№82 Руководство по ремонту. Двигатель Perkins 800 Series

Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
3
Table of Contents
Table of Contents
Index Section
Index ..................................................................... 70
Foreword ................................................................. 4
Safety Section
Safety Signs and Labels ......................................... 6
General Hazard Information ................................... 8
Burn Prevention ...................................................... 9
Fire Prevention and Explosion Prevention ............ 10
Crushing Prevention and Cutting Prevention ........ 12
Before Starting Engine .......................................... 12
Engine Starting ..................................................... 12
Engine Stopping ................................................... 13
Electrical System .................................................. 13
Product Information Section

Model Views ......................................................... 14
Product Identification Information ........................ 19
Operation Section
Lifting and Storage ................................................ 21
Gauges and Indicators .......................................... 24
Engine Starting ..................................................... 25
Engine Operation .................................................. 28
Engine Stopping ................................................... 29
Cold Weather Operation ....................................... 30
Maintenance Section
Lubricant Specifications ........................................ 34
Fuel Specifications ................................................ 38
Cooling System Specifications ............................. 41
Refill Capacities .................................................... 47
Maintenance Interval Schedule ............................ 48
Warranty Section
Warranty Information ............................................ 69
4
Foreword
Foreword
Literature Information
This manual contains safety, operation instructions,
lubrication and maintenance infor mation. This
manual should be stored in or near the engine area
in a literatur e holder or literatur e storage area. Read,
study and keep it with the literatur e and engine
infor mation.
English is the prima ry language for all Perkins
publications. The English used facilitates translation
and consistency in electr onic media deliver y.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regar ding your engine, or this manual, please
consult with your Perkins dealer or your Perkins
distributor for the latest available information.
Recommended service should be per formed

at the appr opriate intervals as indicated in
the Maintenance Interval Schedule. The actual
operating envir onment of the engine also gover ns
the Maintenance Interval Schedule. Therefore,
under extremely sever e, dusty, wet or freezing cold
operating conditions, more frequent lubrication and
maintenance than is specified in the Maintenance
Interval Schedule may be necessar y.
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 requir ed.
The implementation of a preventive maintenance
management program should minimize operating
costs through cost avoidances resulting from
reductions in unscheduled downtime and failur es.
Safety
Maintenance Intervals
This safety section lists basic safety precautions.

In addition, this section identifies hazar dous,
warning situations. Read and understand the basic
precautions listed in the safety section before
operating or per forming lubrication, maintenance
and repair on this product.
Perform maintenance on items at multiples

of the original requi rement.
We recommend that the maintenance schedules
be reproduced and displayed near the engine as
a convenient reminder. We also recommend that a
maintenance record be maintained as part of the
engines permanent record.
Operation
Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques requir ed to operate the engine more
efficiently and economically . Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedur es of inspecting, starting,
operating and stopping the engine.
Maintenance
The maintenance section is a guide to engine
care. The illustrated, step-by-step instructions are
grouped by service hours and/or calendar time
maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions
that follow.
Your authorized Perkins dealer or your Perkins

distributor can assist you in adjusting your
maintenance schedule to meet the needs of your
operating envir onment.
Overhaul
Major engine overhaul details are not cover ed in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs should only be carried out by
Perkins authorized per sonnel . Your Perkins dealer or
your Perkins distributor offer a variety of options
regarding overhaul programs. If you experience a
major engine failure, there are also numerous after
failure overhaul options available .
Consult your Perkins dealer or your Perkins
distributor for information regarding these options.
5
Foreword
California Proposition 65 Warning

Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.
6
Safety Section
Safety Signs and Labels
Safety Section
i01933317

There may be several specific warning signs on
an engine. The exact location of the hazards and
the description of the hazards 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 pictures
are not visible. When the warning signs are
cleaned, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean
the warning signs. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures
the warning signs. The warning signs that are
loosened could drop off of the engine.
Replace any damaged warning signs or missing
warning signs. If a warning sign is attached to a
part of the engine that is replaced, install a new
warning sign on the replacement part. Any Perkins
dealer or any Perkins distributor can provide new
warning signs.
Do not work on the engine and do not operate the
engine unless the instructions and warnings in the
Operation and Maintenance Manual are understood.
Proper care is your responsibility. Failure to follow
the instructions or failure to heed the warnings
could result in injury or in death.
The warning labels that may be found on the engine
are illustrated and described.
7
Safety Section
Illustration 1
g01000440
8
Safety Section
General Hazard Information
Do Not Operate Before Reading the

