Sebu9070 03

SEBU9070-03 (en-us)
January 2021
Operation and
Maintenance
Manual
1506A-E88TA, 1506C-E88TA, 1506D-
E88TA Industrial Engines
LG (Engine)
PK9 (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions correctly.
Incorrect operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. You must not use
this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of
the product in the location of use, including site-specific rules and precautions applicable to the
worksite. If a tool, procedure, work method or operating technique that is not specifically
recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others.
You should also ensure that you are authorized to perform this work, and that the product will not
be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU9070-03 3
Table of Contents
Table of Contents Refill Capacities............................................... 49
Maintenance Recommendations .................... 74

Foreword ........................................................... 4
Maintenance Interval Schedule....................... 77
Safety Section
Safety Messages............................................... 6
Warranty Section
Warranty Information..................................... 104

General Hazard Information.............................. 8
Burn Prevention................................................11 Reference Information Section
Fire Prevention and Explosion Prevention...... 12 Engine Ratings .............................................. 105
Crushing Prevention and Cutting Prevention.. 14 Reference Materials ...................................... 107
Mounting and Dismounting ............................. 15 Index Section
Before Starting Engine .................................... 15 Index...............................................................110
Engine Starting................................................ 15
Engine Stopping .............................................. 15
Electrical System............................................. 16
Engine Electronics........................................... 17
Product Information Section
General Information ........................................ 18
Product Identification Information ................... 27
Operation Section
Lifting and Storage .......................................... 29
Features and Controls..................................... 32
Engine Diagnostics ......................................... 40
Engine Starting................................................ 42
Engine Operation ............................................ 45
Cold Weather Operation ................................. 46
Engine Stopping .............................................. 48
Maintenance Section
4 SEBU9070-03
Foreword
Foreword Some photographs or illustrations in this manual

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

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

that may contain lead.
The maintenance section is a guide to engine care.
Literature Information The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
This manual contains safety, operation instructions, intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
lubrication, and maintenance information. This
manual should be stored in or near the engine area in Recommended service should be performed at the
a literature holder or literature storage area. Read, appropriate intervals as indicated in the Maintenance
study, and keep the manual with the literature and Interval Schedule. The actual operating environment
engine information. of the engine also governs the Maintenance Interval
Schedule. Therefore, under severe, dusty, wet, or
English is the primary language for all Perkins freezing cold operating conditions, more frequent
publications. The English used facilitates translation lubrication, and maintenance than is specified in the
and consistency. Maintenance Interval Schedule may be necessary.
SEBU9070-03 5
Foreword
The maintenance schedule items are organized for a

preventive maintenance management program. If the
preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation, and application. Perkins recommends that
the maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
Perkins also recommends that a maintenance record
be maintained as part of the permanent record of the
engine.
Your authorized Perkins dealer or your Perkins
distributor can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.
Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
authorized Perkins distributor or dealer. Your Perkins
dealer or your Perkins distributor offers various
options regarding overhaul programs. If you
experience a major engine failure, there are also
numerous after failure overhaul options available.
Consult with your Perkins dealer or your Perkins
distributor for information regarding these options.
6 SEBU9070-03
Safety Section
Safety Messages
Safety Section
i06229776
Safety Messages
There may be several specific warning signs on your

engine. The exact location and a description of the
warning signs are reviewed in this section. Please
become familiar with all warning signs.
Ensure that all of the warning signs are legible. Clean
the warning signs or replace the warning signs if the
words cannot be read or if the illustrations are not
visible. Use a cloth, water, and soap to clean the
warning signs. Do not use solvents, gasoline, or
other harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
warning signs. The warning signs that are loosened
could drop off the engine.
Replace any warning sign that is damaged or
missing. If a warning sign is attached to a part of the
engine that is replaced, install a new warning sign on
the replacement part. Your Perkins distributor can
provide new warning signs.
(1) Universal Warning
Do not operate or work on this equipment unless

you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
heed the warnings could result in serious injury
or death.
Illustration 1 g01154807
Typical example
The Universal Warning label (1) is located in two

positions. The warning labels are located on the right
side of the valve mechanism cover and located on
the left side of the valve mechanism cover .
SEBU9070-03 7
Safety Section
Safety Messages
1506A and C
1506D
8 SEBU9070-03
Safety Section
General Hazard Information
i08330649 • Report all necessary repairs.
General Hazard Information Unless other instructions are provided, perform the
maintenance under the following conditions:
• The engine is stopped. Ensure that the engine
cannot be started.
• The protective locks or the controls are in the
applied position.
• Engage the secondary brakes or parking brakes.

• Block the vehicle or restrain the vehicle before
maintenance or repairs are performed.
• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads to help prevent sparks. If equipped,
allow the diesel exhaust fluid to be purged before
disconnecting the battery.
• If equipped, disconnect the connectors for the unit
Attach a “Do Not Operate” warning tag or a similar injectors that are on the valve cover base. This
warning tag to the start switch or to the controls action will help prevent personal injury from the
before the engine is serviced or before the engine is high voltage to the unit injectors. Do not come in
repaired. Attach the warning tags to the engine and
contact with the unit injector terminals while the
to each operator control station. When appropriate,
disconnect the starting controls. engine is operating.
Do not allow unauthorized personnel on the engine, • Do not attempt any repairs or any adjustments to
or around the engine when the engine is being the engine while the engine is operating.
serviced.
• Do not attempt any repairs that are not
• Tampering with the engine installation or understood. Use the proper tools. Replace any
tampering with the OEM supplied wiring can be equipment that is damaged or repair the
dangerous. Personal injury, death and/or engine equipment.
damage could result.
• For initial start-up of a new engine or for starting
• Vent the engine exhaust to the outside when the an engine that has been serviced, make
engine is operated in an enclosed area. provisions to stop the engine if an overspeed
occurs. The stopping of the engine may be
• If the engine is not running, do not release the accomplished by shutting off the fuel supply and/
secondary brake or the parking brake systems or the air supply to the engine. Ensure that only
unless the vehicle is blocked or unless the vehicle the fuel supply line is shut off. Ensure that the fuel
is restrained. return line is open.
• Wear a hard hat, protective glasses, and other • Start the engine from the operators station (cab).
protective equipment, as required. Never short across the starting motor terminals or
the batteries. This action could bypass the engine
• When work is performed around an engine that is neutral start system and/or the electrical system
operating, wear protective devices for ears to help could be damaged.
prevent damage to hearing.
Engine exhaust contains products of combustion
• Do not wear loose clothing or jewelry that can which may be harmful to your health. Always start the
snag on controls or on other parts of the engine. engine and operate the engine in a well-ventilated
area. If the engine is in an enclosed area, vent the
• Ensure that all protective guards and all covers engine exhaust to the outside.
are secured in place on the engine.
Cautiously remove the following parts. To help
• Never put maintenance fluids into glass prevent spraying or splashing of pressurized fluids,
containers. Glass containers can break. hold a rag over the part that is being removed.
• Use all cleaning solutions with care. • Filler caps

SEBU9070-03 9
Safety Section
• Grease fittings • Do not attempt any repairs that are not

understood. Use the proper tools. Replace any
• Pressure taps equipment that is damaged or repair the
equipment.
• Breathers
• Drain plugs Pressurized Air and Water
Use caution when cover plates are removed. Pressurized air and/or water can cause debris and/or
Gradually loosen, but do not remove the last two hot water to be blown out. This action could result in
bolts or nuts that are at opposite ends of the cover personal injury.
plate or the device. Before removing the last two
When pressurized air and/or pressurized water is
bolts or nuts, pry the cover loose to relieve any spring
used for cleaning, wear protective clothing, protective
pressure or other pressure.
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved
correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
• Wear a hard hat, protective glasses, and other
components or parts until pressure has been relieved
protective equipment, as required. or personal injury may occur. Refer to the OEM
information for any procedures that are required to
• When work is performed around an engine that is relieve the hydraulic pressure.
operating, wear protective devices for ears to help
prevent damage to hearing.
• Do not wear loose clothing or jewelry that can

snag on controls or on other parts of the engine.
• Ensure that all protective guards and all covers

are secured in place on the engine.
• Never put maintenance fluids into glass
containers. Glass containers can break.
• Use all cleaning solutions with care.
• Report all necessary repairs.

Unless other instructions are provided, perform
the maintenance under the following conditions:
• The engine is stopped. Ensure that the engine

cannot be started.
• Disconnect the batteries when maintenance is

performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads to help prevent sparks.
10 SEBU9070-03
Safety Section
Avoid static electricity risk when fueling. Ultra-

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

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

Care must be taken to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting, and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or Illustration 7 g00702022
disassembling any component containing fluids.
Exhaust
Dispose of all fluids according to local regulations
and mandates. Use caution. Exhaust fumes can be hazardous to
health. If you operate the equipment in an enclosed
Static Electricity Hazard when area, adequate ventilation is necessary.
Fueling with Ultra-low Sulfur Diesel Hexavalent Chromium
Fuel
Perkins equipment and replacement parts comply
The removal of sulfur and other compounds in ultra- with applicable regulations and requirements where
low sulfur diesel fuel (ULSD fuel) decreases the originally sold. Perkins recommends the use of only
conductivity of ULSD and increases the ability of genuine Perkins replacement parts.
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive. Hexavalent chromium has occasionally been
Many factors can reduce the effectiveness of the detected on exhaust and heat shield systems on
additive over time. Static charges can build up in Perkins engines. Although laboratory testing is the
ULSD fuel while the fuel is flowing through fuel only accurate way to know if hexavalent chromium is,
delivery systems. Static electricity discharge when in fact, present, the presence of a yellow deposit in
combustible vapors are present could result in a fire areas of high heat (for example, exhaust system
or explosion. Ensure that the entire system used to components or exhaust insulation) may be an
refuel your machine (fuel supply tank, transfer pump, indication of the presence of hexavalent chromium.
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel Use caution if you suspect the presence of
system supplier to ensure that the delivery system hexavalent chromium. Avoid skin contact when
handling items that you suspect may contain
complies with fueling standards for proper grounding hexavalent chromium, and avoid inhalation of any
and bonding. dust in the suspect area. Inhalation of, or skin contact
with, hexavalent chromium dust may be hazardous to
your health.
SEBU9070-03 11
Safety Section
Burn Prevention
If such yellow deposits are found on the engine, • Use exhaust ventilation on permanent machining
engine component parts, or associated equipment or jobs.
packages, Perkins recommends following local
health and safety regulations and guidelines, utilizing • Wear an approved respirator if there is no other
good hygiene, and adhering to safe work practices way to control the dust.
when handling the equipment or parts. Perkins also
recommends the following: • Comply with applicable rules and regulations for
the work place. In the United States, use
• Wear appropriate Personal Protective Equipment Occupational Safety and Health Administration
(PPE) (OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Wash your hands and face with soap and water
prior to eating, drinking, or smoking, and also • Obey environmental regulations for the disposal of
during rest room breaks, to prevent ingestion of asbestos.
any yellow powder
• Stay away from areas that might have asbestos
• Never use compressed air for cleaning areas particles in the air.
suspected of containing hexavalent chromium
• Avoid brushing, grinding, or cutting materials Dispose of Waste Properly

suspected of containing hexavalent chromium
• Obey environmental regulations for the disposal of

all materials that may contain or have come into
contact with hexavalent chromium
• Stay away from areas that might have hexavalent

chromium particles in the air.
Asbestos Information
Perkins equipment and replacement parts that are
shipped from Perkins engine company limited are
asbestos free. Perkins recommends the use of only
genuine Perkins replacement parts. Use the following
guidelines when you handle any replacement parts
that contain asbestos or when you handle asbestos Illustration 8 g00706404
debris.
Use caution. Avoid inhaling dust that might be Improperly disposing of waste can threaten the
generated when you handle components that contain environment. Potentially harmful fluids should be
asbestos fibers. Inhaling this dust can be hazardous disposed of according to local regulations.
to your health. The components that may contain Always use leakproof containers when you drain
asbestos fibers are brake pads, brake bands, lining fluids. Do not pour waste onto the ground, down a
material, clutch plates, and some gaskets. The
drain, or into any source of water.
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that i05943062
contains asbestos is generated.
Burn Prevention
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning. Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
• Avoid brushing materials that contain asbestos. performed on the engine. Relieve all pressure in the
air system, in the hydraulic system, in the lubrication
• Avoid grinding materials that contain asbestos. system, in the fuel system, or in the cooling system
before any lines, fittings, or related items are
• Use a wet method to clean up asbestos materials. disconnected.
• A vacuum cleaner that is equipped with a high

efficiency particulate air filter (HEPA) can also be
used.
12 SEBU9070-03
Safety Section
Fire Prevention and Explosion Prevention
Coolant Cooling system conditioner contains alkali. Alkali can

cause personal injury. Do not allow alkali to contact
When the engine is at operating temperature, the the skin, the eyes, or the mouth.
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or Oils
to the engine contain hot coolant
Any contact with hot coolant or with steam can cause Skin may be irritated following repeated or prolonged
severe burns. Allow cooling system components to exposure to mineral and synthetic base oils. Refer to
cool before the cooling system is drained. your suppliers Material Safety Data Sheets for
detailed information. Hot oil and lubricating
Check that the coolant level after the engine has components can cause personal injury. Do not allow
stopped and the engine has been allowed to cool. hot oil to contact the skin. Appropriate personal
protective equipment should be used
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch Diesel Fuel
with a bare hand. Remove the filler cap slowly in
order to relieve pressure. Diesel may be irritating to the eyes, respiratory
system, and skin. Prolonged exposure to diesel may
cause various skin conditions. Appropriate personal
protective equipment should be used. Refer to
supplier Material safety Data sheets for detailed
information.
Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for
servicing batteries. Wash hands after touching the
batteries and connectors. Use of gloves is
recommended.
i05945996
Fire Prevention and Explosion

Prevention
All fuels, most lubricants, and some coolant mixtures

are flammable.
SEBU9070-03 13
Safety Section
Fire Prevention and Explosion Prevention
Flammable fluids that are leaking or spilled onto hot Oil filters and fuel filters must be installed correctly.
surfaces or onto electrical components can cause a The filter housings must be tightened to the correct
fire. Fire may cause personal injury and property torque. Refer to the Disassembly and Assembly
damage. manual for more information.
After the emergency stop button is operated, ensure
that you allow 15 minutes, before the engine covers
are removed.
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
If the application involves the presence of
combustible gases, consult your Perkins dealer and/
or your Perkins distributor for additional information
about suitable protection devices.
Remove all flammable combustible materials or
conductive materials such as fuel, oil, and debris
from the engine. Do not allow any flammable
combustible materials or conductive materials to
accumulate on the engine.
Store fuels and lubricants in correctly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective Illustration 10 g00704059
containers. Do not smoke in areas that are used for
storing flammable materials. Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not
Do not expose the engine to any flame. refuel an engine near open flames or sparks. Always
stop the engine before refueling.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line, a Avoid static electricity risk when fueling. Ultra-low
tube, or a seal failure. Exhaust shields must be Sulfur Diesel fuel (ULSD fuel) poses a greater static
installed correctly.
ignition hazard than earlier diesel formulations with a
Do not weld on lines or tanks that contain flammable higher sulfur content. Avoid death or serious injury
fluids. Do not flame cut lines or tanks that contain from fire or explosion. Consult your fuel or fuel
flammable fluid. Clean any such lines or tanks system supplier to ensure that the delivery system is
thoroughly with a nonflammable solvent prior to in compliance with fueling standards for proper
welding or flame cutting. grounding and bonding practices.
Wiring must be kept in good condition. Ensure that all

electrical wires are correctly installed and securely
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and correctly
maintained battery cables will help to prevent arcing
or sparking.
Ensure that the engine is stopped. Inspect all lines
and hoses for wear or for deterioration. Ensure that
the hoses are correctly routed. The lines and hoses
must have adequate support and secure clamps.
14 SEBU9070-03
Safety Section
Crushing Prevention and Cutting Prevention
Do not store ether cylinders in living areas or in the

engine compartment. Do not store ether cylinders in
direct sunlight or in temperatures above 49° C
(120° F). Keep ether cylinders away from open
flames or sparks.
Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are
damaged.
Leaks can cause fires. Consult your Perkins dealer or
your Perkins distributor for replacement parts.
Replace the parts if any of the following conditions
are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.

• Wires are exposed.
• Outer coverings are ballooning.
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do • Flexible parts of the hoses are kinked.
not smoke in battery charging areas.
• Outer covers have embedded armoring.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a • End fittings are displaced.
hydrometer.
Make sure that all clamps, guards, and heat shields
Incorrect jumper cable connections can cause an are installed correctly. During engine operation,
explosion that can result in injury. Refer to the correct installation will help to prevent vibration,
Operation Section of this manual for specific rubbing against other parts, and excessive heat.
instructions.
Do not charge a frozen battery. A frozen battery may i02143194
cause an explosion.
Crushing Prevention and
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the Cutting Prevention
recommended cables, connections, and battery box
covers when the engine is operated.
Support the component correctly when work beneath
Fire Extinguisher the component is performed.
Make sure that a fire extinguisher is available. Be Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
familiar with the operation of the fire extinguisher.
running.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations Stay clear of all rotating parts and of all moving parts.
on the instruction plate. Leave the guards in place until maintenance is
performed. After the maintenance is performed,
Ether reinstall the guards.
Ether is flammable and poisonous. Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
Do not smoke while you are replacing an ether
cylinder or while you are using an ether spray. When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
SEBU9070-03 15
Safety Section
Mounting and Dismounting
i05463929 i07828827
Mounting and Dismounting Engine Starting
Do not climb on the engine. The engine has not been

designed with mounting or dismounting locations.
Refer to the Original Equipment Manufacture (OEM) Do not use aerosol types of starting aids such as
for the location of foot and hand holds for your ether. Such use could result in an explosion and
specific application. personal injury.
i04257031
Before Starting Engine Engine exhaust contains products of combustion

which may be harmful to your health. Always
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust
NOTICE to the outside.
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make If a warning tag is attached to the engine start switch
provision to shut the engine off should an overspeed or to the controls, DO NOT start the engine or move
occur. This may be accomplished by shutting off the the controls. Consult with the person that attached
air and/or fuel supply to the engine. the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started to perform
service procedures. To help prevent an accident that
Engine exhaust contains products of combustion is caused by parts in rotation, work around the parts
which may be harmful to your health. Always carefully.
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust Start the engine from the operator's compartment or
to the outside. from the engine start switch.
Inspect the engine for potential hazards. Always start the engine according to the procedure
that is described in the Operation and Maintenance
Do not start the engine or move any of the controls if Manual, “Engine Starting” topic in the Operation
there is a “DO NOT OPERATE” warning tag or similar Section. Knowing the correct procedure will help to
warning tag attached to the start switch or to the prevent major damage to the engine components.
controls. Knowing the procedure will also help to prevent
personal injury.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the To ensure that the jacket water heater (if equipped) is
area is free of personnel. working correctly, check the water temperature
gauge and/or the oil temperature gauge during the
If equipped, ensure that the lighting system for the heater operation.
engine is suitable for the conditions. Ensure that all
lights work properly, if equipped. Note: The engine may be equipped with a device for
cold starting. If the engine will be operated in very
All protective guards and all protective covers must cold conditions, then an extra cold starting aid may
be installed if the engine must be started in order to be required. Normally, the engine will be equipped
perform service procedures. To help prevent an with the correct type of starting aid for your region of
accident that is caused by parts in rotation, work operation.
around the parts carefully.
Do not start an engine when the governor linkage is i07668288
disconnected.
Do not bypass the automatic shutoff circuits. Do not
Engine Stopping
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent • Remove the load in increments.
engine damage.
• Open the circuit breaker.
16 SEBU9070-03
Safety Section
Electrical System
• Allow the engine to run for five minutes to cool. Grounding Practice
• Stop the engine.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an
engine that has been overhauled. This may be
accomplished by shutting off the fuel supply to the
engine and/or shutting off the air supply to the
engine.
To stop an electronically controlled engine, cut the
power to the engine.
i06230746
Electrical System
Never disconnect any charging unit circuit or battery Typical example

circuit cable from the battery when the charging unit (1) Battery to grounding stud
is operating. A spark can cause the combustible (2) Battery to starter to grounding stud
gases that are produced by some batteries to ignite.
Correct grounding for the engine electrical system is
To help prevent sparks from igniting combustible necessary for optimum engine performance and
gases that are produced by some batteries, the reliability. Incorrect grounding will result in
negative “−” cable should be connected last from the uncontrolled electrical circuit paths and in unreliable
external power source to the negative “−” terminal of electrical circuit paths.
the starting motor. If the starting motor is not
equipped with a negative “−” terminal, connect the Uncontrolled electrical circuit paths can result in
cable to the engine block. damage to the crankshaft bearing journal surfaces
and to aluminum components.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical Engines that are installed without engine-to-frame
connections before the engine is started. Repair all ground straps can be damaged by electrical
frayed electrical wires before the engine is started. discharge.
See the Operation and Maintenance Manual for
specific starting instructions. To ensure that the engine and the engine electrical
systems function correctly, an engine-to-frame
ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct
engine ground to the frame.
The connections for the grounds should be tight and
free of corrosion. The engine alternator must be
grounded to the negative “-” battery terminal. The
wire that is used must be adequate to handle the full
charging current of the alternator.
SEBU9070-03 17
Safety Section
Engine Electronics
The power supply connections and the ground

connections for the engine electronics should always
be from the isolator to the battery.
i05986490
Engine Electronics
Tampering with the electronic system installation

or the OEM wiring installation can be dangerous
and could result in personal injury or death and/
or engine damage.
This engine has a comprehensive, programmable

Engine Monitoring System. The Engine Control
Module (ECM) will monitor the engine operating
conditions. If any of the engine parameters extend
outside an allowable range, the ECM will initiate an
immediate action.
The following actions are available for engine
monitoring control: WARNING, DERATE and
SHUTDOWN. These engine monitoring modes can
limit engine speed and/or the engine power.
Many of the parameters that are monitored by the
ECM can be programmed for the engine monitoring
functions. The following parameters can be
monitored as a part of the Engine Monitoring System:
• Operating Altitude
• Engine Coolant Level

• Engine Coolant Temperature
• Engine Oil Pressure

• Engine Speed
• Fuel Temperature
• Intake Manifold Air Temperature
• System Voltage
The Engine Monitoring package can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Note: Many of the engine control systems and

display modules that are available for Perkins
Engines will work in unison with the Engine
Monitoring System. Together, the two controls will
provide the engine monitoring function for the specific
engine application. Refer to the Troubleshooting
Manual for more information.
18 SEBU9070-03
General Information
Product Information
Section
General Information
i06230810
Model View Illustrations
The following model views show typical features of

the engine. Due to individual applications, your
engine, may appear different from the illustrations.
1506A and C Engine and Radiator

Views
Typical example
(1) Engine air cleaner service indicator (4) Radiator pressure cap (7) Air cleaner
(2) Inspection guard (5) Air-to-air aftercooler (8) Vacuator valve (Dust valve)
(3) Radiator (6) Rain cap
SEBU9070-03 19
1506A and C Engine Views
Typical example
(9) Cooling fan (12) Fuel priming pump (15) V Belts for fan
(10) Oil filler cap (13) Secondary fuel filter
(11) Starting motor assembly (14) Primary fuel filter
20 SEBU9070-03
Typical example
(16) Rear lifting eye (19) Front lifting location (23) Coolant pump
(17) Coolant sampling valve (20) Belt for coolant pump (24) Oil filter
(18) Housing for coolant temperature (21) Crankshaft damper (25) Oil gauge (Dipstick)
regulator (22) Idler for coolant belt (26) Sample valve for engine oil
SEBU9070-03 21
Typical example
(27) Turbocharger (29) Oil pan (31) Flywheel housing
(28) Alternator (30) Oil drain tap (32) Flywheel
22 SEBU9070-03
Typical example
(33) Unit injector hydraulic pump (35) Crankcase breather (37) Breather outlet hose
(34) Fuel transfer pump (36) Electronic control module (38) Oil drain plug
1506D Engine Views

The following model views show typical features of
the engine. Due to individual applications, your
engine, may appear different from the illustrations.
SEBU9070-03 23
Typical example
(1) Switch for air inlet heater (3) Auto tensioner
(2) Twin compressor (4) Multi V belt
24 SEBU9070-03
Product Description
Typical example
(5) Wastegate actuator
i06231479 Engine Specifications

Product Description Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right
sides of the engine are determined from the flywheel
The 1506 industrial engine has three different end. The number 1 cylinder is the front cylinder.
emissions ratings A, C, and D. The 1506 industrial
engine can be configured for variable speed
applications or constant speed applications.
The 1506A and C industrial engines have five
different ratings. Visually the engines will look similar
the difference is due to the software that is loaded
into the engine Electronic Control Module (ECM).
The 1506D may be configured differently, with an air
inlet heater, automatic tensioner for the drive belt,
and a turbocharger with a wastegate actuator.
The Perkins 1506A, 1506C and 1506D industrial
engines have the following characteristics:
• In-Line 6-cylinder
• Four-stroke cycle
Cylinder and valve location
• Hydraulically Actuated Electronic Unit Injection (A) Exhaust valve
(HEUI) (B) Inlet valve
• Turbocharged with air-to-air aftercooled (ATAAC)

SEBU9070-03 25
Product Description
Table 1
1506 Engine Specifications Engine Diagnostics
Arrangement and Cylinders In-Line 6-cylinder
The engine has built-in diagnostics in order to ensure
Bore 112.0 mm (4.41 inch) that all of the components are functioning properly. In
the event of a deviation from the programmed limits,
Stroke 149.0 mm (5.87 inch) the operator will be alerted to the condition by a
Aspiration ATAAC
“DIAGNOSTIC” lamp. Under certain conditions, the
engine horsepower and the vehicle speed may be
Displacement 8.8 L (537 in3) limited. The electronic service tool may be used to
display the diagnostic code.
Firing Order 1-5-3-6-2-4
There are three types of diagnostic codes: active,
Rotation (flywheel end) Counterclockwise logged and event.
Most of the diagnostic codes are logged and stored in
Electronic Engine Features the ECM. For additional information, refer to the
Operation and Maintenance Manual, “Engine
The engine operating conditions are monitored. The Diagnostics” topic.
ECM controls the response of the engine to these
conditions and to the demands of the operator. These The ECM provides an electronic governor that
conditions and operator demands determine the controls the injector output in order to maintain the
precise control of fuel injection by the ECM. The desired engine rpm.
electronic engine control system provides the
following features: Engine Cooling and Lubrication
• Engine speed governor The cooling system consists of the following
components:
• Automatic air/fuel ratio control
• Centrifugal pump that is driven by a belt
• Torque rise shaping
• Cooling fan driven by belts
• Injection timing control
• Water temperature regulator which regulates the
• System diagnostics engine coolant temperature
For more information on electronic engine features, • Oil cooler and radiator
refer to the Operation and Maintenance Manual,
“Engine Diagnostics” topic. The drive belt can be a multi V belt or a single V belt
design.
Additional Features
The engine lubricating oil that is supplied is cooled.
The following additional features provide increased The engine lubricating oil is also filtered. Bypass
engine fuel economy and serviceability: valves provide unrestricted flow of lubrication oil to
the engine components during the following
• Cold starting capability conditions:
• Tampering detection • High oil viscosity
• Diagnostics • Plugged oil cooler or plugged oil filter element
Hydraulic Electronic Unit Injectors Engine Service Life

