and soot
mance. When initially installed, consideration must be given collecting on the engine around the leak. Contact your local
to the exhaust gas flow requirements, the exhaust tempera- Distributor/Dealer for repair.
tures and the exhaust back-pressure limitations of the spe-
cific engine. Refer to Section 5 for specific engine model NFPA-20 requirements are to have exhaust system high tem-
and operating speed back-pressure limitations. All the com- perature personnel protection. Don't run PDFP engines
ponents in an exhaust system contribute to the back-pressure without insulation blankets installed. Serious injuries may
determination including the flexible section, muffler, result by contact with hot exhaust system components.

Page 19
SECTION 3.2 PDFP

MAINTENANCE AND SERVICE PROCEDURES

Weekly NOTE: Exhaust back pressure, air inlet restriction and

Prior to each engine run make a visual check of the exhaust crankcase pressure limits are listed for each
system to verify condition of piping and muffler. Investigate PDFP Model in Technical Data Section 5. These
thoroughly any areas that would appear to have rusty condi- limits are not to be exceeded. To properly check
tions such as rain water running down pipe and getting these limits, the engine must be producing max-
inside the engine. Severe internal engine damage could imum required horsepower.
occur if water enters the engine exhaust system. While the engine is running inspect exhaust pipe outlet out-
side of the pump room itself for environmental hazards such
Inspect the engine air cleaner for dirt buildup or damage. as excessive smoke conditions. The following could be used
as a guide for general engine operating conditions.
1. Blue Smoke — Possible engine oil consumption - too
many areas to list for possibilities.
6 Months 2. White Smoke — Possibility of water in cylinders
Inspect exhaust system for leaks or plugging, if any are Source — Possible water in fuel or internal engine prob-
found, repair immediately. Inspect and tighten if necessary lem.
exhaust manifold, turbo mount (if equipped) and piping
bolts/nuts. Inspect the insulations condition for any deterio- Should any of these or any other conditions be found, con-
ration or looseness; repair as necessary. Check for any tact your local Distributor/Dealer for assistance. Check con-
petrolium products on the blankets and replace if any are dition of the air inlet system ducting, clamp tightness hose
found. condition.

Exhaust system back pressure limits are not to be exceeded.

Yearly
Re-oil and clean the air cleaner element per the manufactur-
ers directions. Each engine is shipped with the cleaning in-
structions. Refer to Figure 1, Page 18.

Page 20
SECTION 3.3 PDFP

LUBRICATION SYSTEM

Operation
Oil Cooler
Lube Oil Fill
Oil Level Dipstick
Lube Oil Filter
Lubricating Oil Requirements
Changing The Lubricating Oil
Lubricating Oil Analysis
Changing The Lubricating Oil Filter
Maintenance Procedure

OPERATION

The lubricating oil system is schematically illustrated in through the rocker shaft to the bearings of the rocker levers.
Figure 1. The valve stems and valve springs are lubricated by splash and
oil mist.
Pressure lubrication is supplied by a rotor type pump. The
pump is driven through an idler gear from the crankshaft gear. The hub of the idler gear is supplied with lubricating oil from
On all 4 cylinders a balancer unit is used, the pump is fitted to the pressure rail and the timing gears are splash lubricated.
the balancer frame and is driven by the balancer drive shaft.
The oil from this pump circulates through the balancer unit The maximum pressure in the system is controlled by a relief
then passes through a full flow filter to the pressure rail. On 6 valve. This valve controls the pressure of the oil and is located
cylinder units the oil passes directly from the pump to the between the oil cooler and the oil filter.
filters. The filter has a by-pass valve which lets oil pass
directly to the pressure rail, if the filter becomes restricted. All PDFP engines include oil coolers. The oil passes through
From the pressure rail, lubricating oil passes to the main the cooler before the filter. When cold oil increases the
bearings of the crankshaft and through passages in the crank- restriction in the cooler, a by-pass valve lets the lubricating oil
shaft to the end bearings. The pistons and the cylinder bores pass directly to the oil filter.
are lubricated by splash and oil mist.
The turbocharger is lubricated by oil from the pressure rail.
Lubricating oil for the camshaft journals is supplied from the The lubricating oil is sent through a passage across the
main bearings and a reduced supply is sent from the camshaft cylinder block to an adaptor fitted to the right side of the
journal, through passages in the cylinder block and the cylin- engine and then by pipe to the turbocharger. The lubricating
der head, to the rocker assembly. Lubricating oil passes oil returns from the turbocharger to the sump.

Page 21
SECTION 3.3 PDFP

Fig. 1 - Typical PDFP 1000 Series Engine

Lubricating System Schematic

Page 22
SECTION 3.3 PDFP

OIL COOLER OIL LEVEL DIPSTICK

PDFP engines use a plate type oil cooler. The only difference On all PDFP engines the dipstick is located on the left center
is the number of plates used between the 4 and 6 cylinder of the engines. Oil level can only be checked when the engine
models. The number of plates is determined by the amount of is not running and has been off for at least 10 minutes. See Page
cooling that is required. All of the oil cooler systems incor- 24 for lube oil requirements if additional oil is needed.
porate oil bypass valves in the event of plate core plugging.

LUBE OIL FILTER

LUBE OIL FILL All engines use full flow oil filters of the "spin on" type
element. They have a non-replaceable pleated paper cartridge.
On all models the oil fill is located on the rocker cover at the Each engine has an integral bypass valve to bypass the filters
top of the engine. See Fig. 2, for typical oil fill location. (See in the event of plugging or for cold start purposes. The 6
Page 24 for lube oil requirements.) cylinders have dual filters and the 4 cylinders have one.

Use only Perkins filters. Refer to Section 6 for proper service

part numbers.

Figure 2 - Typical Oil Fill Location

Page 23
SECTION 3.3 PDFP

LUBRICATING OIL REQUIREMENTS

Hundreds of commercial oils are marketed today, but labeling This is the only oil recommended for Perkins Engines used in
terminology differs among suppliers and can be confusing. PDFP service. Lubricants meeting these criteria have pro-
Some marketers may claim that their lubricant is suitable for vided maximum engine life when used in conjunction with
all makes of diesel engines and may list engine makes and recommended oil drain and filter maintenance schedules.
types, including Perkins, on their containers. Such claims, by
themselves, are insufficient as a method of lubricant selection API Performance category CF-4 represents an
for PDFP engines. enhanced level of lubricant performance over the
API CE category which it replaces. Lubricants
The proper lubricating oil for all PDFP engines is selected, meeting this new performance level are preferred.
based on SAE Viscosity Grade and API (American Petroleum
Institute) Service Designation. Both of these properties are NOTICE: Monograde oils should not be
displayed in the API Symbol, which is illustrated within the used in these engines regardless of API
specific requirements. For PDFP engines, the proper lubricant Service Classification.
must also possess a sulfated ash content below 1.0% mass.
Sulfur content of the #2-D Diesel fuel used must be limited to
LUBRICANT REQUIREMENTS 0.5% mass. The combustion of high sulfur (greater than 0.5%)
API Symbol: will shorten engine life through accelerated wear of piston
rings.

When the use of High Sulfur Diesel Fuel (greater than 0.5%
mass) is unavoidable, the use of lubricants with higher Total
Base Numbers (alkalinity) are recommended. Refer to Fig. 4
SAE Viscosity Grade: 15W-40 for min TBN numbers for normal service.
API Classification: CF4
HT/HS Viscosity: 3.7 cP min.
Sulfate ASH: MAX 1% MASS

CHANGING THE
LUBRICATING OIL
1 Operate the engine until it is warm. Refer to Page
33 "Manual Starting Instructions" for instruc-
tions.
2 Stop the engine. Remove the sump drain plug
(Fig. 3 - Item 1) and its "O" ring and drain the
lubricating oil from the sump. Ensure that the
"O" ring is not damaged. Fit the drain plug and its
"O" ring and tighten the plug to 34 Nm (25 lbf ft)
3,5 kgf m.
3 Fill the sump to the "MAX" mark on the dipstick
(Fig. 3 - Item 2) with new and clean lubricating
oil of an approved grade.
4 Return the unit back into service by returning the
AEC selector to "automatic" position and the
manual operating lever to manual stop position.
Close cooling system manual by-pass valve.
5 Dispose used oil properly Figure 3 - Changing Oil

Page 24
SECTION 3.3 PDFP

ASTM Condition PDFP

Designation Measured Limit

Pentane Insolubles D 893 Engine 1.0

% Max. Combust.

Carbon (Soot) Content, E-1131 Engine 1.5

TGA Mass % Max. Combust.

Viscosity at 40˚ C cS D 445 & Engine

D 2161 & Oil
% Max. Increase 40.0
% Max. Decrease 15.0

Total Base Number (TBN)

Min. D 664 or D 4739 Oil 1.0
Min. D 2896 2.0

Water Content (dilution) D 95 Engine 0.30

Vol. % Max.

Flash Point ˚ C Engine 20.0

Reduction Max. D 92 Fuel Dil.
*
Fuel Dillution Vol. % Max. Engine 2.5

Glycol Dilution D 2982 Engine 1,000

PPM Max.

Iron Content ** Engine 150

PPM Fe Max. Wear

Copper Content ** Engine 30

PPM Cu Max. Wear

Sodium Content PPM NA ** Engine 50

Over Baselline Max. Coolant

Boron Content PPM B ** Engine 20

Over Baseline Max. Coolant

** Various Methods
** Elemental Analyses are conducted using either emission or atomic absorption spectroscopy. Neither method has an
ASTM designation.
Figure 4 - Oil Analysis Warning Limits

LUBRICATING OIL ANALYSIS

Oil Analysis kits are available through the DDC Distributor/ Oil analysis consists of a series of laboratory tests conducted
Dealer Network for efficient monitoring of the lubricating oil on the engine' s lubricant. Some tests show the condition of the
in a PDFP engine. Refer to Parts Information Section 6 to engine and others show the condition of the lubricant. Refer
order. to Fig. 4 for warning limits.

Page 25
SECTION 3.3 PDFP

CHANGING THE
LUBRICATING OIL FILTER

The filter can have one or two canisters. When equipped with two canisters, both must
be replaced at the same time.

1 Turn engine off by refering to Page 9 "Important" for proper engine shutdown
procedure.
2 Put a tray under the filter to retain spilt lubricating oil.
3 Remove the filter with a strap wrench or similar tool. Ensure that the adaptor (Fig.
5) is secure in the filter head. Then dispose of the filter properly.
4 Clean the filter head.
5 Add clean engine lubricating oil to the new filter. Allow the oil enough time to
pass through the filter element.
6 Lubricate the top of the filter seal with clean engine lubricating oil.
7 Fit the new filter and tighten it by hand only. Do not use a strap wrench.
8 Ensure that there is lubricating oil in the sump. On turbocharged engines, ensure
that the engine will not start and operate the starter motor until oil pressure is
obtained.
9 Operate the engine and check for leakage from the filter. When the engine has
cooled, check the oil level on the dipstick and put more oil into the sump, if necessary.
10 Return the unit back into service by returning the AEC selector to "automatic" position and the manual operating lever to
AUTO-OFF position.
Attention: The filter contains a valve and special tube to ensure that lubricating oil does not drain from the filter. Therefore,
ensure that the correct Perkins POWERPART filter is used. Refer to Section 6 for proper filter.

MAINTENANCE PROCEDURE

Weekly deterioration from combustion by-products and contamina-

tion. For these reasons, regardless of the appearance of the oil,
1). Check oil level with the engine stopped. change oil and filter(s) annually.

2). During and after weekly maintenance run, check over CAUTION: Use only recommended lube oil and oil fil-
entire engine for signs of oil leaks. Repair immediately if ters. Internal engine damage and/or excessive wear could
found or call your authorized Distributor/Dealer for occur using unauthorized materials.
service.

Yearly OIL VOLUME

Stationary diesel engines collect condensation in the engine For specific oil quantities please refer to Technical Data
oil pan while at rest. When in use, lubricating oil undergoes Section 5 for each engine model listing.

Page 26
SECTION 3.4 PDFP

Operation
Engine Coolant
Water
Antifreeze
Coolant Inhibitor
Procedure For Filling Engine
Pressure Cap
Thermostat
Engine Coolant Heater
Heat Exchanger Cooling
Raw Water System (Cooling Loop)
Zinc Electrode
Maintenance And Service Procedures

OPERATION Engine coolant from the heat exchanger passes through the
centrifugal water pump which is fitted on the front of the
The heat resulting from combustion in the engine cannot be timing case. The pump is gear driven from the crank shaft and
fully converted into kinetic energy. A major portion of that provides flow of the coolant through the system. From the
heat is absorbed by the coolant from the cylinder walls and pump, the coolant passes through a passage in the timing case
cylinder heads, and must be carried away from the engine. It to the front of the cylinder block.
is the function of the Heat Exchanger to transfer waste engine
heat to the raw cooling water.
On four cylinder engines the coolant passes through a passage
in the left side of the cylinder block to the rear of the cylinder
Inside the heat exchanger tank is a heat exchanger core,
block. Where a lubricating oil cooler is mounted, some of the
somewhat similar to a miniature radiator. Engine coolant
coolant passes around the element of the cooler and then to the
circulates around the heat exchanger core while cool raw
rear of the cylinder block. The coolant also passes around the
water, from a tap on the pressure side of the fire pump, is
cylinders and up into the cylinder head through a by-pass to
circulated inside the core carrying away the heat. See Fig. 1 for
the inlet side of the water pump. When the thermostat is open,
the raw water supply connection to the engine. The installing
it closes the by-pass and the coolant passes to the heat
contractor makes the raw water discharge connection at time
exchanger.
of system installation.

Discharge

Supply

Fig. 1 - Raw Water Connections

Page 27
SECTION 3.4 PDFP

On six cylinder engines the coolant divides as it enters the Chlorides, sulfates, magnesium and calcium are among the
cylinder block. Most of the coolant passes along the right hand materials which make up dissolved solids that may cause scale
side of the cylinder block and around the outside of the deposits, sludge deposits, corrosion or a combination of these.
cylinders to the rear of the cylinder block. The remainder of Chlorides and/or sulfates tend to accelerate corrosion, while
the coolant passes along a passage on the left hand side of the hardness (percentage of magnesium and calcium salts broadly
cylinder block to the lubricating oil cooler. The coolant flows classified as carbonates) causes deposits of scale. Water
around the element of the lubricating oil cooler to the rear of within the limits specified in Fig. 2 is satisfactory as an engine
the cylinder block. The coolant then passes to the rear of the coolant when properly inhibited. Use of distilled water is
cylinder head. preferred.

Coolant passes forward through the cylinder head and into the
PARTS PER GRAINS PER
thermostat housing. These engines have two thermostats. If MILLION GALLON
the thermostats are closed, the coolant goes, through a by-
pass, directly to the inlet side of the water pump. When the Chlorides (Maximum) 40 2.5
thermostats are open, it closes the by-pass and the coolant Sulfates (Maximum) 100 5.8
passes to the heat exchanger. Total Dissolved Solids (Maximum) 340 20
Total Hardness (Maximum) 170 10

Fig. 2 Satisfactory Water Limits

ENGINE COOLANT

The following information is provided as a guide for PDFP

engine users in the selection of a suitable coolant.
ANTIFREEZE
The water/ethylene glycol/inhibitor coolant mixture used in
PDFP engines must meet the following basic requirements: Use an ethylene glycol coolant (low silicate formulation) that
• Provide for adequate heat transfer. meets or exceeds the standard of either the GM 6038-M
• Provide protection from cavitation damage. formulation (GM 1899-M performance) or ASTM D 4985
• Provide a corrosion/erosion-resistant environment within requirements.
the cooling system.
• Prevent formation of scale or sludge deposits in the cool- A 50% coolant/water solution is recommended. Concentra-
ing system. tions over 70% are not recommended because of poor heat
• Be compatible with engine hose and seal materials. transfer capability, adverse freeze protection and possible
• Provide adequate freeze and boil over protection. silicate dropout. Concentrations below 30% offer little freeze,
boil over or corrosion protection.
WARNING
A water and anti-freeze solution is required for
pump installations. Premixing this solution
COOLANT INHIBITOR
prior to installing is required. This prevents
possible pure anti-freeze chemical reactions to
The importance of a properly inhibited coolant cannot be
block heater elements which can burn out the
over-emphasized. A coolant which has insufficient or no
element. Please see the technical data Section
inhibitors at all, invites the formation of rust, scale, sludge and
5 for proper cooling system capacities of each
mineral deposits. These deposits can greatly reduce the cool-
model.
ing systems efficiency and protection capabilities.

Recommended supplemental coolant inhibitors are a combi-

nation of chemical compounds which provide corrosion pro-
WATER tection, cavitation suppression, pH controls and prevent scale.
These inhibitors are available in various forms, such as liquid
Water can produce a corrosive environment in the cooling packages or integral parts of anti-freeze.
system, and the mineral content may permit scale deposits to
form on internal cooling surfaces. Therefore, inhibitors must It is imperative that supplemental inhibitors be added to all
be added to control corrosion, cavitation, and scale deposits. PDFP engine systems. A pre-charge dosage must be used at

Page 28
SECTION 3.4 PDFP

the initial fill and the maintenance dosage used at each service part number for the Factory Coolant Analysis Kit. This kit can
interval. Serious damage will occur unless inhibitors are used. be purchased for a nominal fee for analyzing the condition of
Some of the more common corrosion inhibitors are borates, the engine' s coolant.
nitrates and silicates.