Manual (1)
i01884947
General Hazard Information
This message is located on the side of the valve

cover.
g00934493
Do not operate or work on this engine unless you

have read and understand the instructions and
warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact
any Perkins dealer for replacement manuals.
Proper care is your responsibility.
Illustration 2
g00104545
Attach a Do Not Operate warning tag or a similar

warning tag to the start switch or to the controls
before you service the equipment or before you
repair the equipment.
Starting Aid (2)

The warning label for the starting aid is located on
top of the air inlet manifold.
Illustration 3
g00702020
Wear a hard hat, protective glasses, and other

protective equipment, as required.
Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the engine.
Make sure that all protective guards and all covers
are secured in place on the engine.
g00283559
If equipped with an air inlet heater (AIH) for cold

weather starting, do not use aerosal types of starting aids such as ether. Such use could result in an
explosion and personal injury.
Keep the engine free from foreign material. Remove

debris, oil, tools, and other items from the deck,
from walkways, and from steps.
Never put maintenance fluids into glass containers.
Drain all liquids into a suitable container.
Obey all local regulations for the disposal of liquids.
9
Safety Section
Burn Prevention
Use all cleaning solutions with care. Report all

necessary repairs.
Do not allow unauthorized personnel on the
equipment.
Unless you are instructed otherwise, perform
maintenance on the engine with the equipment in
the servicing position. Refer to the OEM information
for the procedure for placing the equipment in the
servicing position.
Pressure Air and Water

Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result
in personal injury.
When pressurized air and/or water is used for
cleaning, wear protective clothing, protective shoes,
and eye protection. Eye protection includes goggles
or a protective face shield.
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 in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Make provision to collect the fluid with
a suitable container before any compartment is
opened or before any component is disassembled.
Only use the tools that are suitable for collecting

fluids and equipment that is suitable for collecting
fluids.
Only use the tools that are suitable for containing

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).
fluids and equipment that is suitable for containing

fluids.
Obey all local regulations for the disposal of liquids.
Fluid Penetration
i01480768
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
components or parts until pressure has been
relieved or personal injury may occur. Refer to
the OEM information for any procedures that are
required to relieve the hydraulic pressure.
Burn Prevention
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam
can cause severe burns. Allow cooling system
components to cool before the cooling system is
drained.
Check the coolant level after the engine has
stopped and the engine has been allowed to cool.
Illustration 4
g00687600
10
Safety Section
Fire Prevention and Explosion Prevention
Ensure that the filler cap is cool before removing

the filler cap. The filler cap must be cool enough
to touch with a bare hand. Remove the filler cap
slowly in order to relieve pressure.
Cooling system conditioner contains alkali. Alkali
can cause personal injury. Do not allow alkali to
contact the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.
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.
i01885715
Fire Prevention and Explosion

Prevention
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 materials such as fuel, oil,
and debris from the engine. Do not allow any
flammable materials to accumulate on the engine.
Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
a tube, or a seal failure. Exhaust shields must be
installed correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. All electrical
wires must be properly routed and securely
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate
the engine. Clean all electrical connections and
tighten all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that
are smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Illustration 5
g00704000
All fuels, most lubricants, and some coolant mixtures

are flammable.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after
an emergency shutdown.
Arcing or sparking could cause a fire. Secure

connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
Inspect all lines and hoses for wear or for
deterioration. The hoses must be properly routed.
The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
Oil filters and fuel filters must be properly installed.
The filter housings must be tightened to the proper
torque.
11
Safety Section
Fire Prevention and Explosion Prevention
Improper jumper cable connections can cause

an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. This may cause
an explosion.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery
box covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Illustration 6
g00704059
Use caution when you are refueling an engine. Do

not smoke while you are refueling an engine. Do
not refuel an engine near open flames or sparks.
Always stop the engine before refueling.
Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Perkins dealer for
repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not
use your bare hand to check for leaks. Use a
board or cardboard to check for leaks. Tighten all
connections to the recommended torque.
Replace the parts if any of the following conditions
are present:
End fittings are damaged or leaking.