Hydraulically Actuated Electronic Unit Injectors Engine efficiency and maximum utilization of engine
(HEUI) perform the following function: performance depend on the adherence to proper
operation and maintenance recommendations. In
• Atomizes the fuel addition, use recommended fuels, coolants, and
lubricants. Use the Operation and Maintenance
The unit injectors are controlled by the ECM which Manual as a guide for required engine maintenance.
uses the camshaft position, the engine speed
signals, and the inlet air pressure sensors. The ECM
controls when the fuel is injected into each cylinder.
The rated rpm is identified on the information plate.
26 SEBU9070-03
Product Description
Expected engine life is generally predicted by the

average power that is demanded. The average
power that is demanded is based on fuel
consumption of the engine over a time. Reduced
hours of operation at full throttle and/or operating at
reduced throttle settings result in a lower average
power demand. Reduced hours of operation will
increase the length of operating time before an
engine overhaul is required.
Aftermarket Products and Perkins

Engines
Perkins does not warrant the quality or performance
of non-Perkins fluids and filters.
When auxiliary devices, accessories, or
consumables (filters, additives, catalysts, ) which are
made by other manufacturers are used on Perkins
products, the Perkins warranty is not affected simply
because of such use.
However, failures that result from the installation or
use of other manufacturers devices, accessories, or
consumables are NOT Perkins defects. Therefore,
the defects are NOT covered under the Perkins
warranty.
SEBU9070-03 27
Product Identification Information
Product Identification Serial Number Plate 1

Information
i05951766
Plate Locations and Film

Locations
Engine Identification
Perkins engines are identified by an engine serial
number.
A typical example of an engine serial number is LGE
F**** N00001W.
Illustration 21 g03735788 L Type of engine
Typical example
(1) Location of engine serial plate.
G Application (Table 2 )
E Rating Type (Table 3 )
Perkins engines are identified by serial numbers.
These numbers are shown on the engine serial F Number of cylinders (Table 4 )
number plate. Perkins distributors need these
numbers in order to determine the components that ***** Fixed build number
were included with the engine. This information
permits accurate identification of replacement part N Built in the USA
numbers.
00001 Engine Number
W Year of Manufacture
Table 2
Application
G Genset
Table 3
Type of engine (Diesel)
A TAG1
B TAG2
D TAG3
(continued)
28 SEBU9070-03
Emissions Certification Film
(Table 3, contd) Fan Drive Belt

E TAG4 Coolant Pump Belt
F TAG5
H TAG6
Table 4
Number of Cylinders
F 6
H 8
M 12
R 16
Perkins dealers and Perkins distributors require all of

these numbers in order to determine the components
that were included in the engine. This information
permits accurate identification of replacement part
numbers.
i05951816
Emissions Certification Film
Note: This information is pertinent in the United

States, in Canada and in Europe.
The emissions label is located on the top of the valve
mechanism cover.
i05951812
Reference Information
Information for the following items may be needed to

order parts. Locate the information for your engine.
Record the information in the appropriate space.
Make a copy of this list for a record. Keep the
information for future reference.
Record for Reference

Engine Model
Engine Serial Number
Engine RPM
Primary Fuel Filter
Secondary Fuel Filter Element
Lubrication Oil Filter Element
Total Lubrication System Capacity
Total Cooling System Capacity

Air Cleaner Element
SEBU9070-03 29
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage

i07449107
Product Lifting
NOTICE
Always inspect lifting eyebolts and all other lifting
equipment for damage before performing any lifting.
Never bend the eyebolts and the brackets. Never Illustration 24 g00103219
perform product lifting if components are damaged.
Use a hoist to remove heavy components. Use an
adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
NOTICE parallel to each other. The chains and cables should
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Re- be perpendicular to the top of the object that is being
member that the capacity of an eyebolt is less as the lifted.
angle between the supporting members and the ob- Some removals require lifting the fixtures to obtain
ject becomes less than 90 degrees. proper balance and safety.
When it is necessary to remove a component at an Lifting eyes are designed and installed for the
angle, only use a link bracket that is properly rated for specific engine arrangement. Alterations to the lifting
the weight. eyes and/or the engine make the lifting eyes and the
lifting fixtures obsolete. If alterations are made,
ensure that proper lifting devices are provided.
Consult your Perkins distributor for information
regarding fixtures for proper engine lifting.
i05951855
Product Storage
Your Perkins distributor can assist in preparing the

engine for extended storage periods.
Condition for Storage

The engine must be stored in a water proof building.
The building must be kept at a constant temperature.
Engines that are filled with Perkins ELC will have
coolant protection to an ambient temperature of
−36° C (−32.8° F). The engine must not be subjected
to extreme variations in temperature and humidity.
Storage Period
The lifting eyes (1) are the lifting locations for lifting An engine can be stored for up to 6 months provided
the engine and radiator. all the recommendation are adhered to.
Storage Procedure
Keep a record of the procedure that has been
completed on the engine.
30 SEBU9070-03
Operation Section
Product Storage
Note: Do not store an engine that has biodiesel in the Ensure that the engine is covered completely before
fuel system. storage. Log the procedure in the record for the
engine.
1. Ensure that the engine is clean and dry.
a. If the engine has been operated using Removal from Storage
biodiesel, the system must be drained and new
1. Remove all covers from engine and air cleaner.
filters installed. The fuel tank will require
Check the condition of the air filter element.
flushing.
2. Check the condition of the coolant pump belt and
b. Fill the fuel system with a correct specification
the fan drive belts before tensioning the belts.
of fuel. For more information on acceptable
Tension the coolant pump belts and tension the
fuels refer to this Operation and Maintenance
fan drive belts. Refer to this Operation and
Manual, “Fluid recommendations”. Operate the
Maintenance Manual, “Belts - Inspect/Adjust” for
engine for 15 minutes in order to remove all
more information.
biodiesel from the system.
3. Check the coolant level. Refer to Operation and
2. Drain any water from the primary filter water
Maintenance Manual, “Coolant Level - Check”
separator. Ensure that the fuel tank is full.
4. Remove valve cover, refer to Disassembly and
3. Change the engine oil and filter. Refer to this
Assembly, “Valve Mechanism Cover - Remove
Operation and Maintenance Manual, “Engine Oil
and Install”. Lubricate the valve train. Install the
and Filter - Change”. Ensure that the engine is
valve cover.
operated after the oil and filter has been changed.
Ensure that engine oil pressure is correct before 5. Replace the fuel filters. Refer to the following
stopping the engine. section within the Operation and Maintenance
Manual.
4. For the correct specification of engine oil refer to
this Operation and Maintenance Manual, “Fluid • Fuel System Primary Filter (Water Separator)
recommendations”. Element - Replace
5. Loosen the fan drive belts and loosen the coolant
• Fuel System Secondary Filter - Replace
pump belt. Refer to this Operation and
Maintenance Manual, “Belts - Inspect/Adjust” for • Fuel System - Prime
more information.
6. Use a bar or a turning tool in order to turn the
Sealed Coolant System engine in the normal direction of rotation. The
Ensure that the cooling system is filled with Perkins procedure ensures that no hydraulic locks or
ELC, or an antifreeze that meets “ASTM D6210” resistance exist.
specification.
Open Cooling System
Ensure that all cooling drain plugs have been

opened. Allow the coolant to drain. Install the drain
plugs. Place a vapor phase inhibitor into the system.
The coolant system must be sealed once the vapor
phase inhibitor has been introduced. The effect of the
vapor phase inhibitor will be lost if the cooling system
is open to the atmosphere.
For maintenance procedures ref to this Operation
and Maintenance Manual.
Monthly Checks
The crankshaft must be rotated in order to change
the spring loading on the valve train. Rotate the
crankshaft more than 180 degrees. Also, rotate the
coolant pump pulley. Visibly check for damage or
corrosion to the engine.
SEBU9070-03 31
Operation Section
Product Storage
(1) Plug
7. If an engine is stored for more than 1 year, Perkins

recommends Pre lubrication of the engine in order
to avoid dry starting. Use a suitable pump in order
to put engine oil into the engine oil system.
The pump will need to create a minimum pressure
within the engine of 0.25 bar (3.6 psi). This
pressure is needed for 15 seconds in order to
lubricate the internal surfaces. Remove plug (1) in
order to connect to the engine oil system. The
connection required is 9/16" x 18 tpi. Ensure that
the correct oil specification is used, refer to this
Operation and Maintenance Manual, “Fluid
Recommendations” for more information. After the
engine internal surfaces have been lubricated,
remove connector and install plug (1). Tighten plug
to a torque of 30 N·m (265 lb in). Perkins
recommends that the procedure must be
performed in a minimum ambient temperature of
10° C (50° F).
8. Check engine oil level and visually inspect all
hoses and connections before starting the engine.
Start the engine, refer to this Operation and
Maintenance Manual, “Starting the Engine” for
more information.
After starting the engine and after correct
operation of the engine, stop the engine and check
again the engine oil level. Ensure that engine oil
level is correct.
32 SEBU9070-03
Operation Section
Features and Controls
Features and Controls

i05952344 Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
Gauges and Indicators components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
Your engine may not have the same gauges or all of
the gauges that are described. For more information 4. Check the coolant level.
about the gauge package, see the literature that is
provided by the OEM. Tachometer – This gauge indicates
engine speed. When the throttle control
Gauges provide indications of engine performance. lever is moved to the full throttle
Ensure that the gauges are in good working order. position without load, the engine is running at
Determine the normal operating range by observing high idle. The engine is running at the full load
the gauges over a period of time.
rpm when the throttle control lever is at the full
Noticeable changes in gauge readings indicate throttle position with maximum rated load.
potential gauge or engine problems. Problems may
also be indicated by gauge readings that change Ammeter – This gauge indicates the
even if the readings are within specifications. amount of charge or of discharge in the
Determine and correct the cause of any significant battery charging circuit. Operation of
change in the readings. Consult your Perkins the indicator should be to the right side of “ 0””
distributor or the Perkins dealer for assistance. (zero).
Engine Oil Pressure – Typical oil Service Hour Meter – This gauge
pressure for an engine at rated speed indicates the total number of clock
with SAE 10W30 or with SAE 15W40 is hours of engine operation. Hours of
240 to 480 kPa (35 to 70 psi). operation are logged in the ECM. A service tool is
needed to retrieve the hours from the ECM. A
Engine Oil Temperature – This gauge Service Hour Meter may be installed on the
indicates the engine oil temperature. An engine.
oil temperature that is higher than
normal indicates a heat problem in the lubrication Fuel Level – This gauge indicates the
system and/or the cooling system. This problem level of fuel in the fuel tank. The fuel
can damage the cylinder heads, the cylinder level gauge registers the fuel level only
liners, the pistons, and the crankshaft bearings. when the ignition switch is in the ON position.
Jacket Water Coolant Temperature – Warning Indicators

Typical temperature range is
88 to 102 °C (190 to 215 °F). The There are two warning lamps available.
maximum allowable temperature with the
pressurized cooling system is 105 °C (220 °F). • Warning Lamp
Higher temperatures may occur under certain
conditions. The water temperature reading may • Shutdown Lamp
vary according to load. The reading should never
exceed the boiling point for the pressurized Instrument Panels and Displays
system that is being used.
In order to monitor the engine a wide verity of
If the engine is operating above the normal range or
instrument panels are available. These instrument
steam becomes apparent, perform the following panels can contain the indicator lamps and the
procedure: gauges for the application.
1. Reduce the engine load .
2. Inspect the cooling system for leaks.
3. Determine if the engine must be shut down
immediately or if the engine can be cooled by
reducing the load.
SEBU9070-03 33
Operation Section
Monitoring System
Also available are mini power displays and If the engine is in the warning condition, then the
performance monitors. event will be logged in the memory of the ECM. An
event code will be transmitted over the Perkins data
i05964915
link and the hard wired Warning output will be
energized. If the engine is in the warning condition,
the event code and output will remain while the
Monitoring System condition exists. The electronic service tool is used to
remove the event code from the memory of the ECM.
The trip point for the warning alarm will be set to a
The engine has protection in three stages: factory default in production. The electronic service
tool may be used to alter the trip point for a warning
• Warning within predefined limits.
• Action Alert Action Alert

• Shutdown The action alert informs the OEM that the engine is
approaching a critical condition. The engine should
The engine protection may be overridden by the
be stopped in a controlled manner. Further running of
critical condition mode.
the engine may result in an immediate shutdown.
The Electronic Control Module (ECM) monitors the
following parameters: If the engine is in the action alert condition, the event
will be logged in the memory of the ECM. An event
• Engine Temperatures code will be transmitted over the Perkins data link
and the hard wired action alert will be energized. If
• Engine Pressures the engine is in the action alert condition, the event
code and output will remain while the condition
• Engine Speed exists. The event code cannot be cleared from the
memory of the ECM without using a factory
The indicator lamp will be illuminated after the trip password.
point is triggered. The ECM will log the event code.
Shutdown
The following parameters are monitored for event
codes: If the engine reaches the Shutdown condition, one of
the following events has occurred: low lubricating oil
• Lubricating Oil Pressure pressure, high coolant temperature, or overspeed.
The event will be logged in the memory of the ECM.
• Coolant Temperature The engine will be shut down. An event code will be
transmitted over the Perkins data link and the hard
• Overspeed wired Shutdown output will be energized. The
Shutdown condition will latch until the ECM is reset.
• Intake Manifold Temperature The event code for the shutdown cannot be cleared
from the memory of the ECM without using a factory
• Intake Manifold Pressure password.
• Fuel Temperature
Critical Protection Override
The temperature protection is disabled for a period
when the engine is cranking in order to compensate If the engine is in an application that is critical for
for heat soak solutions. safety, the protection system can be overridden. This
action is in order to ensure the continuation of the
The ECM has dedicated alarm outputs for each of the power supply during engine fault conditions.
three stages of protection. There are also dedicated
alarm outputs for oil pressure, coolant temperature, Critical Protection Override will be set by a switch
and overspeed events which are energized at any input from the OEM. For example, a switch to battery
stage of protection. + in order to disable a critical override. Critical
Protection Override input can be enabled in the
electronic service tool by use of a factory password.
Warning Alarm
The Warning alarm informs the user that the engine
is approaching a critical condition.
34 SEBU9070-03
Operation Section
Monitoring System
When the Critical Protection Override feature is Powering down the electronic control module can be
active, the ECM will continue to run the engine in all achieved by the operation of the keyswitch into sleep
shutdown conditions except for Overspeed mode. The electronic control module can be powered
shutdown. If the shutdown is overridden, an event down by isolating the power supply to the electronic
code is generated. The ECM will log the event code. control module.
The ECM will energize the following: Warning, Action
Alert, Shutdown, oil pressure, coolant temperature Note: The ECM cannot be reset using the reset input
and overspeed outputs as normal. The warranty of until the engine has stopped.
the engine will be invalidated if the engine is
operated in the following conditions: active event
code and Critical Protection Override mode. Diagnostic
If there is a fault with an engine protection sensor on
Standard Warning Outputs the engine, the engine activates a diagnostic code.
The engine communicates the diagnostic code to the
The ECM provides individual outputs in order to drive operator via the Diagnostic output. The diagnostic
warning lamps or relays to indicate each of the code provides an indication to the operator of a fault
following fault conditions: with the engine protection system. Running of the
engine for a prolonged period in this condition may
• Diagnostic Fault result in engine failure. The output can be used to
drive lamps or relays.
• Oil Pressure
The following sensors are monitored in order to
• Coolant Temperature determine if the sensors are out of the normal range,
an open circuit, or a short circuit:
• Overspeed
• Atmosphere Pressure
• Action Alert
• Lubricating Oil Pressure
• Warning
• Inlet Manifold Pressure
• Shutdown
If the ECM detects a warning from the coolant • Inlet Manifold Temperature
temperature sensor, the ECM will energize a warning • Fuel Temperature
output.
If the ECM detects a warning from the coolant • Coolant Temperature
temperature sensor, the ECM will energize a warning • Engine Speed
output. If the ECM detects a warning for the low oil
pressure, the output on the oil pressure will be • Desired Speed Input
energized. The warning output will be energized.
The Diagnostic output differs from the Warning and
If the Action Alert alarms are enabled and the ECM Shutdown outputs. The Warning and Shutdown
detects a coolant temperature condition, the output
on the coolant temperature will be energized. The outputs refer to the operation of the engine. The
output on the Action Alert will be energized. Diagnostic output refers to the condition of the
electronic system and software system.
If the engine shuts down on low oil pressure, the
output on the low oil pressure will be energized. The
output on the shutdown will be energized. If the
engine shuts down on coolant temperature, or the
engine shuts down on overspeed, the dedicated
output, and the shutdown output will be energized.
Shutdown Reset
The cause of an engine shutdown must be
investigated. Corrective action must be taken before
the system is reset in order to operate the engine.
After an engine shutdown, operate the reset input of
the ECM or power down the controller.
SEBU9070-03 35
Operation Section
Sensors and Electrical Components
A diagnostic fault may develop on the lubricating oil

pressure or coolant temperature sensors. For
example, if a Shutdown protection sensor has a fault,
this fault will result in an engine shutdown. Unless the
system, is in critical protection override. If a
diagnostic fault occurs, with one of the engine speed
sensors while the engine is running. The engine
continues to run by using the other timing sensor for
reference.
i06231547
Sensors and Electrical

Components
The illustration within the section shows the typical

locations of the sensors and other electrical
components on the Industrial engine. Specific
engines may appear different due to the application.
Typical example
(1) Coolant sensor (5) Intake air temperature sensor
(2) Injection actuation pressure control valve (6) Injector harness connection
(3) Fuel rail pressure sensor (7) Atmospheric pressure sensor
(4) Intake air pressure sensor (8) Probe for top center position
36 SEBU9070-03
Operation Section
(9) Electronic control module (12) Fuel temperature sensor (15) Speed timing sensor
(10) Starting motor (13) Fuel pressure sensor
(11) Oil pressure sensor (14) Speed timing sensor
Typical example
(16) Alternator
SEBU9070-03 37
Operation Section
Typical example
(1) Coolant sensor (3) Fuel rail pressure sensor (5) Intake air temperature sensor
(2) Injection actuation pressure control valve (4) Intake air pressure sensor (6) Injector harness connection
38 SEBU9070-03
Operation Section
Typical example
(7) Atmospheric pressure sensor (9) Electronic control module (11) Oil pressure sensor
(8) Probe for top center position (10) Starting motor (12) Fuel temperature sensor
SEBU9070-03 39
Operation Section
Typical example
(13) Fuel pressure sensor (14) Speed timing sensor (15) Speed timing sensor
1506D Configuration
Typical example
(16) Alternator Illustration 32 g03864788
Typical example
(1) Switch
(2) Heating element
(3) Air inlet cover
40 SEBU9070-03
Operation Section
Engine Diagnostics
Engine Diagnostics i02651197
i02784187
Engine Operation with Active
Diagnostic Codes
Self-Diagnostics
If a diagnostic lamp illuminates during normal engine
The electronic control module has some self- operation, the system has identified a situation that is
diagnostic ability. When an electronic problem with not within the specification. Use the electronic service
an input or an output is detected, a diagnostic code is tool to check the active diagnostic codes.
generated. This indicates the specific problem with
the circuitry. The active diagnostic code should be investigated.
The cause of the problem should be corrected as
A diagnostic code which represents a problem that soon as possible. If the cause of the active diagnostic
currently exists is called an active code. code is repaired and there is only one active
diagnostic code, the diagnostic lamp will turn off.
A diagnostic code that is stored in memory is called a
logged code. Always service active codes prior to Operation of the engine and performance of the
servicing logged codes. Logged codes may indicate engine can be limited as a result of the active
intermittent problems. diagnostic code that is generated. Acceleration rates
may be significantly slower and power outputs may
Logged codes may not indicate that a repair is be automatically reduced. Refer to Troubleshooting ,
needed. The problems may have been repaired since “Troubleshooting with a Diagnostic Code” for more
the logging of the code. Logged codes may be information on the relationship between each active
helpful to troubleshoot intermittent problems. diagnostic code and the possible effect on engine
performance.
i02572812
i02784585
Diagnostic Lamp
Engine Operation with
Intermittent Diagnostic Codes
The “DIAGNOSTIC” lamp is used to indicate the
existence of an active fault.
A fault diagnostic code will remain active until the If a diagnostic lamp illuminates during normal engine
problem is repaired. operation and the diagnostic lamp shuts OFF, an
intermittent fault may have occurred. If a fault has
i02784192
occurred, the fault will be logged into the memory of
the Electronic Control Module (ECM).
Fault Logging In most cases, it is not necessary to stop the engine
because of an intermittent code. However, the
operator should retrieve the logged fault codes and
The system provides the capability of Fault Logging. the operator should reference the appropriate
When the Electronic Control Module (ECM) information in order to identify the nature of the fault.
generates an active diagnostic code, the code will be The operator should log any observation that could
logged in the memory of the ECM. The Perkins have caused the lamp to light.
electronic service tool can retrieve codes that have
been logged. The codes that have been logged can • Low power
be cleared with the Perkins electronic service tool.
The codes that have been logged in the memory of • Limits of the engine speed
the ECM will be automatically cleared from the
memory after 100 hours. • Excessive smoke, etc
This information can be useful to help troubleshoot
the situation. The information can also be used for
future reference. For more information on diagnostic
codes, refer to the Troubleshooting guide for this
engine.
SEBU9070-03 41
Operation Section
Configuration Parameters
i05985293
Configuration Parameters
The engine electronic control module (ECM) has two

types of configuration parameters. The system
configuration parameters and the customer specified
parameters.
The electronic service tool is required in order to alter
the configuration parameters.
System Configuration Parameters

System configuration parameters affect the
emissions of the engine or the power of the engine.
System configuration parameters are programmed at
the factory. Normally, system configuration
parameters would never require changing through
the life of the engine. System configuration
parameters must be reprogrammed if an ECM is
replaced. System configuration parameters do not
require reprogrammed if the ECM software is
changed. Factory passwords are required to change
these parameters.
For more information on refer to Troubleshooting,
“Configuration Parameters”.
42 SEBU9070-03
Operation Section
Engine Starting
Engine Starting • Ensure that the areas around the rotating parts are
clear.
i05953831 • All of the guards must be put in place. Check for
damaged guards or for missing guards. Repair
Before Starting Engine any damaged guards. Replace damaged guards
and/or missing guards.
• Disconnect any battery chargers that are not

Perform the required daily maintenance and other
protected against the high current drain that is
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can created when the electric starting motor (if
help prevent major repairs at a later date. equipped) is engaged. Check electrical cables and
check the battery for poor connections and for
• For the maximum service life of the engine, make corrosion.
a thorough inspection before starting the engine.
Look for the following items: oil leaks, coolant • Reset any of the shutoff components or alarm
leaks, loose bolts and trash buildup. Remove trash components.
buildup and arrange for repairs, as needed.
• Check the engine lubrication oil level. Maintain the
• Inspect the cooling system hoses for cracks and oil level between the “ADD” mark and the “FULL”
for loose clamps. mark on the oil level gauge.
• Inspect the alternator and accessory drive belts for • Check the coolant level, maintain the coolant level
cracks, breaks, and other damage. within 13 mm (0.5 inch) from the neck of the
radiator cap.
• Inspect the wiring for loose connections and for
worn wires or frayed wires. • Observe the air cleaner service indicator. Service
the air cleaner when the yellow diaphragm enters
• Check the fuel supply. Drain water from the water the red zone, or when the red piston locks in the
separator (if equipped). Open the fuel supply visible position.
valve.
i06231552
NOTICE
All valves in the fuel return line must be open before Cold Weather Starting
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage.
If the engine has not been run for several weeks, fuel Do not use aerosol types of starting aids such as
may have drained from the fuel system. Air may have ether. Such use could result in an explosion and
entered the filter housing. Also, when fuel filters have personal injury.
been changed, some air space will be left in the
housing. In these instances, prime the fuel system. (If equipped), ensure operation of water jacket heater
Refer to the Operation and Maintenance Manual, before starting the engine.
“Fuel System - Prime” for more information on
priming the fuel system. Ensure that all daily maintenance checks are
performed before starting the engine.
If the engine has not been run for several weeks, fuel
may have drained. Air may have moved into the filter
Engine exhaust contains products of combustion housing. Also, when fuel filters have been changed,
which may be harmful to your health. Always some air will be left in the filter housing. Refer to
start and operate the engine in a well ventilated Operation and Maintenance Manual, “Fuel System -
area and, if in an enclosed area, vent the exhaust Prime” in order to remove air from the fuel system.
to the outside.
• Do not start the engine or move any of the controls

if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
to the controls.
SEBU9070-03 43
Operation Section
Starting the Engine
NOTICE NOTICE
Do not engage the starting motor when flywheel is Do not engage the starting motor when flywheel is
turning. Do not start the engine under load. turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release If the engine fails to start within 30 seconds, release
the starter switch or button and wait 30 seconds to al- the starter switch or button and wait two minutes to
low the starting motor to cool before attempting to allow the starting motor to cool before attempting to
start the engine again. start the engine again.
1. Disengage any equipment that is driven by the 3. Turn keyswitch in order to crank engine and when
engine. engine fires release keyswitch.
2. Turn the keyswitch to the ON position and check 4. If the engine fails to start, repeat step 2 to 3 repeat
that all indicator lamps operate correctly. When the these steps three times only.
key is turned to the next position, some engines
5. If the engine fails to start, refer to Troubleshooting,
will operate an air inlet heater. Allow time for the
“Engine Cranks but Does Not Start”.
heater to heat the incoming air.
3. Turn the keyswitch to the START position in order i05954108
to engage the electric starting motor and crank the
engine. Starting with Jump Start
4. During the start procedure, if a warning indicator Cables
becomes active the warning should be
investigated.
5. Repeat steps 2 through to step 3 three times if the
engine fails to start. If the engine fails to start, refer
to Troubleshooting, “Engine Cranks but Does Not Improper jump start cable connections can cause
Start”. an explosion resulting in personal injury.
Prevent sparks near the batteries. Sparks could
Note: Check all gauges and indicators for correct cause vapors to explode. Do not allow jump start
operation. A system fault may be indicated after the cable ends to contact each other or the engine.
engine is started. If this indication occurs, the ECM
has detected a problem with the system. The fault
must be investigated. Note: If possible, first diagnose the reason for the
starting failure. Refer to Troubleshooting, “Engine
6. Oil pressure should rise within 15 seconds after Will Not Crank and Engine Cranks But Will Not Start”
the engine starts. The engine electronic controls for further information. Make any necessary repairs.
monitor the engine oil pressure. The electronic If the engine will not start only due to the condition of
controls will stop the engine if the oil pressure is the battery, either charge the battery, or start the
below normal. engine by using another battery with jump-start
cables. The condition of the battery can be
The original equipment manufacturer may have their rechecked after the engine has been switched OFF.
own systems for starting an engine in cold weather.
NOTICE
i05975875
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
Starting the Engine jump starting. The use of higher voltage will damage
the electrical system.
Do not reverse the battery cables. The alternator can
1. Disengage any equipment that is driven by the be damaged. Attach ground cable last and remove
engine. first.
2. Turn keyswitch to the ON position and check for Turn all electrical accessories OFF before attaching
correct operation of gauges and indicators. Refer the jump start cables.
to original equipment manufacturer for information
Ensure that the main power switch is in the OFF posi-
on the starting control panel. tion before attaching the jump start cables to the en-
gine being started.
44 SEBU9070-03
Operation Section
After Starting Engine
1. Turn the start switch on the stalled engine to the Note: Gauge readings should be observed and the
OFF position. Turn off all the engines accessories. data should be recorded frequently while the engine
is operating. Comparing the data over time will help
2. Connect one positive end of the jump-start cable to to determine normal readings for each gauge.
the positive cable terminal of the discharged Comparing data over time will also help detect
battery. Connect the other positive end of the abnormal operating developments. Significant
jump-start cable to the positive cable terminal of changes in the readings should be investigated.
the electrical source.
3. Connect one negative end of the jump-start cable
Variable Speed Engines
to the negative cable terminal of the electrical
The engine should not be raced in order to speed up
source. Connect the other negative end of the the warm-up process. Allow the engine to idle for 3 to
jump-start cable to the engine block or to the 5 minutes, or allow the engine to idle until the water
chassis ground. This procedure helps to prevent temperature indicator begins to rise. Then, the
potential sparks from igniting the combustible engine can be operated normally.
gases that are produced by some batteries.
Note: The engine ECM must be powered before the
starting motor is operated or damage can occur.
4. Start the engine in the normal operating

procedure. Refer to this Operation and
Maintenance Manual, “Starting the Engine”.
5. Immediately after the engine is started, disconnect
the jump-start cables in reverse order.
After jump starting, the alternator may not be able to
recharge completely the batteries that are severely
discharged. The batteries must be replaced or
charged to the proper voltage with a battery charger
after the engine is stopped. Many batteries which are
considered unusable are still rechargeable. Refer to
Operation and Maintenance Manual, “Battery -
Replace” and Testing and Adjusting Manual, “Battery
- Test”.
i06231640
After Starting Engine
Ensure that the self test for the monitoring system is

completed before operating the engine under load.
Constant Speed Engines

The engine will operate at a content speed. The
speed will be programmed in to the electronic control
unit. Check all gauges and indicator lamps after
starting for correct reading and correct actions.
Visually check for coolant, oil, or fuel leaks.
Allow the engine 3 minutes warm up time before
applying load.
Note: In temperatures from 0 to 60°C (32 to 140°F),

the warm-up time is approximately 3 minutes. In
temperatures below 0°C (32°F), additional warm-up
time may be required.
SEBU9070-03 45
Operation Section
Engine Operation
Engine Operation • Be aware of the properties of the different fuels.