Inhibitors become depleted through normal operation, addi- PROCEDURE FOR FILLING ENGINE
tional inhibitors must be added to the coolant as required to
maintain original strength levels. Refer to Fig. 3 for proper During filling of the cooling system, air pockets may form.
concentrations of inhibitors. The system must be purged of air prior to being put in service.
This is best accomplished by filling with a pre-mix solution
up to the filler neck. Install the pressure cap, start and run
Min. Max. engine until the temperature stabilizes at approximately 160˚
PPM PPM
- 200˚ F (71˚ - 93˚ C). During this warming process, you may
Boron (B) 1000 1500 see coolant coming from the overflow tube attached at the
Nitrite (NO2) 800 2400 pressure cap location. This is a normal condition since the
Nitrates (NO3) 1000 2000 coolant expands as it heats up. When the overflow ceases, stop
Silicon (Si) 50 250 the engine.
Phosphorous (P) 300 500
pH 8.5 10.5 To verify that the coolant is at a safe operating level, it' s best
to wait until the engine temperature drops to approximately
Fig. 3 - Proper Concentrations Of Inhibitors
120˚ F (49˚ C), or lower, before removing the pressure cap.
After the cap is removed, fill as necessary up to the bottom of
Do not use soluble oils or chromate inhibitors in PDFP the fill neck.
engines. Detrimental effects will occur.
CAUTION: Do not remove pressure cap while coolant is at
To properly check inhibitor concentrations it may be neces- normal operating temperatures. Possible per-
sary to contact your local Distributor/Dealer for assistance. sonal injury could result from the expulsion of
Refer to Parts Information Section 6, Page 46, to obtain the hot coolant.

PRESSURE CAP
Like most cooling systems, the heat exchanger type operates All pressure caps include a vacuum valve which opens during
under pressure. A typical cap shown in Fig. 4 maintains cool down. This prevents an internal vacuum from being
system pressure to raise the coolant boiling point and permits formed which could contribute to leaking seals and hoses
a somewhat higher operating temperature without coolant collapsing.
loss. Pressure cap values are 9 psi (62 kPa) on PDFP engines.

Fig. 4 - Typical Coolant Cap

Page 29
SECTION 3.4 PDFP

THERMOSTAT engines lubricating oil at a safe temperature for emergency

start purposes. If pump room temperatures drop below 32˚ F
Each pump engine is equipped with a temperature controlling (0˚ C), consult the factory concerning oil heaters.
thermostat(s). Normal operating range of these thermostat(s)
are: begin opening at 170˚ F (77˚ C), open fully at 198˚ F On the initial installation of each fire pump engine, it is the
(92˚ C). The thermostat(s) are located at the front of the responsibility of the installing contractor to wire the heater to
cylinder heads. the pump room AC circuit. See Section 3.5 Electrical AC
Wiring Diagram, Fig. 6, Page 38, for correct wiring to the
heater.
NOTE: Do not operate PDFP engines without a
thermostat. The engine will overheat and may
cause damage or injury. NOTE: The factory has equipped the heater system with
silicone hoses and constant torque clamps. Re-
placement parts should be original equipment to
prevent coolant leaks.
ENGINE COOLANT HEATER
CAUTION: Do not activate the AC circuit unless the engine
Fire pump engines must be able to assume full load immedi-
cooling system has been filled.
ately when used for emergency service. NFPA-20 specifica-
tions require an engine coolant heater Figure 5, to maintain a A pre-mix solution must be used. Chemical
minimum temperature of 120˚ F. (49˚ C). Maintaining this reactions will occur if pure Ethylene Glycol
temperature assists the engine to start easily and produce anti-freeze is allowed to fill the heater cavity
rated horsepower immediately. For fire pump units operation with AC circuits activated.
in cold climates optional oil heaters are available to keep the

Fig. 5 - Engine Heaters

Page 30
SECTION 3.4 PDFP

Fig. 6 - Heat Exchanger Cooling System

HEAT EXCHANGER COOLING RAW WATER SYSTEM (Cooling Loop)

The heat exchanger cooling system is shown in Fig. 6. Raw This system is provided by the pump manufacturer or the
water from the fire pump passes through the heat exchanger assembler as part of the complete engine-pump-controller
core where it lowers the engine coolant temperature. Typical package. Components for the raw water system are selected to
raw water connection points on the heat exchanger are shown ensure adequate flow through the heat exchanger as required
in Fig. 1. by the engine at specific raw water temperature. The raw water
system is generally referred to as the "cooling loop". A typical
NOTE: The heat exchanger has a maximum raw water cooling loop includes the following components as shown in
pressure rating of 60 psi (414 KPa). Fig. 7.

Page 31
SECTION 3.4 PDFP

1. Indicating manual valves ZINC ELECTRODE

2. Water strainers A sacrificial zinc anode is included with each heat exchanger.
Over a period of time, normal electronic action will occur
3. Pressure regulator between dissimilar metals within the heat exchanger. The rate
of material transfer is dependent on the electrolitic strength of
4. Solenoid valve (DC) the transfer media (raw water). It is the zinc anode that gives
up material in this process and thus preserves the integrity of
5. Pressure gauge the heat exchanger.

The heat exchanger discharge line must be a minimum of one

pipe size larger than the supply line. Discharge is to be made
to an open waste cone as specified in NFPA-20. MAINTENANCE AND SERVICE PROCEDURES

CAUTION: Damage to the heat exchanger may result if Weekly

raw water plumbing (supply or discharge) weight or stress
is applied to the heat exchanger. 1) Check coolant level weekly. The coolant (while being
maintained by the coolant heater) level should be at the
The solenoid valve may be omitted on vertical turbine pump bottom of the filler neck. Because this is a closed system,
installations where no static pressure exists in the heat ex- when operating temperature is reached, the pressure relief
changer supply line while the engine is not running. Each cap may allow some excess coolant to expell out the
engine has a minimum requirement of raw water flow. Correct overflow tube until a stabilized level is reached.
flow through the heat exchanger is critical for maintaining the
proper engine operating temperature.
6 Months
Engine coolant temperature can be adversely affected by
insufficient raw water flow and by excessive ambient tem- Check the condition of the pressure relief cap. The rubber seat
perature of the raw water. See the technical data Section 5 for should be in sound condition. If it is cracked, split or frayed,
each engine model' s minimum raw water flow requirements do not use. Do not attempt to run engine without a pressure
at 60˚ F (16˚ C) and 95˚ F (35˚ C) at specified engine RPM cap. The cap has a 9 P.S.I. (62 kPa) relief rating, which is not
ranges. Do not exceed raw water pressure allowance within to be altered if a replacement cap be required.
the heat exchanger.

NOTE: Although engine operating temperature may Yearly

appear normal, engine cooling may be compro-
mised and possible engine damage will result if 1) Zinc Electrode
raw water flow is reduced. Zinc electrode should be inspected and replaced if more
than half deteriorated.

2) Inhibitor – Check the amount of inhibitor chemicals re-

maining and add if necessary.

NOTE: Coolant should be changed every two years.

Page 32
SECTION 3.5 PDFP

ELECTRICAL SYSTEM

Engine Operating System

Manual Starting Instructions
Fuel Injection Pump Solenoid
Instrumentation And Controls
Speed Switch
Battery Charging Alternator
Starters
Alarms
Batteries
Battery Cables
Wiring Diagram
Maintenance And Service Procedures

ENGINE OPERATING SYSTEM cally connected to the (AEC). Both automatic operation and
test signals are sent to the engine from the AEC. Under
PDFP engines used for fire pump service include two electri- emergency conditions, or if the AEC should become defective
cal systems. The engine heater system (AC), and the engine or disconnected, it is possible to start the engine by operating
starting and control system (DC). The starting and control manual crank switch #1 or #2. Both switches are located on the
circuits are integral with the DC wiring harness but are IP. See Fig. 1. Specific emergency operating instructions are
separated for explaining operation, maintenance and service attached to the IP and explained in detail under MANUAL
procedures. This includes two starting motors, battery charg- STARTING of this section. The IP includes a warning indica-
ing alternator, wiring harness, battery insulator, electric in- tor that will remain on when the mode selector is in manual
strumentation, run-stop solenoid and two battery systems. For mode. Engine wiring diagrams for AC and DC systems are
identification reasons only, usually 12V DC systems have 2 shown in this section.
batteries. Under normal operating conditions, signals for
running and shutdown are transmited from the AEC. With the
AEC switch on "automatic", a specific drop in the fire main
line pressure or other pre-programmed signal will result in a
start of the diesel engine. Reference the DC wiring diagram MANUAL STARTING INSTRUCTIONS
Fig. 5, Page 37.
The engine can be operated without using the engine AEC.
CAUTION: These engines have been pre-set for a specific Use the following procedure when manual starting is re-
operational speed (RPM). When started, the quired. Refer to Fig. 1.
engine will quickly reach this setting. The en-
gines do not have idle speed settings.

With the AEC switch on "Test", the engine can be test started TO START ENGINE
from the AEC using either battery system A or B. Engine
stopping is accomplished by switching the controller selector 1. REFER TO PG. 9 "IMPORTANT" ON AEC OPERA-
to the "Off" position. Consult the AEC operation manual for TION.
specific operational instructions.
2. POSITION MODE SELECTOR TO MANUAL RUN.
NOTE: Prior to turning the AEC to any position other Fig. 1.
than automatic, please read the paragraph labeled
"IMPORTANT" in Section 2, Page 9. 3. LIFT AND HOLD MANUAL CRANK #1 UNTIL
ENGINE STARTS, OR RELEASE AFTER 15 SEC-
ONDS. IF UNIT FAILS TO START, WAIT FOR 15
The engine DC starting and control system terminates at the SECONDS, USE MANUAL CRANK #2 AND REPEAT
Instrument Panel (IP). From this point, the engine is electri- STEP.

Page 33
SECTION 3.5 PDFP

4. IF COOLING WATER IS NOT FLOWING OR INSTRUMENTATION AND CONTROLS

ENGINE TEMPERATURE IS TOO HIGH, OPEN
COOLING SYSTEM MANUAL BY-PASS VALVE. Figure 1, shows the instrumentation panel which contains the
following guages:

TO STOP ENGINE 1. Tachometer with integral Hourmeter

2. Oil Pressure In P.S.I.
1. RETURN MODE SELECTOR SWITCH TO AUTO- 3. Two-Battery Voltmeters
MATIC, AND MANUAL STOP POSITION, ENGINE 4. Engine Coolant Temperature
WILL STOP.
TACHOMETER AND INTEGRAL HOURMETER –
2. CLOSE COOLING SYSTEM MANUAL BY-PASS This meter receives its signal from the overspeed switch to
VALVE. read engine RPM, in addition the hourmeter records a cumu-
lative total of engine operating hours.
IMPORTANT:
DO NOT LEAVE THE MODE SELECTOR SWITCH OIL PRESSURE – This electrical guage indicates engine
IN THE MANUAL RUN POSITION DURING AUTO- oil pressure readings in English and Metric Units (PSI &
MATIC OPERATION. (THE CONTROLLER WILL BE KPA). The pressure sensor unit signaling the gauge is found
UNABLE TO STOP THE ENGINE AND DAMAGE on the Lower Rear Left Side of the engine.
MAY RESULT).
ENGINE COOLANT TEMPERATURE – This electri-
cal gauge indicates degrees of coolant operating temperature
in fahrenheit (˚ F) and celsius (˚ C). The sensor is located in the
FUEL INJECTION PUMP SOLENOID right side of the thermostat housing.

The DC solenoid is an integral part of the fuel injection pump. VOLTMETERS – Each PDFP gauge panel contains two
This essential item, when energized allows the fuel injection battery voltmeters, one for battery #1 and one for battery #2.
pump internal governor to take control of fuel injection. This
solenoid remains energized during engine operation, when
De-energized the engine stops.

2 1

1 Emergency Operating
Instructions

2 Automatic-Manual
Mode Selecter

3 Instrument Panel

3 Fig. 1 - Instrument Panel

Page 34
SECTION 3.5 PDFP

Fig. 2 - Engine Heaters Fig. 3 - Magnetic Pickup

SPEED SWITCH screw remove the small cover plate on the face of the speed
switch located in the Instrument Panel.
After the engine has started and reached 1000 RPM, the speed
switch signals the AEC to terminate the starter cranking Crank terminate (SW#1) adjustment should be done reading
action. In the event of an engine overspeed, the speed switch "engine crankshaft" speed at the front of the engine using a
signals the AEC and also effects an engine shutdown. The hand held tachometer. For starter protection and optimum
OVERSPEED RESET switch is included on the instrument engine stability, this switch should be calibrated to 1000
panel. Should an overspeed condition occur, investigate the RPM.
cause and make necessary corrections before placing engine
back in service. The OVERSPEED RESET must be manu- Overspeed (SW#2) adjustment should be done reading "en-
ally lifted to reset. gine crankshaft" speed at the front of the engine using a hand
held tachometer. This switch should be calibrated to 120% of
NOTE: This reset operation must be completed to allow rated speed, but never higher than 3300 RPM. Refer to the
a restart. If not, the engine will not start thru the stainless steel nameplate located on the left rear engine mount
AEC or manually. for the correct rated speed.

A magnetic-pickup mounted in the flywheel housing Fig. 3,

provides the input signal for the overspeed switch. The mag- OVERSPEED VARIFICATION
netic-pickup senses the speed of the engine by counting
flywheel ring gear teeth per second. There should be a 0.03" To varify the function of the overspeed signal (SW#2) without
air gap between the top of the ring gear. With one tooth overspeeding the engine, install a jumper wire on terminals "2
centered in the magnetic pickup hole, thread the pickup in & 3" of the speed switch. This will provide the AEC with an
until it touches the gear tooth and then back it out 1/2 turn. overspeed signal and engine shutdown at 67% of the set
Tighten jam nut while holding the pickup in position. Reconnect overspeed RPM.
to wiring harness.
Start the engine via the AEC, the speed switch will effect an
overspeed signal and shutdown protecting both the engine and
CALIBRATION pump.

Both crank terminate (SW#1) and overspeed (SW#2) set

points, are set at the factory and should not require additional EXAMPLE
calibration. Adjustments can be made to the set points of
SW#1 and/or SW#2 if required using a jewelers screw driver. Rated Speed : 2100 RPM
Turning the corresponding adjustment screw CW to increase Overspeed Shutdown : 2520 RPM (120% of 2100 RPM)
or CCW to decrease the set point. To access either adjustment Varification Shutdown : 1688 RPM (67% of 2520 RPM)

Page 35
SECTION 3.5 PDFP

CAUTION coolant temperature reaches 205˚ F (96˚ C), the switch closes
and causes a light to burn and sounds an alarm bell on the
After varification of SW#2 the jumper wire must be removed AEC. A dual switch oil pressure switch is also provided. If oil
and the "reset button" pushed in to re-instate normal operation pressure drops to 20 PSI (138 kPA), the normally closed
of the engine and speed switch. switch returns to a closed position, which causes a light to
burn and sound an alarm on the AEC. The normally open
switch is used to disable the high temperature circuit when the
WARNING: All current production PDFP engines use elec- engine is not running.
tronic overspeed protection controls. Due to
the delicate nature of this device, it is manda- Neither a high coolant temperature or a low oil pressure
tory that diagnostic probing or continuiny condition will cause the AEC to stop the engine. The alarm
checks of the circuity be done with the electri- bell can be silenced at the AEC. Upon doing so an investiga-
cal power off. Probing with any device that tion must be made to determine the cause. AEC lights will
causes surges to exceed ratings will damage continue to burn until the fault is corrected.
this control. This warning applies to terminals
of the overspeed switch and terminal strip
inside the IP. All failed speed switches must be
returned to Clarke. Pending inspections will
determine if the failed switch is warrantable. BATTERIES

NFPA-20 requires that fire pump systems include two inde-

pendent battery units. Each battery bank must have capacity,
BATTERY CHARGING ALTERNATOR at 40˚ F (4.5˚ C), sufficient to maintain cranking speed
through a 6 minute cycle (15 seconds cranking and 15 seconds
The belt driven alternator provides power to recharge both rest, in 12 consecutive cycles). Battery recommendations are
battery banks directly through the battery isolator. The battery shown for each engine on the respective model in Section 5.
isolator prevents cross current from one battery bank to the
other. The alternator is mounted on the front of the engine as
shown in Fig. 4. The alternator belt is driven from the crank-
shaft pulley.
BATTERY CABLES

Customer Supplied Battery Cables should be sized as recom-

STARTERS mended in Section 5.

The DC electric starting motors provide cranking effort to

initiate an engine start. Two starters are mounted in the
Flywheel Housing (one on each side). Starter #1 is on the left
side, #2 on the right side of the engine. When a start signal is
received the AEC will automatically alternate starters de-
pending on available voltage. For automatic or test operation
the start control signal is initiated from the AEC. Manual start
is accomplished at the engine instrument panel. Refer to the
panel for detail instructions.

NOTE: An over-running clutch is included on the starter

drive to prevent damage from overspeeding.

ALARMS

Two alarm switches provide condition signals to the engine

controller. A coolant temperature switch is provided and
mounts at the right front of the thermostat housing. When the Fig. 4 - Typical Alternator

Page 36
SECTION 3.5 PDFP

Fig. 5 - DC Wiring Diagram

Engines With Mechanical Guages

Page 37
SECTION 3.5 PDFP

Fig. 6 - AC Wiring Diagram

Jacket Water Heater

Page 38
SECTION 3.5 PDFP

WIRING DIAGRAM
the installing contractor. The only AC wiring requirement is
In this section two wiring diagrams are provided Fig. 5, for the Engine Heaters. This is also the responsibility of the
Drawing C07575 for DC circuits, Fig. 6, Drawing C07591 for installing contractor.
AC circuits. All DC wiring is color coded on PDFP engines up
to the strip connector inside the instrument panel. Connec- NOTE: The Engine Coolant Heater is not to be energized
tions made to the AEC from this point are the responsibility of unless the cooling system is filled.