Outer coverings are chafed or cut.
Wires are exposed.
Outer coverings are ballooning.
Illustration 7
g00704135
Gases from a battery can explode. Keep any open

flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.
Flexible part of the hoses are kinked.

Outer covers have embedded armoring.
End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.
12
Safety Section
Crushing Prevention and Cutting Prevention
Crushing Prevention and

Cutting Prevention
All protective guards and all protective covers must

be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Support the component properly when work

beneath the component is performed.
Do not bypass the automatic shutoff circuits. Do not

disable the automatic shutoff circuits. The circuits
are provided in order to help prevent personal
injury. The circuits are also provided in order to help
prevent engine damage.
i01359666
Unless other maintenance instructions are provided,

never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
reinstall the guards.
See the Service Manual for repairs and for

adjustments.
i01933350
Engine Starting
Keep objects away from moving fan blades. The

fan blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Chips or other debris may fly off objects when
objects are struck. Before objects are struck, ensure
that no one will be injured by flying debris.
i01805780
Before Starting Engine

NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.
Overspeed shutdown should occur automatically.
If automatic shutdown does not occur, press the
emergency stop button in order to cut the fuel
and/or air to the engine.
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights work properly, if equipped.
Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
personal injury.
If a warning tag is attached to the engine start
switch or to the controls, DO NOT start the engine
or move the controls. Consult with the person that
attached the warning tag before the engine is
started.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Start the engine from the operators compartment or
from the engine start switch.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, Engine Starting topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
properly, check the water temperature gauge
and the oil temperature gauge during the heater
operation.
13
Safety Section
Engine Stopping
Engine exhaust contains products of combustion

which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
Note: The engine is equipped with an automatic
device for cold starting for normal conditions of
operation. If the engine will be operated in very
cold conditions, then an extra cold starting aid may
be required. Normally, the engine will be equipped
with the correct type of starting aid for your region
of operation.
The 800 Series engine is equipped with a glow plug
starting aid in each individual cylinder that heats
the intake air in order to improve starting.
Check the electrical wires daily for wires that are

loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. See
the Operation and Maintenance Manual for specific
starting instructions.
Grounding Practices
Proper grounding for the engine electrical system
is necessary for optimum engine performance
and reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.
i01032808
Engines that are installed without engine-to-frame

ground straps can be damaged by electrical
discharge.
Engine Stopping
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
according to this Operation and Maintenance
Manual, Engine Stopping topic (Operation
Section).
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.
On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop the
engine if an overspeed condition occurs. This may
be accomplished by shutting off the fuel supply
and/or the air supply to the engine.
i01940471
Electrical System
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative jump start cable should be connected
last from the external power source to the negative
terminal of the starting motor. If the starting
motor is not equipped with a negative terminal,
connect the jump start cable to the engine block.
To ensure that the engine and the engine electrical

systems function properly, an engine-to-frame
ground strap with a direct path to the battery must
be used. This path may be provided by way of a
direct engine ground to the frame.
All grounds should be tight and free of corrosion.
The engine alternator must be grounded to the
negative - battery terminal with a wire that is
adequate to handle the full charging current of the
alternator.
14
Model Views
Product Information
Section
Model Views
i01933688
Model View Illustrations
Illustration 8
g00988037
15
Model Views
Left side view of naturally aspirated 800 Series engine

This view is shown without one of the fuel injection nozzles for clarity.
(1)
(2)
(3)
(4)
(5)
Fan
Water pump
Oil filler
Fuel injection pump
Oil pressure switch
(6) Oil drain plug

(7) Relief valve
(8) Oil filter
(9) Flywheel housing
(10) Oil level gauge
Water drain plug

Lifting eye
Oil filler cap
Glow plug
Fuel injection nozzle
g00988038
Illustration 9
Right side view of a naturally aspirated 800 Series engine
(15) Exhaust manifold
(16) Starter
(17) Crankshaft vibration damper
(18) V-Belt
(11)
(12)
(13)
(14)
(15)
(19)
(20)
(21)
(22)
Alternator
Thermostat
Lifting eye
Oil filler cap
16
Model Views
g00987267
Illustration 10
Left side view of turbocharged 800 Series engine
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Oil cooler
Fan
Water pump
Oil filler
Fuel injection pump
Oil pressure switch
Oil drain plug
Relief valve
(9) Oil filter