Use only the recommended fuels.
i05954288 • Avoid unnecessary operation at no load.
Engine Operation Shut off the engine instead of operating the engine at
no load for long periods of time.
• Observe the service indicator for the air cleaner
Proper operation and maintenance are key factors in frequently. Keep the air cleaner elements clean.
obtaining the maximum life and economy of the
engine. If the directions in the Operation and • Maintain a good electrical system.
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized. One bad battery cell will overwork the alternator and
will consume excess power and excess fuel.
The time that is needed for the engine to reach
normal operating temperature can be less than the • Ensure that the belts are properly adjusted. The
time needed for a walk-around inspection of the belts should be in good condition.
engine.
• Ensure that all of the connections of the hoses are
After the engine is started and after the engine tight. The connections should not leak.
reaches normal operating temperature, the engine
can be operated at load. • Ensure that the driven equipment is in good
Gauge readings should be observed and the data working order.
should be recorded frequently while the engine is • Cold engines consume excess fuel. Keep cooling
operating. Comparing the data over time will help to
system components clean and keep cooling
determine normal readings for each gauge.
Comparing data over time will also help detect system components in good repair. Never operate
abnormal operating developments. Significant the engine without water temperature regulators.
changes in the readings should be investigated. All of these items will help maintain operating
temperatures.
i05954310
Engaging the Driven

Equipment
If possible, engage the driven equipment without a

load. With the engine in a stable operating mode,
apply the load.
With load applied check for correct operation of
gauges and indicators.
i05954305
Fuel Conservation Practices
The efficiency of the engine can affect the fuel

economy. The design and technology used
byPerkins in manufacturing provides maximum fuel
efficiency in all applications. Follow the
recommended procedures in order to attain optimum
performance for the life of the engine.
• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
46 SEBU9070-03
Operation Section
Cold Weather Operation
Cold Weather Operation The cloud point of the fuel is the temperature at
which waxes naturally found in the diesel fuel begin
to form crystals. The cloud point of the fuel must be
i05954317 below lowest ambient temperature to prevent filters
from plugging.
Radiator Restrictions Cold Filter Plugging Point is a temperature at which a
particular fuel will pass through a standardized
filtration device. This CFPP gives an estimate of the
Perkins discourages the use of airflow restriction lower operability temperature of fuel
devices that are mounted in front of radiators. Airflow
restriction can cause the following conditions: Pour point is the last temperature before the fuel flow
stops and waxing of the fuel will start.
• High exhaust temperatures
Be aware of these properties when diesel fuel is
• Power loss purchased. Consider the average ambient air
temperature for the engines application. Engines that
• Excessive fan usage are fueled in one climate may not operate well if the
engines are shipped to colder climate. Problems can
• Reduction in fuel economy result due to changes in temperature.
If an airflow restriction device must be used, the Before troubleshooting for low power or for poor
device should have a permanent opening directly in performance in the winter, check the fuel for waxing
line with the fan hub. The device must have a 2
minimum opening dimension of at least 770 cm The following components can provide a means of
(120 in2). minimizing fuel waxing problems in cold weather:
A centered opening that is directly in line with the fan
• Fuel heaters, which may be an OEM option
hub is specified in order to prevent an interrupted
airflow on the fan blades. Interrupted airflow on the • Fuel line insulation, which may be an OEM option
fan blades could cause a fan failure.
Perkins recommends a warning device for the inlet Winter and arctic grades of diesel fuel are available in
manifold temperature and/or the installation of an the countries and territories with severe winters. For
more information refer to the Operation and
inlet air temperature gauge. The warning device for Maintenance Manual, “Fuel For Cold Weather
the inlet manifold temperature should be set at 75 °C Operation”
(167 °F). The inlet manifold air temperature should
not exceed 75 °C (167 °F). Temperatures that Another important fuel property which can affect cold
exceed this limit can cause power loss and potential start and operation of diesel engine is Cetane
engine damage. number. Detail and requirements of this property are
given in this Operation and Maintenance Manual,
i05954321 “Fluid Recommendations”.
Fuel and the Effect from Cold i05955135
Weather Fuel Related Components in

Cold Weather
Note: Only use grades of fuel that are recommended
by Perkins. Refer to this Operation and Maintenance
Manual, “Fluid Recommendations”. Fuel Tanks
Properties of the diesel fuel can have a significant
effect on the engine cold start capability. It is critical Condensation can form in partially filled fuel tanks.
that the low temperature properties of diesel fuel are Top off the fuel tanks after operating the engine.
acceptable for the minimum ambient temperature the
engine is expected to see in the operation. Fuel tanks should contain some provision for draining
water and sediment from the bottom of the tanks.
Following properties are used to define fuels low Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
temperature capability: supply pipe.
• Cloud point Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is
• Pour point equipped with this system, regular maintenance of
• Cold Filter Plugging Point (CFPP) the fuel system filter is important.
SEBU9070-03 47
Operation Section
Fuel Related Components in Cold Weather
Drain the water and sediment from any fuel storage

tank at the following intervals:
• Weekly
• Oil changes
• Refueling of the fuel tank

Draining the fuel tank will help prevent water and/or
sediment from being pumped from the fuel storage
tank and into the engine fuel tank.
Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in order for the fuel to be heated before
the fuel enters the primary fuel filter.
Select a fuel heater that is mechanically simple, yet
adequate for the application. The fuel heater should
also help to prevent overheating of the fuel. High fuel
temperatures reduce engine performance and the
availability of engine power. Choose a fuel heater
with a large heating surface. The fuel heater should
be practical in size. Small heaters can be too hot due
to the limited surface area.
Disconnect the fuel heater in warm weather.
Note: Fuel heaters that are controlled by the water

temperature regulator or self-regulating fuel heaters
should be used with this engine. Fuel heaters that are
not controlled by the water temperature regulator can
heat the fuel in excess of 65° C (149° F). A loss of
engine power can occur if the fuel supply
temperature exceeds 37° C (100° F).
Note: Heat exchanger type fuel heaters should have
a bypass provision in order to prevent overheating of
the fuel in warm-weather operation.
For further information on fuel heaters, consult your
Perkins dealer or your Perkins distributor.
48 SEBU9070-03
Operation Section
Engine Stopping
Engine Stopping 2. Stop the engine after the cool down period
according to the shutoff system on the engine and
turn the ignition keyswitch to the OFF position. If
i05955161
necessary, refer to the instructions that are
provided by the OEM.
Emergency Stopping
i02583411
NOTICE After Stopping Engine

Emergency shutoff controls are for EMERGENCY
use ONLY. DO NOT use emergency shutoff devices
or controls for normal stopping procedure.
Note: Before you check the engine oil, do not
The OEM may have equipped the application with an operate the engine for at least 10 minutes in order to
emergency stop button. For more information about allow the engine oil to return to the oil pan.
the emergency stop button, refer to the OEM
information. • Check the crankcase oil level. Maintain the oil
level between the “LOW” mark and the “HIGH”
Ensure that any components for the external system mark on the oil level gauge.
that support the engine operation are secured after
the engine is stopped. Note: Only use oil that is recommended in this
i05955160 Recommendations”. Failure to use the recommended
oil may result in engine damage.
Manual Stop Procedure • If necessary, perform minor adjustments. Repair
any leaks and tighten any loose bolts.
• Note the service hour meter reading. Perform the

Stopping the Engine maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
NOTICE Schedule”.
Stopping the engine immediately after it has been
working under load, can result in overheating and ac- • Fill the fuel tank in order to help prevent
celerated wear of the engine components. accumulation of moisture in the fuel. Do not overfill
the fuel tank.
Avoid accelerating the engine prior to shutting it
down. • Allow the engine to cool. Check the coolant level.
Maintain the cooling system at 13 mm (0.5 inch)
Avoiding hot engine shutdowns will maximize turbo-
from the bottom of the pipe for filling.
charger shaft and bearing life.
Note: Only use coolant that is recommended in this
Note: Individual applications will have different
Recommendations”. Failure to use the recommended
control systems. Ensure that the shutoff procedures
oil may result in engine damage.
are understood. Use the following general guidelines
in order to stop the engine. • If freezing temperatures are expected, check the
coolant for proper antifreeze protection. The
1. Remove the load from the engine. Allow the cooling system must be protected against freezing
engine to run under no load conditions for 5 to the lowest expected outside temperature. Add
minutes in order to cool the engine. the proper coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all
driven equipment. This maintenance is outlined in
the instructions from the OEM.
SEBU9070-03 49
Maintenance Section
Refill Capacities
Maintenance Section (Table 6, contd)

(1) The External System includes a radiator or an expansion tank
with the following components: heat exchanger and piping. Re-
fer to the OEM specifications. Enter the value for the capacity
Refill Capacities of the External System in this row.
i06231649
i05955174
Refill Capacities Fluid Recommendations
General Coolant Information

Lubrication System
The refill capacities for the engine crankcase reflect NOTICE
the approximate capacity of the crankcase or sump Never add coolant to an overheated engine. Engine
plus standard oil filters. Auxiliary oil filter systems will damage could result. Allow the engine to cool first.
require additional oil. Refer to the OEM specifications
for the capacity of the auxiliary oil filter. Refer to the
Operation and Maintenance Manual, “Maintenance NOTICE
Section” for more information on Lubricant If the engine is to be stored in, or shipped to an area
Specifications. with below freezing temperatures, the cooling system
Table 5 must be either protected to the lowest outside tem-
perature or drained completely to prevent damage.
Engine
Refill Capacities
Compartment or At Commissioning In Service NOTICE

System Frequently check the specific gravity of the coolant
for proper freeze protection or for anti-boil protection.
Crankcase Oil Sump 41 L 39 L
(1) Clean the cooling system for the following reasons:
(1) These values are the approximate capacities for the crankcase
oil sump (aluminum) which includes the standard factory in- • Contamination of the cooling system
stalled oil filters. Engines with auxiliary oil filters will require ad-
ditional oil. Refer to the OEM specifications for the capacity of • Overheating of the engine
the auxiliary oil filter.
• Foaming of the coolant
Cooling System
NOTICE
Refer to the OEM specifications for the External Never operate an engine without water temperature
System capacity. This capacity information will be regulators in the cooling system. Water temperature
needed in order to determine the amount of coolant regulators help to maintain the engine coolant at the
that is required for the Total Cooling System. proper operating temperature. Cooling system prob-
lems can develop without water temperature
Table 6 regulators.
Engine
Refill Capacities
Many engine failures are related to the cooling
Compartment or System Liters system. The following problems are related to cooling
system failures: Overheating, leakage of the water
Engine Only 14 pump and plugged radiators or heat exchangers.
External System Per OEM(1) 33 These failures can be avoided with correct cooling
system maintenance. Cooling system maintenance is
as important as maintenance of the fuel system and
(continued) the lubrication system. Quality of the coolant is as
important as the quality of the fuel and the lubricating
oil.
Coolant is normally composed of three elements:
Water, additives and glycol.
50 SEBU9070-03
Maintenance Section
Fluid Recommendations
Water • Leakage of the water pump seal

Water is used in the cooling system in order to • Plugging of radiators, coolers, and small passages
transfer heat.
Distilled water or deionized water is
Glycol
recommended for use in engine cooling systems.
Glycol in the coolant helps to provide protection
DO NOT use the following types of water in cooling against the following conditions:
systems: Hard water, softened water that has been
conditioned with salt and sea water. • Boiling
If distilled water or deionized water is not available, • Freezing

use water with the properties that are listed in Table 7
. • Cavitation of the water pump
Table 7
For optimum performance, Perkins recommends a
Acceptable Water 1:1 mixture of a water/glycol solution.
Property Maximum Limit
Note: Use a mixture that will provide protection
Chloride (Cl) 40 mg/L against the lowest ambient temperature.
Sulfate (SO4) 100 mg/L Note: 100 percent pure glycol will freeze at a
170 mg/L
temperature of −13 °C (8.6 °F).
Total Hardness
Total Solids 340 mg/L Most conventional antifreezes use ethylene glycol.
Propylene glycol may also be used. In a 1:1 mixture
Acidity pH of 5.5 to 9.0 with water, ethylene and propylene glycol provide
similar protection against freezing and boiling. Refer
to Table 8 and refer to table 9 .
For a water analysis, consult one of the following
sources: Table 8
Ethylene Glycol
• Local water utility company
Concentration Freeze Protection
• Agricultural agent
50 Percent −36 °C (−33 °F)
• Independent laboratory −51 °C (−60 °F)
60 Percent
Additives
Additives help to protect the metal surfaces of the NOTICE
Do not use propylene glycol in concentrations that
cooling system. A lack of coolant additives or
exceed 50 percent glycol because of the reduced
insufficient amounts of additives enable the following
conditions to occur: heat transfer capability of propylene glycol. Use ethyl-
ene glycol in conditions that require additional protec-
• Corrosion tion against boiling or freezing.
• Formation of mineral deposits Table 9

Propylene Glycol
• Rust
Concentration Freeze Protection
• Scale
50 Percent −29 °C (−20 °F)
• Foaming of the coolant
Many additives are depleted during engine operation. To check the concentration of glycol in the coolant,
These additives must be replaced periodically. measure the specific gravity of the coolant.
Additives must be added at the correct concentration. Coolant Recommendations

Over concentration of additives can cause the
inhibitors to drop out-of-solution. The deposits can • ELC Extended Life Coolant
enable the following problems to occur:
• SCA Supplement Coolant Additive
• Formation of gel compounds
• ASTM American Society for Testing and
• Reduction of heat transfer Materials
SEBU9070-03 51
Maintenance Section
The following two coolants are used in Perkins diesel The anti-corrosion package for ELC is different from
engines: the anti-corrosion package for other coolants. ELC is
an ethylene glycol base coolant. However, ELC
Preferred – Perkins ELC contains organic corrosion inhibitors and antifoam
agents with low amounts of nitrite. Perkins ELC has
Acceptable – A commercial heavy-duty antifreeze been formulated with the correct amount of these
additives in order to provide superior corrosion
that meets “ASTM D6210 ” specifications protection for all metals in engine cooling systems.
ELC is available in a premixed cooling solution with
NOTICE distilled water. ELC is a 1:1 mixture. The Premixed
The 1500 series industrial engines must be oper- ELC provides freeze protection to −36 °C (−33 °F).
ated with a 1:1 mixture of water and glycol. This The Premixed ELC is recommended for the initial fill
concentration allows the NOx reduction system of the cooling system. The Premixed ELC is also
to operate correctly at high ambient recommended for topping off the cooling system.
temperatures.
Containers of several sizes are available. Consult
your Perkins distributor for the part numbers.
NOTICE
Do not use a commercial coolant/antifreeze that only ELC Cooling System Maintenance
meets the ASTM D3306 specification. This type of
coolant/antifreeze is made for light automotive
applications.
Correct additions to the Extended Life
Coolant
Perkins recommends a 1:1 mixture of water and
glycol. This mixture of water and glycol will provide NOTICE
optimum heavy-duty performance as an antifreeze. Use only Perkins products for pre-mixed or concen-
This ratio may be increased to 1:2 water to glycol if trated coolants.
extra freezing protection is required.
Mixing Extended Life Coolant with other products re-
A mixture of SCA inhibitor and water is acceptable duces the Extended Life Coolant service life. Failure
to follow the recommendations can reduce cooling
but will not give the same level of corrosion, boiling
system components life unless appropriate corrective
and, freezing protection as ELC. Perkins
action is performed.
recommends a 6 percent to 8 percent concentration
of SCA in those cooling systems. Distilled water or In order to maintain the correct balance between the
deionized water is preferred. Water which has the antifreeze and the additives, you must maintain the
recommended properties may be used. recommended concentration of ELC. Lowering the
Table 10 proportion of antifreeze lowers the proportion of
Coolant Service Life
additive. This lowering will lower the ability of the
coolant to protect the system from pitting, from
Coolant Type Service Life (1) cavitation, from erosion, and from deposits.
6,000 Service Hours or Three
Perkins ELC
Years NOTICE
Do not use a conventional coolant to top-off a cooling
Commercial Heavy-Duty Anti- system that is filled with Extended Life Coolant
freeze that meets “ASTM 3000 Service Hours or Two Year (ELC).
D6210”
Do not use standard supplemental coolant additive
Commercial SCA inhibitor and (SCA).
3000 Service Hours or One Year
Water
(1) Use the interval that occurs first. The cooling system must also When using Perkins ELC, do not use standard SCA's
be flushed out at this time. or SCA filters.
ELC
ELC Cooling System Cleaning
Perkins provides ELC for use in the following
applications: Note: If the cooling system is already using ELC,
cleaning agents are not required to be used at the
• Heavy-duty spark ignited gas engines specified coolant change interval. Cleaning agents
are only required if the system has been
• Heavy-duty diesel engines contaminated by the addition of some other type of
• Automotive applications coolant or by cooling system damage.
52 SEBU9070-03
Maintenance Section
Clean water is the only cleaning agent that is ELC Cooling System Contamination
required when ELC is drained from the cooling
system.
NOTICE
Before the cooling system is filled, the heater control Mixing ELC with other products reduces the effective-
(if equipped) must be set to the HOT position. Refer ness of the ELC and shortens the ELC service life.
to the OEM in order to set the heater control. After Use only Perkins Products for premixed or concen-
the cooling system is drained and the cooling system trate coolants. Failure to follow these recommenda-
is refilled, operate the engine until the coolant level tions can result in shortened cooling system
reaches the normal operating temperature and until component life.
the coolant level stabilizes. As needed, add the
coolant mixture in order to fill the system to the ELC cooling systems can withstand contamination to
specified level. a maximum of 10 percent of conventional heavy-duty
antifreeze or SCA. If the contamination exceeds 10
percent of the total system capacity, perform ONE of
Changing to Perkins ELC the following procedures:
To change from heavy-duty antifreeze to the Perkins • Drain the cooling system into a suitable container.
ELC, perform the following steps: Dispose of the coolant according to local
regulations. Flush the system with clean water. Fill
NOTICE the system with the Perkins ELC.
Care must be taken to ensure that all fluids are con-
tained during performance of inspection, mainte- • Drain a portion of the cooling system into a
nance, testing, adjusting and the repair of the suitable container according to local regulations.
product. Be prepared to collect the fluid with suitable Then, fill the cooling system with premixed ELC.
containers before opening any compartment or disas-
This procedure should lower the contamination to
sembling any component containing fluids.
less than 10 percent.
Dispose of all fluids according to local regulations
and mandates. • Maintain the system as a conventional Heavy-
Duty Coolant. Treat the system with an SCA.
Change the coolant at the interval that is
1. Drain the coolant into a suitable container. recommended for the conventional Heavy-Duty
Coolant.
2. Dispose of the coolant according to local
regulations. Commercial Heavy-Duty Antifreeze and
3. Fill the cooling system with a 33 percent solution of SCA
Perkins ELC and operate the engine, ensure that
the thermostat opens. Stop the engine and allow NOTICE
the engine to cool. Drain the coolant. Commercial Heavy-Duty Coolant which contains
Amine as part of the corrosion protection system
Note: Use distilled or deionized water in the solution. must not be used.
4. Again, fill the cooling system with a 33 percent
solution of Perkins ELC and operate the engine NOTICE
ensure that the thermostat opens. Stop the engine Never operate an engine without water temperature
and allow to cool. regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
5. Drain the drain the cooling system. correct operating temperature. Cooling system prob-
lems can develop without water temperature
NOTICE regulators.
Incorrect or incomplete flushing of the cooling system
can result in damage to copper and other metal Check the antifreeze (glycol concentration) in order
components. to ensure adequate protection against boiling or
freezing. Perkins recommends the use of a
refractometer for checking the glycol concentration. A
6. Fill the cooling system with the Perkins Premixed hydrometer should not be used.
ELC. Operate the engine. Ensure that all coolant
valves open then stop the engine. When cool Perkins engine cooling systems should be tested at
500 hour intervals for the concentration of SCA.
check the coolant level.
Additions of SCA are based on the results of the test.
An SCA that is liquid may be needed at 500 hour
intervals.
SEBU9070-03 53
Maintenance Section
Adding the SCA to Heavy-Duty Coolant Table 14

at the Initial Fill Example Of The Equation For Adding The SCA To The Heavy-
Duty Coolant For Maintenance
Use the equation that is in Table 11 to determine the
amount of SCA that is required when the cooling Total Volume of the Multiplication Amount of SCA
system is initially filled. Cooling System (V) Factor that is Required
(X)
Table 11
Equation For Adding The SCA To The Heavy-Duty Coolant At 15 L (4 US gal) × 0.014 0.2 L (7 oz)
The Initial Fill
V × 0.045 = X Cleaning the System of Heavy-Duty
V is the total volume of the cooling system. Antifreeze
X is the amount of SCA that is required.
• Clean the cooling system after used coolant is
drained or before the cooling system is filled with
Table 12 is an example for using the equation that is new coolant.
in Table 11 .
Table 12 • Clean the cooling system whenever the coolant is
Example Of The Equation For Adding The SCA To The Heavy-
contaminated or whenever the coolant is foaming.
Duty Coolant At The Initial Fill
i06231742
Total Volume of the Multiplication Amount of SCA
Cooling System (V) Factor that is Required
(X)
15 L (4 US gal) × 0.045 0.7 L (24 oz)
(Lubricant Information for 1506A
and 1506C Engines)
Adding The SCA to The Heavy-Duty
Coolant For Maintenance S/N: LG
Heavy-duty antifreeze of all types REQUIRE periodic
additions of an SCA.
Test the antifreeze periodically for the concentration General Lubricant Information
of SCA. For the interval, refer to the Operation and
Maintenance Manual, “Maintenance Interval Because of government regulations regarding the
Schedule” (Maintenance Section). Cooling System certification of exhaust emissions from the engine,
Supplemental Coolant Additive (SCA) Test/Add. the lubricant recommendations must be followed.
Additions of SCA are based on the results of the test. • API American Petroleum Institute
The size of the cooling system determines the
amount of SCA that is needed. • SAE Society Of Automotive Engineers Inc.
Use the equation that is in Table 13 to determine the • ACEA Association des Constructers
amount of SCA that is required, if necessary: European Automobiles.
Table 13
Equation For Adding The SCA To The Heavy-Duty Coolant • ECF Engine Crankcase Fluid
For Maintenance
• TBN Total Base Number
V × 0.014 = X
• PPM Parts Per Million
V is the total volume of the cooling system.
X is the amount of SCA that is required. Licensing
Table 14 is an example for using the equation that is The Engine Oil Licensing and Certification System by
in Table 13 . the API and the ACRA is recognized by Perkins. For
detailed information about this system, see the latest
edition of the “API publication No. 1509”. Engine oils
that bear the API symbol are authorized by API.
54 SEBU9070-03
Maintenance Section
Lubricant Information for 1506A and 1506C Engines
Table 16
TBN Recommendations (1)
TBN of Commercial En-
Fuel Sulfur Level percent (ppm)
gine Oils
≤0.05 percent (≤500 ppm) Min 7
0. 1- 0.05 percent (1000-500 ppm) Min 7
Above 0.1 percent (above 1000 ppm)

(2) Min 10
(1) When using fuel with 0.10% sulfur (1000 ppm) or higher, refer
to this Operation and Maintenance Manual, “Severe Service
Application” for more information.
(2) For fuels of sulfur levels that exceed 1.0 percent (10,000 ppm),
refer to TBN and engine oil guidelines given in this section.
Typical API symbol Lubricant Viscosity Recommendations
for Direct Injection (DI) Diesel Engines
Terminology
The correct SAE viscosity grade of oil is determined
Certain abbreviations follow the nomenclature of by the minimum ambient temperature during cold
“SAE J754”. Some classifications follow “SAE J183”
abbreviations, and some classifications follow the engine start-up, and the maximum ambient
“EMA Recommended Guideline on Diesel Engine temperature during engine operation.
Oil”. In addition to Perkins definitions, there are other
definitions that will be of assistance in purchasing Refer to illustration 34 (minimum temperature) in
lubricants. Recommended oil viscosities can be order to determine the required oil viscosity for
found in this publication, “Fluid Recommendations/ starting a cold engine.
Engine Oil” topic (Maintenance Section).
Refer to illustration 34 (maximum temperature) in
order to select the oil viscosity for engine operation at
Engine Oil the highest ambient temperature that is anticipated.
Commercial Oils Generally, use the highest oil viscosity that is

available to meet the requirement for the temperature
at start-up.
NOTICE
Perkins require the use of the following specifica-
tion of engine oil. Failure to use the appropriate
specification of engine oil will reduce the life of
your engine.
Table 15
Classifications for the 1506A and C Industrial Engine
Oil Specification
CH-4
Total Base Number (TBN) and Fuel Sulfur

Levels
The minimum required TBN for oil depends on the
fuel sulfur level. The TBN for new oil is typically
determined by the “ASTM D2896” procedure. For
direct injection engines that use distillate fuel, the
following guidelines apply:
SEBU9070-03 55
Maintenance Section
Lubricant Information for 1506A and 1506C Engines
Aftermarket Oil Additives