MAINTENANCE AND SERVICE PROCEDURES

ENGINE HEATER drive belts every 6 months and adjust if necessary as described
in the drive belts section on Page 8.
The engine heaters are required by NFPA-20 specification to
maintain the engine coolant temperature. Check the engine Refer to "Important" Pg. 9 to turn off the AEC. Run engine by
temperature gauge. Temperature will cycle approximately following steps 1-3 Pg. 33 "To Start Engine". While engine is
20˚ F (– 7˚ C). See Fig. 6 for AC wiring, diagram. running check the voltages on the instrument panel to verify
a 12 volt system. Stop the engine by following step 1-2 Pg. 34
A. Condition: - Maintains Temperature "To Stop Engine" and return the AEC selecter to "Automatic"
Service: - No Service Required position and the manual operating lever to AUTO-OFF posi-
tion.
B. Condition: - Engine coolant at room temperature
Service: - 1. Check 120V-AC POWER SOURCE.
2. Check wiring connections.
3. Check thermostat function. STARTER
4. Replace element if defective.
Inspect the terminals for corrosion and loose connections and
CAUTION: DISCONNECT AC POWER TO HEATER the wiring for broken wires. Replace or repair as necessary.
SYSTEM BEFORE DRAINING ENGINE Service alternator with authorized service dealer.
COOLANT.

BATTERIES
INSTRUMENTS
Check the specific gravity of the electrolyte in each cell of the
Check instruments while running unit to be sure they are battery each week. In warm weather it should be checked
functional. Replace broken or defective instruments. If hour- more frequently due to a more rapid loss of water from the
meter is replaced, record accumulated hours from replaced electrolyte. The electrolyte level should be maintained in
hourmeter. accordance with the battery manufacturer' s recommenda-
tions. Keep all terminals clean and free from corrosion.

NOTE: Coating terminal connection with petroleum jelly

will prevent rapid corrosion buildup.
BATTERY CHARGING ALTERNATOR

Inspect the terminals for corrosion and loose connections and

the wiring for broken wires. Replace or repair as necessary.
Service alternator with authorized service dealer. WIRING SYSTEM

Annually, open the instrument panel to check tightness of all

New standard V-belts will stretch after the first few hours of terminal connections. Additionally, reference DC wiring dia-
operation. Run the engine for 15 minutes to seat the belts, then gram, Fig. 5, Page 37, and check tightness of all terminal
readjust the tension. Check the belts and tighten after 1/2 hour connections. Use caution during this process to prevent unin-
and again after 6 months. Thereafter, check the tension of the tentional grounding of any circuits which may cause damage.

Page 39
SECTION 3.6 PDFP

FALK COUPLING
Many PDFP engines shipped, are equipped with a standard Other pump drive options are available such as a standard
FALK drive hub, (engine half only). engine flywheel which can be purchased through Clarke or for
vertical turbine drives please refer to the OEM Pump manuals.
If your engine includes this type coupling, please read this
Section for service and maintenance information.

Steelflex ® Couplings • Installation and Maintenance

™
a good name in industry Type T10 • Sizes 1020 –1140 & 20–140 (Page 1 of 6)

How To Use This Manual TYPE T10 STEELFLEX COUPLING

This manual provides detailed instructions on maintenance,
lubrication, installation, and parts identification. Use the table
of contents below to locate required information.

Table of Contents
Introduction................................................. Page 1
Lube Fittings................................................ Page 1
Limited End Float........................................ . . Page 1
Lubrication.............................................. Pages 1-2
Installation & Alignment Instructions................. Pages 2-4
Annual Maintenance, Relube & Disassembly........... Page 4
Installation & Alignment Data............................. Page 5
Parts Identification &Parts Interchangeability........... Page 6

CAREFULLY FOLLOW THE INSTRUCTIONS IN THIS

MANUAL FOR OPTIMUM PERFORMANCE AND TROUBLE LUBRICATION
FREE SERVICE. Adequate lubrication is essential for satisfactory operation. Page
2 provides a list of typical lubricants and specifications for
INTRODUCTION general purpose and long term greases. Because of its superior
lubricating characteristics and low centrifuge properties, Falk
This manual applies to Sizes 1020T thru 1140T and 20T thru
Long Term Grease (LTG) is highly recommended. Sizes 1020T
140T10 Falk SteelfIex Tapered Grid Couplings. Unless
to 1090T10 are furnished with a pre-measured amount of
otherwise stated, information for Sizes 1020T thru 1140T
grease for each coupling. The grease can be ordered for larger
applies to Sizes 20T thru 140T respectively, e.g. 1020T = 20T,
size couplings.
1100T = 100T, etc. These couplings are designed to operate
in either the horizontal or vertical position without modification. The use of general purpose grease requires re-lubrication of the
Beginning in 1994, these couplings are being supplied with coupling at least annually.
one set of inch series fasteners and one set of metric fasteners.
Use either set of fasteners, depending on your preference.
Refer to Page 6 for part interchangeability. Long Term Grease (LTG)
The performance and life of the couplings depend largely upon The high centrifugal forces encountered in couplings separate
how you install and service them. Carefully follow the the base oil and thickener of general purpose greases. Heavy
instructions in this manual for optimum performance and thickener, which has no lubrication qualities, accumulates
trouble free service. in the grid-groove area of Steelflex couplings resulting in
premature hub or grid failure unless periodic lubrication cycles
CAUTION: Consult applicable local and national safety codes
are maintained.
for proper guarding of rotating members. Observe all safety
rules when installing or servicing couplings. Falk Long Term Grease (LTG) was developed specifically for
couplings. It resists separation of the oil and thickener and is an
WARNING: Lockout starting switch of prime mover and remove extreme pressure grease.
all external loads from drive before installing or servicing couplings.
Steelflex couplings initially lubricated with LTG will not require
re-lubrication until the connected equipment is stopped for
LUBE FITTINGS servicing. If a coupling leaks grease, is exposed to extreme
Cover halves have 1/8 NPT Iube holes. Use a standard grease temperatures, excessive moisture, or experiences frequent
gun and Iube fitting as instructed on Page 4. reversals, more frequent lubrication may be required.
Although LTG grease is compatible with most other coupling
LIMITED END FLOAT greases, the mixing of greases may dilute the benefits of LTG.
When electric motors, generators, engines, compressors and
other machines are fitted with sleeve or straight roller bearings, USDA Approval
limited axial end float kits are recommended for protecting the LTG has the United States Department of Agriculture Food
bearings. Falk Steelflex couplings are easily modified to limit Safety & Inspection Service approval for applications where
end float; refer to Manual 428-820 for instructions. there is no possibility of contact with edible products. (H-2
ratings).
CAUTION: Do not use LTG in bearings.

Page 40
SECTION 3.6 PDFP

Installation and Maintenance • Steelflex ® Couplings

®
(Page 2 of 6) Type T10 • Sizes 1020 –1140 & 20–140 a good name in industry

Specifications — Falk LTG General Purpose Greases Meeting Falk

The values shown are typical and slight variations are permissible. Specifications
AMBIENT TEMPERATURE RANGE — -20˚F (-29˚C) to 250˚F Lubricants listed below are typical products only and should not
(121˚C). be construed as exclusive recommendations.
MINIMUM BASE OIL VISCOSITY — 3300SSU (715cST) @
100˚F (38˚C)
THICKENER — less than 12% by weight.
TABLE 1 — General Purpose Greases
CENTRIFUGE SEPARATION CHARACTERISTICS — ASTM
#D4425 (Centrifuge Test) — K36 = 2/24 max., very high
resistance to centrifuging.
NLGI GRADE (ASTM D-217) — 1/2
MINIMUM DROPPING POINT — with 60 stroke worked
penetration value in the range of 320 to 365 —
350˚F (177˚C) min.
MINIMUM TIMKEN O.K. LOAD — 40 lbs.
ADDITIVES — Rust and oxidation inhibitors that do not corrode
steel or swell or deteriorate synthetic seals.

Packaging
14 OZ. CARTRIDGES — For use in standard grease guns.
Sufficient quantity to initially lubricate sizes thru 1090T.
35 LB. PAIL — Ideal for larger size couplings or many
smaller sizes.
120 LB. KEG & 400 LB. DRUM — For plants with central
storage areas. A pump with a pressurized follower plate is
required for dispensing grease.
CASE LOTS OF 24-14 OZ. CARTRIDGES — also available.

General Purpose Grease

Annual Lubrication — The following specifications and
lubricants for general purpose grease apply to Falk Steelflex INSTALLATION OF TYPE T10 STEELFLEX
couplings that are lubricated annually and operate within TAPERED GRID COUPLINGS
ambient temperatures of 0˚F to 150˚F (-18˚C to 66˚C). For
temperatures beyond this range (see Table 1), consult
the Factory. Installation
If a coupling leaks grease, is exposed to extreme temperatures, Only standard mechanics tools, wrenches, a straight edge and
excessive moisture or experiences frequent reversals, more feeler gauges are required to install Falk Steelflex couplings.
frequent lubrication may be required. Coupling Sizes 1020T thru 1090T are generally furnished
for CLEARANCE FIT with setscrew over the keyway. Sizes
Specifications — General Purpose Coupling 1100T and larger are furnished for an INTERFERENCE FIT
Lubricants without a setscrew.
The values shown are typical and slight variations are CLEARANCE FIT HUBS — Clean all parts using a non-
permissible. flammable solvent. Check hubs, shafts and keyways for burrs.
Do not heat clearance fit hubs. Install keys, mount hubs with
DROPPING POINT — 300˚F (149˚C) or higher. flange face flush with shaft ends or as otherwise specified and
CONSISTENCY — NLGI No. 2 with 60 stroke worked tighten setscrews.
penetration value in the range of 250 to 300. INTERFERENCE FIT HUBS — Furnished without setscrews. Heat
SEPARATION AND RESISTANCE — Low oil separation rate hubs to a maximum of 275˚F (135˚C) using an oven, torch,
and high resistance to separation from centrifuging. induction heater or an oil bath.
LIQUID CONSTITUENT — Possess good lubricating properties When an oxy-acetylene or blow torch is used, use an excess
... equivalent to a high quality, well refined petroleum oil. acetylene mixture. Mark hubs near the center of their length in
INACTIVE — Must not corrode steel or cause swelling or several places on hub body with a temperature sensitive crayon,
deterioration of synthetic seals. 275˚F (135˚C) melt temperature. Direct flame towards hub bore
using constant motion to avoid overheating an area.
CLEAN — Free from foreign inclusions.

Page 41
SECTION 3.6 PDFP

Steelflex ® Couplings • Installation and Maintenance

®
a good name in industry Type T10 • Sizes 1020 –1140 & 20–140 (Page 3 of 6)

WARNING: If an oil bath is used, the oil must have a flash Use a spacer bar equal in thickness to the gap specified in
point of 350˚F (177˚C) or higher. Do not rest hubs on the Table 2, Page 5. Insert bar as shown below left, to same depth
bottom of the container. Do not use an open flame in a at 90˚intervals and measure clearance between bar and hub
combustible atmosphere or near combustible materials. face with feelers. The difference in minimum and maximum
Heat hubs as instructed above. Mount hubs as quickly as possible measurements must not exceed the ANGULAR installation limits
with hub flange face flush with shaft end. Allow hubs to cool before specified in Table 2.
proceeding. Insert setscrews (if required) and tighten.
3 — Offset Alignment

Maximize Performance And Life

The performance and life of couplings depend largely upon
how you install and maintain them. Before installing couplings,
make certain that foundations of equipment to be connected
meet manufacturersí requirements. Check for soft foot. The use
of stainless steel shims is recommended. Measuring
misalignment and positioning equipment within alignment
tolerances is simplified with an alignment computer. These
calculations can also be done graphically or mathematically.
Alignment is shown using spacer bar and straight edge. This
practice has proven to be adequate for many industrial
applications. However, for superior final alignment, the use of
dial indicators (see Manual 458-834 for instructions), lasers,
alignment computers or graphical analysis is recommended. Align so that a straight edge rests squarely (or within the limits
specified in Table 2) on both hubs as shown above and also at
1 — Mount Seals And Hubs 90˚intervals. Check with feelers. The clearance must not
exceed the PARALLEL OFFSET installation limits specified in
Table 2. Tighten all foundation bolts and repeat Steps 2 and 3.
Realign coupling if necessary.

4 — Insert Grid

Lock out starting switch of prime mover. Clean all metal parts
using a non-flammable solvent. Lightly coat seals with grease
and place on shafts BEFORE mounting hubs. Heat interference
fit hubs as previously instructed. Seal keyways to prevent
leakage. Mount hubs on their respective shafts so the hub face
is flush with the end of its shaft unless otherwise indicated.
Tighten setscrews when furnished.

2 — Gap and Angular Alignment

Pack gap and grooves with specified lubricant before inserting grid.
When grids are furnished in two or more segments, install them so
that all cut ends extend in the same direction (as detailed in the
exploded view picture above); this will assure correct grid contact
with non-rotating pin in cover halves. Spread the grid slightly to
pass over the coupling teeth and seat with a soft mallet.

Page 42
SECTION 3.6 PDFP

Installation and Maintenance • Steelflex ® Couplings

®
(Page 4 of 6) Type T10 • Sizes 1020 –1140 & 20–140 a good name in industry

5 — Pack With Grease And Assemble Covers ANNUAL MAINTENANCE

For extreme or unusual operating conditions, check coupling
more frequently.
1. Check alignment per steps on Page 3. If the maximum oper-
ating misalignment limits are exceeded, realign the coupling
to the recommended installation limits. See Table 2 for in-
stallation and operating alignment limits.
2. Check tightening torques of all fasteners.
3. Inspect seal ring and gasket to determine if replacement is
required. If leaking grease, replace.
4. When connected equipment is serviced, disassemble the
coupling and inspect for wear. Replace worn parts. Clean
grease from coupling and repack with new grease. Install
coupling using new gasket as instructed in this manual.

Periodic Lubrication

The required frequency of lubrication is directly related to the type

of lubricant chosen, and the operating conditions. Steelflex
Pack the spaces between and around the grid with as much couplings lubricated with common industrial lubricants, such as
lubricant as possible and wipe off excess flush with top of grid. those shown in Table 1, should be relubed annually. The use of
Position seals on hubs to line up with grooves in cover. Position Falk Long Term Grease (LTG) will allow relube intervals to be
gaskets on flange of lower cover half and assemble covers so extended to beyond five years. When relubing, remove both lube
that the match marks are on the same side (see above). If shafts plugs and insert lube fitting. Fill with recommended lubricant until
are not level (horizontal) or coupling is to be used vertically, an excess appears at the opposite hole. CAUTION: Make certain
assemble cover halves with the lug and match mark all plugs have been inserted after lubricating.
MATCH MARK LUG UP Coupling Disassembly And Grid Removal

VERTICAL COUPLINGS

Whenever it is necessary to disconnect the coupling, remove

the cover halves and grid. A round rod or screwdriver that will
UP or on the high side. Push gaskets in until they stop against conveniently fit into the open loop ends of the grid is required.
the seals and secure cover halves with fasteners, tighten to Begin at the open end of the grid section and insert the rod or
torque specified in Table 2. Make sure gaskets stay in position screwdriver into the loop ends. Use the teeth adjacent to each
during tightening of fasteners. CAUTION: Make certain lube loop as a fulcrum and pry the grid out radially in even, gradual
plugs are installed before operating. stages, proceeding alternately from side to side.
Page 43
SECTION 3.6 PDFP

Steelflex ® Couplings • Installation and Maintenance

®
a good name in industry Type T10 • Sizes 1020 –1140 & 20–140 (Page 5 of 6)

TYPE T COUPLING INSTALLATION & Values may be combined for an installation or operating condition.
ALIGNMENT DATA Example: 1060T max. operating misalignment is .016" parallel
Maximum life and minimum maintenance for the coupling and plus .018" angular.
connected machinery will result if couplings are accurately NOTE: For applications requiring greater misalignment, refer
aligned. Coupling life expectancy between initial alignment and application details to the Factory.
maximum operating limits is a function of load, speed and Angular misalignment is dimension X minus Y as illustrated below.
lubrication. Maximum operating values listed in Table 2 are
Parallel misalignment is distance P between the hub center lines
based on cataloged allowable rpm.
as illustrated below.
Values listed are based upon the use of the gaps listed,
End float (with zero angular and parallel misalignment) is the axial
standard coupling components, standard assemblies and
movement of the hubs(s) within the cover(s) measured from“O” gap.
cataloged allowable speeds.

ANGULAR MISALIGNMENT END FLOAT

Y PARALLEL MISALIGNMENT F F
P

X GAP

TABLE 2 — Misalignment & End Float

TABLE 3 — Coupling Cover Fastener Identification

SAE Grade 8 SAE Grade 8 Property Class 10.9

SAE Grade 8 SAE Grade 8 Property Class 10.9

SAE Grade 5 SAE Grade 5 Property Class 8.8

1 Older style covers, Sizes 1020T10 thru1070T10 must utilize socket head cap screws and locknuts held by the cover.

Page 44
SECTION 3.6 PDFP

Installation and Maintenance • Steelflex ® Couplings

®
(Page 6 of 6) Type T10 • Sizes 1020 –1140 & 20–140 a good name in industry

PARTS IDENTIFICATION CAUTION: Blue grids may be used in all applications, but DO
NOT substitute orange grids for blue.
All coupling parts have identifying part numbers as shown
below. Parts 3 and 4 (Hubs and Grids), are the same for both COVERS — CAUTION: DO NOT mix cover halves of different
Type T10 and T20 couplings. All other coupling parts are unique to designs. Sizes 1020T thru 1070T10 covers have been
Type T10. When ordering parts, always SPECIFY SIZE and TYPE manufactured in several different two-rib designs and 80T thru
shown on the COVER. 140T covers have been manufactured with two and three ribs.
HARDWARE ó Older style covers, Sizes 1020T10 thru
PARTS INTERCHANGEABILITY 1070T10, utilized socket head cap screws with captured
locknuts. The new style covers use hex head cap screws (either
Parts are interchangeable between Sizes 20T and 1020T, 30T
inch or metric) and unrestrained locknuts. Specify either inch
and 1030T, etc. except as noted.
series SOCKET head or inch or metric series HEX head cap
GRIDS — Size 1020T thru 1140T Steelflex couplings use blue screws when ordering replacement parts.
grids. Older models, 20T thru 140T, use orange grids.