Perkins does not recommend the use of aftermarket
additives in oil. It is not necessary to use aftermarket
additives in order to achieve the engines maximum
service life, or rated performance. Fully formulated,
finished oils consist of base oils and of commercial
additive packages. These additive packages are
blended into the base oils at precise percentages in
order to help provide finished oils with performance
characteristics that meet industry standards.
There are no industry standard tests that evaluate
the performance or the compatibility of aftermarket
additives in finished oil. Aftermarket additives may
not be compatible with the finished oils additive
package, which could lower the performance of the
finished oil. The aftermarket additive could fail to mix
with the finished oil and could produce sludge in the
crankcase. Perkins discourages the use of
aftermarket additives in finished oils.
To achieve the best performance from a Perkins
engine, conform to the following guidelines:
Lubricant Viscosities • Select the correct oil, or a commercial oil that
Supplemental heat is recommended for cold soaked meets the recommended API classification.
starts below the minimum ambient temperature.
Supplemental heat may be required for cold soaked • See the appropriate “Lubricant Viscosities” table in
starts that are above the minimum temperature that order to find the correct oil viscosity grade for your
is stated, depending on the parasitic load and other engine.
factors. Cold soaked starts occur when the engine
has not been operated for a period of time. This • At the specified interval, service the engine. Use
interval will allow the oil to become more viscous due new oil and install a new oil filter.
to cooler ambient temperatures.
• Perform maintenance at the intervals that are
Synthetic Base Stock Oils specified in the Operation and Maintenance
Manual, “Maintenance Interval Schedule”.
Synthetic base oils are acceptable for use in these
engines if these oils meet the performance Oil analysis
requirements that are specified for the engine.
Some engines may be equipped with an oil sampling
Synthetic base oils generally perform better than valve. If oil analysis is required, the oil sampling valve
conventional oils in the following two areas: is used to obtain samples of the engine oil. The oil
analysis will complement the preventive maintenance
• Synthetic base oils have improved flow at low program.
temperatures especially in arctic conditions.
The oil analysis is a diagnostic tool that is used to
• Synthetic base oils have improved oxidation determine oil performance and component wear
stability especially at high operating temperatures. rates. Contamination can be identified and measured
by using the oil analysis. The oil analysis includes the
Some synthetic base oils have performance following tests:
characteristics that enhance the service life of the oil.
Perkins does not recommend the automatic • The Wear Rate Analysis monitors the wear of the
extending of the oil change intervals for any type of engines metals. The amount of wear metal and
oil. type of wear metal that is in the oil is analyzed.
The increase in the rate of engine wear metal in
the oil is as important as the quantity of engine
wear metal in the oil.
• Tests are conducted in order to detect

contamination of the oil by water, glycol, or fuel.
56 SEBU9070-03
Maintenance Section
• The oil condition analysis determines the loss of Terminology

the oils lubricating properties. An infrared analysis
is used to compare the properties of new oil to the Certain abbreviations follow the nomenclature of
properties of the used oil sample. This analysis “SAE J754”. Some classifications follow “SAE J183”
allows technicians to determine the amount of abbreviations, and some classifications follow the
“EMA Recommended Guideline on Diesel Engine
deterioration of the oil during use. This analysis Oil”. In addition to Perkins definitions, there are other
also allows technicians to verify the performance definitions that will be of assistance in purchasing
of the oil according to the specification during the lubricants. Recommended oil viscosities can be
entire oil change interval. found in this publication, “Fluid Recommendations/
Engine Oil” topic (Maintenance Section).
i06231746
Engine Oil
Commercial Oils
S/N: PK9 NOTICE

Perkins require the use of the following specifica-
General Lubricant Information for tion of engine oil. Failure to use the appropriate
specification of engine oil will reduce the life of
the 1506D Engine your engine.
Because of government regulations regarding the Table 17

certification of exhaust emissions from the engine,
Oil Specification for the 1506D Industrial Engine
the lubricant recommendations must be followed.
Preferred Oil Specification Acceptable
• API American Petroleum Institute
API CI-4 Plus API CI-4
• SAE Society Of Automotive Engineers Inc.
API CI-4 Plus meets the designed life of the product,
Licensing the use of the appropriate engine oil is essential.
The Engine Oil Licensing and Certification System by API CI-4 Plus provide two design improvements over
the American Petroleum Institute (API). For detailed API CI-4 oil specification, soot viscosity control and
information about this system, see the latest edition product shear stability.
of the “API publication No. 1509”. Engine oils that
bear the API symbol are authorized by API. Maintenance intervals for engines that use
biodiesel – The oil change interval can be adversely
affected by the use of biodiesel. Use oil analysis in
order to monitor the condition of the engine oil. Use
oil analysis also in order to determine the oil change
interval that is optimum.
Note: These engine oils are not approved by

Perkins and these engine oils must not be used:
CC, CD, CD-2, CF-4, CG-4 and CH-4.
Lubricant Viscosity Recommendations

for Direct Injection (DI) Diesel Engines
The correct SAE viscosity grade of oil is determined
by the minimum ambient temperature during cold
engine start-up, and the maximum ambient
Typical API symbol temperature during engine operation.
Refer to illustration 36 (minimum temperature) in
order to determine the required oil viscosity for
starting a cold engine.
Refer to illustration 36 (maximum temperature) in
order to select the oil viscosity for engine operation at
the highest ambient temperature that is anticipated.
SEBU9070-03 57
Maintenance Section
Generally, use the highest oil viscosity that is • See the appropriate “Lubricant Viscosities”. Refer
available to meet the requirement for the temperature to the illustration 36 in order to find the correct oil
at start-up. viscosity grade for your engine.
• At the specified interval, service the engine. Use

new oil and install a new oil filter.
• Perform maintenance at the intervals that are

specified in the Operation and Maintenance
Manual, “Maintenance Interval Schedule”.
Oil analysis
Some engines may be equipped with an oil sampling
valve. If oil analysis is required, the oil sampling valve
is used to obtain samples of the engine oil. The oil
analysis will complement the preventive maintenance
program.
The oil analysis is a diagnostic tool that is used to
determine oil performance and component wear
rates. Contamination can be identified and measured
by using oil analysis. The oil analysis includes the
following tests:
• The Wear Rate Analysis monitors the wear of the

Illustration 36 g03329707 engines metals. The amount of wear metal and
Lubricant Viscosities type of wear metal that is in the oil is analyzed.
Supplemental heat is recommended for cold soaked The increase in the rate of engine wear metal in
starts below the minimum ambient temperature. the oil is as important as the quantity of engine
Supplemental heat may be required for cold soaked wear metal in the oil.
starts that are above the minimum temperature that
is stated. The requirement also depends on the • Tests are conducted in order to detect
parasitic load and other factors. Cold soaked starts contamination of the oil by water, glycol, or fuel.
occur when the engine has not been operated for a
longtime. This interval will allow the oil to become • The Oil Condition Analysis determines the loss of
more viscous due to cooler ambient temperatures. the oils lubricating properties. An infrared analysis
is used to compare the properties of new oil to the
Aftermarket Oil Additives properties of the used oil sample. This analysis
allows technicians to determine the amount of
Perkins does not recommend the use of aftermarket deterioration of the oil during use. This analysis
additives in oil. The use of aftermarket additives in also allows technicians to verify the performance
order to achieve the engines maximum service life or of the oil according to the specification during the
rated performance is not necessary. Fully formulated, entire oil change interval.
finished oils consist of base oils and of commercial
additive packages. Additive packages are blended
into the base oils at precise percentages in order to i06231780
provide finished oils with performance characteristics
that meet industry standards. Fluid Recommendations
There are no industry standard tests that evaluate (Fuel Recommendations for the
the performance or the compatibility of aftermarket
additives in finished oil. Aftermarket additives may 1506A and 1506C Engines)
not be compatible with the finished oils additive
package, which could lower the performance of the
finished oil. The aftermarket additive could fail to mix S/N: LG
with the finished oil. This failure could produce sludge
in the crankcase. Perkins discourages the use of
aftermarket additives in finished oils.
• Glossary
To achieve the best performance from a Perkins
engine, conform to the following guidelines: • ISO International Standards Organization
• ASTM American Society for Testing and Materials
58 SEBU9070-03
Maintenance Section
Fuel Recommendations for the 1506A and 1506C Engines
• HFRR High Frequency Reciprocating Rig for

Lubricity testing of diesel fuels
• FAME Fatty Acid Methyl Esters

• CFR Co-ordinating Fuel Research
• LSD Low Sulfur Diesel
• ULSD Ultra Low Sulfur Diesel

• RME Rape Methyl Ester
• SME Soy Methyl Ester

• EPA Environmental Protection Agency of the
United States
General Information
NOTICE
Every attempt is made to provide accurate, up-to-
date information. By use of this document you agree
that Perkins Engines Company Limited is not respon-
sible for errors or omissions.
NOTICE
These recommendations are subject to change with-
out notice. Contact your local Perkins distributor for
the most up-to-date recommendations.
Diesel Fuel Requirements

Perkins is not in a position to evaluate continuously
and monitor all worldwide distillate diesel fuel
specifications that are published by governments and
technological societies.
Table 18 provides a known reliable baseline in order
to judge the expected performance of distillate diesel
fuels that are derived from conventional sources.
Satisfactory engine performance is dependent on the
use of a good quality fuel. The use of a good quality
fuel will give the following results: long engine life and
acceptable exhaust emissions levels. The fuel must
meet the minimum requirements that are stated in
table 18 .
NOTICE
The footnotes are a key part of the Perkins Specifica-
tion for Distillate Diesel Fuel Table. Read ALL of the
footnotes.
SEBU9070-03 59
Maintenance Section
Table 18
Perkins Specification for Distillate Diesel Fuel
Property UNITS Requirements “ASTM Test” “ISO Test”
Aromatics %Volume 35% maximum D1319 “ISO 3837”
Ash %Weight 0.01% maximum D482 “ISO 6245”
Carbon Residue on 10% %Weight 0.35% maximum D524 “ISO 4262”

Bottoms
Cetane Number (1) - 40 minimum D613 or D6890 “ISO 5165”
Cloud Point °C The cloud point must not ex- D2500 “ISO 3015”
ceed the lowest expected
ambient temperature.
Copper Strip Corrosion - No. 3 maximum D130 “ISO 2160”
Distillation °C 10% at 282 °C (539.6 °F) D86 “ISO 3405”

maximum
90% at 360 °C (680 °F)
maximum
Density at 15 °C (59 °F) Kg / M 3 800 minimum and 860 No equivalent test “ISO 3675 ” or “ISO 12185”
(2) maximum
Flash Point °C legal limit D93 “ISO 2719”
Thermal Stability - Minimum of 80% reflec- D6468 No equivalent test

tance after aging for 180 mi-
nutes at 150 °C (302 °F)
Pour Point °C 6 °C (10°F) D97 “ISO 3016”

Minimum below ambient
temperature
Sulfur %mass (3) D5453 or /D26222 “ISO 20846 ” or “ISO 20884”

(4) 2
Kinematic Viscosity “MM” “/S (cSt)” The viscosity of the fuel that D445 “ISO 3405”
is delivered to the fuel injec-
tion pump. “1.4 minimum
and /4.5 maximum”
Water and sediment % weight 0.05% maximum D1796 “ISO 3734”
Water % weight 0.05% maximum D1744 No equivalent test
Sediment % weight 0.05% maximum D473 “ISO 3735”
Gums and Resins (5) mg/100mL 10 mg per 100 mL D381 “ISO 6246”
maximum
Lubricity corrected wear mm 0.46 maximum D6079 “ISO 12156-1”
scar diameter at 60 °C
(140 °F). (6)
Fuel cleanliness (7) - “ISO”18/16/13 7619 “ISO 4406”

(1) In order to insure minimum cetane number of 40 a distillate diesel fuel should have minimum cetane index of 44 when ASTM D4737 test
method is used. A fuel with a higher cetane number is recommended in order to operate at a higher altitude or in cold weather.
(2) Density range allowed includes summer and winter diesel fuel grades. Fuel density varies depending on the sulfur level where high sulfur
fuels have higher densities. Some unblended alternative fuels have lower densities which are acceptable, if all the other properties meet this
specification.
(3) Regional regulations, national regulations, or international regulations can require a fuel with a specific sulfur limit. Consult all applicable reg-
ulations before selecting a fuel for a given engine application. Perkins fuel systems and engine components can operate on high sulphur
fuels where allowed by legislation. Fuel sulfur levels affect exhaust emissions. High sulfur fuels also increase the potential for corrosion of in-
ternal components. Fuel sulfur levels above 0.5% may significantly shorten the oil change interval. For additional information, refer to Gener-
al lubricant Information.
(continued)
60 SEBU9070-03
Maintenance Section
(Table 18, contd)

(4) The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscos-
ity requirement and the fuel should meet the maximum viscosity requirements at 40° C (104° F) of either the "ASTM D445" test method or
the "ISO 3104" test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain 1.4 cSt or greater viscosity at
the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to lower the viscosity to 4.5 cSt at the fuel injection
pump.
(5) Follow the test conditions and procedures for gasoline (motor).
(6) The lubricity of a fuel is a concern with low sulfur and ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1 or ASTM
D6079 High Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel
supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in
the fuel system.
(7) Recommended cleanliness level for fuel as dispensed into machine or engine fuel tank is "ISO 18/16/13 or cleaner as per ISO 4406. Refer to
the "Contamination Control Recommendations for Fuels" in this chapter.
NOTICE
Viscosity
Operating with fuels that do not meet the Perkins rec-
ommendations can cause the following effects: Start- Viscosity is the property of a liquid of offering
ing difficulty, poor combustion, deposits in the fuel resistance to shear or flow. Viscosity decreases with
injectors, reduced service life of the fuel system, de- increasing temperature. This decrease in viscosity
posits in the combustion chamber and reduced serv- follows a logarithmic relationship for normal fossil
ice life of the engine. fuel. The common reference is to kinematic viscosity.
Kinematic viscosity is the quotient of the dynamic
Engines that are manufactured by Perkins are certi- viscosity that is divided by the density. The
fied with the fuel that is prescribed by the United determination of kinematic viscosity is normally by
States Environmental Protection Agency. Engines readings from gravity flow viscometers at standard
that are manufactured by Perkins are certified with temperatures. Refer to “ISO 3104” for the test
the fuel that is prescribed by the European Certifica- method.
tion and other regulatory agencies. Perkins does not
The viscosity of the fuel is significant because fuel
certify diesel engines on any other fuel.
serves as a lubricant for the fuel system components.
Fuel must have sufficient viscosity in order to
Note: The owner and the operator of the engine has lubricate the fuel system in both cold temperatures
and hot temperatures. If the kinematic viscosity of the
the responsibility of using the fuel that is prescribed fuel is lower than 1.4 cSt at the fuel injection pump,
by the Environmental Protection Agency (EPA) and damage to the fuel injection pump can occur. This
other appropriate regulatory agencies. damage can be excessive scuffing and seizure. Low
viscosity may lead to difficult hot restarting, stalling,
Diesel Fuel Characteristics and loss of performance. High viscosity may result in
seizure of the pump.
Perkins Recommendations
Perkins recommends kinematic viscosities of 1.4 and
4.5 cSt that is delivered to the fuel injection pump. If a
Cetane Number fuel with a low viscosity is used, cooling of the fuel
Fuel that has a high cetane number will give a shorter may be required to maintain 1.4 cSt or greater
ignition delay. A high cetane number will produce a viscosity at the fuel injection pump. Fuels with a high
better ignition quality. Cetane numbers are derived viscosity might require fuel heaters in order to lower
for fuels against proportions of cetane and the viscosity to 4.5 cSt at the fuel injection pump.
heptamethylnonane in the standard CFR engine.
Refer to “ISO 5165” for the test method. Density
Cetane numbers in excess of 45 are normally Density is the mass of the fuel per unit volume at a
expected from current diesel fuel. However, a cetane specific temperature. This parameter has a direct
number of 40 may be experienced in some territories. influence on engine performance and a direct
The United States of America is one of the territories influence on emissions. This influence determines
that can have a low cetane value. A minimum cetane the heat output from a given injected volume of fuel.
value of 40 is required during average starting This parameter is quoted in the following kg/m3 at
conditions. A higher cetane value may be required for 15 °C (59 °F).
operations at high altitudes or in cold-weather
operations. Perkins recommends a value of density of 841 kg/m3
in order to obtain the correct power output. Lighter
Fuel with a low cetane number can be the root cause fuels are acceptable but these fuels will not produce
of problems during cold start. the rated power.
SEBU9070-03 61
Maintenance Section
Sulfur In case of the fuels which do not meet specified

lubricity requirement appropriate lubricity additive can
The level of sulfur is governed by emissions be used to enhance the lubricity of the fuel. UMK8276
legislations. Regional regulation, national Perkins Diesel Fuel Conditioner is the approved
regulations, or international regulations can require a additive refer to “Perkins Diesel Fuel Conditioner, and
fuel with a specific sulfur limit. The sulfur content of Perkins”.
the fuel and the fuel quality must comply with all
existing local regulations for emissions. Contact your fuel supplier for those circumstances
when fuel additives are required. Your fuel supplier
LSD fuel 0.05 percent (≤ 15 ppm (mg/kg)) sulfur is can make recommendations for additives to use and
strongly recommended for use in these engine for the proper level of treatment.
models.
Distillation
ULSD and sulphur fuel diesel fuels are acceptable to
use in all engine models. The lubricity of these fuels Distillation will give an indication of the mixture of
must not exceed wear scar diameter of 0.46 mm different hydrocarbons in the fuel. A high ratio of light
(0.01811 inch) as per “ISO 12156-1”. Refer to weight hydrocarbons can affect the characteristics of
“Lubricity” for more information. Fuels with sulphur combustion.
content higher than 0.05 percent (500 PPM) can be
used where allowed by legislation. Classification of the Fuels
In some parts of the world and for some applications,
Diesel engines have an ability to burn wide variety of
high sulfur fuels above 0.5% by mass might only be
fuels. Below is a list of typically encountered fuel
available. Fuel with a high sulfur content can cause
specifications that have been assessed as to their
engine wear. High sulfur fuel will have a negative
acceptability and are divided into following
impact on emissions of particulates. High sulfur fuel
categories:
can be used if the local emissions legislation will
allow the use. High sulfur fuel can be used in Group 1: Preferred Fuels
countries that do not regulate emissions.
The following fuel specifications are considered
When only high sulfur fuels are available, it will be acceptable.
necessary that high alkaline lubricating oil is used in
the engine or that the lubricating oil change interval is Fuels that meet the requirements that are listed in the
reduced. Refer to Operation and Maintenance table 18 .
Manual, “Fluid Recommendations (Lubricant
Information)” for information on sulfur in fuel. “EN590 - Grades A to F and class 0 to 4”
“ASTM D975 Grade No. 1-D and 2-D”
Lubricity
“JIS K2204 Grades 1, 2 & 3 & Special Grade 3”
Lubricity is the capability of the fuel to prevent pump acceptable provided lubricity ware scar diameter
wear. The lubricity of the fluid describes the ability of does not exceed of 0.46 mm (0.01811 inch) as per
the fluid to reduce the friction between surfaces that “ISO 12156-1” .
are under load. This ability reduces the damage that
is caused by friction. Fuel injection systems rely on “BS2869 - Class A2 Off Highway Gas Oil, Red
the lubricating properties of the fuel. Until fuel sulfur Diesel”
limits were mandated, the lubricity of the fuel was
believed to be a function of fuel viscosity. Note: The lubricity of these fuels must not exceed
wear scar diameter of 0.46 mm (0.01811 inch) as per
The lubricity has particular significance to the current “ISO 12156-1” . Refer to “Lubricity”.
low viscosity fuel, low sulfur fuel, and low aromatic
fossil fuel. These fuels are made in order to meet Group 2: Aviation Kerosene Fuels
stringent exhaust emissions.
Following kerosene and jet fuel specifications are
The lubricity of these fuels must not exceed wear acceptable alternative fuels, and may be used on a
scar diameter of 0.46 mm (0.01811 inch). The fuel contingency base for emergency or continuous use,
lubricity test must be performed on an HFRR, where standard diesel fuel is not available and where
operated at 60 °C (140 °F). Refer to “ISO 12156-1 ”. legislation allows their use:
NOTICE “MIL-DTL-83133 NATO F34 (JP-8)”

The fuels system has been qualified with fuel having
lubricity up to 0.46 mm (0.01811 inch) wear scar di- “MIL-DTL-83133 NATO F35”
ameter as tested by “ISO 12156-1 ”. Fuel with higher “MIL-DTL-5624 NATO F44 (JP-5)”
wear scar diameter than 0.46 mm (0.01811 inch) will
lead to reduced service life and premature failure of “MIL-DTL-38219 (USAF) (JP7)”
the fuel system.
“NATO XF63”
62 SEBU9070-03
Maintenance Section
“ASTM D1655 JET A” Biodiesel can be blended with distillate diesel fuel.
The blends can be used as fuel. The most commonly
“ASTM D1655 JET A1” available biodiesel blends are B5, which is 5 percent
biodiesel and 95 percent distillate diesel fuel. B20,
NOTICE which is 20 percent biodiesel and 80 percent distillate
These fuels are only acceptable when used with ap- diesel fuel.
propriate lubricity additive and must meet minimum
requirements that are listed in table 18 . The lubricity Note: The percentages given are volume-based. The
of these fuels must not exceed wear scar diameter of U.S. distillate diesel fuel specification “ASTM D975-
0.46 mm (0.01811 inch) as per “ISO 12156-1” . Refer 09a” includes up to B5 (5 percent) biodiesel.
to “Lubricity”.
European distillate diesel fuel specification
“EN590:2010” includes up B7 (7 percent) biodiesel.
Note: Minimum cetane number of 40 is
recommended otherwise cold starting problems or Note: Engines that are manufactured by Perkins are
light load misfire might occur. Since jet fuel certified by use of the prescribed Environmental
specifications do not mention cetane requirements, Protection Agency (EPA) and European Certification
Perkins recommends that a fuel sample is taken to fuels. Perkins does not certify engines on any other
determine the cetane number. fuel. The user of the engine has the responsibility of
using the correct fuel that is recommended by the
Note: Fuels must have minimum viscosity of 1.4 cSt manufacturer and allowed by the EPA and other
delivered to the fuel injection pump. Cooling of the appropriate regulatory agencies.
fuel may be required to maintain 1.4 cSt or greater
viscosity at the fuel injection pump. Perkins Specification Requirements
recommends that the actual viscosity of the fuel, be
measured in order to determine if a fuel cooler is The neat biodiesel must conform to “EN14214” or
needed. Refer to “Viscosity”. “ASTM D6751” (in the USA) and can only be blended
in mixture of up to 20 percent, by volume in
Note: Rated power loss of up to 10 percent is acceptable mineral diesel fuel meeting requirements
possible due to lower density and lower viscosity of that are listed in table 18 or the latest edition of
“EN590” and “ASTM D 975” commercial standards.
jet fuels compared to diesel fuels. This blend is commonly known as B20.
Biodiesel Fuel Biodiesel blends are denoted as “BXX” with “XX”
representing the content of neat biodiesel contained
Biodiesel is a fuel that can be defined as mono-alkyl in the blend with mineral diesel fuel (for example B5,
esters of fatty acids. Biodiesel is a fuel that can be B10, B20).
made from various feedstock. The most commonly
available biodiesel in Europe is Rape Methyl Ester In United States Biodiesel blends of B6 to B20 must
(REM). This biodiesel is derived from rapeseed oil. meet the requirements listed in the latest edition of
Soy Methyl Ester (SME) is the most common “ASTM D7467” (B6 to B20) and must be of an API
biodiesel in the United States. This biodiesel is gravity of 30-45.
derived from soybean oil. Soybean oil or rapeseed oil
are the primary feedstocks. These fuels are together In North America biodiesel and biodiesel blends must
known as Fatty Acid Methyl Esters (FAME). be purchased from the BQ-9000 accredited
producers and BQ-9000 certified distributors.
Raw pressed vegetable oils are NOT acceptable for
In other areas of the world, the use of biodiesel that is
use as a fuel in any concentration in compression BQ-9000 accredited and certified, or that is
engines. Without esterification, these oils may gel in accredited and certified by a comparable biodiesel
the crankcase and the fuel tank. These fuels may not quality body to meet similar biodiesel quality
be compatible with many of the elastomers that are standards is required.
used in engines that are manufactured today. In
original forms, these oils are not suitable for use as a Engine Service Requirements with B20
fuel in compression engines. Alternate base stocks
for biodiesel may include animal tallow, waste Aggressive properties of biodiesel fuel may cause
cooking oils, or various other feedstocks. In order to debris in the fuel tank and fuel lines. The aggressive
use any of the products that are listed as fuel, the oil properties of biodiesel will clean the fuel tank and fuel
must be esterified. lines. This cleaning of the fuel system can
prematurely block of the fuel filters. Perkins
Fuel made of 100 percent FAME is generally referred recommends that after the initial usage of B20
to as B100 biodiesel or neat biodiesel. biodiesel blended fuel the fuel filters must be
replaced at 50 hours.
SEBU9070-03 63
Maintenance Section
Glycerides present in biodiesel fuel will also cause General Requirements

fuel filters to become blocked more quickly. Therefore
the regular service interval should be reduced to 250 Biodiesel has poor oxidation stability, which can
hours. result in long-term problems in the storage of
biodiesel. Biodiesel fuel should be used within 6
When biodiesel fuel is used, crank case oil and months of manufacture. Equipment should not be
aftertreatment systems may be influenced. This stored with the B20 biodiesel blends in the fuel
influence is due to the chemical composition and system for longer than 3 months.
characteristics of biodiesel fuel, such as density and
volatility, and to chemical contaminants that can be Due to poor oxidation stability and other potential
present in this fuel, such as alkali and alkaline metals issues, Perkins strongly recommends that engines
(sodium, potassium, calcium, and magnesium). with limited operational time either not use B20
biodiesel blends or, while accepting some risk, limit
• Crankcase oil fuel dilution can be higher when biodiesel blend to a maximum of B5. Examples of
biodiesel or biodiesel blends are used. This applications that should limit the use of biodiesel are
increased level of fuel dilution when using the following: Standby generator sets and certain
biodiesel or biodiesel blends is related to the emergency vehicles.
typically lower volatility of biodiesel. In cylinder
emissions control strategies utilized in many of the Perkins strongly recommends that seasonally
industrial latest engine designs may lead to a operated engines have the fuel systems, including
fuel tanks, flashed with conventional diesel fuel
higher level of biodiesel concentration in the before prolonged shutdown periods. An example of
engine oil pan. The long-term effect of biodiesel an application that should seasonally flush the fuel
concentration in crankcase oil is currently system is a combine harvester.
unknown.
Microbial contamination and growth can cause
• Perkins recommends the use of oil analysis in corrosion in the fuel system and premature plugging
order to check the quality of the engine oil if of the fuel filter. Consult your supplier of fuel for
biodiesel fuel is used. Ensure that the level of assistance in selecting appropriate antimicrobial
biodiesel in the fuel is noted when the oil sample is additive.
taken.
Water accelerates microbial contamination and
Performance Related Issues with B20 growth. When biodiesel is compared to distillate
fuels, water is naturally more likely to exist in the
Due to the lower energy content than the standard biodiesel. It is therefore essential to check frequently
distillate fuel B20 will cause a power loss in order of 2 and if necessary, drain the water separator.
to 4 percent. In addition, over time the power may Materials such as brass, bronze, copper, led, tin, and
deteriorate further due to deposits in the fuel zinc accelerate the oxidation process of the biodiesel
injectors. fuel. The oxidation process can cause deposits
Biodiesel and biodiesel blends are known to cause formation therefore these materials must not be used
an increase in fuel system deposits, most significant for fuel tanks and fuel lines.
of which are deposits within the fuel injector. These
deposits can cause a loss in power due to restricted Fuel for Cold Weather Operation
or modified fuel injection or cause other functional
issues associated with these deposits. The European standard “EN590” contains climate
dependant requirements and a range of options. The
Perkins T400012 Fuel Cleaner is most effective in options can be applied differently in each country.
cleaning and preventing the formation of deposits. There are five classes that are given to arctic
Refer to “Perkins Diesel Fuel System Cleaner, and climates and severe winter climates. 0, 1, 2, 3 and 4.
Perkins” for more information. Perkins UMK8276
Perkins Diesel Fuel Conditioner helps to limit deposit Fuel that complies with “EN590” CLASS 4 can be
issues by improving the stability of biodiesel while used at temperatures as low as −44 °C (−47.2 °F).
also hindering the production of new deposits. For Refer to “EN590” for a detailed discretion of the
more information refer to “Perkins Diesel Fuel physical properties of the fuel.
Conditioner, and Perkins”. Therefore the use of
Diesel Fuel Cleaner and or Diesel Fuel Conditioner is The diesel fuel “ASTM D975 1-D” that is used in the
strongly recommended when running biodiesel United States of America may be used in cold
blends, especially B20. temperatures that are below −18 °C (−0.4 °F).
In extreme cold ambient conditions, you may use the
aviation kerosene fuels that are specified in
“Classification of the Fuels”. These fuels are intended
to be used in temperatures that can be as low as
−54 °C (−65.2 °F). Refer to “Classification of the
Fuels” for detail and conditions of use of the aviation
kerosene fuels.
64 SEBU9070-03
Maintenance Section
Perkins fuel cleaner will remove deposits that can

form in the fuel system with the use of biodiesel and
Mixing alcohol or gasoline with diesel fuel can biodiesel blends. These deposits can create a loss of
produce an explosive mixture in the engine power and engine performance.
crankcase or the fuel tank. Alcohol or gasoline Once the fuel cleaner has been added to the fuel, the
must not be used in order to dilute diesel fuel. deposits within the fuel system are removed after 30
Failure to follow this instruction may result in hours of engine operation. For maximum results,
death or personal injury. continue to use the fuel cleaner for up to 80 hours.
Perkins fuel cleaner can be used on an on-going
There are many other diesel fuel specifications that basis with no adverse impact on engine or fuel
are published by governments and by technological system durability.
societies. Usually, those specifications do not review
Detailed instructions on the rate of which the fuel
all the requirements that are addressed in table 18 . cleaner must be use are on the container.
To ensure optimum engine performance, a complete
fuel analysis should be obtained before engine
operation. The fuel analysis should include all of the Perkins Diesel Fuel Conditioner
properties that are stated in the table 18 .
The Perkins Diesel Fuel Conditioner part number
21820275/(U5MK8276) is the only fuel conditioner
Aftermarket Fuel Additives recommended by Perkins. The diesel fuel conditioner
is a proprietary metal and ash free formulation that
NOTICE has been extensively tested for use with distillate
Perkins does not warrant the quality or performance diesel fuels for use in Perkins diesel engines. The
of non-Perkins fluids and filters. diesel fuel conditioner helps address many of the
challenges that various fuels worldwide present in
When auxiliary devices, accessories, or consum- regards to fuel life/stability, engine startability, injector
ables (filters, additives) which are made by other deposits, fuel system life, and long-term engine
manufacturers are used on Perkins products, the performance.
Perkins warranty is not affected simply because of
such use. Note: Diesel fuel additives/conditioners may not
improve markedly poor diesel fuel properties enough
However, failures that result from the installation to make poor diesel acceptable for use.
or use of other manufacturers devices, accesso-
ries, or consumables are NOT Perkins defects. Diesel fuel conditioner is a proven high performance,
Therefore, the defects are NOT covered under the
Perkins warranty. multipurpose diesel fuel conditioner that is designed
to improve:
Supplemental diesel fuel additives are not
recommended and is due to potential damage to the • Fuel economy (through fuel system clean-up)
fuel system or the engine. Your fuel supplier or the
fuel manufacturer will add the appropriate • Lubricity
supplemental diesel fuel additives.
• Oxidation stability
Perkins recognizes the fact that additives may be
required in some special circumstances. Fuel • Detergency/dispersancy
additives need to be used with caution. Contact your
fuel supplier for those circumstances when fuel • Moisture dispersancy
additives are required. Your fuel supplier can
recommend the appropriate fuel additive and the • Corrosion protection
correct level of treatment.
• Cetane (typically 2-3 cetane numbers)
Note: For the best results, your fuel supplier should The diesel fuel conditioner also reduces the
treat the fuel when additives are required. The formation of gums, resins, and sludge, and disperses
treated fuel must meet the requirements that are insoluble gums.
stated in table 18 .
Perkins Diesel Fuel System Cleaner

Perkins T400012 Fuel Cleaner is the only fuel
cleaner that is recommended by Perkins.
If biodiesel or biodiesel blends of fuel are to be used,
Perkins require the use of Perkins fuel cleaner. For
more information on the use of biodiesel and
biodiesel blends refer to “Biodiesel Fuel”.
SEBU9070-03 65
Maintenance Section
For maximum overall benefits, ask your fuel supplier • Ensure that you use Perkins Advanced Efficiency
to add the fuel conditioner at the recommended treat Fuel Filters. Change your fuel filters per
rate before fuel delivery. Or you may add the fuel recommended service requirements or as needed.
conditioner at the recommended treat rate during the
early weeks of fuel storage. • Drain your water separators daily .
Contamination Control • Drain your fuel tanks of sediment and water per
the Operation and Maintenance Manual
Recommendations for Fuels instructions.
Fuels of “ISO 18/16/13” cleanliness level or cleaner • Install and maintain a properly designed bulk filter
as dispensed into the engine or application fuel tank / coalescer filtration system. Continuous bulk
should be used. Reduce power loss, failures, and
related down time of engines will result. This filtration systems may be required to ensure that
cleanliness level is important for new fuel system dispensed fuel meets the cleanliness target.
designs such as common rail injection systems and Consult your Perkins distributor for availability of
unit injection systems. Injection system designs bulk filtration products.
utilize higher fuel pressures and tight clearances
between moving parts in order to meet required • Centrifugal filters may need to be used as a pre-
stringent emissions regulations. Peak injection filter with fuel that is severely contaminated with
pressures in current fuel injection systems may gross amounts of water and/or large particulate
exceed 30,000 psi. Clearances in these systems are contaminants. Centrifugal filters can effectively
less than 5 µm. As a result, particle contaminants as remove large contaminants, but may not be able
small as 4 µm can cause scoring and scratching of to remove the small abrasive particles required to
internal pump and injector surfaces and of injector achieve the recommended “ISO” cleanliness level.
nozzles. Bulk filter / coalescers are necessary as a final
filter in order to achieve the recommended
Water in the fuel causes cavitation, corrosion of fuel
system parts, and provides an environment where cleanliness level.
microbial growth in the fuel can flourish. Other
sources of fuel contamination are soaps, gels, or • Install desiccant type breathers of 4 µm or less
other compounds that may result from undesirable absolute efficiency with the ability to remove water
chemical interactions in the fuels, particularly in on bulk storage tanks.
ULSD. Gels and other compounds can also form in
biodiesel fuel at low temperatures or if biodiesel is • Follow proper practices of fuel transportation.
stored for extended periods. The best indication of Filtration from the storage tank to the application
microbial contamination, fuel additives, or cold promotes the delivery of clean fuel. Fuel filtration
temperature gel is rapid filter plugging of bulk fuel can be installed at each transport stage in order to
filters or application fuel filters. keep the fuel clean.
In order to reduce downtime due to contamination, • Cover, protect, and ensure cleanliness of all
follow these fuel maintenance guidelines. connection hoses, fittings, and dispensing
nozzles.
• Use high-quality fuels per recommended and
required specifications Consult your local Perkins distributor for additional
information on Perkins designed and produced
• Fill fuel tanks with fuels of “ISO 18/16/13” filtration products.
cleanliness level or cleaner, in particular for
engines with common rail and unit injection i06231828
systems. When you refuel the tank, filter the fuel
through a 4 µm absolute filter (Beta 4 = 75 up to
200) in order to reach the recommended
cleanliness level. This filtration should be located (Fuel Recommendations for the
at the device that dispenses the fuel to the fuel
tank. In addition, filtration at the dispensing point 1506D Engine)
should remove water to ensure that fuel is
dispensed at 500 ppm water or less.
S/N: PK9
• Perkins recommends the use of bulk fuel filter /
coalescer units which clean the fuel of both • Glossary
particulate contamination and water in a single
pass. • ISO International Standards Organization
• ASTM American Society for Testing and Materials
66 SEBU9070-03
Maintenance Section
Fuel Recommendations for the 1506D Engine
• HFRR High Frequency Reciprocating Rig for

Lubricity testing of diesel fuels
• FAME Fatty Acid Methyl Esters

• CFR Co-ordinating Fuel Research
• LSD Low Sulfur Diesel
• ULSD Ultra Low Sulfur Diesel

• RME Rape Methyl Ester
• SME Soy Methyl Ester

• EPA Environmental Protection Agency of the
United States
General Information
NOTICE
Every attempt is made to provide accurate, up-to-
date information. By use of this document you agree
that Perkins Engines Company Limited is not respon-
sible for errors or omissions.
NOTICE
These recommendations are subject to change with-
out notice. Contact your local Perkins distributor for
the most up-to-date recommendations.
Diesel Fuel Requirements

Perkins is not in a position to evaluate continuously
and monitor all worldwide distillate diesel fuel
specifications that are published by governments and
technological societies.
Table 19 provides a known reliable baseline in order
to judge the expected performance of distillate diesel
fuels that are derived from conventional sources.
Satisfactory engine performance is dependent on the
use of a good quality fuel. The use of a good quality
fuel will give the following results: long engine life and
acceptable exhaust emissions levels. The fuel must
meet the minimum requirements that are stated in
table 19 .
NOTICE
The footnotes are a key part of the Perkins Specifica-
tion for Distillate Diesel Fuel Table. Read ALL of the
footnotes.
Table 19
Perkins Specification for Distillate Diesel Fuel
Property UNITS Requirements “ASTM Test” “ISO Test”
(continued)
SEBU9070-03 67
Maintenance Section
(Table 19, contd)

Aromatics %Volume 35% maximum “D1319” “ISO 3837”
Ash %Weight 0.01% maximum “D482” “ISO 6245”
Carbon Residue on 10% %Weight 0.35% maximum “D524” “ISO 4262”

Bottoms
Cetane Number (1) - 40 minimum “D613 or D6890” “ISO 5165”
Cloud Point °C The cloud point must not ex- “D2500” “ISO 3015”
ceed the lowest expected
ambient temperature.
Copper Strip Corrosion - No. 3 maximum “D130” “ISO 2160”
Distillation °C 10% at 282 °C (539.6 °F) “D86” “ISO 3405”

maximum
90% at 360 °C (680 °F)
maximum
Density at 15 °C (59 °F) Kg / M 3 800 minimum and 860 No equivalent test “ISO 3675 ” or “ISO 12185”
(2) maximum
Flash Point °C legal limit “D93” “ISO 2719”
Thermal Stability - Minimum of 80% reflec- “D6468” No equivalent test

tance after aging for 180 mi-
nutes at 150 °C (302 °F)
Pour Point °C 6 °C (10°F) “D97” “ISO 3016”

Minimum below ambient
temperature
Sulfur %mass (3) “D5453 or /D26222” “ISO 20846 ” or “ISO 20884”

2
Kinematic Viscosity (4) “MM /S (cSt)” The viscosity of the fuel that “D445” “ISO 3405”
is delivered to the fuel injec-
tion pump. “1.4 minimum
and /4.5 maximum”
Water and sediment % weight 0.05% maximum “D1796” “ISO 3734”
Water % weight 0.05% maximum “D1744” No equivalent test
Sediment % weight 0.05% maximum “D473” “ISO 3735”
Gums and Resins (5) mg/100mL 10 mg per 100 mL “D381” “ISO 6246”
maximum
Lubricity corrected wear mm 0.46 maximum “D6079” “ISO 12156-1”
scar diameter at 60 °C
(140 °F). (6)
Fuel cleanliness (7) - “ISO”18/16/13 “7619” “ISO 4406”

(1) In order to insure minimum cetane number of 40 a distillate diesel fuel should have minimum cetane index of 44 when ASTM D4737 test
method is used. A fuel with a higher cetane number is recommended in order to operate at a higher altitude or in cold weather.
(2) Density range allowed includes summer and winter diesel fuel grades. Fuel density varies depending on the sulfur level where high sulfur
fuels have higher densities. Some unblended alternative fuels have lower densities which are acceptable, if all the other properties meet this
specification.
(3) Regional regulations, national regulations, or international regulations can require a fuel with a specific sulfur limit. Consult all applicable reg-
ulations before selecting a fuel for a given engine application. LSD fuel with less than 0.05 percent (≤ 500 ppm (mg/kg)) sulfur is strongly rec-
ommended for use in these engine models. Diesel fuel with more than 0.05 percent (≥ 500 ppm (mg/kg)) sulphur can be used only where
allowed by legislation. Fuel sulfur levels affect exhaust emissions. High sulfur fuels also increase the potential for corrosion of internal compo-
nents. Fuel sulfur levels above 0.05% may significantly shorten the oil change interval. For additional information, refer to General lubricant
Information.
(continued)
68 SEBU9070-03
Maintenance Section
(Table 19, contd)

(4) The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscos-
ity requirement and the fuel should meet the maximum viscosity requirements at 40° C (104° F) of either the "ASTM D445" test method or
the "ISO 3104" test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain 1.4 cSt or greater viscosity at
the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to lower the viscosity to 4.5 cSt at the fuel injection
pump.
(5) Follow the test conditions and procedures for gasoline (motor).
(6) The lubricity of a fuel is a concern with low sulfur and ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1 or ASTM
D6079 High Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel
supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in
the fuel system.
(7) Recommended cleanliness level for fuel as dispensed into machine or engine fuel tank is "ISO 18/16/13 or cleaner as per ISO 4406. Refer to
the "Contamination Control Recommendations for Fuels" in this chapter.
NOTICE
Viscosity
Operating with fuels that do not meet the Perkins rec-
ommendations can cause the following effects: Start- Viscosity is the property of a liquid of offering
ing difficulty, poor combustion, deposits in the fuel resistance to shear or flow. Viscosity decreases with
injectors, reduced service life of the fuel system, de- increasing temperature. This decrease in viscosity
posits in the combustion chamber and reduced serv- follows a logarithmic relationship for normal fossil
ice life of the engine. fuel. The common reference is to kinematic viscosity.
Kinematic viscosity is the quotient of the dynamic
Engines that are manufactured by Perkins are certi- viscosity that is divided by the density. The
fied with the fuel that is prescribed by the United determination of kinematic viscosity is normally by
States Environmental Protection Agency. Engines readings from gravity flow viscometers at standard
that are manufactured by Perkins are certified with temperatures. Refer to “ISO 3104” for the test
the fuel that is prescribed by the European Certifica- method.
tion and other regulatory agencies. Perkins does not
The viscosity of the fuel is significant because fuel
certify diesel engines on any other fuel.
serves as a lubricant for the fuel system components.
Fuel must have sufficient viscosity in order to
Note: The owner and the operator of the engine has lubricate the fuel system in both cold temperatures
and hot temperatures. If the kinematic viscosity of the
the responsibility of using the fuel that is prescribed fuel is lower than 1.4 cSt at the fuel injection pump,
by the Environmental Protection Agency (EPA) and damage to the fuel injection pump can occur. This
other appropriate regulatory agencies. damage can be excessive scuffing and seizure. Low
viscosity may lead to difficult hot restarting, stalling,
Diesel Fuel Characteristics and loss of performance. High viscosity may result in
seizure of the pump.
Perkins Recommendations
Perkins recommends kinematic viscosities of 1.4 and
4.5 cSt that is delivered to the fuel injection pump. If a
Cetane Number fuel with a low viscosity is used, cooling of the fuel
Fuel that has a high cetane number will give a shorter may be required to maintain 1.4 cSt or greater
ignition delay. A high cetane number will produce a viscosity at the fuel injection pump. Fuels with a high
better ignition quality. Cetane numbers are derived viscosity might require fuel heaters in order to lower
for fuels against proportions of cetane and the viscosity to 4.5 cSt at the fuel injection pump.
heptamethylnonane in the standard CFR engine.
Refer to “ISO 5165” for the test method. Density
Cetane numbers in excess of 45 are normally Density is the mass of the fuel per unit volume at a
expected from current diesel fuel. However, a cetane specific temperature. This parameter has a direct
number of 40 may be experienced in some territories. influence on engine performance and a direct
The United States of America is one of the territories influence on emissions. This influence determines
that can have a low cetane value. A minimum cetane the heat output from a given injected volume of fuel.
value of 40 is required during average starting This parameter is quoted in the following kg/m3 at
conditions. A higher cetane value may be required for 15 °C (59 °F).
operations at high altitudes or in cold-weather
operations. Perkins recommends a value of density of 841 kg/m3
in order to obtain the correct power output. Lighter
Fuel with a low cetane number can be the root cause fuels are acceptable but these fuels will not produce
of problems during cold start. the rated power.
SEBU9070-03 69
Maintenance Section
Sulfur In case of the fuels which do not meet specified

lubricity requirement appropriate lubricity additive can
The level of sulfur is governed by emissions be used to enhance the lubricity of the fuel.
legislations. Regional regulation, national 21820275 Perkins Diesel Fuel Conditioner is the
regulations, or international regulations can require a approved additive refer to “Perkins Diesel Fuel
fuel with a specific sulfur limit. The sulfur content of Conditioner, and Perkins”.
the fuel and the fuel quality must comply with all
existing local regulations for emissions. Contact your fuel supplier for those circumstances
when fuel additives are required. Your fuel supplier
LSD fuel with less than 0.05 percent (≤ 500 ppm (mg/ can make recommendations for additives to use and
kg)) sulfur is strongly recommended for use in these for the proper level of treatment.
engine models.
Distillation
ULSD less than 0.0015% (≤15 PPM (mg/Kg)) sulphur
is acceptable to use in these engine models. The Distillation will give an indication of the mixture of
lubricity of these fuels must not exceed wear scar different hydrocarbons in the fuel. A high ratio of light
diameter of 0.46 mm (0.01811 inch) as per “ISO weight hydrocarbons can affect the characteristics of
12156-1”. Refer to “Lubricity” for more information. combustion.
Fuels with sulphur content higher than 0.05 percent Classification of the Fuels
(500 PPM) can be used where allowed by legislation.
Diesel engines have an ability to burn wide variety of
Fuel with a high sulfur content can cause engine fuels. Below is a list of typically encountered fuel
wear. High sulfur fuel will have a negative impact on specifications that have been assessed as to their
emissions of particulates. High sulfur fuel can be acceptability and are divided into following
used if the local emissions legislation will allow the categories:
use. High sulfur fuel can be used in countries that do
not regulate emissions.
Group 1: Preferred Fuels
When only high sulfur fuels are available, it will be
necessary that high alkaline lubricating oil is used in The following fuel specifications are considered
the engine or that the lubricating oil change interval is acceptable.
reduced. Refer to Operation and Maintenance
Manual, “Fluid Recommendations (Lubricant • Fuels that meet the requirements that are listed in
Information)” for information on sulfur in fuel. the table 19 .
• “EN590 - Grades A to F and class 0 to 4”
Lubricity
• “ASTM D975 Grade No. 1-D and 2-D”
Lubricity is the capability of the fuel to prevent pump
wear. The lubricity of the fluid describes the ability of • “JIS K2204 Grades 1, 2 & 3 & Special Grade 3”
the fluid to reduce the friction between surfaces that acceptable provided lubricity ware scar diameter
are under load. This ability reduces the damage that
does not exceed of 0.46 mm (0.01811 inch) as
is caused by friction. Fuel injection systems rely on
the lubricating properties of the fuel. Until fuel sulfur per “ISO 12156-1” .
limits were mandated, the lubricity of the fuel was
• “BS2869 - Class A2 Off Highway Gas Oil, Red
believed to be a function of fuel viscosity.
Diesel”
The lubricity has particular significance to the current
low viscosity fuel, low sulfur fuel, and low aromatic Note: The lubricity of these fuels must not exceed
fossil fuel. These fuels are made in order to meet wear scar diameter of 0.46 mm (0.01811 inch) as per
stringent exhaust emissions. “ISO 12156-1” . Refer to “Lubricity”.
The lubricity of these fuels must not exceed wear Group 2: Aviation Kerosene Fuels
scar diameter of 0.46 mm (0.01811 inch). The fuel
lubricity test must be performed on an HFRR, Following kerosene and jet fuel specifications are
operated at 60 °C (140 °F). Refer to “ISO 12156-1 ”. acceptable alternative fuels, and may be used on a
contingency base for emergency or continuous use,
NOTICE where standard diesel fuel is not available and where
The fuels system has been qualified with fuel having legislation allows their use:
lubricity up to 0.46 mm (0.01811 inch) wear scar di-
ameter as tested by “ISO 12156-1 ”. Fuel with higher • “MIL-DTL-83133 NATO F34 (JP-8)”
wear scar diameter than 0.46 mm (0.01811 inch) will
lead to reduced service life and premature failure of • “MIL-DTL-83133 NATO F35”
the fuel system.
• “MIL-DTL-5624 NATO F44 (JP-5)”
70 SEBU9070-03
Maintenance Section
• “MIL-DTL-38219 (USAF) (JP7)” Biodiesel can be blended with distillate diesel fuel.
The blends can be used as fuel. The most commonly
• “NATO XF63” available biodiesel blends are B5, which is 5 percent
biodiesel and 95 percent distillate diesel fuel. B20,
• “ASTM D1655 JET A” which is 20 percent biodiesel and 80 percent distillate
diesel fuel.
• “ASTM D1655 JET A1”
Note: The percentages given are volume-based. The
U.S. distillate diesel fuel specification “ASTM D975-
NOTICE
These fuels are only acceptable when used with ap- 09a” includes up to B5 (5 percent) biodiesel.
propriate lubricity additive and must meet minimum
requirements that are listed in table 19 . The lubricity European distillate diesel fuel specification
of these fuels must not exceed wear scar diameter of “EN590:2010” includes up B7 (7 percent) biodiesel.
0.46 mm (0.01811 inch) as per “ISO 12156-1” . Refer
to “Lubricity” and Perkins Diesel Fuel Conditioner. Note: Engines that are manufactured by Perkins are
certified by use of the prescribed Environmental
Protection Agency (EPA) and European Certification
Note: Minimum cetane number of 40 is fuels. Perkins does not certify engines on any other
recommended otherwise cold starting problems or fuel. The user of the engine has the responsibility of
light load misfire might occur. Since jet fuel using the correct fuel that is recommended by the
specifications do not mention cetane requirements, manufacturer and allowed by the EPA and other
Perkins recommends that a fuel sample is taken to appropriate regulatory agencies.
determine the cetane number.
Specification Requirements
Note: Fuels must have minimum viscosity of 1.4 cSt
delivered to the fuel injection pump. Cooling of the The neat biodiesel must conform to “EN14214” or
fuel may be required to maintain 1.4 cSt or greater “ASTM D6751” (in the USA) and can only be blended
in mixture of up to 20 percent, by volume in
viscosity at the fuel injection pump. Perkins
acceptable mineral diesel fuel meeting requirements
recommends that the actual viscosity of the fuel, be that are listed in table 19 or the latest edition of
measured in order to determine if a fuel cooler is “EN590” and “ASTM D 975” commercial standards.
needed. Refer to “Viscosity”. This blend is commonly known as B20.
Note: Rated power loss of up to 10 percent is Biodiesel blends are denoted as “BXX” with “XX”
possible due to lower density and lower viscosity of representing the content of neat biodiesel contained
jet fuels compared to diesel fuels. in the blend with mineral diesel fuel (for example B5,
B10, B20).
Biodiesel Fuel In United States Biodiesel blends of B6 to B20 must
meet the requirements listed in the latest edition of
Biodiesel is a fuel that can be defined as mono-alkyl “ASTM D7467” (B6 to B20) and must be of an API
esters of fatty acids. Biodiesel is a fuel that can be gravity of 30-45.
made from various feedstock. The most commonly
available biodiesel in Europe is Rape Methyl Ester In North America biodiesel and biodiesel blends must
(REM). This biodiesel is derived from rapeseed oil. be purchased from the BQ-9000 accredited
Soy Methyl Ester (SME) is the most common producers and BQ-9000 certified distributors.
biodiesel in the United States. This biodiesel is
derived from soybean oil. Soybean oil or rapeseed oil In other areas of the world, the use of biodiesel that is
are the primary feedstocks. These fuels are together BQ-9000 accredited and certified, or that is
known as Fatty Acid Methyl Esters (FAME). accredited and certified by a comparable biodiesel
quality body to meet similar biodiesel quality
Raw pressed vegetable oils are NOT acceptable for standards is required.
use as a fuel in any concentration in compression
engines. Without esterification, these oils may gel in Engine Service Requirements with B20
the crankcase and the fuel tank. These fuels may not
be compatible with many of the elastomers that are Aggressive properties of biodiesel fuel may cause
used in engines that are manufactured today. In debris in the fuel tank and fuel lines. The aggressive
original forms, these oils are not suitable for use as a properties of biodiesel will clean the fuel tank and fuel
fuel in compression engines. Alternate base stocks lines. This cleaning of the fuel system can
for biodiesel may include animal tallow, waste prematurely block of the fuel filters. Perkins
cooking oils, or various other feedstocks. In order to recommends that after the initial usage of B20
use any of the products that are listed as fuel, the oil biodiesel blended fuel the fuel filters must be
must be esterified. replaced at 50 hours.
Fuel made of 100 percent FAME is generally referred

to as B100 biodiesel or neat biodiesel.
SEBU9070-03 71
Maintenance Section
Glycerides present in biodiesel fuel will also cause General Requirements