PART NUMBER LOCATION

PART NUMBERS
1. Seal (T10)
2. Cover (T10)
3. Hub (Specify bore
and keyway)
4. Grid
5. Gasket (T10)
(2.) COVER 6. Fasteners (T10) ó Coupling
(7.) 1030 T 10 B
may be supplied with one
COUPLING TYPE MODEL set each of inch series fas-
SIZE
teners and metric fasteners.
PRODUCT 7. Lube Plug
CLASSIFICATION

SIZE &
PART (1.) SEAL (3.) HUB (4.) GRID SIZE
NUMBER

ORDER INFORMATION
1. Identify part(s) required by
SIZE, PART NUMBER & (5.) GASKET
BORE name above.
PART NUMBER
SIZE 2. Furnish the following
information.
EXAMPLE:
PART NUMBER Coupling Size: 1030
Coupling Type: T10
Model: B
(6.)
Bore: 1.375
Keyway: .375 x .187
3. Price parts from Price List
422-110 and appropriate
discount sheet.

Page 45
SECTION 4 PDFP

ENGINE TUNE-UP

There is no scheduled interval for performing an engine tune- dance with NFPA-20 requirements, this is a tamper-proof
up. As long as the engine is performing satisfactorily, no tune- mechanism.
up should be necessary.
NOTE: This engine has no idle speed setting.
SPEED CONTROL
The engine speed is pre-set at the factory to provide the If engine performance is not satisfactoy, contact your local
horsepower indicated on the FM/UL nameplate. In accor- Distributor/Dealer for assistance.

MECHANICAL GOVERNOR - SPEED ADJUSTMENT

A mechanical governor controls the engine speed. The gover- All governors are adjusted to the FM/UL/ULC nameplate
nor on the PDFP engines is built into the fuel injection pump BHP and full load pump speed before leaving Clarke. During
located on the left side of the engine. Figure 1 shows the Start-Up Inspection or when placing reconditioned units into
governor and pump location on each engine. service, some minor speed adjustment may be required. It is
recommended that this adjustment be performed by the
authorized Distributor Dealer representative.

Droop Adjustment

Jam Nut

Long Adjuster

Figure 1 - Governor and Pump Location (Adjustments)

Page 46
SECTION 4 PDFP

To adjust the speed on the PDFP engines requires adjustments 2.) Speed Adjustment:
of two settings on the governor. The first is the droop setting,
and second is the speed setting which are accomplished as A.) Start engine by following the "Important" instruc-
follows: tions on Page 9 and manual starting instructions on
Page 33.

1.) Droop Adjustment: B.) Let the engine warm-up. Loosen the jam nut (Fig. 1).

A.) This adjustment requires a standard screwdriver and C.) While observing the instrument panel tach rotate the
is located on the rear of the governor as shown in long adjustor clockwise to lower the RPM and counter
Figure 1. clockwise to raise the RPMs, until desired speed is
obtained (shown in Figure 1).
B.) Rotate the set screw counter clockwise until it stops.
D.) Holding secure the long adjustor with a wrench
CAUTION: Do not use excess force.
tighten the jam nut.

E.) Stop engine by following "To Stop Engine" on Page

C.) If the speed setting you require is between 1470 RPM
34.
and 1900 RPM turn the set screw clockwise one full
turn, and if the speed you require is between 2100
RPM and 3000 RPM turn the set screw 41/2 times
clockwise.

Page 47
SECTION 5 PDFP

TECHNICAL DATA

This section includes the Installation and Operating Data for all PDFP
engine models. Additionally, the basic Engine Materials and Construction
are also provided. The specific model and page reference are listed below.

Installation & Engine Mat'l

Engine Model Operation Data & Construction
Page Page

PDFP-L4YN 48 - A - 1 & 2 48 - Z - 1
PDFP-L4YT 48 - B - 1 & 2 48 - Z - 2
PDFP-04YT 48 - C - 1 & 2 48 - Z - 2
1&2
PDFP-L6YN 48 - D - 1 & 2 48 - Z - 1
PDFP-L6YT 48 - E - 1 & 2 48 - Z - 2
PDFP-06YT 48 - F - 1 & 2 48 - Z - 2
PDFP-L6YW 48 - G - 1 & 2 48 - Z - 2

................................................................................
Fig. Page
Engine Control Wiring Diagram - DC .................................... 5 37
Engine Heater Wiring Diagram - AC ...................................... 6 38

Page 48
 PDFP-L4YN
INSTALLATION & OPERATION DATA

Basic Engine Description All Speeds

Engine Manufacturer........................................................................................................ Perkins/Detroit Diesel
Ignition Type .................................................................................................................... Compression (Diesel)
Number of Cylinders ........................................................................................................ 4
Bore and Stroke - in. (mm).............................................................................................. 3.937 (100) 5.0 (127)
Displacement - in.3 (L) .................................................................................................... 243 (3.99)
Compression Ratio .......................................................................................................... 16.5:1
Combustion System ........................................................................................................ Direct Injection
Engine Type...................................................................................................................... In-Line, 4 Cycle
Aspiration ........................................................................................................................ Natural
Firing Order (CW Rotation) .............................................................................................. 1-3-4-2
Charge Air Cooling Type .................................................................................................. None
Rotation (Viewed from Front)
Clockwise .................................................................................................................... Standard
Counter-Clockwise ...................................................................................................... Not Available
Engine Crankcase Vent System........................................................................................ Open
Dimensions and Weight
Length - in. (mm) (From Drive Flange)........................................................................ 38.2 (971)
Width - in. (mm) .......................................................................................................... 26.1 (663)
Height - in. (mm) (Above Crankshaft Center Line) .................................................... 32.6 (828)
Weight, Dry - lb. (kg) .................................................................................................. 996 (452)
Wet - lb. (kg) ........................................................................................................ 1054 (478)
Installation Drawing ........................................................................................................ D-472

Cooling System 1470 1760 2100 2350 2600

Engine H2O Heat - Btu/sec. (kJ/sec.) ........................................ 32 (34) 35 (37) 39 (41) 42 (44) 45 (47)
Engine Radiated Heat - Btu/sec. (kJ/sec.).................................. 6 (6.3) 6.5 (6.9) 7.6 (8.0) 8.3 (8.8) 9.2 (9.7)
Heat Exchanger Minimum Flow
60˚F Raw H2O - gal./min. (L/min.) ........................................ 3.9 (15) 4.6 (17) 6.2 (23) 6.7 (25) 7 (26)
95˚F Raw H2O - gal./min. (L/min.) ........................................ 4.3 (16) 4.9 (18) 6.6 (25) 7 (26) 8.4 (32)
Heat Exchanger Maximum Cooling H2O
Inlet Pressure - lb./in.2 (kPa) ...................................................................................... 60 (414)
Flow - gal./min. (L/min.) .............................................................................................. 40 (151)
Thermostat, Start to Open - ˚F (˚C) .................................................................................. 170 (77)
Fully Open - ˚F (˚C) ................................................................................................ 198 (92)
Engine Coolant Capacity - qt. (L) .................................................................................... 21 (20)
Coolant Pressure Cap - lb./in.2 (kPa) .............................................................................. 9 (62)
Maximum Engine H2O Temperature - ˚F (C) .................................................................... 200 (93)
Minimum Engine H2O Temperature - ˚F (˚C).................................................................... 160 (71)

Electric System - DC All Speeds

System Voltage (Nominal) .............................................................................................. 12
Battery Capacity for Ambients Above 32˚F - CCA @ 0˚F .................................................. 640
Voltage (Nominal) ........................................................................................................ 12
Qty. per Battery Bank .................................................................................................. 1
SAE size per J537 ........................................................................................................ 4D-640
Battery Cable Circuit*, Max Resistance - ohm ................................................................ 0.0017
Battery Cable Minimum Size
0-120 in. Circuit* Length ........................................................................................ No. 00
121-160 in. Circuit* Length ........................................................................................ No. 000
161-200 in. Circuit* Length ........................................................................................ No. 0000
Charging Alternator Output - Amp. .................................................................................. 42
Starter Cranking Amps - @ 60˚ F .................................................................................... 275

*Positive and Negative Cables Combined Length

(Continued)
NOTE: This Engine Is Intended For Indoor Installation Or In A Weatherproof Enclosure. Page 48-A-1
 PDFP-L4YN
INSTALLATION & OPERATION DATA (Continued)
Exhaust System 1470 1760 2100 2350 2600
Exhaust Flow - ft.3/min. (m3/min.)............................................ 242 (6.8) 319 (9.0) 357 (10) 414 (12) 429 (12)
Exhaust Temperature - ˚F (˚C).................................................... 923 (495) 1127 (608) 1088 (587) 1175 (635) 1097 (592)
Maximum Allowable Back Pressure -
in. H2O (kPa) ........................................................................ 30 (7.5) 30 (7.5) 30 (7.5) 30 (7.5) 30 (7.5)
Minimum Exhaust Pipe Dia. - in. (mm)** ................................ 2.5 (64) 2.5 (64) 2.5 (64) 2.5 (64) 2.5 (64)

Fuel System
Fuel Consumption - gal./hr. (L/hr.) ............................................ 2.0 (7.6) 3.0 (11) 3.4 (13) 4.0 (15) 4.1 (16)
Fuel Pressure - lb./in.2 (kPa) .......................................................................................... 5-10 (35-70)
Minimum Line Size - Supply - in. (mm)** ...................................................................... 0.37 Sch. 40 - Black
Minimum Line Size - Return - in. (mm)** ...................................................................... 0.25 Sch. 40 - Black
Maximum Allowable Fuel Pump Suction
with Clean Filter - in. H2O (kPa) .......................................................................... 54 (100)
Maximum Allowable Head on
Fuel Pump - ft(m) ................................................................................................ 9.8 (3.0)
Fuel Filter Micron Size - Primary...................................................................................... 30
Secondary .................................................................................................... 5
Fuel Modulator/Setting .................................................................................................... None/None

Heater System All Speeds

Jacket Water Heater ........................................................................................................ Standard
Wattage (Nominal) ...................................................................................................... 1500
Voltage - AC, 1P .......................................................................................................... 120 (+5%, –10%)
Optional Voltage - AC, 1P ............................................................................................ 240 (+5%, –10%)
Lube Oil Heater (Required When Ambient Is Below 32˚F (0˚C)........................................ Consult Factory

Induction Air System 1470 1760 2100 2350 2600

Air Cleaner Type ........................................................................ Indoors Service Only - Washable
Air Intake Restriction Maximum Limit
Dirty Air Cleaner - in. H2O (kPa) .......................................... 26 (6.5) 26 (6.5) 26 (6.5) 26 (6.5) 26 (6.5)
Clean Air Cleaner - in. H2O (kPa) .......................................... 12 (3.0) 12 (3.0) 12 (3.0) 12 (3.0) 12 (3.0)
Engine Air Flow - ft.3/min. (m3/min.) .................................... 94 (2.6) 108 (3.1) 124 (3.5) 136 (3.8) 148 (4.2)
Maximum Allowable Temperature (Air To Engine Inlet) - ˚F (˚C)***................................ 130 (54)

Lubrication System All Speeds

Oil Pressure - normal - lb./in.2 (kPa) .............................................................................. 40-60 (276-414)
In Pan Oil Temperature - ˚F (˚C) ...................................................................................... 220-240 (88-116)
Oil Pan Capacity - High - qt. (L) ...................................................................................... 7.3 (6.9)
Low - qt. (L)...................................................................................................... 5.9 (5.6)
Total Oil Capacity with Filters - qt. (L).............................................................................. 8.0 (7.6)

Performance 1470 1760 2100 2350 2600

2
BMEP - lb./in. (kPa) ................................................................ 100 (690) 111 (765) 104 (717) 100 (690) 92.5 (638)
Piston Speed - ft./min. (m/min.)................................................ 1225 (373) 1467 (447) 1750 (583) 1958 (597) 2167 (660)
Noise - dB (A) @ 1m ................................................................ 100 (EST) 102 (EST) 103 (EST) 104 (EST) 96 (EST)
Power Curve .................................................................................................................... CDDA - Y044 - 01

**Based On Nominal System. Flow Analysis Must Be Done To Assure Adherance To System Limitations.
(Minimum Exhaust Pipe Diameter is based on 15 feet of pipe, one elbow, and a silencer
pressure drop no greater than one half the max. allowable back pressure.)
CDDA MAR 97 JTW ***Review For Power Deration If Air Entering Engine Exceeds 77˚ F (25˚ C).
Page 48-A-2
 PDFP-L4YT
INSTALLATION & OPERATION DATA
Basic Engine Description All Speeds
Engine Manufacturer........................................................................................................ Perkins/Detroit Diesel
Ignition Type .................................................................................................................... Compression (Diesel)
Number of Cylinders ........................................................................................................ 4
Bore and Stroke - in. (mm).............................................................................................. 3.937 (100) 5.0 (127)
Displacement - in.3 (L) .................................................................................................... 243 (3.99)
Compression Ratio .......................................................................................................... 16:1
Combustion System ........................................................................................................ Direct Injection
Engine Type...................................................................................................................... In-Line, 4 Cycle
Aspiration ........................................................................................................................ Turbocharged
Firing Order (CW Rotation) .............................................................................................. 1-3-4-2
Charge Air Cooling Type .................................................................................................. None
Rotation (Viewed from Front)
Clockwise .................................................................................................................... Standard
Counter-Clockwise ...................................................................................................... Not Available
Engine Crankcase Vent System........................................................................................ Open
Dimensions and Weight
Length - in. (mm) (From Drive Flange)........................................................................ 38.2 (971)
Width - in. (mm) .......................................................................................................... 25.5 (648)
Height - in. (mm) (Above Crankshaft Center Line) .................................................... 32.6 (828)
Weight, Dry - lb. (kg) .................................................................................................. 1020 (463)
Wet - lb. (kg) ........................................................................................................ 1080 (490)
Installation Drawing ........................................................................................................ D-472

Cooling System 1470 1760 2100 2350 2600

Engine H2O Heat - Btu/sec. (kJ/sec.) ........................................ 32 (34) 34 (36) 39 (41) 42 (44) 45 (48)
Engine Radiated Heat - Btu/sec. (kJ/sec.).................................. 6.7 (7.1) 7.5 (7.9) 8.8 (9.3) 9.7 (10) 10 (11)
Heat Exchanger Minimum Flow
60˚F Raw H2O - gal./min. (L/min.) ........................................ 4.2 (16) 4.8 (18) 5.7 (22) 7.2 (27) 8.4 (32)
95˚F Raw H2O - gal./min. (L/min.) ........................................ 5.5 (21) 6.0 (23) 7.8 (30) 8.4 (32) 10.5 (40)
Heat Exchanger Maximum Cooling H2O
Inlet Pressure - lb./in.2 (kPa) ...................................................................................... 60 (414)
Flow - gal./min. (L/min.) .............................................................................................. 40 (151)
Thermostat, Start to Open - ˚F (˚C) .................................................................................. 170 (77)
Fully Open - ˚F (˚C) ................................................................................................ 198 (92)
Engine Coolant Capacity - qt. (L) .................................................................................... 22 (21)
Coolant Pressure Cap - lb./in.2 (kPa) .............................................................................. 9 (62)
Maximum Engine H2O Temperature - ˚F (C) .................................................................... 200 (93)
Minimum Engine H2O Temperature - ˚F (˚C).................................................................... 160 (71)

Electric System - DC All Speeds

System Voltage (Nominal) .............................................................................................. 12
Battery Capacity for Ambients Above 32˚F - CCA @ 0˚F .................................................. 640
Voltage (Nominal) ........................................................................................................ 12
Qty. per Battery Bank .................................................................................................. 1
SAE size per J537 ........................................................................................................ 4D-640
Battery Cable Circuit*, Max Resistance - ohm ................................................................ 0.0017
Battery Cable Minimum Size
0-120 in. Circuit* Length ........................................................................................ No. 00
121-160 in. Circuit* Length ........................................................................................ No. 000
161-200 in. Circuit* Length ........................................................................................ No. 0000
Charging Alternator Output - Amp. .................................................................................. 42
Starter Cranking Amps - @ 60˚ F .................................................................................... 275

*Positive and Negative Cables Combined Length

(Continued)
NOTE: This Engine Is Intended For Indoor Installation Or In A Weatherproof Enclosure. Page 48-B-1
 PDFP-L4YT
INSTALLATION & OPERATION DATA (Continued)
Exhaust System 1470 1760 2100 2350 2600
Exhaust Flow - ft.3/min. (m3/min.)............................................ 294 (8.3) 411 (12) 519 (15) 618 (17) 742 (21)
Exhaust Temperature - ˚F (˚C).................................................... 900 (482) 992 (533) 956 (513) 953 (512) 953 (512)
Maximum Allowable Back Pressure -
in. H2O (kPa) ........................................................................ 30 (7.5) 30 (7.5) 30 (7.5) 30 (7.5) 30 (7.5)
Minimum Exhaust Pipe Dia. - in. (mm)** ................................ 3.0 (76) 3.0 (76) 3.0 (76) 3.0 (76) 4.0 (102)