fuel filters to become blocked more quickly. Therefore
the regular service interval should be reduced to 250 Biodiesel has poor oxidation stability, which can
hours. result in long-term problems in the storage of
biodiesel. Biodiesel fuel should be used within 6
When biodiesel fuel is used, crank case oil and months of manufacture. Equipment should not be
aftertreatment systems (if installed) may be stored with the B20 biodiesel blends in the fuel
influenced. This influence is due to the chemical system for longer than 3 months.
composition and characteristics of biodiesel fuel,
such as density and volatility, and to chemical Due to poor oxidation stability and other potential
contaminants that can be present in this fuel, such as issues, Perkins strongly recommends that engines
alkali and alkaline metals (sodium, potassium, with limited operational time either do not use
calcium, and magnesium). biodiesel blends or, while accepting some risk, limit
biodiesel blend to a maximum of B5. Examples of
• Crankcase oil fuel dilution can be higher when applications that should limit the use of biodiesel are
biodiesel or biodiesel blends are used. This the following: Standby generator sets and certain
increased level of fuel dilution when using emergency vehicles.
biodiesel or biodiesel blends is related to the
typically lower volatility of biodiesel. In cylinder If biodiesel must be used, then the quality of the fuel
emissions control strategies utilized in many of the needs to be periodically tested. The test must comply
industrial latest engine designs may lead to a with “EN15751”, commonly known as the Rancimat
higher level of biodiesel concentration in the Test.
engine oil pan. The long-term effect of biodiesel Perkins strongly recommends that seasonally
concentration in crankcase oil is currently operated engines have the fuel systems, including
unknown. fuel tanks, flashed with conventional diesel fuel
before prolonged shutdown periods. An example of
• Perkins recommends the use of oil analysis in an application that should seasonally flush the fuel
order to check the quality of the engine oil if system is a combine harvester.
biodiesel fuel is used. Ensure that the level of
biodiesel in the fuel is noted when the oil sample is Microbial contamination and growth can cause
taken. corrosion in the fuel system and premature plugging
of the fuel filter. Consult your supplier of fuel for
Performance Related Issues with B20 assistance in selecting appropriate antimicrobial
additive.
Due to the lower energy content than the standard
distillate fuel B20 will cause a power loss in order of 2 Water accelerates microbial contamination and
growth. When biodiesel is compared to distillate
to 4 percent. In addition, over time the power may fuels, water is naturally more likely to exist in the
deteriorate further due to deposits in the fuel biodiesel. It is therefore essential to check frequently
injectors.
and if necessary, drain the water separator.
Biodiesel and biodiesel blends are known to cause
an increase in fuel system deposits, most significant Materials such as brass, bronze, copper, led, tin, and
of which are deposits within the fuel injector. These zinc accelerate the oxidation process of the biodiesel
deposits can cause a loss in power due to restricted fuel. The oxidation process can cause deposits
or modified fuel injection or cause other functional formation therefore these materials must not be used
for fuel tanks and fuel lines.
issues associated with these deposits.
Perkins T400012 Fuel Cleaner is most effective in Fuel for Cold Weather Operation
cleaning and preventing the formation of deposits.
Refer to “Perkins Diesel Fuel System Cleaner, and The European standard “EN590” contains climate
Perkins” for more information. Perkins UMK8276 dependant requirements and a range of options. The
Diesel Fuel Conditioner helps to limit deposit issues options can be applied differently in each country.
by improving the stability of biodiesel while also There are five classes that are given to arctic
hindering the production of new deposits. For more climates and severe winter climates. 0, 1, 2, 3 and 4.
information refer to “Perkins Diesel Fuel Conditioner,
and Perkins”. Therefore the use of Diesel Fuel Fuel that complies with “EN590” CLASS 4 can be
Cleaner and or Diesel Fuel Conditioner is strongly used at temperatures as low as −44 °C (−47.2 °F).
recommended when running biodiesel blends, Refer to “EN590” for a detailed discretion of the
especially B20. physical properties of the fuel.
The diesel fuel “ASTM D975 1-D” that is used in the
United States of America may be used in cold
temperatures that are below −18 °C (−0.4 °F).
72 SEBU9070-03
Maintenance Section
In extreme cold ambient conditions, you may use the Perkins Diesel Fuel System Cleaner
aviation kerosene fuels that are specified in “Group 1:
Preferred Fuels”. These fuels are intended to be Perkins T400012 Fuel Cleaner is the only fuel
used in temperatures that can be as low as −54 °C cleaner that is recommended by Perkins.
(−65.2 °F). Refer to “Group 1: Preferred Fuels” for
detail and conditions of use of the aviation kerosene If biodiesel or biodiesel blends of fuel are to be used,
fuels. Perkins require the use of Perkins fuel cleaner. For
more information on the use of biodiesel and
biodiesel blends refer to “Biodiesel Fuel”.
Perkins fuel cleaner will remove deposits that can
Mixing alcohol or gasoline with diesel fuel can form in the fuel system with the use of biodiesel and
produce an explosive mixture in the engine biodiesel blends. These deposits can create a loss of
crankcase or the fuel tank. Alcohol or gasoline power and engine performance.
must not be used in order to dilute diesel fuel.
Failure to follow this instruction may result in Once the fuel cleaner has been added to the fuel, the
death or personal injury. deposits within the fuel system are removed after 30
hours of engine operation. For maximum results,
continue to use the fuel cleaner for up to 80 hours.
There are many other diesel fuel specifications that Perkins fuel cleaner can be used on an on-going
are published by governments and by technological basis with no adverse impact on engine or fuel
societies. Usually, those specifications do not review system durability.
all the requirements that are addressed in table 19 .
To ensure optimum engine performance, a complete Detailed instructions on the rate of which the fuel
fuel analysis should be obtained before engine cleaner must be use are on the container.
operation. The fuel analysis should include all of the
properties that are stated in the table 19 . Perkins Diesel Fuel Conditioner
Aftermarket Fuel Additives The Perkins Diesel Fuel Conditioner part number
21820275/(U5MK8276) is the only fuel conditioner
recommended by Perkins. The diesel fuel conditioner
NOTICE is a proprietary metal and ash free formulation that
Perkins does not warrant the quality or performance
has been extensively tested for use with distillate
of non-Perkins fluids and filters.
diesel fuels for use in Perkins diesel engines. The
When auxiliary devices, accessories, or consum- diesel fuel conditioner helps address many of the
ables (filters, additives) which are made by other challenges that various fuels worldwide present in
manufacturers are used on Perkins products, the regards to fuel life/stability, engine startability, injector
Perkins warranty is not affected simply because of deposits, fuel system life, and long-term engine
such use. performance.
However, failures that result from the installation Note: Diesel fuel additives/conditioners may not
or use of other manufacturers devices, accesso- improve markedly poor diesel fuel properties enough
ries, or consumables are NOT Perkins defects. to make poor diesel acceptable for use.
Therefore, the defects are NOT covered under the
Perkins warranty. Diesel fuel conditioner is a proven high performance,
Supplemental diesel fuel additives are not multipurpose diesel fuel conditioner that is designed
recommended and is due to potential damage to the to improve:
fuel system or the engine. Your fuel supplier or the
• Fuel economy (through fuel system cleanup)
fuel manufacturer will add the appropriate
supplemental diesel fuel additives. • Lubricity
Perkins recognizes the fact that additives may be
• Oxidation stability
required in some special circumstances. Fuel
additives need to be used with caution. Contact your • Detergency/dispersancy
fuel supplier for those circumstances when fuel
additives are required. Your fuel supplier can • Moisture dispersancy
recommend the appropriate fuel additive and the
correct level of treatment. • Corrosion protection
Note: For the best results, your fuel supplier should • Cetane (typically 2-3 cetane numbers)
treat the fuel when additives are required. The
treated fuel must meet the requirements that are The diesel fuel conditioner also reduces the
stated in table 19 . formation of gums, resins, and sludge, and disperses
insoluble gums.
SEBU9070-03 73
Maintenance Section
For maximum overall benefits, ask your fuel supplier • Ensure that you use Perkins Advanced Efficiency
to add the fuel conditioner at the recommended treat Fuel Filters. Change your fuel filters per
rate before fuel delivery. Or you may add the fuel recommended service requirements or as needed.
conditioner at the recommended treat rate during the
early weeks of fuel storage. • Drain your water separators daily.
Contamination Control • Drain your fuel tanks of sediment and water per
the Operation and Maintenance Manual
Recommendations for Fuels instructions.
Fuels of “ISO 18/16/13” cleanliness level or cleaner • Install and maintain a properly designed bulk filter
as dispensed into the engine or application fuel tank
/ coalescer filtration system. Continuous bulk
should be used. Reduce power loss, fuel system
failures, and related down time of engines will result. filtration systems may be required to ensure that
This cleanliness level is important for new fuel dispensed fuel meets the cleanliness target.
system designs such as common rail injection Consult your Perkins distributor for availability of
systems and unit injection systems. Injection system bulk filtration products.
designs utilize higher fuel pressures and tight
clearances between moving parts in order to meet • Centrifugal filters may need to be used as a pre-
required stringent emissions regulations. Peak filter with fuel that is severely contaminated with
injection pressures in current fuel injection systems gross amounts of water and/or large particulate
may exceed 30,000 psi. Clearances in these systems contaminants. Centrifugal filters can effectively
are less than 5 µm. As a result, particle contaminants remove large contaminants. Centrifugal filters may
as small as 4 µm can cause scoring and scratching of not be able to remove the small abrasive particles
internal pump and injector surfaces and of injector required to achieve the recommended “ISO”
nozzles. cleanliness level. Bulk filter / coalescers are
necessary as a final filter in order to achieve the
Water in the fuel causes cavitation, corrosion of fuel
system parts, and provides an environment where recommended cleanliness level.
microbial growth in the fuel can flourish. Other
sources of fuel contamination are soaps, gels, or • Install desiccant type breathers of 4 µm or less
other compounds that may result from undesirable absolute efficiency with the ability to remove water
chemical interactions in the fuels, particularly in on bulk storage tanks.
ULSD. Gels and other compounds can also form in
biodiesel fuel at low temperatures or if biodiesel is • Follow proper practices of fuel transportation.
stored for extended periods. The best indication of Filtration from the storage tank to the application
microbial contamination, fuel additives, or cold promotes the delivery of clean fuel. Fuel filtration
temperature gel is rapid filter plugging of bulk fuel can be installed at each transport stage in order to
filters or application fuel filters. keep the fuel clean.
In order to reduce downtime due to contamination, • Cover, protect, and ensure cleanliness of all
follow these fuel maintenance guidelines. connection hoses, fittings, and dispensing
nozzles.
• Use high-quality fuels per recommended and
required specifications Consult your local Perkins distributor for additional
information on Perkins designed and produced
• Fill fuel tanks with fuels of “ISO 18/16/13” filtration products.
cleanliness level or cleaner, in particular for
engines with common rail and unit injection
systems. When you refuel the tank, filter the fuel
through a 4 µm absolute filter (Beta 4 = 75 up to
200) in order to reach the recommended
cleanliness level. This filtration should be located
at the device that dispenses the fuel to the fuel
tank. In addition, filtration at the dispensing point
should remove water to ensure that fuel is
dispensed at 500 ppm water or less.
• Perkins recommends the use of bulk fuel filter /
coalescer units which clean the fuel of both
particulate contamination and water in a single
pass.
74 SEBU9070-03
Maintenance Section
Maintenance Recommendations
Maintenance • The high-pressure fuel lines are constantly

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

ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve To relieve pressure from the lubricating system, turn
the pressure. off the engine.
i05963859
Welding on Engines with

When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid person- Electronic Controls
al injury, always remain clear of the the engine
when the engine is in the AUTOMATIC mode.
The engine can have the ability to auto start. Ensure NOTICE
that the power supply is isolated before any service Because the strength of the frame may decrease,
or repair is performed. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your Perkins distributor regarding welding on
off the engine. Allow the cooling system pressure cap a chassis frame or rail.
to cool. Remove the cooling system pressure cap
slowly to relieve pressure. Proper welding procedures are necessary in order to
avoid damage to the engines ECM, sensors, and
associated components. When possible, remove the
Fuel System component from the unit and then weld the
component. If removal of the component is not
To relieve the pressure from the fuel system, turn off possible, the following procedure must be followed
the engine. when you weld on a unit equipped with an Electronic
Engine. The following procedure is considered to be
High-Pressure Fuel Lines the safest procedure to weld on a component. This
procedure should provide a minimum risk of damage
to electronic components.
NOTICE
Contact with high pressure fuel may cause fluid Do not ground the welder to electrical components
penetration and burn hazards. High pressure fuel such as the ECM or sensors. Improper grounding
spray may cause a fire hazard. Failure to follow can cause damage to the drive train bearings, hy-
these inspection, maintenance and service in- draulic components, electrical components, and oth-
structions may cause personal injury or death. er components.
The high-pressure fuel lines are the fuel lines that are Clamp the ground cable from the welder to the com-
between the high-pressure fuel pump and the high- ponent that will be welded. Place the clamp as close
pressure fuel manifold and the fuel lines that are as possible to the weld. This will help reduce the pos-
between the fuel manifold and the fuel injectors. sibility of damage.
The high-pressure fuel lines are different from fuel
lines on other fuel systems, the differences are as Note: Perform the welding in areas that are free from
follows: explosive hazards.
SEBU9070-03 75
Maintenance Section
Welding on Engines with Electronic Controls
1. Stop the engine. Turn the switched power to the

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

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

part that will be welded. Place the ground cable as
close as possible to the weld in order to reduce the
possibility of welding current damage to the
following components. Bearings, hydraulic
components, electrical components, and ground
straps.
Note: If electrical/electronic components are used as

a ground for the welder, or electrical/electronic
components are located between the welder ground
and the weld, current flow from the welder could
severely damage the component.
6. Protect the wiring harness from welding debris and

spatter.
76 SEBU9070-03
Maintenance Section
Severe Service Application
7. Use standard welding practices to weld the dusty, unless the equipment is cleaned regularly.
materials. Mud, dirt, and dust can encase components.
Maintenance can be difficult. The buildup can contain
i04150276
corrosive chemicals.
Buildup – Compounds, elements, corrosive
Severe Service Application chemicals, and salt can damage some components.
Altitude – Problems can arise when the engine is
operated at altitudes that are higher than the
Severe service is the application of an engine that intended settings for that application. Necessary
exceeds the current published standards for that adjustments should be made.
engine. Perkins maintains standards for the following
engine parameters:
• Performance such as power range, speed range, Incorrect Operating Procedures
and fuel consumption
• Extended operation at low idle
• Fuel quality
• Frequent hot shutdowns
• Operational Altitude
• Operating at excessive loads
• Maintenance intervals
• Operating at excessive speeds
• Oil selection and maintenance
• Operating outside the intended application
• Coolant type and maintenance
Incorrect Maintenance Procedures
• Environmental qualities
• Extending the maintenance intervals
• Installation
• Failure to use recommended fuel, lubricants, and
• The temperature of the fluid in the engine
coolant/antifreeze
Refer to the standards for the engine or consult your
Perkins dealer or your Perkins distributor in order to
determine if the engine is operating within the defined
parameters.
Severe service operation can accelerate component
wear. Engines that operate under severe conditions
may need more frequent maintenance intervals in
order to ensure maximum reliability and retention of
full service life.
Due to individual applications, it is not possible to
identify all of the factors which can contribute to
severe service operation. Consult your Perkins
dealer or your Perkins distributor for the unique
maintenance that is necessary for the engine.
The operating environment, incorrect operating
procedures, and incorrect maintenance procedures
can be factors which contribute to a severe service
application.
Environmental Factors
Ambient temperatures – The engine may be
exposed to extended operation in cold environments
or hot environments. Valve components can be
damaged by carbon buildup if the engine is
frequently started and stopped in cold temperatures.
Hot intake air reduces engine performance.
Quality of the air – The engine may be exposed to
extended operation in an environment that is dirty or
SEBU9070-03 77
Maintenance Section
Maintenance Interval Schedule
i08330686 “ Fuel System Primary Filter (Water Separator)

Element - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 96
Maintenance Interval Schedule “ Fuel System Secondary Filter - Replace“. . . . . . . 98
“ Hoses and Clamps - Inspect/Replace“. . . . . . . . 100
When Required “ Radiator - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . 101
“ Battery - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 80
Every 2000 Service Hours
“ Battery or Battery Cable - Disconnect“ . . . . . . . . . 81
“ Aftercooler Core - Inspect/Clean/Test“ . . . . . . . . . 79
“ Engine - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
“ Alternator - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . 80
“ Engine Oil Sample - Obtain“ . . . . . . . . . . . . . . . . . 92
“ Belt Tensioner - Check“ . . . . . . . . . . . . . . . . . . . . . 81
“ Fuel System - Prime“ . . . . . . . . . . . . . . . . . . . . . . . 95
“ Belts - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Daily “ Engine Valve Lash - Check“ . . . . . . . . . . . . . . . . . 94
“ Coolant Level - Check“ . . . . . . . . . . . . . . . . . . . . . 86 Every 2000 Service Hours or 1 Year

“ Driven Equipment - Check“ . . . . . . . . . . . . . . . . . . 88
“ Engine Crankcase Breather - Clean“ . . . . . . . . . . 90
“ Engine Air Cleaner Service Indicator - Inspect“ . . 90
“ Engine Oil Level - Check“ . . . . . . . . . . . . . . . . . . . 91
Every 3000 Service Hours or 2
Years
“ Fuel System Primary Filter/Water Separator -
Drain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 “ Coolant (DEAC) - Change“ . . . . . . . . . . . . . . . . . . 84
“ Walk-Around Inspection“ . . . . . . . . . . . . . . . . . . . 102
Every 4000 Service Hours or 2
Every Week Years
“ Engine Air Precleaner - Check/Clean“ . . . . . . . . . 90 “ Coolant Temperature Regulator - Replace“ . . . . . 87
“ Jacket Water Heater - Check“. . . . . . . . . . . . . . . 100 “ Crankshaft Vibration Damper - Inspect“ . . . . . . . . 87

“ Engine Mounts - Inspect“ . . . . . . . . . . . . . . . . . . . 91
Every 50 Service Hours or Weekly
“ Fuel Tank Water and Sediment - Drain“ . . . . . . . . 99
“ Starting Motor - Inspect“ . . . . . . . . . . . . . . . . . . . 101
“ Turbocharger - Inspect“ . . . . . . . . . . . . . . . . . . . . 101
“ Battery Electrolyte Level - Check“ . . . . . . . . . . . . 80
“ Water Pump - Inspect“. . . . . . . . . . . . . . . . . . . . . 103
“ Engine Air Cleaner Element (Single Element) -
Inspect/Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Every 6000 Service Hours or 3
“ Fan Clearance - Check“ . . . . . . . . . . . . . . . . . . . . 94 Years
“ Coolant Extender (ELC) - Add“ . . . . . . . . . . . . . . . 86
Every 500 Service Hours or 1 Year
“ Air Shutoff - Test“ . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Every 10 000 Service Hours
“ Belt Tensioner - Check“ . . . . . . . . . . . . . . . . . . . . . 81 “ Grounding Stud - Inspect/Clean/Tighten“. . . . . . . 99
“ Belts - Inspect/Adjust“ . . . . . . . . . . . . . . . . . . . . . . 82
“ Belts - Inspect/Adjust“ . . . . . . . . . . . . . . . . . . . . . . 83
“ Engine Oil and Filter - Change“. . . . . . . . . . . . . . . 92
78 SEBU9070-03
Maintenance Section
Maintenance Interval Schedule
“ Overhaul Considerations“ . . . . . . . . . . . . . . . . . . 101
Every 12 000 Service Hours or 6

Years
“ Coolant (ELC) - Change“. . . . . . . . . . . . . . . . . . . . 85
Commissioning
“ Fan Clearance - Check“ . . . . . . . . . . . . . . . . . . . . 94
SEBU9070-03 79
Maintenance Section
Aftercooler Core - Inspect/Clean/Test
i05963992 4. Wash the core with hot, soapy water.

5. Flush the core thoroughly in order to remove
Aftercooler Core - Inspect/ residue and remaining debris. Flush the core with
Clean/Test clean, fresh water until the water that is exiting the
core is clear and free of debris.
Inspect
Personal injury can result from air pressure.
Inspect the aftercooler for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil and other Personal injury can result without following prop-
debris. Clean the aftercooler, if necessary. er procedure. When using pressure air, wear a
protective face shield and protective clothing.
Inspect these items for good condition: welds,
mounting brackets, oil lines, water lines, connections, The maximum air pressure for cleaning purposes
clamps and seals. Make repairs, if necessary. must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
Inspect the fins for damage. Bent fins may be opened
with a “comb”.
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
Clean
Note: Adjust the frequency of cleaning according to Test
the effects of the operating environment. Clean and
test the aftercooler every 4000 service hours unless 1. Inspect the core for trapped debris and
the inspection indicates the need for more frequent cleanliness. If necessary, remove the debris and
cleaning. repeat the cleaning procedure.
Remove the core. Refer to the Disassembly and 2. Inspect the core for damage and perform a
Assembly Manual for the procedure. pressure test in order to detect leaks. Many shops
that service radiators are equipped to perform
1. Place the aftercooler on the side in order to
pressure tests.
remove debris Remove the debris that is
accessible. 3. Plug both ends of the aftercooler core and
pressurize the core to 205 kPa (30 psi).
NOTICE Submerge the core in water. Look for bubbles
Do not use a high concentration of caustic cleaner to which are being emitted from the core. The
clean the core. A high concentration of caustic
cleaner can attack the internal metals of the core and bubbles are evidence of leaks.
cause leakage. Only use the recommended concen- 4. If any leaks are found, do not attempt to repair the
tration of cleaner.
core.
2. Back flush the core with cleaner. Install a core that is clean and that passes the
pressure test in step 3. Refer to the Disassembly and
Table 20
Assembly Manual for the procedure.
Hydrosolv Liquid Cleaners(1)
i05975681
Part Number Description Size
Hydrosolv 4165 19 L (5 US gallon) Air Shutoff - Test

Hydrosolv 100 19 L (5 US gallon)
(1) Use a 2 percent to a 5 percent concentration of the cleaner at
temperatures up to 93°C (200°F). Consult your Perkins distrib-
If the engine has been equipped with an air shutoff
utor for more information on a suitable cleaner. valve, the valve should be tested regularly. For
information on the test procedure, refer to the original
equipment manufacturer for the correct procedure.
3. Use a pressure steam cleaner in order to remove
residue from the core. Flush the fins of the
aftercooler core. Remove any other trapped debris
from the inside and from the outside of the core.
Note: Do not use high pressure when the fins are

cleaned. High pressure can damage the fins.
80 SEBU9070-03
Maintenance Section
Alternator - Inspect
i02322311 2. Turn off any battery chargers. Disconnect any

battery chargers.
Alternator - Inspect 3. Ensure that the battery disconnect switch is in the
OFF position.
Perkins recommends a scheduled inspection of the 4. Disconnect the NEGATIVE “-” cable from the
alternator. Inspect the alternator for loose NEGATIVE “-” battery terminal.
connections and correct battery charging. Check the
ammeter (if equipped during engine operation in 5. Disconnect the POSITIVE “+” cable from the
order to ensure correct battery performance and/or POSITIVE “+” battery terminal.
correct performance of the electrical system. Make
repairs, as required. Note: Always recycle a battery. Never discard a
battery. Dispose of used batteries to an appropriate
Check the alternator and the battery charger for recycling facility.
correct operation. If the batteries are correctly
charged, the ammeter reading should be very near 6. Remove the used battery.
zero. All batteries should be kept charged. The
batteries should be kept warm because temperature 7. Install the new battery.
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. When the Note: Before the cables are connected, ensure that
engine is not run for long periods of time or if the the battery disconnect switch is in the OFF position.
engine is run for short periods, the batteries may not
fully charge. A battery with a low charge will freeze 8. Connect the POSITIVE “+” cable to the POSITIVE
more easily than a battery with a full charge. “+” battery terminal.
i05425759 9. Connect the NEGATIVE “-” cable to the

NEGATIVE “-” battery terminal.
Battery - Replace 10. Turn the battery disconnect switch to the ON
position.
i02747977
Batteries give off combustible gases which can Battery Electrolyte Level -
explode. A spark can cause the combustible
gases to ignite. This can result in severe personal Check
injury or death.
Ensure proper ventilation for batteries that are in When the engine is not run for long periods of time or
an enclosure. Follow the proper procedures in or- when the engine is run for short periods, the batteries
der to help prevent electrical arcs and/or sparks may not fully recharge. Ensure a full charge in order
near batteries. Do not smoke when batteries are to help prevent the battery from freezing. If batteries
serviced. are correctly charged, the ammeter reading should
be very near zero, when the engine is in operation.
The battery cables or the batteries should not be

removed with the battery cover in place. The bat- All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a
tery cover should be removed before any servic- face shield and protective clothing when working
ing is attempted. on or near batteries.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion 1. Remove the filler caps. Maintain the electrolyte
resulting in personal injury.
level to the “FULL” mark on the battery.
1. Switch the engine to the OFF position. Remove all If the addition of water is necessary, use distilled
electrical loads. water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
Note: After the engine has stopped, allow 2 minutes softened water.
in order for the diesel exhaust fluid lines to be purged
before disconnecting the power. 2. Check the condition of the electrolyte with a
suitable battery tester.
SEBU9070-03 81
Maintenance Section
Battery or Battery Cable - Disconnect
3. Install the caps. i06233840
4. Keep the batteries clean.

Belt Tensioner - Check
Clean the battery case with one of the following
cleaning solutions:
(Model LG)
• Use a solution of 0.1 kg (0.2 lb) baking soda
and 1 L (1 qt) of clean water. S/N: LG1
• Use a solution of ammonium hydroxide.
Thoroughly rinse the battery case with clean

water.
i07819485
Battery or Battery Cable -

Disconnect
The battery cables or the batteries should not be

removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the start switch to the OFF position. Turn the Typical example
ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads. With this design of belt the tensioning pulley (1)
should be checked at 500 hours or each year.
2. Disconnect the negative battery terminal. Ensure
that the cable cannot contact the terminal. When Remove the belt. Refer to Disassembly and
four 12 volt batteries are involved, two negative Assembly, “Alternator Belt - Remove and Install”.
connection must be disconnected. Ensure that the belt tensioner is securely installed.
3. Remove the positive connection. Visually inspect the belt tensioner (1) for damage.
Check that the pulley on the tensioner rotates freely
4. Clean all disconnected connection and battery and that the bearing is not loose.
terminals.
i06233841
5. Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
Belt Tensioner - Check
remove material excessively. Excessive removal (Model PK9)
of material can cause the clamps to not fit
correctly. Coat the clamps and the terminals with a
suitable silicone lubricant or petroleum jelly. S/N: PK9
6. Tape the cable connections to help prevent
accidental starting.
7. Proceed with necessary system repairs.
8. To connect the battery, connect the positive
connection before the negative connection.
82 SEBU9070-03
Maintenance Section
Belts - Inspect/Adjust
Fan Belts Adjust
Typical example
Remove the belt. Refer to Disassembly and Typical example
Assembly, “Alternator Belt - Remove and Install”.
Ensure that the belt tensioner (1) is securely
installed. Visually inspect the belt tensioner for
damage. Check that the pulley on the tensioner
rotates freely and that the bearing is not loose.
Inspect the idler pulley (2). Ensure that the idler
pulley is securely installed. Visually inspect the idler
pulley for damage. Ensure that the idler pulley can
rotate freely and that the bearing is not loose. If
necessary, replace damaged components.
Install the belt. Refer to Disassembly and Assembly,
“Alternator Belt - Remove and Install”.
i06233845
(Model LG)
S/N: LG
To maximize the engine performance, inspect the Typical example

belt for wear and for cracking. Replace the belt if the
belt is worn or damaged. 1. Loosen bolts (1) and (2), also loosen nut (3).
2. Loosen bolt (4) and nut (7).
Fan Belts
Adjust nuts (5) and (7) in order to increase or
• Inspect each belt for cracks, splits, glazing, decrease the tension on union (6). This action will
grease, displacement of the cord and evidence of tension the belts, the belts must be tensioned to
fluid contamination. 730 N (164 lb). To check accurately the belt tension,
a suitable gauge should be used.
SEBU9070-03 83
Maintenance Section
1. Tighten nuts (5) and (7) securely. Tighten bolts (1) Recheck new belts after 10 hours of operation.
and (2), also tighten nut (3). Tighten nut and bolts
to a torque of 89 N·m (65 lb ft). Tighten bolt (4) to i06233847
a torque of 100 N·m (73 lb ft).
Coolant Pump Drive Belt (Model PK9)
• Inspect the belt for cracks, splits, glazing, grease,
displacement of the cord and evidence of fluid
contamination. S/N: PK9
Coolant Pump Drive Belt Adjust
(1) Auto tensioner
Typical example
Inspect
To maximize the engine performance, inspect the
1. Loosen bolts (1) and (3). Using square (A) adjust belt for wear and for cracking. Replace the belt if the
pulley assembly (2) in order to increase or belt is worn or damaged.
decrease the tension on the coolant drive belt.
• Inspect the belt for cracks, splits, glazing, grease,
2. The tension on the belt must be set to 560 N displacement of the cord and evidence of fluid
(125 lb). contamination.
3. With the correct tension on the belt, tighten bolts
(1) and (3). Tighten bolts to a torque of 28 N·m
Adjust
(247 lb in). This engine option the belt adjustment is automatic.
Also, the belt tension is controlled by the auto
New belts tensioner (1).
Table 21
i05985281
Tension for New Belts
Fan belt Coolant pump Drive Belts - Replace
Tension Belt
912 N (205 lb) 734 N (165 lb)
The fan belts must be replaced as a set.
84 SEBU9070-03
Maintenance Section
Coolant (DEAC) - Change
For the correct procedure for removing and installing

the drive belts, refer to the Disassembly and
Assembly, “V-Belts remove and Install”.
i05985305
Coolant (DEAC) - Change
• DEAC Diesel Engine Antifreeze Coolant

Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.

• Foaming is observed.
• The oil has entered the cooling system and the

coolant is contaminated.
• The fuel has entered the cooling system and the Illustration 44 g03748670
coolant is contaminated. Typical example
NOTICE Note: Refer to this Operation and Maintenance

When any servicing or repair of the engine cooling Manual, “General Hazard Information” for information
system is performed, the procedure must be per- on Containing Fluid Spillage.
formed with the engine on level ground. Level ground
will allow you to check accurately the coolant level. 2. Remove drain plug (1). Also remove the drain plug
This procedure will also help in avoiding the risk of in- on the radiator.
troducing an air lock into the coolant system.
Allow the coolant to drain into a suitable container.
Note: Inspect the water pump and the water 3. Properly dispose of the drained material. Obey
temperature regulator after the cooling system has local regulations for the disposal of the material.
been drained. This inspection is a good opportunity
to replace the water pump, the water temperature Flush
regulator, and the hoses, if necessary.
1. Flush the cooling system with clean water and a
Drain suitable cleaning agent in order to remove any
debris. Refer to your Perkins distributor for
suitable cleaning agents.
Pressurized System: Hot coolant can cause seri- 2. Install the system drain plugs.
stop the engine and wait until the cooling system NOTICE
components are cool. Loosen the cooling system Do not fill the cooling system faster than 5 L
pressure cap slowly in order to relieve the (1.3 US gal) per minute to avoid air locks.
pressure.
Cooling system air locks may result in engine
damage.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
3. Fill the cooling system with clean water and install
order to relieve any pressure. Remove the cooling
the cooling system filler cap.
system filler cap.
4. Start and run the engine until normal operating
temperature.
SEBU9070-03 85
Maintenance Section
Coolant (ELC) - Change
5. Stop the engine and allow the engine to cool. Clean the cooling system and flush the cooling
Loosen the cooling system filler cap slowly in system before the recommended maintenance
order to relieve any pressure. Remove the cooling interval if the following conditions exist:
system filler cap. Remove the cooling system • The engine overheats frequently.
drain plugs. Allow the water to drain. Flush the
cooling system with clean water. • Foaming is observed.
6. Check the O ring seal on the drain plugs, replace if • The oil has entered the cooling system and the
damaged. Install the system drain plugs. Tighten coolant is contaminated.
the drain plug (1) to a torque of 80 N·m (59 lb ft).
• The fuel has entered the cooling system and the
Fill coolant is contaminated.
Note: When the cooling system is cleaned, only

NOTICE clean water is needed when the ELC is drained and
Do not fill the cooling system faster than 5 L replaced.
(1.3 US gal) per minute to avoid air locks.
Note: Inspect the water pump and the water
Cooling system air locks may result in engine temperature regulator after the cooling system has
damage. been drained. Replace the water pump, the water
temperature regulator, and the hoses, if necessary.
1. Fill the cooling system with the coolant/antifreeze.
Refer to this Operation and Maintenance Manual, NOTICE
“Refill Capacities and Recommendations” topic Service or repair of the engine cooling system must
be performed on level ground. The engine must be
(Maintenance Section) for more information on level in order to check the coolant level. The engine
cooling system specifications. Do not install the must be level in order to avoid the risk of introducing
cooling system filler cap. an air lock into the coolant system.
temperature.
Drain
3. Maintain the coolant level at the maximum mark
that is correct for your application.
4. Clean the cooling system filler cap. Inspect the
Pressurized System: Hot coolant can cause seri-
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap is stop the engine and wait until the cooling system
damaged, discard the old cooling system filler cap components are cool. Loosen the cooling system
and install a new cooling system filler cap. If the pressure cap slowly in order to relieve the
gasket that is on the cooling system filler cap is not pressure.
damaged, perform a pressure test. If the cooling
system filler cap does not retain the correct 1. Stop the engine and allow the engine to cool.
pressure, install a new cooling system filler cap. Loosen the cooling system filler cap slowly in
5. Start the engine. Inspect the cooling system for order to relieve any pressure. Remove the cooling
leaks and for the correct operating temperature. system filler cap.
i05985294
Coolant (ELC) - Change
NOTICE
Perkins ELC must be using with an extender in order
to achieve 12000 hours operation. For more informa-
tion on a suitable extender contact your Perkins
distributor.
86 SEBU9070-03
Maintenance Section
Coolant Extender (ELC) - Add
5. Check the O ring seal on the drain plug, replace if

damaged. Install the system drain plugs. Tighten
the drain plug (1) to a torque of 80 N·m (59 lb ft).
Fill
NOTICE
Do not fill the cooling system faster than 5 L
Cooling system air locks may result in engine
damage.
1. Fill the cooling system with Extended Life Coolant

(ELC). Refer to this Operation and Maintenance
Manual, “Refill Capacities ” topic (Maintenance
Section) for more information on cooling system
specifications. Do not install the cooling system
filler cap.
temperature. Stop the engine.
2. Remove drain plug (1). Also, remove the drain plug 3. Maintain the coolant level at the maximum mark
from the radiator. that is correct for your application.
Allow the coolant to drain. 4. Clean the cooling system filler cap. Inspect the
For information regarding the disposal and the gasket that is on the cooling system filler cap. If
recycling of used coolant, consult your Perkins the gasket that is on the cooling system filler cap is
distributor. damaged, discard the old cooling system filler cap
and install a new cooling system filler cap. If the
Flush gasket that is on the cooling system filler cap is not
damaged, pressure test the cooling system filler
1. Flush the cooling system with clean water in order cap. The correct pressure for the cooling system
to remove any debris. filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
NOTICE does not retain the correct pressure, install a new
Do not fill the cooling system faster than 5 L cooling system filler cap.
5. Start the engine. Inspect the cooling system for
Cooling system air locks may result in engine leaks and for proper operating temperature.
damage.
i05197396
2. Fill the cooling system with clean water. Install the
cooling system filler cap. Coolant Extender (ELC) - Add
temperature. In order for Perkins ELC to achieve 12000 hours an
4. Stop the engine and allow the engine to cool. extender must be added at 6000 hours. For a
suitable extender, contact your Perkins dealer or
Loosen the cooling system filler cap slowly in Perkins distributor.
order to relieve any pressure. Remove the cooling
system filler cap. Remove the cooling system i05966993
drain plugs. Allow the water to drain. Flush the
cooling system with clean water. Coolant Level - Check
Check the coolant level when the engine is stopped

and cool.
SEBU9070-03 87
Maintenance Section
Coolant Temperature Regulator - Replace
3. Clean the cooling system filler cap and check the

condition of the filler cap gaskets. Replace the
cooling system filler cap if the filler cap gaskets are
damaged. Reinstall the cooling system filler cap.
4. Inspect the cooling system for leaks.
i05975694
Coolant Temperature
Regulator - Replace
Replacing the water temperature regulator reduces

Illustration 46 g00285520 the chances for unscheduled downtime.
Cooling system filler cap
A water temperature regulator that fails in a partially
opened position can cause overheating or
overcooling of the engine.
Pressurized System: Hot coolant can cause seri- A water temperature regulator that fails in the closed
ous burns. To open the cooling system filler cap, position can cause excessive overheating. Excessive
stop the engine and wait until the cooling system overheating could result in cracking of the cylinder
components are cool. Loosen the cooling system head or piston seizure problems.
pressure cap slowly in order to relieve the
pressure. A water temperature regulator that fails in the open
position will cause the engine operating temperature
to be too low during partial load operation. Low
1. Remove the cooling system filler cap slowly in engine operating temperatures during partial loads
order to relieve pressure. could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
2. Maintain the coolant level within 13 mm (0.5 inch) in an accelerated wear of the piston rings and wear of
of the bottom of the filler pipe. If the engine is the cylinder liner.
equipped with a sight glass, maintain the coolant Refer to Disassembly and Assembly, “Water
level to the proper level in the sight glass. Temperature Regulator Housing - Remove and
Install” for the replacement procedure of the water
temperature regulator, or consult your Perkins
distributor.
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system
to a level that is below the housing.
i05967790
Crankshaft Vibration Damper -

Inspect
Damage to the crankshaft vibration damper or failure

of the crankshaft vibration damper can increase
torsional vibrations. This torsional vibration can result
in damage to the crankshaft and to other engine
components. A deteriorating damper can cause
excessive gear train noise at variable points in the
speed range.
Illustration 47 g02590196 The damper is mounted to the crankshaft which is

Typical filler cap gaskets located behind the belt guard on the front of the
engine.
88 SEBU9070-03
Maintenance Section
Driven Equipment - Check
Ensure that the cooling fins (2) are clean and free
from damage.
Removal and Installation

Refer to the Disassembly and Assembly Manual,
“Vibration Damper and Pulley - Remove and Install”
for information on removing and installing the
damper.
i02151646
Driven Equipment - Check
Refer to the OEM specifications for more information

on the following maintenance recommendations for
the driven equipment:
• Inspection
• Adjustment
Typical example • Lubrication
(1) Vibration damper
(2) Cooling fins • Other maintenance recommendations
Perform any maintenance for the driven equipment
Inspection which is recommended by the OEM.
Inspect the damper for the following conditions: i02568158
• The damper is dented, cracked, or fluid is leaking

from the damper.
Engine - Clean
• The paint on the damper is discolored from
excessive heat.
• The damper is bent.

Personal injury or death can result from high
• The bolt holes are worn or there is a loose fit for voltage.
the bolts.
Moisture can create paths of electrical
• The engine has had a crankshaft failure due to conductivity.
torsional forces. Make sure that the electrical system is OFF. Lock
Replace the damper if any of these conditions exist. out the starting controls and tag the controls “ DO
NOT OPERATE”” .
NOTICE
Accumulated grease and oil on an engine is a fire
hazard. Keep the engine clean. Remove debris and
fluid spills whenever a significant quantity accumu-
lates on the engine.
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
benefits:
• Easy detection of fluid leaks
• Maximum heat transfer characteristics
SEBU9070-03 89
Maintenance Section
Engine Air Cleaner Element (Single Element) - Inspect/Replace
• Ease of maintenance
Note: Caution must be used in order to prevent
electrical components from being damaged by
excessive water when you clean the engine. Avoid
electrical components such as the alternator, the
starter, and the Electronic Control Module (ECM).
i05985308
Engine Air Cleaner Element

(Single Element - Inspect/
Replace
Perform the Operation and Maintenance Manual,

“Engine Air Cleaner Service Indicator-Inspect”
procedure and perform the Operation and
Maintenance Manual, “Engine Air Precleaner Check/
Clean” procedure (if equipped before performing the
following procedure.
NOTICE
Never run the engine without an air cleaner element 1. Remove the six clips (2) and remove the cover (3).
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements
with damaged pleats, gaskets or seals. Dirt entering
the engine causes premature wear and damage to
engine components. Air cleaner elements help to pre-
vent airborne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
2. Remove element (5) and discard old element.

3. Ensure that the cover (3) cap (1) and valve (4) are
clean and free from dirt.
4. Install new element (5), install cover (3). Install
clips (2). Insure that valve (4) is vertically down.
5. If necessary, reset the air cleaner service indicator.
90 SEBU9070-03
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
i05967801 i05967804
Engine Air Cleaner Service Engine Air Precleaner - Check/

Indicator - Inspect Clean
(If Equipped) (If Equipped)
Some engines may be equipped with a different

service indicator.
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element, and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner housing.
Typical example
(1) Wing nut
(2) Cover
(3) Body
Remove wing nut (1) and cover (2). Check for an

accumulation of dirt and debris in body (3). Clean the
body, if necessary.
After cleaning the precleaner, install cover (2) and
wing nut (1).
Note: When the engine is operated in dusty
applications, more frequent cleaning is required.
(1) Reset button i05967836
(2) View area
Observe the service indicator. The air cleaner

Engine Crankcase Breather -
element should be cleaned or the air cleaner element
should be replaced when the following condition
Clean
occurs:
• The red piston locks in the visible position of the

view area (2). NOTICE
Perform this maintenance with the engine stopped.
The reset button (1) reset the red piston.
NOTICE
If the crankcase breather is not maintained on a regu-
lar basis, it can become plugged. A plugged breather
will cause excessive crankcase pressure that may
cause crankshaft seal leakage.
SEBU9070-03 91
Maintenance Section
Engine Mounts - Inspect
i07819538
Engine Mounts - Inspect
Note: The engine mounts may not have been

supplied by Perkins. Refer to the Original Equipment
Manufacturer (OEM information for further details on
the engine mounts and the correct bolt torque.
Inspect the engine mounts for deterioration and for
correct bolt torque. Excessive engine vibration can
be caused by the following conditions:
• Incorrect mounting of the engine

• Deterioration of the engine mounts
• Loose engine mounts
Any engine mount that shows deterioration should be
replaced. Refer to the OEM information for the
Illustration 53 g03741874 recommended torques.
(1) Sealing washer
(2) Bolt
When the engine mounts are supplied by Perkins the
(3) Hose clamp maintenance procedure will be supplied in the
(4) Hose Disassembly and Assembly manual for your engine.
(5) Housing
(6) Breather assembly i05967878
1. Thoroughly clean the breather assembly before Engine Oil Level - Check
removing any parts.
2. Loosen hose clamp (3) and remove hose (4) from
breather assembly (6).
3. Remove bolt (2) and the washer (1). Remove the
breather assembly (6) from housing (5). Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
4. Wash the breather element in solvent that is clean contact the skin.
and nonflammable. Allow the breather element to
dry before installation.
5. Ensure that the hose (4) is clean and free from
damage.
6. Install a breather element that is clean and dry.
Install breather assembly (6) to housing (5).
7. Install new sealing washer (1) to bolt (2) and install
into breather assembly. Tighten bolt (2) to a torque Illustration 54 g00110310
of 28 N (6.3 lb). (Y) “Add” mark. (X) “Full” mark.
8. Install hose (4) and clip (3) to breather assembly.

Tighten clip (3) to a torque of 7 N·m (62 lb in). NOTICE
Perform this maintenance with the engine stopped.
Note: Ensure that the engine is either level or that

the engine is in the normal operating position in order
to obtain a true level indication.
92 SEBU9070-03
Maintenance Section
Engine Oil Sample - Obtain
Note: After the engine has been switched OFF, wait Obtain the Sample and the
for 10 minutes in order to allow the engine oil to drain
to the oil pan. Then, check the oil level.
Analysis
1. Maintain the oil level between the “ADD” mark (Y)
and the “FULL” mark (X) on the engine oil dipstick.
Do not fill the crankcase above the “FULL” mark Hot oil and hot components can cause personal
(X). injury. Do not allow hot oil or hot components to
contact the skin.
NOTICE
Operating your engine when the oil level is above the In order to help obtain the most accurate analysis,
“FULL” mark could cause your crankshaft to dip into record the following information before an oil sample
the oil. The air bubbles created from the crankshaft is taken:
dipping into the oil reduces the oil's lubricating char-
acteristics and could result in the loss of power. • The date of the sample
• Engine model
2. Remove the oil filler cap and add oil, if necessary.
Clean the oil filler cap. Install the oil filler cap. • Engine number
• Service hours on the engine
i05969787
• The number of hours that have accumulated since
Engine Oil Sample - Obtain the last oil change
• The amount of oil that has been added since the

last oil change
The condition of the engine lubricating oil may be
checked at regular intervals as part of a preventive Ensure that the container for the sample is clean and
maintenance program. Perkins include an oil dry. Also ensure that the container for the sample is
sampling valve (1 as an option. The oil sampling clearly labeled.
valve is included in order to sample regularly the
engine lubricating oil. To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, mixed well oil
sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
The sample can be checked for the following: The
quality of the oil, the existence of any coolant in the
oil, the existence of any ferrous metal particles in the
oil and the existence of any nonferrous metal
particles in the oil.
i05969790
Engine Oil and Filter - Change
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
Typical example
Perkins recommends using a sampling valve in order

to obtain oil samples. The quality and the consistency
of the samples are better when a sampling valve is
used. The location of the sampling valve allows oil
that is flowing under pressure to be obtained during
normal engine operation.
SEBU9070-03 93
Maintenance Section
Engine Oil and Filter - Change
Do not drain the oil when the engine is cold. As the oil After the oil has drained, the oil drain plug should be
cools, suspended waste particles settle on the cleaned. Install a new O ring seal to the oil drain plug.
bottom of the oil pan. The waste particles are not Reinstall the oil drain plug. Tighten drain plug to
removed with the draining cold oil. Drain the 40 N·m (29 lb ft), for aluminum oil pan. Remove
crankcase with the engine stopped. Drain the container and disposal of the waste oil in accordance
crankcase with the oil warm. This draining method with local regulations.
allows the waste particles that are suspended in the
oil to be drained properly. Replace the Oil Filter
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
Drain the Engine Oil

After the engine has been run at the normal
operating temperature, stop the engine. Use one of
the following methods to drain the engine crankcase
oil:
• Use a container that is large enough to collect the
engine oil.
• If the engine is equipped with a drain valve, turn

the drain valve knob counterclockwise in order to
drain the oil. After the oil has drained, turn the
drain valve knob clockwise in order to close the
drain valve.
• If the engine is not equipped with a drain valve,

remove the oil drain plug in order to allow the oil to
drain. Discard the O ring seal. If the engine is
equipped with a shallow sump, remove the bottom Illustration 56 g03742429
oil drain plugs from both ends of the oil pan. Typical example
1. Ensure that the oil filter assembly is clean before

starting the procedure for removing the spin on
filter. Place a suitable container below the oil filter
assembly.
2. Using a suitable tool, remove the oil filter (3) from
housing (1). Discard old filter.
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contami-
nated. Contaminated oil can cause accelerated wear
to engine components.
3. Apply clean engine oil to the O ring seal (2) and

install the new spin on oil filter.
94 SEBU9070-03
Maintenance Section
Engine Valve Lash - Check
4. Install the spin on oil filter (3) and tighten by hand The initial valve lash adjustment on new engines,
only. When the O ring seal contacts the sealing rebuilt engines, or remanufactured engines is
surface, rotate the oil filter 1 full turn. Remove the recommended only on engine ratings 522 kW
container and disposal of the waste oil in (700 hp) and greater. The adjustment is necessary
due to the initial wear of the valve train components
accordance with local regulations. and to the seating of the valve train components.
Fill the Engine Crankcase This maintenance is recommended as part of a

lubrication and preventive maintenance schedule to
1. Remove the oil filler cap. Refill the engine help provide maximum engine life. For engine ratings
less than 522 kW (700 hp), the initial valve lash
crankcase with engine oil. Refer to the Operation adjustment is not necessary.
and Maintenance Manual, “Refill Capacities ” and
Operation and Maintenance Manual, “Fluid Note: All engine ratings must have the engine valve
recommendations” for more information. lash performed at 2500 hours.
NOTICE Ensure that the engine is stopped before measuring

If equipped with an auxiliary oil filter system or a re- the valve lash. To obtain an accurate measurement,
mote oil filter system, follow the OEM or filter manu- allow the valves to cool before this maintenance is
performed.
facturer's recommendations. Under filling or
overfilling the crankcase with oil can cause engine During valve adjustment, visibly inspect the valve
damage. train of wear or damage.
Refer to Systems Operation, Testing and Adjusting,
2. Start the engine and run the engine for 2 minutes. “Engine Valve Lash - Inspect/Adjust” for more
Perform this procedure in order to ensure that the information.
lubrication system has oil and that the oil filter is
filled. Inspect the oil filter for oil leaks. i06023929
3. Stop the engine and allow the oil to drain back to

the sump for a minimum of 10 minutes.
Fan Clearance - Check
4. Remove the oil level gauge in order to check the oil
level. Maintain the oil level between the “Low” and Ensure that the engine is stopped and that the
“High” marks on the oil level gauge. battery disconnect switch is in the OFF position.
Ensure that the radiator is full of the correct coolant.
i07512811
Engine Valve Lash - Check
Ensure that the engine cannot be started while

this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before
measuring/adjusting valve lash clearance.
NOTICE
Only qualified service personel should perform this
maintenance. Refer to the Service Manual or your au-
thorized Perkins dealer or your Perkins distributor for
the complete valve lash adjustment procedure.
Operation of Perkins engines with incorrect valve
lash can reduce engine efficiency, and also reduce
engine component life.
SEBU9070-03 95
Maintenance Section
Fuel System - Prime
Typical example
1. The clearance between the cover (1) and the fan If necessary, perform minor adjustments. Repair any
(2) must be checked at four equal distances. leaks from the fuel system and from the cooling,
Measure the distance between the fan tip and the lubrication, or air systems. Ensure that all
adjustments and repairs are performed by authorized
edge of the cover.
personnel that have had the correct training.
2. The gap (A) must be between 8 to 10 mm
The fuel system should be primed under the following
(0.31 to 0.39 inch). conditions:
i05969962 • The fuel tank is empty or the fuel tank has been
partially drained.
Fuel System - Prime
• The engine has been in storage.
• The fuel filter has been replaced.
• The pressure fuel lines have been disconnected.

Fuel leaked or spilled onto hot surfaces or electri- 1. Ensure that the key switch is in the OFF position.
cal components can cause a fire. To help prevent
possible injury, turn the start switch off when Ensure that the fuel tank is full of clean diesel fuel.
changing fuel filters or water separator elements. Check that the fuel supply valve (if equipped) is in
Clean up fuel spills immediately. the “ON” position.
Refer to this Operation and Maintenance Manual ,

“General Hazard Information” before any
adjustments or repairs are performed
96 SEBU9070-03
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
i05970884
Fuel System Primary Filter

(Water Separator Element -
Replace
Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
NOTICE
2. Unlock the fuel priming pump handle (1). Turn Do not allow dirt to enter the fuel system. Thoroughly
handle counter clockwise. Operate the fuel pump clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
handle until strong pressure can be felt. nected fuel system component.
3. When strong pressure can be felt, press in the fuel
pump handle and lock the handle into the fuel 1. Turn the fuel supply valve (if equipped) to the OFF
pump body (2). In order to lock the handle, turn position. Place a suitable container under the fuel
handle clockwise. filter assembly. Clean the outside of the primary
fuel filter assembly.
Note: The stronger the pressure in the fuel system
the quicker the engine will start.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. Start the engine, refer to this Operation and

Maintenance Manual, “Starting the Engine” for
more information.
5. If the engine will not start, repeat Steps 2 to Step 3.
6. Once the engine starts, allow the engine to operate
with no load for 5 minutes.
7. If the engine will not start, refer to Troubleshooting,
“Engine Cranks but will not Start”.
SEBU9070-03 97
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
5. Spin on the fuel filter by hand. When the O ring

seal (3) contacts the sealing surface rotate the fuel
filter ¾ of a full turn. Remove the container and
disposal of the waste fuel in accordance with local
regulations.
6. Turn the valves for the fuel lines (if equipped) to
the ON position. Prime the fuel system. Refer to
the Operation and Maintenance Manual, “Fuel
System - Prime” for more information.
The primary fuel filter and the secondary fuel filter
should be serviced together.
i05970923
Fuel System Primary Filter/

Water Separator - Drain
2. Pace a suitable container below the primary fuel Fuel leaked or spilled onto hot surfaces or electri-
filter. Drain the fuel from the primary fuel filter. cal components can cause a fire. To help prevent
Open the drain valve (1) and allow the fluid to possible injury, turn the start switch off when
changing fuel filters or water separator elements.
drain. Then, close the drain valve. Clean up fuel spills immediately.
NOTICE
Ensure that the engine is stopped before any servic-
1. Place a suitable container below the primary filter.
3. Using a suitable tool, remove the primary fuel filter

(4) from housing (2). Discard the old primary fuel
filter.
4. Lubricate the O ring seal (3) with clean diesel fuel.
Install the new primary fuel filter (4).
98 SEBU9070-03
Maintenance Section
Fuel System Secondary Filter - Replace
1. Residual fuel pressure should be relieved from the

fuel system before the fuel filter is removed. After
the engine has stopped, wait for one to 5 minutes
until the fuel pressure has lowered. Use a suitable
container in order to catch any fuel that may spill.
2. Turn the fuel supply valve (if equipped) to the OFF
position. Place a suitable container under the fuel
filter assembly. Clean the outside of the secondary
fuel filter assembly.
2. Open drain valve (1) and allow the fluid to drain.

When clean fuel can be seen, close the drain
valve. Remove the container and disposal of the
waste fuel in accordance with local regulations.
i05970937
Fuel System Secondary Filter -

Replace Illustration 62 g03743006
3. Using a suitable tool, remove the secondary fuel

filter (3) from housing (1). Discard the old
secondary fuel filter.
Fuel leaked or spilled onto hot surfaces or electri- NOTICE
cal components can cause a fire. To help prevent Do not fill the secondary fuel filter with fuel before in-
possible injury, turn the start switch off when stalling. The fuel would not be filtered and could be
changing fuel filters or water separator elements. contaminated. Contaminated fuel will cause acceler-
Clean up fuel spills immediately. ated wear to fuel system parts.
NOTICE 4. Lubricate O ring seal (2) with clean diesel fuel.