Fuel System
Fuel Consumption - gal./hr. (L/hr.) ............................................ 2.5 (9.5) 3.7 (14) 4.3 (16) 5.0 (19) 5.5 (21)
2
Fuel Pressure - lb./in. (kPa) .......................................................................................... 5-10 (35-70)
Minimum Line Size - Supply - in. (mm)** ...................................................................... 0.37 Sch. 40 - Black
Minimum Line Size - Return - in. (mm)** ...................................................................... 0.25 Sch. 40 - Black
Maximum Allowable Fuel Pump Suction
with Clean Filter - in. H2O (kPa) .................................................................................. 54 (100)
Maximum Allowable Head on
Fuel Pump - ft(m) ................................................................................................ 9.8 (3.0)
Fuel Filter Micron Size - Primary...................................................................................... 30
Secondary .................................................................................................... 5
Fuel Modulator/Setting .................................................................................................... Boost/None

Heater System All Speeds

Jacket Water Heater ........................................................................................................ Standard
Wattage (Nominal) ...................................................................................................... 1500
Voltage - AC, 1P .......................................................................................................... 120 (+5%, –10%)
Optional Voltage - AC, 1P ............................................................................................ 240 (+5%, –10%)
Lube Oil Heater (Required When Ambient Is Below 32˚F (0˚C)........................................ Consult Factory

Induction Air System 1470 1760 2100 2350 2600

Air Cleaner Type ........................................................................ Indoors Service Only - Washable
Air Intake Restriction Maximum Limit
Dirty Air Cleaner - in. H2O (kPa) .......................................... 32 (8.0) 32 (8.0) 32 (8.0) 32 (8.0) 32 (8.0)
Clean Air Cleaner - in. H2O (kPa) .......................................... 20 (5.0) 20 (5.0) 20 (5.0) 20 (5.0) 20 (5.0)
Engine Air Flow - ft.3/min. (m3/min.) .................................... 116 (8.3) 152 (4.3) 197 (5.6) 235 (6.7) 282 (8.0)
Maximum Allowable Temperature (Air To Engine Inlet) - ˚F (˚C)***................................ 130 (54)

Lubrication System All Speeds

Oil Pressure - normal - lb./in.2 (kPa) .............................................................................. 40-60 (276-414)
In Pan Oil Temperature - ˚F (˚C) ...................................................................................... 220-240 (88-116)
Oil Pan Capacity - High - qt. (L) ...................................................................................... 7.3 (6.9)
Low - qt. (L)...................................................................................................... 5.9 (5.6)
Total Oil Capacity with Filters - qt. (L).............................................................................. 8.0 (7.6)

Performance 1470 1760 2100 2350 2600

2
BMEP - lb./in. (kPa) ................................................................ 111 (765) 135 (931) 2350
124 (855) 121 (834) 115 (793)
Piston Speed - ft./min. (m/min.)................................................ 1225 (373) 1467 (447) 1750 (583) 1958 (597) 2167 (660)
Noise - dB (A) @ 1m ................................................................ 100 (EST) 102 (EST) 103 (EST) 104 (EST) 96 (EST)
Power Curve .................................................................................................................... CDDA - Y044 - 03

**Based On Nominal System. Flow Analysis Must Be Done To Assure Adherance To System Limitations.
(Minimum Exhaust Pipe Diameter is based on 15 feet of pipe, one elbow, and a silencer
pressure drop no greater than one half the max. allowable back pressure.)
CDDA MAR 97 JTW ***Review For Power Deration If Air Entering Engine Exceeds 77˚ F (25˚ C).
Page 48-B-2
 INSTALLATION & OPERATION DATA

Basic Engine Description All Speeds

Engine Manufacturer........................................................................................................ Perkins/Detroit Diesel
Ignition Type .................................................................................................................... Compression (Diesel)
Number of Cylinders ........................................................................................................ 4
Bore and Stroke - in. (mm).............................................................................................. 3.937 (100) 5.0 (127)
Displacement - in.3 (L) .................................................................................................... 243 (3.99)
Compression Ratio .......................................................................................................... 16:1
Combustion System ........................................................................................................ Direct Injection
Engine Type...................................................................................................................... In-Line, 4 Cycle
Aspiration ........................................................................................................................ Turbocharged
Firing Order (CW Rotation) .............................................................................................. 1-3-4-2
Charge Air Cooling Type .................................................................................................. None
Rotation (Viewed from Front)
Clockwise .................................................................................................................... Standard
Counter-Clockwise ...................................................................................................... Not Available
Engine Crankcase Vent System........................................................................................ Open
Dimensions and Weight
Length - in. (mm) (From Drive Flange)........................................................................ 38.2 (971)
Width - in. (mm) .......................................................................................................... 25.5 (648)
Height - in. (mm) (Above Crankshaft Center Line) .................................................... 32.6 (828)
Weight, Dry - lb. (kg) .................................................................................................. 1020 (463)
Wet - lb. (kg) ........................................................................................................ 1080 (490)
Installation Drawing ........................................................................................................ D-472

Cooling System 1470 1760 2100 2350 2600

Engine H2O Heat - Btu/sec. (kJ/sec.) ........................................ 35 (37) 38 (40) 43 (45) 46 (49) 50 (52)
Engine Radiated Heat - Btu/sec. (kJ/sec.).................................. 7.4 (7.8) 8.2 (8.7) 9.7 (10.2) 10.7 (11.3) 11.8 (12.4)
Heat Exchanger Minimum Flow
60˚F Raw H2O - gal./min. (L/min.) ........................................ 5.0 (19) 5.8 (22) 7.2 (27) 7.5 (28) 9 (34)
95˚F Raw H2O - gal./min. (L/min.) ........................................ 6.9 (26) 7.7 (29) 8.9 (34) 9.6 (36) 11 (42)
Heat Exchanger Maximum Cooling H2O
Inlet Pressure - lb./in.2 (kPa) ...................................................................................... 60 (414)
Flow - gal./min. (L/min.) .............................................................................................. 40 (151)
Thermostat, Start to Open - ˚F (˚C) .................................................................................. 170 (77)
Fully Open - ˚F (˚C) ................................................................................................ 198 (92)
Engine Coolant Capacity - qt. (L) .................................................................................... 22 (21)
Coolant Pressure Cap - lb./in.2 (kPa) .............................................................................. 9 (62)
Maximum Engine H2O Temperature - ˚F (C) .................................................................... 200 (93)
Minimum Engine H2O Temperature - ˚F (˚C).................................................................... 160 (71)

Electric System - DC All Speeds

System Voltage (Nominal) .............................................................................................. 12
Battery Capacity for Ambients Above 32˚F - CCA @ 0˚F .................................................. 640
Voltage (Nominal) ........................................................................................................ 12
Qty. per Battery Bank .................................................................................................. 1
SAE size per J537 ........................................................................................................ 4D-640
Battery Cable Circuit*, Max Resistance - ohm ................................................................ 0.0017
Battery Cable Minimum Size
0-120 in. Circuit* Length ........................................................................................ No. 00
121-160 in. Circuit* Length ........................................................................................ No. 000
161-200 in. Circuit* Length ........................................................................................ No. 0000
Charging Alternator Output - Amp. .................................................................................. 42
Starter Cranking Amps - @ 60˚ F .................................................................................... 275

*Positive and Negative Cables Combined Length

(Continued)
NOTE: This Engine Is Intended For Indoor Installation Or In A Weatherproof Enclosure. Page 48-C-1
 PDFP-04YT
INSTALLATION & OPERATION DATA (Continued)
Exhaust System 1470 1760 2100 2350 2600
Exhaust Flow - ft.3/min. (m3/min.)............................................ 316 (8.9) 445 (13) 556 (16) 645 (18) 754 (21)
Exhaust Temperature - ˚F (˚C).................................................... 954 (512) 1034 (557) 1004 (540) 977 (525) 970 (521)
Maximum Allowable Back Pressure -
in. H2O (kPa) ........................................................................ 30 (7.5) 30 (7.5) 30 (7.5) 30 (7.5) 30 (7.5)
Minimum Exhaust Pipe Dia. - in. (mm)** ................................ 3.0 (76) 3.0 (76) 3.0 (76) 4.0 (102) 4.0 (102)

Fuel System
Fuel Consumption - gal./hr. (L/hr.) ............................................ 2.7 (10) 4.1 (16) 4.8 (18) 5.3 (20) 5.9 (22)
2
Fuel Pressure - lb./in. (kPa) .......................................................................................... 5-10 (35-70)
Minimum Line Size - Supply - in. (mm)** ...................................................................... 0.37 Sch. 40 - Black
Minimum Line Size - Return - in. (mm)** ...................................................................... 0.25 Sch. 40 - Black
Maximum Allowable Fuel Pump Suction
with Clean Filter - in. H2O (kPa) .......................................................................... 54 (100)
Maximum Allowable Head on
Fuel Pump - ft(m) ................................................................................................ 9.8 (3.0)
Fuel Filter Micron Size - Primary...................................................................................... 30
Secondary .................................................................................................... 5
Fuel Modulator/Setting .................................................................................................... None/None

Heater System All Speeds

Jacket Water Heater ........................................................................................................ Standard
Wattage (Nominal) ...................................................................................................... 1500
Voltage - AC, 1P .......................................................................................................... 120 (+5%, –10%)
Optional Voltage - AC, 1P ............................................................................................ 240 (+5%, –10%)
Lube Oil Heater (Required When Ambient Is Below 32˚F (0˚C)........................................ Consult Factory

Induction Air System 1470 1760 2100 2350 2600

Air Cleaner Type ........................................................................ Indoors Service Only - Washable
Air Intake Restriction Maximum Limit
Dirty Air Cleaner - in. H2O (kPa) .......................................... 32 (8.0) 32 (8.0) 32 (8.0) 32 (8.0) 32 (8.0)
Clean Air Cleaner - in. H2O (kPa) .......................................... 20 (5.0) 20 (5.0) 20 (5.0) 20 (5.0) 20 (5.0)
Engine Air Flow - ft.3/min. (m3/min.) .................................... 120 (3.4) 160 (4.5) 204 (5.8) 241 (6.8) 283 (8.0)
Maximum Allowable Temperature (Air To Engine Inlet) - ˚F (˚C)***................................ 130 (54)

Lubrication System All Speeds

Oil Pressure - normal - lb./in.2 (kPa) .............................................................................. 40-60 (276-414)
In Pan Oil Temperature - ˚F (˚C) ...................................................................................... 220-240 (88-116)
Oil Pan Capacity - High - qt. (L) ...................................................................................... 7.3 (6.9)
Low - qt. (L)...................................................................................................... 5.9 (5.6)
Total Oil Capacity with Filters - qt. (L).............................................................................. 8.0 (7.6)

Performance 1470 1760 2100 2350 2600

2
BMEP - lb./in. (kPa) ................................................................ 120 (827) 148 (1020) 141 (972) 132 (910) 125 (862)
Piston Speed - ft./min. (m/min.)................................................ 1225 (373) 1467 (447) 1750 (583) 1958 (597) 2167 (660)
Noise - dB (A) @ 1m ................................................................ 100 (EST) 102 (EST) 103 (EST) 104 (EST) 96 (EST)
Power Curve .................................................................................................................... CDDA - Y044 - 04

**Based On Nominal System. Flow Analysis Must Be Done To Assure Adherance To System Limitations.
(Minimum Exhaust Pipe Diameter is based on 15 feet of pipe, one elbow, and a silencer
pressure drop no greater than one half the max. allowable back pressure.)
CDDA MAR 97 JTW ***Review For Power Deration If Air Entering Engine Exceeds 77˚ F (25˚ C).
Page 48-C-2
 PDFP-L6YN
INSTALLATION & OPERATION DATA
Basic Engine Description All Speeds
Engine Manufacturer........................................................................................................ Perkins/Detroit Diesel
Ignition Type .................................................................................................................... Compression (Diesel)
Number of Cylinders ........................................................................................................ 6
Bore and Stroke - in. (mm).............................................................................................. 3.937 (100) 5.0 (127)
Displacement - in.3 (L) .................................................................................................... 365 (5.98)
Compression Ratio .......................................................................................................... 16.5:1
Combustion System ........................................................................................................ Direct Injection
Engine Type...................................................................................................................... In-Line, 4 Cycle
Aspiration ........................................................................................................................ Natural
Firing Order (CW Rotation) .............................................................................................. 1-5-3-6-2-4
Charge Air Cooling Type .................................................................................................. None
Rotation (Viewed from Front)
Clockwise .................................................................................................................... Standard
Counter-Clockwise ...................................................................................................... Not Available
Engine Crankcase Vent System........................................................................................ Open
Dimensions and Weight
Length - in. (mm) (From Drive Flange)........................................................................ 47.9 (1217)
Width - in. (mm) .......................................................................................................... 26.1 (663)
Height - in. (mm) (Above Crankshaft Center Line) .................................................... 32.6 (828)
Weight, Dry - lb. (kg) .................................................................................................. 1206 (547)
Wet - lb. (kg) ........................................................................................................ 1287 (584)
Installation Drawing ........................................................................................................ D-472

Cooling System 1470 1760 2100 2350 2600

Engine H2O Heat - Btu/sec. (kJ/sec.) ........................................ 46 (49) 47 (50) 55 (58) 59 (63) 64 (67)
Engine Radiated Heat - Btu/sec. (kJ/sec.).................................. 8.4 (8.8) 9.3 (9.8) 10 (11) 12 (13) 13 (14)
Heat Exchanger Minimum Flow
60˚F Raw H2O - gal./min. (L/min.) ........................................ 6.1 (23) 6.8 (26) 8.6 (33) 9.4 (36) 10 (38)
95˚F Raw H2O - gal./min. (L/min.) ........................................ 8 (30) 9.0 (34) 13 (49) 14 (53) 14 (53)
Heat Exchanger Maximum Cooling H2O
Inlet Pressure - lb./in.2 (kPa) ...................................................................................... 60 (414)
Flow - gal./min. (L/min.) .............................................................................................. 40 (151)
Thermostat, Start to Open - ˚F (˚C) .................................................................................. 170 (77)
Fully Open - ˚F (˚C) ................................................................................................ 198 (92)
Engine Coolant Capacity - qt. (L) .................................................................................... 26 (25)
Coolant Pressure Cap - lb./in.2 (kPa) .............................................................................. 9 (62)
Maximum Engine H2O Temperature - ˚F (C) .................................................................... 200 (93)
Minimum Engine H2O Temperature - ˚F (˚C).................................................................... 160 (71)

Electric System - DC All Speeds

System Voltage (Nominal) .............................................................................................. 12
Battery Capacity for Ambients Above 32˚F - CCA @ 0˚F .................................................. 640
Voltage (Nominal) ........................................................................................................ 12
Qty. per Battery Bank .................................................................................................. 1
SAE size per J537 ........................................................................................................ 4D-640
Battery Cable Circuit*, Max Resistance - ohm ................................................................ 0.0017
Battery Cable Minimum Size
0-120 in. Circuit* Length ........................................................................................ No. 00
121-160 in. Circuit* Length ........................................................................................ No. 000
161-200 in. Circuit* Length ........................................................................................ No. 0000
Charging Alternator Output - Amp. .................................................................................. 42
Starter Cranking Amps - @ 60˚ F .................................................................................... 394

*Positive and Negative Cables Combined Length

(Continued)
NOTE: This Engine Is Intended For Indoor Installation Or In A Weatherproof Enclosure. Page 48-D-1
 PDFP-L6YN
INSTALLATION & OPERATION DATA (Continued)
Exhaust System 1470 1760 2100 2350 2600
Exhaust Flow - ft.3/min. (m3/min.)............................................ 361 (10) 457 (13) 555 (16) 610 (17) 668 (19)
Exhaust Temperature - ˚F (˚C).................................................... 1018 (548) 1073 (578) 1093 (589) 1101 (594) 1135 (613)
Maximum Allowable Back Pressure -
in. H2O (kPa) ........................................................................ 30 (7.5) 30 (7.5) 30 (7.5) 30 (7.5) 30 (7.5)
Minimum Exhaust Pipe Dia. - in. (mm)** ................................ 3.0 (7.6) 3.0 (7.6) 3.0 (76) 3.0 (76) 3.0 (76)

Fuel System
Fuel Consumption - gal./hr. (L/hr.) ............................................ 3.7 (14) 4.6 (17) 5.4 (20) 5.7 (22) 6.2 (23)
2
Fuel Pressure - lb./in. (kPa) .......................................................................................... 5-10 (35-70)
Minimum Line Size - Supply - in. (mm)** ...................................................................... 0.37 Sch. 40 - Black
Minimum Line Size - Return - in. (mm)** ...................................................................... 0.25 Sch. 40 - Black
Maximum Allowable Fuel Pump Suction
with Clean Filter - in. H2O (kPa) .......................................................................... 54 (100)
Maximum Allowable Head on
Fuel Pump - ft(m) ................................................................................................ 9.8 (3.0)
Fuel Filter Micron Size - Primary...................................................................................... 30
Secondary .................................................................................................... 5
Fuel Modulator/Setting .................................................................................................... None/None

Heater System All Speeds

Jacket Water Heater ........................................................................................................ Standard
Wattage (Nominal) ...................................................................................................... 1500
Voltage - AC, 1P .......................................................................................................... 120 (+5%, –10%)
Optional Voltage - AC, 1P ............................................................................................ 240 (+5%, –10%)
Lube Oil Heater (Required When Ambient Is Below 32˚F (0˚C)........................................ Consult Factory

Induction Air System 1470 1760 2100 2350 2600

Air Cleaner Type ........................................................................ Indoors Service Only - Washable
Air Intake Restriction Maximum Limit
Dirty Air Cleaner - in. H2O (kPa) .......................................... 26 (6.5) 26 (6.5) 26 (6.5) 26 (6.5) 26 (6.5)
Clean Air Cleaner - in. H2O (kPa) .......................................... 20 (5.0) 20 (5.0) 20 (5.0) 20 (5.0) 20 (5.0)
Engine Air Flow - ft.3/min. (m3/min.) .................................... 131 (3.7) 160 (4.5) 192 (5.4) 210 (5.9) 225 (6.4)
Maximum Allowable Temperature (Air To Engine Inlet) - ˚F (˚C)***................................ 130 (54)