Ensure that the engine is stopped before any servic- Install new secondary fuel filter (3) to housing (1).
5. Spin on new secondary fuel filter, when the O ring
seal (2) contacts the sealing surface rotate the fuel
NOTICE filter ¾ of a full turn. Remove the container and
Do not allow dirt to enter the fuel system. Thoroughly disposal of the waste fuel in accordance with local
clean the area around a fuel system component that regulations.
will be disconnected. Fit a suitable cover over any
disconnected fuel system components. 6. Turn the valves for the fuel lines (if equipped) to
the ON position. Prime the fuel system. Refer to
the Operation and Maintenance Manual, “Fuel
System - Prime” for more information.
The primary fuel filter and the secondary fuel filter
should be serviced together.
SEBU9070-03 99
Maintenance Section
Fuel Tank Water and Sediment - Drain
i02568194 Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
Fuel Tank Water and Sediment supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If the
- Drain engine is equipped with this system, regular
maintenance of the fuel system filter is important.
Fuel Storage Tanks

NOTICE
Care must be taken to ensure that fluids are con- Drain the water and the sediment from the fuel
tained during performance of inspection, mainte- storage tank at the following intervals:
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain- • Service intervals
ers before opening any compartment or disassem-
bling any component containing fluids. • Refill of the tank
Dispose of all fluids according to local regulations This will help prevent water or sediment from being
and mandates. pumped from the storage tank into the engine fuel
tank.
If a bulk storage tank has been refilled or moved
Fuel Tank recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
Fuel quality is critical to the performance and to the
baffles in the bulk storage tank will also help trap
service life of the engine. Water in the fuel can cause
sediment. Filtering fuel that is pumped from the
excessive wear to the fuel system.
storage tank helps to ensure the quality of the fuel.
Water can be introduced into the fuel tank when the When possible, water separators should be used.
fuel tank is being filled.
i05970985
Condensation occurs during the heating and cooling
of fuel. The condensation occurs as the fuel passes Grounding Stud - Inspect/
through the fuel system and the fuel returns to the
fuel tank. This causes water to accumulate in fuel Clean/Tighten
tanks. Draining the fuel tank regularly and obtaining
fuel from reliable sources can help to eliminate water
in the fuel.
Drain the Water and the Sediment

The connection of battery cables to a battery and
Fuel tanks should contain some provision for draining the disconnection of battery cables from a battery
water and draining sediment from the bottom of the may cause an explosion which may result in in-
fuel tanks. jury or death. The connection and the disconnec-
tion of other electrical equipment may also cause
Open the drain valve on the bottom of the fuel tank in an explosion which may result in injury or death.
order to drain the water and the sediment. Close the The procedures for the connection and the dis-
drain valve.
connection of battery cables and other electrical
Check the fuel daily. Allow five minutes after the fuel equipment should only be performed in a nonex-
tank has been filled before draining water and plosive atmosphere.
sediment from the fuel tank.
Fill the fuel tank after operating the engine in order to
drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The fuel
expands as the fuel gets warm. The tank may
overflow.
100 SEBU9070-03
Maintenance Section
Hoses and Clamps - Inspect/Replace
Check for the following conditions:

• End fittings that are damaged or leaking
• Outer covering that is chafed or cut

• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally

• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering

A constant torque hose clamp can be used in place
of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard
clamp.
The electronics grounding stud is located on the
upper left corner of the engine control module. Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
Inspect the OEM harness for good connections. This action can result in leaks. A constant torque
Inspect the condition of the OEM harness. hose clamp will help to prevent loose hose clamps.
The electronics grounding stud must have a wire Each installation application can be different. The
ground to the battery. Tighten the electronics differences depend on the following factors:
grounding stud at every oil change. Ground wires
and straps should be combined at engine grounds. • Type of hose
All grounds should be tight and free of corrosion.
• Type of fitting material
• Clean the electronics grounding stud and the
terminals for the ground strap with a clean cloth. • Anticipated expansion and contraction of the hose
• If the connections are corroded, clean the • Anticipated expansion and contraction of the
connections with a solution of baking soda and fittings
water.
• Keep the electronics grounding stud and the strap
Replace the Hoses and the Clamps
clean and coated with MPGM grease or petroleum Replace hoses that are cracked or soft. Tighten any
jelly. loose clamps. For information on replacing hoses
and clamps refer to the Disassembly and Assembly
i05971027 Manual.
Hoses and Clamps - Inspect/ i05971073
Replace Jacket Water Heater - Check

Inspect all hoses for leaks that are caused by the
following conditions: Jacket water heaters help to improve startability in
ambient temperatures that are below 21 °C (70 °F.
• Cracking All installations that require automatic starting should
have jacket water heaters.
• Softness
Check the operation of the jacket water heater.
• Loose clamps Check the operation of the circulation pump, if
equipped. For an ambient temperature of 0 °C
(32 °F, the heater should maintain the jacket water
NOTICE coolant temperature at approximately 32 °C (90 °F.
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the
recommended torque.
SEBU9070-03 101
Maintenance Section
Overhaul Considerations
i05971077 i02568202
Overhaul Considerations Starting Motor - Inspect
For an overhaul solution, contact your Perkins Perkins recommends a scheduled inspection of the
distributor. starting motor. If the starting motor fails, the engine
may not start in an emergency situation.
i05971137
Check the starting motor for proper operation. Check
the electrical connections and clean the electrical
Radiator - Clean connections. Refer to the Service Manual for more
information on the checking procedure and for
specifications or consult your Perkins distributors for
assistance.
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
i02568203
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil and other Turbocharger - Inspect
debris. Clean the radiator, if necessary.
Periodic inspection and cleaning is recommended for

the turbocharger compressor housing (inlet side.
Personal injury can result from air pressure. Any fumes from the crankcase are filtered through
the air inlet system. Therefore, by-products from oil
Personal injury can result without following prop- and from combustion can collect in the turbocharger
er procedure. When using pressure air, wear a compressor housing. Over time, this buildup can
protective face shield and protective clothing. contribute to loss of engine power, increased black
smoke and overall loss of engine efficiency.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air If the turbocharger fails during engine operation,
nozzle is deadheaded. damage to the turbocharger compressor wheel and/
or to the engine may occur. Damage to the
turbocharger compressor wheel can cause additional
Pressurized air is the preferred method for removing damage to the pistons, the valves, and the cylinder
loose debris. Direct the air in the opposite direction of head.
the air flow. Hold the nozzle approximately 6 mm
(0.25 inch) away from the fins. Slowly move the air NOTICE
nozzle in a direction that is parallel with the tubes. Turbocharger bearing failures can cause large quan-
This movement will remove debris that is between tities of oil to enter the air inlet and exhaust systems.
the tubes. Loss of engine lubricant can result in serious engine
Pressurized water may also be used for cleaning. damage.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized Minor leakage of a turbocharger housing under ex-
water in order to soften mud. Clean the core from tended low idle operation should not cause problems
both sides. as long as a turbocharger bearing failure has not
occurred.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core When a turbocharger bearing failure is accompanied
with detergent and hot water. Thoroughly rinse the by a significant engine performance loss (exhaust
core with clean water. smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
After cleaning, start the engine and operate the replaced.
engine with no load. This procedure will help in the
removal of debris and drying of the core. Stop the
engine. Use a light bulb behind the core in order to An inspection of the turbocharger can minimize
inspect the core for cleanliness. Repeat the cleaning, unscheduled downtime. An inspection of the
if necessary. turbocharger can also reduce the chance for potential
damage to other engine parts.
Inspect the fins for damage. Bent fins may be opened
with a “comb”. Inspect these items for good condition:
welds, mounting brackets, connections, clamps and
seals. Make repairs, if necessary.
102 SEBU9070-03
Maintenance Section
Walk-Around Inspection
Note: Turbocharger components require precision 6. Clean the turbocharger housing with standard
clearances. The turbocharger cartridge must be shop solvents and a soft bristle brush.
balanced due to high rpm. Severe Service
Applications can accelerate component wear. Severe 7. Fasten the air inlet piping and the exhaust outlet
Service Applications require more frequent piping to the turbocharger housing.
inspections of the cartridge.
i02568213
Removal and Installation
Walk-Around Inspection
For options regarding the removal, installation, repair
and replacement, consult your Perkins distributor.
Refer to the Service Manual for this engine for the
procedure and specifications. Inspect the Engine for Leaks and
for Loose Connections
Cleaning and Inspecting
A walk-around inspection should only take a few
1. Remove the exhaust outlet piping and remove the minutes. When the time is taken to perform these
air inlet piping from the turbocharger. Visually checks, costly repairs and accidents can be avoided.
inspect the piping for the presence of oil. Clean the
For maximum engine service life, make a thorough
interior of the pipes in order to prevent dirt from inspection of the engine compartment before starting
entering during reassembly. the engine. Look for items such as oil leaks or
coolant leaks, loose bolts, worn belts, loose
2. Turn the compressor wheel and the turbine wheel connections and trash buildup. Make repairs, as
by hand. The assembly should turn freely. Inspect needed:
the compressor wheel and the turbine wheel for
contact with the turbocharger housing. There • The guards must be in the proper place. Repair
should not be any visible signs of contact between damaged guards or replace missing guards.
the turbine wheel or compressor wheel and the • Wipe all caps and plugs before the engine is
turbocharger housing. If there is any indication of serviced in order to reduce the chance of system
contact between the rotating turbine wheel or the contamination.
compressor wheel and the turbocharger housing,
the turbocharger must be reconditioned. NOTICE
3. Check the compressor wheel for cleanliness. If For any type of leak (coolant, lube, or fuel) clean up
the fluid. If leaking is observed, find the source and
only the blade side of the wheel is dirty, dirt and/or correct the leak. If leaking is suspected, check the flu-
moisture is passing through the air filtering id levels more often than recommended until the leak
system. If oil is found only on the back side of the is found or fixed, or until the suspicion of a leak is
wheel, there is a possibility of a failed turbocharger proved to be unwarranted.
oil seal.
The presence of oil may be the result of extended NOTICE
engine operation at low idle. The presence of oil Accumulated grease and/or oil on an engine or deck
may also be the result of a restriction of the line for is a fire hazard. Remove this debris with steam clean-
ing or high pressure water.
the inlet air (plugged air filters), which causes the
turbocharger to slobber.
• Ensure that the cooling lines are properly clamped
4. Use a dial indicator to check the end clearance on
and that the cooling lines are tight. Check for
the shaft. If the measured end play is greater than leaks. Check the condition of all pipes.
the Service Manual specifications, the
turbocharger should be repaired or replaced. An • Inspect the water pumps for coolant leaks.
end play measurement that is less than the
minimum Service Manual specifications could Note: The water pump seal is lubricated by coolant in
indicate carbon buildup on the turbine wheel. The the cooling system. It is normal for a small amount of
leakage to occur as the engine cools down and the
turbocharger should be disassembled for cleaning
parts contract.
and for inspection if the measured end play is less
than the minimum Service Manual specifications.
5. Inspect the bore of the turbine housing for
corrosion.
SEBU9070-03 103
Maintenance Section
Water Pump - Inspect
Excessive coolant leakage may indicate the need to • Other potential damage to the engine
replace the water pump seal. For the removal of
water pumps and the installation of water pumps and/ Visually inspect the water pump for leaks. If any
or seals, refer to the Service Manual for the engine or leaking is observed, replace the water pump seal or
consult your Perkins distributor. the water pump assembly. Refer to the Service
Manual for the disassembly and assembly
• Inspect the lubrication system for leaks at the front procedure.
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover. Note: Refer to the Service Manual or consult your
Perkins distributor if any repair is needed or any
• Inspect the fuel system for leaks. Look for loose replacement is needed.
fuel line clamps or for loose fuel line tie-wraps.
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
• Inspect the alternator belt and the accessory drive
belts for cracks, breaks or other damage.
Belts for multiple groove pulleys must be replaced as
matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.
• Drain the water and the sediment from fuel tanks

on a daily basis in order to ensure that only clean
fuel enters the fuel system.
• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires.
• Inspect the ground strap for a good connection
and for good condition.
• Inspect the ECM to the cylinder head ground strap

for a good connection and for good condition.
• Disconnect any battery chargers that are not

protected against the current drain of the starting
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.
• Check the condition of the gauges. Replace any
gauges that are cracked. Replace any gauge that
can not be calibrated.
i02568235
Water Pump - Inspect
A failed water pump might cause severe engine

overheating problems that could result in the
following conditions:
• Cracks in the cylinder head
• A piston seizure
104 SEBU9070-03
Warranty Section
Warranty Information
Warranty Section
Warranty Information
i06590874
Emissions Warranty
Information
This engine may be certified to comply with exhaust

emission and gaseous emission standards that are
prescribed by the law at the time of manufacture.
This engine may be covered by an Emissions
Warranty. Consult your authorized Perkins dealer or
distributor to determine if your engine is emissions
certified and if your engine is subject to an Emissions
Warranty.
SEBU9070-03 105
Reference Information Section
Engine Ratings
Reference Information i05986477
Section Engine Rating Definitions
Engine Ratings It is important to know the use of the engine so that

the rating will match the operating profile. The proper
rating selection is also important so that the
i08274659 customers perception of price and value is realized.
Engine Rating Conditions In selecting a rating for a specific application, the

most important consideration is the time that is spent
at full throttle. These rating definitions identify the
percent of time at full throttle. The definitions also
All engine ratings are in compliance with the following identify the corresponding times below rated rpm.
standard ambient air conditions of “SAE J1349”:
Note: The examples of the applications are only for
• 99 kPa (29.3 inches of Hg) reference. For an exact determination of the
appropriate rating, follow the OEM specifications or
• 30 percent relative humidity
consult your Perkins distributor .
• A temperature of 25 °C (77 °F) A Rating – This rating is used for heavy-duty
Ratings relate to the standard conditions of applications that are operated at rated load and at
“ISO8665”, of “ISO3046/1”, of “DIN6271”, and of rated rpm up to 100 percent. This rating is used for
“BS5514”. engines that operate without interruption of load
cycling. Typical applications include the following
The engine ratings are based on the following fuel examples: pipeline pumping and ventilation.
specifications:
B Rating – This rating is used when power and/or
• Low heat value (LHV) of the fuel of 42 780 kJ/kg rpm are cyclic. The engine should be run at full load.
(18,390 Btu/lb) at 29 °C (84 °F) The engine should not exceed 80 percent of the duty
cycle. Typical applications include the following
• Gravity (API) of 35 degrees at 15 °C (60 °F) examples: irrigation, operation where normal pump
demand is 85 percent of the engine rating, oil
• Specific gravity of .849 at 15 °C (60 °F) pumping/drilling, field mechanical pumping/drilling
and stationary/plant air compressors.
• Density of 850 kg/m3 (7.085 lb/US gal)
C Rating – This rating is used when power and/or
The engine ratings are gross output ratings. rpm are cyclic. The horsepower and the rpm of the
engine can be utilized continuously for 1 hour.
Gross Output Ratings – The total output capability Followed by 1 hour of operation at the A rating or
of the engine that is equipped with standard below the A rating. The engine should be run at full
accessories. load. The engine should not exceed 50 percent of the
duty cycle. Typical applications include the following
examples: agricultural tractors, harvesters and
Standard accessories include the following combines, off-highway trucks, fire pumps, blast hole
components: drills, rock crushers, wood chippers with high torque
rise and oil field hoisting.
• Oil pumps
D Rating – This rating is used when rated power is
• Fuel pumps required for periodic overloads. The maximum
horsepower and the rpm of the engine can be utilized
• Water pumps continuously for a maximum of 30 minutes. Followed
by 1 hour of operation at the C rating. The engine
Subtract the power that is required to drive auxiliary should be run at full load. The engine should not
components from the gross output. This action will exceed 10 percent of the duty cycle. Typical
produce the net power that is available for the applications include the following examples: offshore
external load (flywheel). cranes, runway snow blowers, water well drills,
portable air compressors and fire pump certification
power.
E Rating – This rating is used when rated power is
required for a short time for initial starting or for
sudden overload. The rating is also used for
emergency service when standard power is not
106 SEBU9070-03
Engine Rating Definitions
available. The horsepower and the rpm of the engine

can be utilized continuously for a maximum of 15
minutes. Followed by 1 hour of operation at the C
rating or by the duration of the emergency. The
engine should be run at full load. The engine should
not exceed 5 percent of the duty cycle. Typical
applications include the following examples: standby
centrifugal water pumps, oil field well servicing, crash
trucks, portable air compressors and gas turbine
starting motors.
NOTICE
Operating engines above the rating definitions can
result in shorter service life before overhaul.
SEBU9070-03 107
Reference Materials
Reference Materials
i05204672
Maintenance Records
Perkins recommends the retention of accurate

maintenance records. Accurate maintenance records
can be used for the following purposes:
• Determine operating costs.
• Establish maintenance schedules for other

engines that are operated in the same
environment.
• Show compliance with the required maintenance

practices and maintenance intervals.
Maintenance records can be used for various other
business decisions that are related to engine
maintenance.
Maintenance records are a key element of a
maintenance program that is correctly managed.
Accurate maintenance records can help your Perkins
dealer to fine-tune the recommended maintenance
intervals in order to meet the specific operating
situation. This should result in a lower engine
operating cost.
Records should be kept for the following items:
Fuel Consumption – A record of fuel consumption is
essential in order to determine when the load
sensitive components should be inspected or
repaired. Fuel consumption also determines overhaul
intervals.
Service Hours – A record of service hours is
essential to determine when the speed sensitive
components should be inspected or repaired.
Documents – These items should be easy to obtain,
and these items should be kept in the engine history
file. All of the documents should show this
information: date, service hours, fuel consumption,
unit number and engine serial number. The following
types of documents should be kept as proof of
maintenance or repair for warranty:
Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:
• Dealer work orders and itemized bills
• Owners repair costs

• Owners receipts
• Maintenance log
108 SEBU9070-03
Maintenance Log
i05204675
Maintenance Log
Table 22
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity Of
Service Item Date Authorization
Hours Fuel
SEBU9070-03 109
Reference Material
i07677995
Reference Material
(Extended Service Contract)
Extended Service Contracts - purchased in minutes,

protected for years.
Extended Service Contracts (ESC protect you from
the stress that unexpected repair work brings to your
life by covering the cost of getting your engine up and
running again. Unlike other extended warranties,
Perkins Platinum ESC protects you against all
component part failures.
Purchase peace of mind from only £0.03 / $0.05 /
euro 0.04 a day and let an ESC make your dreams a
reality.
Why buy an Extended Service Contract?
1. No surprises - total protection from unexpected
repair cost (parts, labor, and travel).
2. Enjoy longer lasting product support from Perkins
global network.
3. Genuine Perkins parts ensure continued engine
performance.
4. Highly trained technicians carry out all repairs.
5. Transferable coverage should you sell your
machine.
Flexible coverage provides the right level of
protection for your Perkins Engine. Coverage can be
extended to 2 years/ 1,000 hours right up to 10 year/
40,000
You can buy an ESC at any time during standard
warranty - even the last day!
Each Perkins Distributor has highly trained and
experienced Perkins Product Support Service
Technicians. The Support Service is equipped, and
available around the clock to get your engine running
again with the minimum of downtime. Buying an ESC
means that you get all this for free.
To purchase an Extended Service Contract, is quick
and simple! Contact your local Perkins Distributor
now and the distributor can provide you with a quote
in minutes. You can locate your nearest Perkins
Distributor by visiting:
www.perkins.com
NOTICE
Dependant upon engine type and application.
110 SEBU9070-03
Index Section
Index
A Coolant Temperature Regulator - Replace ..... 87
Crankshaft Vibration Damper - Inspect........... 87
After Starting Engine ....................................... 44
Inspection .................................................... 88
Constant Speed Engines............................. 44
Removal and Installation ............................. 88
Variable Speed Engines .............................. 44
Crushing Prevention and Cutting Prevention.. 14
After Stopping Engine ..................................... 48
Aftercooler Core - Inspect/Clean/Test ............. 79
Clean............................................................ 79 D
Inspect ......................................................... 79 Diagnostic Lamp.............................................. 40
Test .............................................................. 79 Driven Equipment - Check .............................. 88
Air Shutoff - Test .............................................. 79
Alternator - Inspect .......................................... 80
E
B Electrical System............................................. 16
Grounding Practice...................................... 16
Battery - Replace............................................. 80 Emergency Stopping....................................... 48
Battery Electrolyte Level - Check .................... 80 Emissions Certification Film ............................ 28
Battery or Battery Cable - Disconnect............. 81 Emissions Warranty Information ................... 104
Before Starting Engine .............................. 15, 42 Engaging the Driven Equipment ..................... 45
Belt Tensioner - Check (Model LG) ................. 81 Engine - Clean................................................. 88
Belt Tensioner - Check (Model PK9) ............... 81 Engine Air Cleaner Element (Single
Belts - Inspect/Adjust (Model LG) ................... 82 Element) - Inspect/Replace ........................... 89
Coolant Pump Drive Belt ............................. 83 Engine Air Cleaner Service Indicator -
Fan Belts...................................................... 82 Inspect (If Equipped) ..................................... 90
New belts ..................................................... 83 Engine Air Precleaner - Check/Clean (If
Belts - Inspect/Adjust (Model PK9) ................. 83 Equipped) ...................................................... 90
Inspect ......................................................... 83 Engine Crankcase Breather - Clean ............... 90
Belts - Replace ................................................ 83 Engine Diagnostics ......................................... 40
Burn Prevention................................................11 Engine Electronics........................................... 17
Batteries....................................................... 12 Engine Mounts - Inspect.................................. 91
Coolant ........................................................ 12 Engine Oil and Filter - Change ........................ 92
Diesel Fuel ................................................... 12 Drain the Engine Oil..................................... 93
Oils............................................................... 12 Fill the Engine Crankcase............................ 94
Replace the Oil Filter ................................... 93
C Engine Oil Level - Check................................. 91
Engine Oil Sample - Obtain............................. 92
Cold Weather Operation ................................. 46
Obtain the Sample and the Analysis ........... 92
Cold Weather Starting ..................................... 42
Engine Operation ............................................ 45
Configuration Parameters ............................... 41
Engine Operation with Active Diagnostic
System Configuration Parameters .............. 41
Codes ............................................................ 40
Coolant (DEAC) - Change............................... 84
Engine Operation with Intermittent
Drain ............................................................ 84
Diagnostic Codes .......................................... 40
Fill ................................................................ 85
Engine Rating Conditions.............................. 105
Flush ............................................................ 84
Engine Rating Definitions.............................. 105
Coolant (ELC) - Change.................................. 85
Engine Ratings .............................................. 105
Drain ............................................................ 85
Engine Starting.......................................... 15, 42
Fill ................................................................ 86
Engine Stopping ........................................ 15, 48
Flush ............................................................ 86
Engine Valve Lash - Check ............................. 94
Coolant Extender (ELC) - Add ........................ 86
Coolant Level - Check ..................................... 86
SEBU9070-03 111
Index Section
F Fuel System Secondary Filter - Replace ........ 98

Fuel Tank Water and Sediment - Drain ........... 99
Fan Clearance - Check ................................... 94
Drain the Water and the Sediment .............. 99
Fault Logging................................................... 40
Fuel Storage Tanks...................................... 99
Features and Controls..................................... 32
Fuel Tank ..................................................... 99
Fire Prevention and Explosion Prevention...... 12
Ether ............................................................ 14
Fire Extinguisher.......................................... 14 G
Lines, Tubes, and Hoses ............................. 14 Gauges and Indicators .................................... 32
Fluid Recommendations ........................... 49, 56 Instrument Panels and Displays.................. 32
ELC Cooling System Maintenance.............. 51 Warning Indicators....................................... 32
Engine Oil .................................................... 56 General Hazard Information.............................. 8
General Coolant Information ....................... 49 Containing Fluid Spillage............................. 10
General Lubricant Information for the 1506D Dispose of Waste Properly ...........................11
Engine........................................................ 56 Fluid Penetration ........................................... 9
Fluid Recommendations (Fuel Inhalation ..................................................... 10
Recommendations for the 1506A and Pressurized Air and Water............................. 9
1506C Engines)............................................. 57 Static Electricity Hazard when Fueling with
Contamination Control Recommendations for Ultra-low Sulfur Diesel Fuel ....................... 10
Fuels .......................................................... 65 General Information ........................................ 18
Diesel Fuel Characteristics.......................... 60 Grounding Stud - Inspect/Clean/Tighten......... 99
Diesel Fuel Requirements ........................... 58
General Information..................................... 58
H
Fluid Recommendations (Fuel
Recommendations for the 1506D Engine) .... 65 Hoses and Clamps - Inspect/Replace........... 100
Contamination Control Recommendations for Replace the Hoses and the Clamps .......... 100
Fuels .......................................................... 73
Diesel Fuel Characteristics.......................... 68 I
Diesel Fuel Requirements ........................... 66
General Information..................................... 66 Important Safety Information............................. 2
Fluid Recommendations (Lubricant
Information for 1506A and 1506C Engines).. 53 J
Engine Oil .................................................... 54
Jacket Water Heater - Check ........................ 100
General Lubricant Information..................... 53
Foreword ........................................................... 4
California Proposition 65 Warning ................. 4 L
Literature Information .................................... 4 Lifting and Storage .......................................... 29
Maintenance .................................................. 4
Maintenance Intervals ................................... 5
M
Operation ....................................................... 4
Overhaul ........................................................ 5 Maintenance Interval Schedule....................... 77
Safety............................................................. 4 Commissioning ............................................ 78
Fuel and the Effect from Cold Weather ........... 46 Daily ............................................................. 77
Fuel Conservation Practices ........................... 45 Every 10 000 Service Hours ........................ 77
Fuel Related Components in Cold Weather ... 46 Every 12 000 Service Hours or 6 Years....... 78
Fuel Heaters ................................................ 47 Every 2000 Service Hours........................... 77
Fuel Tanks ................................................... 46 Every 2000 Service Hours or 1 Year ........... 77
Fuel System - Prime ........................................ 95 Every 3000 Service Hours or 2 Years ......... 77
Fuel System Primary Filter (Water Every 4000 Service Hours or 2 Years ......... 77
Separator) Element - Replace....................... 96 Every 50 Service Hours or Weekly.............. 77
Fuel System Primary Filter/Water Every 500 Service Hours ............................. 77
Separator - Drain ........................................... 97 Every 500 Service Hours or 1 Year ............. 77
112 SEBU9070-03
Index Section
Every 5000 Service Hours........................... 77 Record for Reference .................................. 28

Every 6000 Service Hours or 3 Years ......... 77 Reference Information Section ..................... 105
Every Week ................................................. 77 Reference Material (Extended Service
When Required............................................ 77 Contract)...................................................... 109
Maintenance Log........................................... 108 Reference Materials ...................................... 107
Maintenance Recommendations .................... 74 Refill Capacities............................................... 49
Maintenance Records ................................... 107 Cooling System............................................ 49
Maintenance Section....................................... 49 Lubrication System ...................................... 49
Manual Stop Procedure .................................. 48
Stopping the Engine .................................... 48 S
Model View Illustrations .................................. 18
1506A and C Engine and Radiator Views ... 18 Safety Messages............................................... 6
1506D Engine Views ................................... 22 (1) Universal Warning .................................... 6
Monitoring System........................................... 33 Safety Section ................................................... 6
Action Alert .................................................. 33 Self-Diagnostics .............................................. 40
Critical Protection Override.......................... 33 Sensors and Electrical Components............... 35
Diagnostic .................................................... 34 1506D Configuration.................................... 39
Shutdown..................................................... 33 Severe Service Application ............................. 76
Shutdown Reset .......................................... 34 Environmental Factors................................. 76
Standard Warning Outputs .......................... 34 Incorrect Maintenance Procedures ............. 76
Warning Alarm ............................................. 33 Incorrect Operating Procedures .................. 76
Mounting and Dismounting ............................. 15 Starting Motor - Inspect ................................. 101
Starting the Engine.......................................... 43
Starting with Jump Start Cables...................... 43
O
System Pressure Release............................... 74
Operation Section............................................ 29 Coolant System ........................................... 74
Overhaul Considerations............................... 101 Engine Oil .................................................... 74
Fuel System................................................. 74
P
T
Plate Locations and Film Locations ................ 27
Engine Identification .................................... 27 Table of Contents .............................................. 3
Serial Number Plate 1.................................. 27 Turbocharger - Inspect .................................. 101
Product Description ......................................... 24 Cleaning and Inspecting ............................ 102
Aftermarket Products and Perkins Removal and Installation ........................... 102
Engines ...................................................... 26
Electronic Engine Features ......................... 25 W
Engine Cooling and Lubrication .................. 25
Engine Service Life...................................... 25 Walk-Around Inspection ................................ 102
Engine Specifications .................................. 24 Inspect the Engine for Leaks and for Loose
Product Identification Information ................... 27 Connections ............................................. 102
Product Information Section............................ 18 Warranty Information..................................... 104
Product Lifting ................................................. 29 Warranty Section ........................................... 104
Product Storage .............................................. 29 Water Pump - Inspect.................................... 103
Condition for Storage................................... 29 Welding on Engines with Electronic
Removal from Storage................................. 30 Controls ......................................................... 74
R
Radiator - Clean ............................................ 101
Radiator Restrictions....................................... 46
Reference Information..................................... 28
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identification Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name: Branch:
Address:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
SEBU9070
©2021 Perkins Engines Company Limited
All Rights Reserved
114 January 2021

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The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Refill Capacities............................................... 49

Maintenance Recommendations .................... 74

Warranty Information..................................... 104

Burn Prevention................................................11 Reference Information Section

Fire Prevention and Explosion Prevention...... 12 Engine Ratings .............................................. 105

Crushing Prevention and Cutting Prevention.. 14 Reference Materials ...................................... 107

Mounting and Dismounting ............................. 15 Index Section

Before Starting Engine .................................... 15 Index...............................................................110

Engine Stopping .............................................. 15

Product Information Section

General Information ........................................ 18

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

Lifting and Storage .......................................... 29

Features and Controls..................................... 32

Engine Diagnostics ......................................... 40

Engine Operation ............................................ 45

Cold Weather Operation ................................. 46

Engine Stopping .............................................. 48

Foreword Some photographs or illustrations in this manual

WARNING – This product can Safety

Wash hands after handling components Maintenance

The maintenance schedule items are organized for a

There may be several specific warning signs on your

(1) Universal Warning

Do not operate or work on this equipment unless

The Universal Warning label (1) is located in two

i08330649 • Report all necessary repairs.

• Engage the secondary brakes or parking brakes.

• Use all cleaning solutions with care. • Filler caps

• Grease fittings • Do not attempt any repairs that are not

• Do not wear loose clothing or jewelry that can

• Ensure that all protective guards and all covers

• Report all necessary repairs.

• The engine is stopped. Ensure that the engine

• Disconnect the batteries when maintenance is

Avoid static electricity risk when fueling. Ultra-

Always use a board or cardboard when you check for

Containing Fluid Spillage

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

• Obey environmental regulations for the disposal of

• Stay away from areas that might have hexavalent

• A vacuum cleaner that is equipped with a high

Coolant Cooling system conditioner contains alkali. Alkali can

Fire Prevention and Explosion

All fuels, most lubricants, and some coolant mixtures

Wiring must be kept in good condition. Ensure that all

Do not store ether cylinders in living areas or in the

Lines, Tubes, and Hoses

• Outer coverings are chafed or cut.

Mounting and Dismounting Engine Starting

Do not climb on the engine. The engine has not been

Before Starting Engine Engine exhaust contains products of combustion

Never disconnect any charging unit circuit or battery Typical example

The power supply connections and the ground