Lubrication System All Speeds

Oil Pressure - normal - lb./in.2 (kPa) .............................................................................. 40-60 (276-414)
In Pan Oil Temperature - ˚F (˚C) ...................................................................................... 220-240 (88-116)
Oil Pan Capacity - High - qt. (L) ...................................................................................... 13.8 (13.1)
Low - qt. (L)...................................................................................................... 11.5 (10.9)
Total Oil Capacity with Filters - qt. (L).............................................................................. 15.2 (14.4)

Performance 1470 1760 2100 2350 2600

2
BMEP - lb./in. (kPa) ................................................................ 156 (1076) 160 (1103) 156 (1076) 145 (1000) 138 (952)
Piston Speed - ft./min. (m/min.)................................................ 1225 (373) 1467 (447) 1750 (583) 1958 (597) 2167 (660)
Noise - dB (A) @ 1m ................................................................ 100 (EST) 102 (EST) 103 (EST) 104 (EST) 96 (EST)
Power Curve .................................................................................................................... CDDA - Y064 - 01

**Based On Nominal System. Flow Analysis Must Be Done To Assure Adherance To System Limitations.
(Minimum Exhaust Pipe Diameter is based on 15 feet of pipe, one elbow, and a silencer
pressure drop no greater than one half the max. allowable back pressure.)
CDDA MAR 97 JTW ***Review For Power Deration If Air Entering Engine Exceeds 77˚ F (25˚ C).
Page 48-D-2
 PDFP-L6YT
INSTALLATION & OPERATION DATA
Basic Engine Description All Speeds
Engine Manufacturer........................................................................................................ Perkins/Detroit Diesel
Ignition Type .................................................................................................................... Compression (Diesel)
Number of Cylinders ........................................................................................................ 6
Bore and Stroke - in. (mm).............................................................................................. 3.937 (100) 5.0 (127)
Displacement - in.3 (L) .................................................................................................... 365 (5.98)
Compression Ratio .......................................................................................................... 16:1
Combustion System ........................................................................................................ Direct Injection
Engine Type...................................................................................................................... In-Line, 4 Cycle
Aspiration ........................................................................................................................ Turbocharged
Firing Order (CW Rotation) .............................................................................................. 1-5-3-6-2-4
Charge Air Cooling Type .................................................................................................. None
Rotation (Viewed from Front)
Clockwise .................................................................................................................... Standard
Counter-Clockwise ...................................................................................................... Not Available
Engine Crankcase Vent System........................................................................................ Open
Dimensions and Weight
Length - in. (mm) (From Drive Flange)........................................................................ 47.9 (1217)
Width - in. (mm) .......................................................................................................... 27.9 (709)
Height - in. (mm) (Above Crankshaft Center Line) .................................................... 32.6 (828)
Weight, Dry - lb. (kg) .................................................................................................. 1223 (555)
Wet - lb. (kg) ........................................................................................................ 1304 (591)
Installation Drawing ........................................................................................................ D-472

Cooling System 1470 1760 2100 2350 2600

Engine H2O Heat - Btu/sec. (kJ/sec.) ........................................ 49 (52) 52 (55) 58 (61) 6.3 (67) 68 (73)
Engine Radiated Heat - Btu/sec. (kJ/sec.).................................. 10 (11) 11 (12) 12 (13) 13 (14) 15 (16)
Heat Exchanger Minimum Flow
60˚F Raw H2O - gal./min. (L/min.) ........................................ 7 (26) 8.7 (33) 10 (38) 11 (42) 14 (53)
95˚F Raw H2O - gal./min. (L/min.) ........................................ 8.8 (33) 11 (42) 12 (45) 14 (53) 16 (61)
Heat Exchanger Maximum Cooling H2O
Inlet Pressure - lb./in.2 (kPa) ...................................................................................... 60 (414)
Flow - gal./min. (L/min.) .............................................................................................. 40 (151)
Thermostat, Start to Open - ˚F (˚C) .................................................................................. 170 (77)
Fully Open - ˚F (˚C) ................................................................................................ 198 (92)
Engine Coolant Capacity - qt. (L) .................................................................................... 26 (25)
Coolant Pressure Cap - lb./in.2 (kPa) .............................................................................. 9 (62)
Maximum Engine H2O Temperature - ˚F (C) .................................................................... 200 (93)
Minimum Engine H2O Temperature - ˚F (˚C).................................................................... 160 (71)

Electric System - DC All Speeds

System Voltage (Nominal) .............................................................................................. 12
Battery Capacity for Ambients Above 32˚F - CCA @ 0˚F .................................................. 640
Voltage (Nominal) ........................................................................................................ 12
Qty. per Battery Bank .................................................................................................. 1
SAE size per J537 ........................................................................................................ 4D-640
Battery Cable Circuit*, Max Resistance - ohm ................................................................ 0.0017
Battery Cable Minimum Size
0-120 in. Circuit* Length ........................................................................................ No. 00
121-160 in. Circuit* Length ........................................................................................ No. 000
161-200 in. Circuit* Length ........................................................................................ No. 0000
Charging Alternator Output - Amp. .................................................................................. 42
Starter Cranking Amps - @ 60˚ F .................................................................................... 394

*Positive and Negative Cables Combined Length

(Continued)
NOTE: This Engine Is Intended For Indoor Installation Or In A Weatherproof Enclosure. Page 48-E-1
 PDFP-L6YT
INSTALLATION & OPERATION DATA (Continued)
Exhaust System 1470 1760 2100 2350 2600
Exhaust Flow - ft.3/min. (m3/min.)............................................ 444 (13) 591 (17) 738 (21) 862 (24) 1025 (29)
Exhaust Temperature - ˚F (˚C).................................................... 873 (467) 874 (468) 831 (444) 815 (435) 841 (449)
Maximum Allowable Back Pressure -
in. H2O (kPa) ........................................................................ 30 (7.5) 30 (7.5) 30 (7.5) 30 (7.5) 30 (7.5)
Minimum Exhaust Pipe Dia. - in. (mm)** ................................ 3.0 (76) 3.0 (7.6) 4.0 (102) 4.0 (102) 4.0 (102)

Fuel System
Fuel Consumption - gal./hr. (L/hr.) ............................................ 4.3 (16) 5.3 (20) 6.1 (23) 6.7 (25) 7.7 (23)
Fuel Pressure - lb./in.2 (kPa) .......................................................................................... 5-10 (35-70)
Minimum Line Size - Supply - in. (mm)** ...................................................................... 0.37 Sch. 40 - Black
Minimum Line Size - Return - in. (mm)** ...................................................................... 0.25 Sch. 40 - Black
Maximum Allowable Fuel Pump Suction
with Clean Filter - in. H2O (kPa) .......................................................................... 54 (100)
Maximum Allowable Head on
Fuel Pump - ft(m) ................................................................................................ 9.8 (3.0)
Fuel Filter Micron Size - Primary...................................................................................... 30
Secondary .................................................................................................... 5
Fuel Modulator/Setting .................................................................................................... None/None

Heater System All Speeds

Jacket Water Heater ........................................................................................................ Standard
Wattage (Nominal) ...................................................................................................... 1500
Voltage - AC, 1P .......................................................................................................... 120 (+5%, –10%)
Optional Voltage - AC, 1P ............................................................................................ 240 (+5%, –10%)
Lube Oil Heater (Required When Ambient Is Below 32˚F (0˚C)........................................ Consult Factory

Induction Air System 1470 1760 2100 2350 2600

Air Cleaner Type ........................................................................ Indoors Service Only - Washable
Air Intake Restriction Maximum Limit
Dirty Air Cleaner - in. H2O (kPa) .......................................... 32 (8.0) 32 (8.0) 32 (8.0) 32 (8.0) 32 (8.0)
Clean Air Cleaner - in. H2O (kPa) .......................................... 20 (5.0) 20 (5.0) 20 (5.0) 20 (5.0) 20 (5.0)
Engine Air Flow - ft.3/min. (m3/min.) .................................... 179 (5) 238 (7) 307 (9) 363 (10) 423 (12)
Maximum Allowable Temperature (Air To Engine Inlet) - ˚F (˚C)***................................ 130 (54)

Lubrication System All Speeds

Oil Pressure - normal - lb./in.2 (kPa) .............................................................................. 40-60 (276-414)
In Pan Oil Temperature - ˚F (˚C) ...................................................................................... 220-240 (88-116)
Oil Pan Capacity - High - qt. (L) ...................................................................................... 13.8 (13.1)
Low - qt. (L)...................................................................................................... 11.5 (10.9)
Total Oil Capacity with Filters - qt. (L).............................................................................. 15.2 (14.4)

Performance 1470 1760 2100 2350 2600

2
BMEP - lb./in. (kPa) ................................................................ 133 (917) 136 (938) 124 (855) 115 (793) 113 (779)
Piston Speed - ft./min. (m/min.)................................................ 1225 (373) 1467 (447) 1750 (583) 1958 (597) 2167 (660)
Noise - dB (A) @ 1m ................................................................ 100 (EST) 102 (EST) 103 (EST) 104 (EST) 96 (EST)
Power Curve .................................................................................................................... CDDA - Y064 - 03

**Based On Nominal System. Flow Analysis Must Be Done To Assure Adherance To System Limitations.
(Minimum Exhaust Pipe Diameter is based on 15 feet of pipe, one elbow, and a silencer
pressure drop no greater than one half the max. allowable back pressure.)
CDDA MAR 97 JTW ***Review For Power Deration If Air Entering Engine Exceeds 77˚ F (25˚ C).
Page 48-E-2
 PDFP-O6YT
INSTALLATION & OPERATION DATA
Basic Engine Description All Speeds
Engine Manufacturer........................................................................................................ Perkins/Detroit Diesel
Ignition Type .................................................................................................................... Compression (Diesel)
Number of Cylinders ........................................................................................................ 6
Bore and Stroke - in. (mm).............................................................................................. 3.937 (100) 5.0 (127)
Displacement - in.3 (L) .................................................................................................... 365 (5.98)
Compression Ratio .......................................................................................................... 16:1
Combustion System ........................................................................................................ Direct Injection
Engine Type...................................................................................................................... In-Line, 4 Cycle
Aspiration ........................................................................................................................ Turbocharged
Firing Order (CW Rotation) .............................................................................................. 1-5-3-6-2-4
Charge Air Cooling Type .................................................................................................. None
Rotation (Viewed from Front)
Clockwise .................................................................................................................... Standard
Counter-Clockwise ...................................................................................................... Not Available
Engine Crankcase Vent System........................................................................................ Open
Dimensions and Weight
Length - in. (mm) (From Drive Flange)........................................................................ 47.9 (1217)
Width - in. (mm) .......................................................................................................... 27.9 (709)
Height - in. (mm) (Above Crankshaft Center Line) .................................................... 32.6 (828)
Weight, Dry - lb. (kg) .................................................................................................. 1223 (555)
Wet - lb. (kg) ........................................................................................................ 1304 (591)
Installation Drawing ........................................................................................................ D-472

Cooling System 1470 1760 2100 2350 2600

Engine H2O Heat - Btu/sec. (kJ/sec.) ........................................ 53 (56) 56 (59) 63 (66) 68 (72) 73 (77)
Engine Radiated Heat - Btu/sec. (kJ/sec.).................................. 11 (12) 12 (13) 13 (14) 14 (15) 16 (17)
Heat Exchanger Minimum Flow
60˚F Raw H2O - gal./min. (L/min.) ........................................ 7.2 (23) 9 (33) 11 (42) 12 (36) 15 (57)
95˚F Raw H2O - gal./min. (L/min.) ........................................ 9 (30) 11 (42) 13 (49) 15 (53) 17 (64)
Heat Exchanger Maximum Cooling H2O
Inlet Pressure - lb./in.2 (kPa) ...................................................................................... 60 (414)
Flow - gal./min. (L/min.) .............................................................................................. 40 (151)
Thermostat, Start to Open - ˚F (˚C) .................................................................................. 170 (77)
Fully Open - ˚F (˚C) ................................................................................................ 198 (92)
Engine Coolant Capacity - qt. (L) .................................................................................... 26 (25)
Coolant Pressure Cap - lb./in.2 (kPa) .............................................................................. 9 (62)
Maximum Engine H2O Temperature - ˚F (C) .................................................................... 200 (93)
Minimum Engine H2O Temperature - ˚F (˚C).................................................................... 160 (71)

Electric System - DC All Speeds

System Voltage (Nominal) .............................................................................................. 12
Battery Capacity for Ambients Above 32˚F - CCA @ 0˚F .................................................. 640
Voltage (Nominal) ........................................................................................................ 12
Qty. per Battery Bank .................................................................................................. 1
SAE size per J537 ........................................................................................................ 4D-640
Battery Cable Circuit*, Max Resistance - ohm ................................................................ 0.0017
Battery Cable Minimum Size
0-120 in. Circuit* Length ........................................................................................ No. 00
121-160 in. Circuit* Length ........................................................................................ No. 000
161-200 in. Circuit* Length ........................................................................................ No. 0000
Charging Alternator Output - Amp. .................................................................................. 42
Starter Cranking Amps - @ 60˚ F .................................................................................... 394

*Positive and Negative Cables Combined Length

(Continued)
NOTE: This Engine Is Intended For Indoor Installation Or In A Weatherproof Enclosure. Page 48-F-1
 PDFP-O6YT
INSTALLATION & OPERATION DATA (Continued)
Exhaust System 1470 1760 2100 2350 2600
Exhaust Flow - ft.3/min. (m3/min.)............................................ 462 (13) 638 (18) 789 (22) 930 (26) 1068 (30)
Exhaust Temperature - ˚F (˚C).................................................... 934 (501) 932 (500) 877 (469) 858 (459) 865 (463)
Maximum Allowable Back Pressure -
in. H2O (kPa) ........................................................................ 30 (7.5) 30 (7.5) 30 (7.5) 30 (7.5) 30 (7.5)
Minimum Exhaust Pipe Dia. - in. (mm)** ................................ 3.0 (76) 4.0 (102) 4.0 (102) 4.0 (102) 4.0 (102)

Fuel System
Fuel Consumption - gal./hr. (L/hr.) ............................................ 4.7 (18) 5.8 (22) 6.8 (26) 7.4 (28) 8.1 (31)
Fuel Pressure - lb./in.2 (kPa) .......................................................................................... 5-10 (35-70)
Minimum Line Size - Supply - in. (mm)** ...................................................................... 0.37 Sch. 40 - Black
Minimum Line Size - Return - in. (mm)** ...................................................................... 0.25 Sch. 40 - Black
Maximum Allowable Fuel Pump Suction
with Clean Filter - in. H2O (kPa) .......................................................................... 54 (100)
Maximum Allowable Head on
Fuel Pump - ft(m) ................................................................................................ 9.8 (3.0)
Fuel Filter Micron Size - Primary...................................................................................... 30
Secondary .................................................................................................... 5
Fuel Modulator/Setting .................................................................................................... None/None

Heater System All Speeds

Jacket Water Heater ........................................................................................................ Standard
Wattage (Nominal) ...................................................................................................... 1500
Voltage - AC, 1P .......................................................................................................... 120 (+5%, –10%)
Optional Voltage - AC, 1P ............................................................................................ 240 (+5%, –10%)
Lube Oil Heater (Required When Ambient Is Below 32˚F (0˚C)........................................ Consult Factory

Induction Air System 1470 1760 2100 2350 2600

Air Cleaner Type ........................................................................ Indoors Service Only - Washable
Air Intake Restriction Maximum Limit
Dirty Air Cleaner - in. H2O (kPa) .......................................... 32 (8.0) 32 (8.0) 32 (8.0) 32 (8.0) 32 (8.0)
Clean Air Cleaner - in. H2O (kPa) .......................................... 20 (5.0) 20 (5.0) 20 (5.0) 20 (5.0) 20 (5.0)
Engine Air Flow - ft.3/min. (m3/min.) .................................... 178 (5.0) 246 (6.9) 317 (9.0) 379 (11) 433 (12)
Maximum Allowable Temperature (Air To Engine Inlet) - ˚F (˚C)***................................ 130 (54)

Lubrication System All Speeds

Oil Pressure - normal - lb./in.2 (kPa) .............................................................................. 40-60 (276-414)
In Pan Oil Temperature - ˚F (˚C) ...................................................................................... 220-240 (88-116)
Oil Pan Capacity - High - qt. (L) ...................................................................................... 13.8 (13.1)
Low - qt. (L)...................................................................................................... 11.5 (10.9)
Total Oil Capacity with Filters - qt. (L).............................................................................. 15.2 (14.4)

Performance 1470 1760 2100 2350 2600

2
BMEP - lb./in. (kPa) ................................................................ 143 (986) 148 (1020) 137 (944) 129 (889) 121 (834)
Piston Speed - ft./min. (m/min.)................................................ 1225 (373) 1467 (447) 1750 (583) 1958 (597) 2167 (660)
Noise - dB (A) @ 1m ................................................................ 100 (EST) 102 (EST) 103 (EST) 104 (EST) 96 (EST)
Power Curve .................................................................................................................... CDDA - Y064 - 04

**Based On Nominal System. Flow Analysis Must Be Done To Assure Adherance To System Limitations.
(Minimum Exhaust Pipe Diameter is based on 15 feet of pipe, one elbow, and a silencer
pressure drop no greater than one half the max. allowable back pressure.)
CDDA MAR 97 JTW ***Review For Power Deration If Air Entering Engine Exceeds 77˚ F (25˚ C).
Page 48-F-2
 PDFP-L6YW
INSTALLATION & OPERATION DATA
Basic Engine Description All Speeds
Engine Manufacturer........................................................................................................ Perkins/Detroit Diesel
Ignition Type .................................................................................................................... Compression (Diesel)
Number of Cylinders ........................................................................................................ 6
Bore and Stroke - in. (mm).............................................................................................. 3.937 (100) 5.0 (127)
Displacement - in.3 (L) .................................................................................................... 365 (5.98)
Compression Ratio .......................................................................................................... 16:1
Combustion System ........................................................................................................ Direct Injection
Engine Type...................................................................................................................... In-Line, 4 Cycle
Aspiration ........................................................................................................................ Turbocharged
Firing Order (CW Rotation) .............................................................................................. 1-5-3-6-2-4
Charge Air Cooling Type .................................................................................................. Jacket Water Cooled
Rotation (Viewed from Front)
Clockwise .................................................................................................................... Standard
Counter-Clockwise ...................................................................................................... Not Available
Engine Crankcase Vent System........................................................................................ Open
Dimensions and Weight
Length - in. (mm) (From Drive Flange)........................................................................ 47.9 (1217)
Width - in. (mm) .......................................................................................................... 30.9 (785)
Height - in. (mm) (Above Crankshaft Center Line) .................................................... 32.6 (828)
Weight, Dry - lb. (kg) .................................................................................................. 1252 (568)
Wet - lb. (kg) ........................................................................................................ 1335 (606)
Installation Drawing ........................................................................................................ D-472

Cooling System 1470 1760 2100 2350 2600

Engine H2O Heat - Btu/sec. (kJ/sec.) ........................................ 55 (59) 58 (61) 65 (69) 74 (78) 83 (88)
Engine Radiated Heat - Btu/sec. (kJ/sec.).................................. 11 (12) 12 (13) 14 (15) 16 (17) 17 (18)
Heat Exchanger Minimum Flow
60˚F Raw H2O - gal./min. (L/min.) ........................................ 9 (34) 11 (33) 12 (45) 12 (45) 13 (49)
95˚F Raw H2O - gal./min. (L/min.) ........................................ 11 (42) 13 (49) 14 (53) 14 (53) 15 (57)
Heat Exchanger Maximum Cooling H2O
Inlet Pressure - lb./in.2 (kPa) ...................................................................................... 60 (414)
Flow - gal./min. (L/min.) .............................................................................................. 40 (151)
Thermostat, Start to Open - ˚F (˚C) .................................................................................. 170 (77)
Fully Open - ˚F (˚C) ................................................................................................ 198 (92)
Engine Coolant Capacity - qt. (L) .................................................................................... 27 (26)
Coolant Pressure Cap - lb./in.2 (kPa) .............................................................................. 9 (62)
Maximum Engine H2O Temperature - ˚F (C) .................................................................... 200 (93)
Minimum Engine H2O Temperature - ˚F (˚C).................................................................... 160 (71)

Electric System - DC All Speeds

System Voltage (Nominal) .............................................................................................. 12
Battery Capacity for Ambients Above 32˚F - CCA @ 0˚F .................................................. 640
Voltage (Nominal) ........................................................................................................ 12
Qty. per Battery Bank .................................................................................................. 1
SAE size per J537 ........................................................................................................ 4D-640
Battery Cable Circuit*, Max Resistance - ohm ................................................................ 0.0017
Battery Cable Minimum Size
0-120 in. Circuit* Length ........................................................................................ No. 00
121-160 in. Circuit* Length ........................................................................................ No. 000
161-200 in. Circuit* Length ........................................................................................ No. 0000
Charging Alternator Output - Amp. .................................................................................. 42
Starter Cranking Amps - @ 60˚ F .................................................................................... 394

*Positive and Negative Cables Combined Length

(Continued)
NOTE: This Engine Is Intended For Indoor Installation Or In A Weatherproof Enclosure. Page 48-G-1
 PDFP-L6YW
INSTALLATION & OPERATION DATA (Continued)
Exhaust System 1470 1760 2100 2350 2600
Exhaust Flow - ft.3/min. (m3/min.)............................................ 506 (14) 680 (19) 639 (18) 752 (21) 865 (24)
Exhaust Temperature - ˚F (˚C).................................................... 1008 (542) 977 (525) 921 (494) 898 (481) 875 (468)
Maximum Allowable Back Pressure -
in. H2O (kPa) ........................................................................ 30 (7.5) 30 (7.5) 30 (7.5) 30 (7.5) 30 (7.5)
Minimum Exhaust Pipe Dia. - in. (mm)** ................................ 4.0 (102) 4.0 (102) 4.0 (102) 4.0 (102) 4.0 (102)

Fuel System
Fuel Consumption - gal./hr. (L/hr.) ............................................ 5.2 (20) 6.3 (24) 7.7 (29) 8.4 (32) 9.2 (35)
Fuel Pressure - lb./in.2 (kPa) .......................................................................................... 5-10 (35-70)
Minimum Line Size - Supply - in. (mm)** ...................................................................... 0.37 Sch. 40 - Black
Minimum Line Size - Return - in. (mm)** ...................................................................... 0.25 Sch. 40 - Black
Maximum Allowable Fuel Pump Suction
with Clean Filter - in. H2O (kPa) .......................................................................... 54 (100)
Maximum Allowable Head on
Fuel Pump - ft(m) ................................................................................................ 9.8 (3.0)
Fuel Filter Micron Size - Primary...................................................................................... 30
Secondary .................................................................................................... 5
Fuel Modulator/Setting .................................................................................................... Boost/None

Heater System All Speeds

Jacket Water Heater ........................................................................................................ Standard
Wattage (Nominal) ...................................................................................................... 1500
Voltage - AC, 1P .......................................................................................................... 120 (+5%, –10%)
Optional Voltage - AC, 1P ............................................................................................ 240 (+5%, –10%)
Lube Oil Heater (Required When Ambient Is Below 32˚F (0˚C)........................................ Consult Factory

Induction Air System 1470 1760 2100 2350 2600

Air Cleaner Type ........................................................................ Indoors Service Only - Washable
Air Intake Restriction Maximum Limit
Dirty Air Cleaner - in. H2O (kPa) .......................................... 32 (8.0) 32 (8.0) 32 (8.0) 32 (8.0) 32 (8.0)
Clean Air Cleaner - in. H2O (kPa) .......................................... 20 (5.0) 20 (5.0) 20 (5.0) 20 (5.0) 20 (5.0)
Engine Air Flow - ft.3/min. (m3/min.) .................................... 185 (5.0) 254 (7.0) 344 (10) 414 (12) 488 (14)
Maximum Allowable Temperature (Air To Engine Inlet) - ˚F (˚C)***................................ 130 (54)

Lubrication System All Speeds

Oil Pressure - normal - lb./in.2 (kPa) .............................................................................. 40-60 (276-414)
In Pan Oil Temperature - ˚F (˚C) ...................................................................................... 220-240 (88-116)
Oil Pan Capacity - High - qt. (L) ...................................................................................... 13.8 (13.1)
Low - qt. (L)...................................................................................................... 11.5 (10.9)
Total Oil Capacity with Filters - qt. (L).............................................................................. 15.2 (14.4)

Performance 1470 1760 2100 2350 2600

2
BMEP - lb./in. (kPa) ................................................................ 156 (1076) 160 (1103) 156 (1076) 145 (1000) 138 (952)
Piston Speed - ft./min. (m/min.)................................................ 1225 (373) 1467 (447) 1750 (583) 1958 (597) 2167 (660)
Noise - dB (A) @ 1m ................................................................ 100 (EST) 102 (EST) 103 (EST) 104 (EST) 96 (EST)
Power Curve .................................................................................................................... CDDA - Y064 - 05

**Based On Nominal System. Flow Analysis Must Be Done To Assure Adherance To System Limitations.
(Minimum Exhaust Pipe Diameter is based on 15 feet of pipe, one elbow, and a silencer
pressure drop no greater than one half the max. allowable back pressure.)
CDDA MAR 97 JTW ***Review For Power Deration If Air Entering Engine Exceeds 77˚ F (25˚ C).
Page 48-G-2
 PDFP-L4YN; -L6YN
ENGINE MATERIALS AND CONSTRUCTION

Air Cleaner Valves

Type ......................................Indoor Dry Type ......................................Poppet
Material..................................Pleated Paper Arrangement..........................Overhead Valve
Galvanized Steel Housing Number/Cylinder....................1 Intake
..................1 Exhaust
Operating Mechanism............Mechanical Rocker Arm
Air Cleaner Type of Lifter ........................Large Head
Type ......................................Indoor Usage Only Valve Spring
Oiled Fabric Pleats Number/Valve ......................2
Material..................................Surgical Cotton Valve Seat Insert....................Replaceable
Aluminum Mesh
Fuel Pump
Balancer (-L4YN only) Type ......................................Diaphragm
Type ......................................Counter Rotating Shafts Drive ......................................Cam Lobe
For Second Order Control
Heat Exchanger
Camshaft Type ......................................Tube & Bundle
Material..................................Cast Iron Materials
Chill Hardened Tubes & Headers ................80/20 CU/NI
Location ................................In Block Shell ....................................Copper
Drive ......................................Gear, Helical Electrode..............................Zinc
Type of Cam ..........................Ground
Injection Pump
Type ......................................Rotary Distributor
Coolant Pump Drive ......................................Gear
Type ......................................Centrifugal
Drive ......................................Gear Liners
Type ......................................Dry Liner
Connecting Rod Material..................................Cast Iron
Type ......................................H Section Silicon Carbide
Material..................................Forged Molybdenum Honed
Steel Alloy Lubrication Pump
Type ......................................Rotor
Crank Pin Bearings Drive ......................................Gear
Type ......................................Precision Half Shell
Number..................................1 Pair Per Cylinder Main Bearings
Material..................................Aluminum Type ......................................Precision Half Shells
Tin Alloy Material..................................Steel Backed-Aluminum/
Tin
Crankshaft Piston
Material..................................Forged Chrome Type and Material ..................Aluminum Alloy With
Molybdenum Steel Reinforce Top Ring
Type of Balance ....................Dynamic Groove

Piston Pin
Cylinder Block
Type ......................................Full Floating
Type ......................................One Piece With
Non-Siamese Cylinders
Material..................................Cast Iron Alloy Piston Pin Bushing
Material..................................Steel Backed Bronze

Cylinder Head Piston Rings

Type ......................................Slab 2 Valve Number/Piston ......................3
Material..................................Cast Iron Top ......................................Barrel Faced
Second ................................Taper Faced
Third ....................................Chromium Faced

CDDA MAR 97 JTW Page 48-Z-1

 PDFP-L4YT; -04YT; -L6YT; -06YT; -L6YW
ENGINE MATERIALS AND CONSTRUCTION
Air Cleaner Valves
Type ......................................Indoor Dry Type ......................................Poppet
Material..................................Pleated Paper Arrangement..........................Overhead Valve
Galvanized Steel Housing Number/Cylinder....................1 Intake
..................1 Exhaust
Operating Mechanism............Mechanical Rocker Arm
Air Cleaner Type of Lifter ........................Large Head
Type ......................................Indoor Usage Only Valve Spring
Oiled Fabric Pleats Number/Valve ......................2
Material..................................Surgical Cotton Valve Seat Insert....................Replaceable
Aluminum Mesh
Fuel Pump
Balancer (-L4YT & -04YT only) Type ......................................Diaphragm
Type ......................................Counter Rotating Shafts Drive ......................................Cam Lobe
For Second Order Control
Heat Exchanger
Camshaft Type ......................................Tube & Bundle
Material..................................Cast Iron Materials
Chill Hardened Tubes & Headers ................80/20 CU/NI
Location ................................In Block Shell ....................................Copper
Drive ......................................Gear, Helical Electrode..............................Zinc
Type of Cam ..........................Ground
Injection Pump
Type ......................................Rotary Distributor
Coolant Pump Drive ......................................Gear
Type ......................................Centrifugal
Drive ......................................Gear Liners
Type ......................................Dry Liner
Connecting Rod Material..................................Cast Iron
Type ......................................H Section Silicon Carbide
Material..................................Forged Molybdenum Honed
Steel Alloy Lubrication Pump
Type ......................................Rotor
Crank Pin Bearings Drive ......................................Gear
Type ......................................Precision Half Shell
Number..................................1 Pair Per Cylinder Main Bearings
Material..................................Lead Bronze Type ......................................Precision Half Shells
Material..................................Steel Backed-Aluminum/
Tin
Crankshaft Piston
Material..................................Forged Chrome Type and Material ..................Aluminum Alloy With
Molybdenum Steel Reinforce Top Ring
Type of Balance ....................Dynamic Groove
Cooling ..................................Oil Jet Spray
Cylinder Block
Piston Pin
Type ......................................One Piece With
Type ......................................Full Floating
Non-Siamese Cylinders
Material..................................Cast Iron Alloy
Piston Pin Bushing
Material..................................Steel Backed Bronze
Cylinder Head
Type ......................................Slab 2 Valve Piston Rings
Material..................................Cast Iron Number/Piston ......................3
Top ......................................Barrel Faced
Second ................................Taper Faced
Third ....................................Chromium Faced

CDDA MAR 97 JTW Page 48-Z-2

SECTION 6 PDFP

PARTS INFORMATION
The parts that make up the PDFP diesel driver are provided time nor the inclination to search for specific part number data.
from two sources. The basic engine is manufactured and Distributor/Dealer organization stands ready to meet your
assembled by Perkins . The basic engine is shipped to Clarke needs. When you contact the Distributor/Dealer, provide the
DD-A in Cincinnati, Ohio, U.S.A. and prepared to NFPA-20 following data from the engine data located on the left of the
requirements. Any parts required for this product can be engine:
obtained by ordering through the authorized DDC Distribu-
tor/Dealer in U.S. or Canada and at your local Perkins Dis- Serial Number ________________________
tributor/Dealer outside U.S. or Canada.

The basic engine parts ordering data is contained in the

"BASIC ENGINE PARTS" section that follows. The special
Other Useful Information:
parts to meet NFPA-20 requirements are detailed under the
"OPTION PARTS" section provided as a supplement to this
To help identify basic engine items that may require periodic
manual.
service, replacement or repair, the following parts are identi-
fied.

BASIC ENGINE PARTS ITEM Perkins P/N Stanadyne P/N

Primary 26560920 30727
Progress in industry comes at a rapid pace. In order for the Fuel Filters
Secondary 26560919 30729
engine manufacturer to keep pace with progress, he needs a
versatile product for the many models and arrangements of Oil Filters 2654403
accessories and mounting parts needed to suit a variety of
equipment. In addition, engine refinements and improve-
ments are constantly being introduced. All of this dynamic
action must be documented so that the equipment can be ITEM Clarke P/N
serviced if and when it' s needed. It is fully documented in the Air Filter C03249
manufacturer' s plant and in dealer Parts Departments with
Master Files and adequate supporting records. But, what Cleaning Agent C121158
about YOU the user of this equipment? You have neither the Air Filter Oil C121157

Page 49
SECTION 6 PDFP

OPTION PARTS

At Clarke DD-A the following "OPTION PARTS" are added to the basic Perkins Diesel engine:

• Engine Heater System (jacket water) • Falk Coupling, Engine Half

• Speed Switch with magnetic pickup • Vertical Turbine Drive Plate (optional)

• Battery Isolator, alternator charging system • FM/UL/ULC Nameplate

• Air Cleaner System • Fuel Junction Block with Supply & Return Lines

• Speed Control (tamper proof) • Wiring Harness

• Heat Exchanger System • DC Junction Terminal Strip (in Instrument Panel)

• Flex Fuel Lines - stainless steel • Instrument Panel & Gauges

• Exhaust Flex Connection • Two Starting Motors

• Front & Rear Engine Mounts • Battery Charging Alternator & Guard

• Turbocharger outlet elbow (-L6YW only) • Alternator Pulley, Fan, Drive Belt and Support System

• Exhaust Blanket Insulation

Specific replacement parts for your engine can be ordered The authorized DDC Distribution/Dealer will obtain the re-
through the authorized Distributor/Dealer. When ordering placement option parts through Clarke DDA, Cincinnati,
"OPTION PARTS", provide Distributor/Dealer with the fol- Ohio.
lowing data from the FM/UL/ULC Nameplate:

A. Engine Model No. _______________________________

B. Engine Serial No. _______________________________

C. Mfg. Date _____________________________________

And Part Number from the "Option Parts Supplement".

________________________________________________

ANALYSIS PROGRAM
Analysis Kits are currently available through your local DDC pose of laboratory uniformity, please use the DDC model and
Distributor. These kits can be purchased for a nominal fee to Serial number as found on the valve rocker cover.
provide the capability of taking oil or coolant samples and
mailing them to a testing laboratory. By a series of laboratory Results will include warnings and recommendations should a
test they can determine operating conditions that may be problem be found.
harmful to your engine. Sample results are mailed to the
sender provided they have completed the sample processing Coolant Analysis Kit P/N 23508774
form with the current address. Each kit contains sampling Oil Analysis Kit P/N 12345678
instructions and enngine identification request. For the pur-

Page 50
SECTION 7 PDFP

OWNER ASSISTANCE

The satisfaction and goodwill of the owners of PDFP diesel Prior to this call, have the following information available:
engines is of primary concern to the PDFP organization —Name and location of Distributor/Dealer contacted
including their Distributors/Dealers. —Pump OEM equipment: Model and Rating
—Engine Model and S/N
As an owner/operator of a PDFP diesel engine, you have a —Engine delivery date and hours of operation
complete network of Distributor locations plus their dealers in —Nature of problem
the United States, Canada and worldwide. Consult your —Chronological summary of units history
"Yellow Page" telephone directory under ENGINES-
DIESEL for the authorized agent serving your area. The Step 3 - If the problem is still not resolved to your satisfaction,
Distributor/Dealer organization provide: present the entire matter in writing or by phone to the factory:

• Field service by trained personnel

• Emergency service 24 hours per day If located in U.S. or Canada write to:
• Complete parts support
• Sales assistance for your power needs Director,
• Product information and literature Reliability and Materials Engr.
Detroit Diesel Corporation
We recognize, however, that despite the best intentions of 13400 Outer Drive, West
everyone concerned, misunderstandings may occur. Nor- Detroit, Michigan 48239-4001
mally, any such situation that arises in connection with the Phone: (313) 592-7357
sale, operation or service of your engine will be handled by the
Distributor/Dealer in your area.
If located outside U.S. or Canada write to:
To further assure your complete satisfaction the following
procedure should be followed in the event you have a problem Perkins Power Sales & Service Limited
that has not been handled satisfactorily. Frank Perkins Way
Peterborough
Step 1 - Discuss your problem with a member of management PE1 5NA
from the distributorship or dealership in your area. Fre- United Kingdom
quently, complaints are the result of a breakdown in commu- Tel: [44] (733) 67474
nication and can quickly be resolved by a member of manage- Fax: [44] (733) 582440
ment. If you have already discussed the problem with the Sales Telex: 32501 Perken G
or Service Manager, contact the General Manager. If your
problem originates with a dealer, explain the matter to a
management member of the distributorship with whom the If the additional review by the factory of all the facts involved
dealer has his service agreement. indicates that some further action can be taken, the modifica-
tion center and/or the Distribution/Dealer will be so in-
Step 2 - When it appears that your problem cannot be resolved structed.
at the Distributor level without additional assistance, contact:
When contacting Clarke DD-A, please keep in mind that
Clarke Detroit Diesel-Allison ultimately your problem will likely be resolved at the Dis-
3133 E. Kemper Road tributorship/Dealership utilizing their facilities, equipment
Cincinnati, OH 45241 and personnel. Therefore, it is suggested that you follow the
above steps in sequence when requiring assistance.
Attention: Fire Pump Service Manager

Phone: 513-771-2200

Fax: 513-771-0520

Page 51
SECTION 7 PDFP

Eastern Region AUSTRALIA Contact Area of Responsibility

187 Monmouth Park Hwy. Perkins Engines (Pty) Ltd Mr R P Cook Australia
West Long Branch, New Jersey 07704 P.O. Box 470 Tel: [61] (59) 75 1877 New Zealand
Phone: (908) 222-1888 Mornington 3931 Fax: [61] (59) 75 1305 Pacific Islands
Melbourne
Victoria
Southeastern Region
FRANCE
5111 Bowden Rd.
Jacksonville, Florida 32216 Moteurs Perkins SA Mr P Chambrillon France
Phone: (904) 448-8833 9 Avenue Michelet Tel: [33] (1) 4010 4246 Algeria
93583 Saint Ouen Fax: [33] (1) 4010 4245 Morocco
CEDEX Tunisia
Central Region
GERMANY
13400 Outer Drive, West
Perkins Motoren GmbH Mr R Dehm Germany
Detroit, Michigan 48239-4001
Postfach 1180 Tel: [49] (6027) 501113 Austria, Switzerland
Phone: (313) 592-5420 Saaläcer Str 4 Fax: [49] (6027) 501130 Czechoslovakia
8752 Kleinostheim Hungary, Poland
Southwestern Region ITALY
2711 LBJ Freeway, Suite 1036 Motori Perkins Spa Mr A Cantu Italy
Dallas, Texas 75234 Via Socrate 8 Tel: [39] (31) 564712
Phone: (214) 247-4313 22070 Casnate Con Bernate Fax: [39] (31) 249092
(Como)

Western Region SINGAPORE

10645 Studebaker Road Perkins Engines Eastern Mr Wilson Choy Singapore
Downey, California 90241 (Singapore) Pte Limited Tel: [65] (-) 265 6333
Phone: (213) 929-7016 4 Kian Tech Drive Fax: [65] (-) 264 1188
Singapore 2262 Telex: 37729 Perkoil RS

Canadian Region SOUTH AMERICA

150 Dufferin Ave. Perkins Engines (Latin America) Inc Mr G Reaves Central and
Suite 701 Suite 620 Tel: [1] (305) 442 7413 South America
London, Ontario N6A 5N6, Canada 999 Ponce de Leon Blvd Fax: [1] (305) 442 7419
Phone: (519) 661-0149 Coral Gables
Florida 22134

Identify the U.S. regional area from the map below:

Page 52
SECTION 8 PDFP

Warranty On New Detroit Diesel

Series 53, 71, 92 and 149 Engines
Used In Stand-by Pump Applications
Terms of Coverage: This Warranty Does Not Cover:
Uses Repairs Due To Accidents, Misuse, Storage Damage,
This warranty applies to the first retail purchaser and subsequent owners Negligence Or Certain Modifications
during the WARRANTY PERIOD of new Detroit Diesel Series 53, 71, 92 and Repairs due to an accident, misuse, misapplication, storage damage, negli-
149 Engines (referred to as Engine) and attached air compressor, starting gence or modification exceeding DDC specifications, are not covered by this
motor, alternator and hydraulic pump (referred to as Accessories) manufac- warranty.
tured or supplied by Detroit Diesel Corporation* (referred to as DDC) which
are used in stand-by pump applications operated in the United States or Engine Removal And Reinstallation
Canada and delivered on or after May 1, 1992. Labor and material costs for engine removal and reinstallation, when neces-
sary to make a warranty repair, are not covered by this warranty.
Defects
This warranty covers Engine REPAIRS to correct any malfunction occurring Non-DDC Supplied/Manufactured Components
during the WARRANTY PERIOD resulting from defects in material or DDC is not responsible for repair of components and/or assemblies which are
workmanship. manufactured or supplied by another manufacturer, such as power take-offs,
intake and exhaust systems. Such items are covered by the equpment
Repairs manufacturer.
To obtain warranty repairs, you must request the needed repairs within the
WARRANTY PERIOD from an authorized DDC service outlet. Only new Maintenance
genuine parts or remanufactured parts or components supplied or approved DDC is not responsible for the cost of maintenance or repairs due to lack of
by DDC will be used. DDC may, at its discretion, replace rather than repair performance of required maintenance services or the failure to use fuel, oil,
components. A reasonable time must be allowed to perform the warranty lubricants and coolant meeting DDC-recommended specifications. Perfor-
repair. Repairs will be performed during normal business hours. The owner mance of required maintenance and use of proper fuel, oil, lubricants and
is responsible for the percentage of repair costs shown under WARRANTY coolant are the responsibility of the owner. See the Operator' s Guide for full
PERIOD. details.

Warranty Period Incidental or Consequential Damages

The WARRANTY PERIOD begins on the date the Engine is delivered to the DDC is not responsible for incidental or consequential costs or expenses
first retail purchaser or put in use prior to sale at retail, whichever date occurs which the owner may incur as a result of a malfunction or failure covered by
first, and ends at the time limits shown below: this warranty, such as communication expenses, meals, lodging, overtime,
towing, loss of use of the Engine or equipment, loss of time, inconvenience,
cargo loss or damage, and other similar costs and expenses.
WARRANTY PERIOD
Warranty Limitations Repair Charge To Be
Item (Whichever Occurs First) Paid By The Owner
Other Limitations
MONTHS ENGINE HOURS PARTS LABOR The performance of REPAIRS is the exclusive Owner' s remedy under this
warranty. DDC does not authorize any person to assume or create for it any
0-24 0-1,500 No Charge No Charge
Engine other obligation or liability in connection with the Engine or the Accessories.
100% of
25-60 0-1,500 No Charge service outlet' s
normal charge THIS WARRANTY IS THE ONLY WARRANTY APPLICABLE TO
Accessories 0-12 0-1,500 No Charge No Charge THE ENGINE AND ACCESSORIES AS USED IN STAND-BY PUMP
APPLICATIONS. DETROIT DIESEL CORPORATION MAKES NO
OTHER WARRANTIES EXPRESS OR IMPLIED, INCLUDING ANY
Service Supplies IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR
The cost of service supplies such as coolant, oil and filters which are not A PARTICULAR,PURPOSE. DETROIT DIESEL CORPORATION
reusable due to needed repairs is covered by this warranty. SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSE-
QUENTIAL DAMAGES AS DESCRIBED ABOVE.
Like Replacement Engine
Engine(s) supplied by DDC as a replacement for an Engine still under DETROIT DIESEL ®
warranty will assume the identity of the Engine being replaced and be entitled
CORPORATION
to the remaining warranty coverage.

Mechanic's Travel Expenses 13400 Outer Drive, West / Detroit, Michigan 48239-4001
DDC will pay reasonable travel expenses for the repairing mechanic to travel
Telephone: 313-592-5000
to and from the repair site.
Telex: 4320091 / TWX: 810-221-1649
*In Canada, the reference is to Detroit Diesel or Canada Limited.

17SE192 April 1992 Conditions of this offer are subject to change without notice. Litho in U.S.A.
Detroit Diesel姞 and the spinning arrows are registered trademarks of Detroit Diesel Corporation.

Page 53
SECTION 8 PDFP

Warranty on New Perkins Engines

1. Products Covered that the combined total use does not exceed 500 hours. Low usage
This warranty applies to Prima, 500 Series, 700 Series, 900 Series, extended warranty does not apply to 100 Series or 200 Series engines.
3.152 family, 4.41, 4.236 family, 6.354 family, 1000 Series, Phaser,
1300 Series, Peregrine, 100 Series, 200 Series, 2000 Series, 3000 6. Long Storage
Series Diesel and Spark Ignited Engines. The standard warranty allows for a maximum of 12 months storage
before sale. Long storage is not encouraged but at the same time
2. Duration Perkins realize that there will be occasions when the engine has not
The duration of this warranty shall be for a period of 12 months from been sold. Validation Procedures and warranty limitations are avail-
delivery of any new engine to the first user or for a period of 24 able from a Perkins Distributor.
months from the date of dispatch of the engine from Perkins,
whichever period expires first. In addition, the following major 7. Limitations and Exclusions
components will be covered for a further 12 months: cylinder block, Perkins shall not be liable under this warranty for:
casting, cylinder head casting, crankshaft (excluding bearings), cam- a. Any accessories or proprietary equipment not fitted by Perkins.
shaft and connecting rods. b. Any engine used without the prior written approval of Perkins for
3. Scope of Warranty a purpose for which it was not designed.
Perkins will, by repair or (at its option) replacement, remedy any c. Any engine or part which is in the opinion of Perkins has been
failure of such engine which is due to a defect in the workmanship or altered, used, maintained, serviced or stored otherwise than in
materials thereof and will accept responsibility for labor and material accordance with the Company’s recommendations as published.
costs which apply when effecting such remedy. Repair time will be
as per Perkins Repair Time schedule or as agreed in cases of d. Any engine or part from which the Perkins number or markings
application difficulty. Parts and labor rates will be as agreed with have been removed or altered.
Perkins. All repairs must be carried out by an authorized outlet. e. The costs of normal maintenance or regular servicing of the
Engine(s) or components supplied as replacements for engines under engine.
warranty will assume the identity of the engine or part being replaced f. Expenses such as towing, carriage, subsistence, overtime pre-
and be entitled to the remaining warranty coverage. Any engine or miums, owners own labor charges, hire of special equipment.
component replaced by Perkins shall be disposed of in accordance
with Perkins directions. g. Component parts considered by Perkins to be consumable items
as identified in the applicable users handbook except where
The warranty extends to the costs of engine removal and reinstal- replacement is necessary consequent to the nature of the failure
lation where appropriate and necessary subject to a maximum of 15 and at a time when the owner could not reasonably be expected to
hours labor for industrial, generating set and vehicle applications and pay for these items.
a maximum of 18 hours for marine applications.
h. Gradual reduction in operating performance commensurate with
For 100 Series Engines, the maximum time allowed for removal and the age, kilometers covered or operating hours, including but not
refit is 7 hours and 12 hours for 200 Series Engines. limited to, gradual loss of engine compression or gradual increase
4. Proprietary Equipment Fitted by Perkins in oil consumption due to normal operating functions.
All proprietary equipment sourced and fitted by Perkins prior to i. Any failure to meet its obligations hereunder which are due to
dispatch of the engine is covered by this warranty except that: circumstances beyond its reasonable control including but not
Fuel injection equipment will be serviced and guaranteed through the limited to industrial disputes, fire, severe weather conditions,
Fuel Injection Suppliers Service organization who will carry out ‘free government decisions, materials shortage, power or machinery
of charge’ any agreed warranty repair. breakdown or failure or war.

Electrical equipment fitted by Perkins will be serviced and guar- j. Any claims made more than 60 days from the date of alleged
anteed by the Electrical Suppliers Service organization who will failure. Perkins obligations under this warranty are limited to the
carry out ‘free of charge’ any agreed warranty repair. proper costs incurred by its authorized agents of repair or replace-
ment as set out herein.
Labor charges to remove and refit such equipment will be paid by
Perkins as per normal warranty procedures in line with the repair time k. Perkins shall not be liable whether in contract or tort for any other
schedule. loss, damage or expense, whether direct, indirect or consequential
and whether suffered by the owner or any third party and any other
5. Low Usage Warranty warranties expressed or implied, statutory or otherwise are ex-
In cases where the total use of the engine is restricted to 250 hours or pressly excluded to the extent that the same may be lawfully so
less within 12 months from the date of sale to the first user, the excluded.
warranty will be extended to the second year of operation, providing

Page 54
INDEX SECTION 9
PDFP

ALPHABETICAL INDEX

Subject Page Subject Page

A F
Alternator ................................................................ 36 Filters:
Air Cleaner ............................................................. 17 Fuel ..................................................................... 14
Alarm System ......................................................... 36 Lubricating Oil ................................................... 23
Assistance, Owner .................................................. 47 Air Cleaner ......................................................... 17
Air Intake System ................................................... 17 Firing Order ........................................................ 44
Fuel Specifications ................................................. 11
Fuel System Operation ........................................... 10
Pump, Injection ................................................... 11
B
Injector ................................................................ 11
Battery Cables ........................................................ 36
Pump, Lift ........................................................... 10
Battery Recommendations ...................................... 36
System Schematic ............................................... 12
Maintenance ....................................................... 12
Service ................................................................ 13
C
Coolant Recommendations ..................................... 28
Cooling System ...................................................... 27
G
Anti-Freeze Solutions ......................................... 28
General Description ................................................ 2
Cooling System Capacity ................................... 44
Governor, Engine ................................................... 11
Cooling System Components ............................. 27
Filling Procedure ................................................ 29 Governor Speed Adjustment .................................. 42
Heat Exchanger .................................................. 31
Inhibitors ............................................................. 28
Operation ............................................................ 27 H
Maintenance ....................................................... 32 Heaters, Engine ....................................................... 30
Raw Water Cooling Loop ................................... 31 Hourmeter ............................................................... 34
Water .................................................................. 28
Crankcase Ventilation ............................................ 19

I
D Identification Tag (FM/UL/ULC) .......................... 3
Injector .................................................................... 11
Description, General ............................................... 2 Instruments ............................................................. 34
Diesel Principle ...................................................... 1 Installation Data ...................................................... 44
Dipstick, Oil Level ................................................. 23

L
E Lubricating Oil Volume ......................................... 44
Electronic Speed Switch ......................................... 35 Lubricating System ................................................. 21
Engine Equipment .................................................. 5 Lube Oil Recommendations ................................... 24
Engine Heater ......................................................... 30
Engine Models ........................................................ 44
Engine Out of Fuel ................................................. 15
Engine Protective Systems (overspeed) ................. 35 M
Engine Start-Up ...................................................... 6 Maintenance Schedule ............................................ 9
Engine Tune-Up ..................................................... 42 Manual Operation ................................................... 33
Electrical System .................................................... 33 Materials of Construction ....................................... 44
Exhaust Gas: Temp. & Volume .............................. 44 Model Number Identification ................................. 3
Exhaust Operation .................................................. 19 Magnetic Pickup ..................................................... 35

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SECTION 9 INDEX
PDFP

ALPHABETICAL INDEX (CONTINUED)

Subject Page Subject Page

N Specifications:
Name Plate (FM-UL-ULC) .................................... 3 Fuel ..................................................................... 10
Name Plate (Engine) ............................................... 3 Lubrication Oil ................................................... 24
Speed Adjustment ................................................... 42
Speed Switch .......................................................... 35
O Starting System, Electric ........................................ 33
Oil Cooler ............................................................... 23 Storage, Extended ................................................... 6
Oil Filter ................................................................. 23
Oil Pressure ............................................................ 44
Oil Specifications/Recommendations .................... 24
T
Operating Instructions ............................................ 33
Tachometer ............................................................. 34
Overspeed Reset ..................................................... 35
Thermostat .............................................................. 30
Owner Assistance ................................................... 47
Tune-Up Procedures ............................................... 42
Operation Data ........................................................ 44
Technical Data ........................................................ 44
Out Of Fuel Procedures .......................................... 15
Oil Level Dipstick .................................................. 23

U
P Underwriters Labs Nameplate ................................ 3
Parts Information .................................................... 45
Preventive Maintenance Schedule .......................... 9
Principles of Operation ........................................... 1
Pump: V
Water (Coolant) .................................................. 27 Voltmeter ................................................................ 34
Lube Oil .............................................................. 21
Fuel Lift Pump .................................................... 10
Fuel Injection Pump ........................................... 11
W
Water Temperature ................................................. 44
R Wiring Diagram:
Raw Water Cooling Loop ....................................... 31 DC System .......................................................... 37
Raw Water Flow Requirements .............................. 32 AC Heater Systems ............................................. 38
Warranty on Engine ................................................ 49
Warranty on Optional Equipment and
S NFPA-20 Trim Material ..................................... 49
Serial Number ......................................................... 2
Service Assistance .................................................. 47 Z
Shutdown Systems .................................................. 34 Zinc Electrode ........................................................ 32

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