(11) Water drain plug
(12) Oil level gauge
(13) Crankcase breather
(14) Inlet manifold
(15) Glow plug
(16) Fuel injection nozzle
17
Model Views
g00987270
Illustration 11
Right side view of turbocharged 800 Series engine
(17) Lifting eye
(19) Starter
(20) Crankshaft vibration damper

(21) V-Belt
(22) Alternator
(23) Thermostat
(24) Lifting eye
(25) Turbocharger
18
Model Views
i01933689
Engine Description
Table 1
Naturally Aspirated 800 Series Specifications

Type
Four Stroke Cycle
Number of Cylinders
4 In-Line
Bore
94 mm (3.70 inch)
Stroke
120 mm (4.72 inch)
Aspiration
Naturally Aspirated
22:1
Compression ratio
3.33 L (203 in3)
Displacement
1-3-4-2
Firing Order
Rotation that is viewed
from the flywheel
Oil cooler
The engine lubricating oil is supplied by a gear
type pump. The engine lubricating oil is cooled
and the engine lubricating oil is filtered. Bypass
valves provide unrestricted flow of lubrication oil
to the engine parts when oil viscosity is high.
Bypass valves can also provide unrestricted flow of
lubrication oil to the engine parts if the oil cooler
should become plugged or if the oil filter element
should become plugged.
Engine efficiency, efficiency of emission
controls, and engine performance depend on
adherence to proper operation and maintenance
recommendations. Engine performance and
efficiency also depend on the use of recommended
fuels, lubrication oils, and coolants. Refer to the
Operation and Maintenance Manual, Maintenance
Interval Schedule for more information on
maintenance items.
Counterclockwise
Valve Lash Setting (Inlet)
0.25 mm (0.0098 inch)
Valve Lash Setting

(Exhaust)
0.25 mm (0.0098 inch)
Table 2
Turbocharged 800 Series Specifications

Type
Four Stroke Cycle
Number of Cylinders
4 In-Line
Bore
94 mm (3.70 inch)
Stroke
120 mm (4.72 inch)
Aspiration
Turbocharged
19:1
Compression ratio
3.33 L (203 in3)
Displacement
1-3-4-2
Firing Order
Rotation that is viewed
from the flywheel
Counterclockwise
Valve Lash Setting (Inlet)
0.25 mm (0.0098 inch)
Valve Lash Setting

(Exhaust)
0.25 mm (0.0098 inch)
Engine Cooling and Lubrication

The cooling system consists of the following
components:
Gear-driven centrifugal water pump

Water temperature regulators which regulate the
engine coolant temperature
Gear-driven oil pump (gear type)
Engine Service Life

Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operation and maintenance recommendations. In
addition, use recommended fuels, coolants and
lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.
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 period of 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.
19
Product Identification Information
Product Identification
Information
The Serial Number Plate is located on the left side

of the cylinder block.
i01933733
The following information is stamped on the Serial

Number Plate: Engine serial number, Model, and
Arrangement number.
Engine Identification
i01892045
Reference Numbers
Perkins engines are identified by a serial number.
This number is shown on a serial number plate that
is mounted on the left hand side of the engine block.
An example of an engine number is UEU090001H.
UE _________________________________________Type of engine
Information for the following items may be needed

to order parts. Locate the information for your
engine. Record the information on the appropriate
space. Make a copy of this list for a record. Keep
the information for future reference.
U __________________________Built in the United Kingdom

0900001 ________________________Engine Serial Number
H ____________________________________Year of Manufacture
Perkins dealers need all of these numbers in order
to determine the components that were included
with the engine. This permits accurate identification
of replacement part numbers.
i01933737
Serial Number Plate
Record for Reference

Engine Model ______________________________________________
Engine Serial No. __________________________________________
Engine Low Idle rpm _____________________________________
Engine Full Load rpm ____________________________________
Primary Fuel Filter No. ___________________________________
Water Separator Element No. __________________________
Secondary Fuel Filter Element No. ____________________
Lubrication Oil Filter Element No. _____________________
Auxiliary Oil Filter Element No. _________________________
Total Lubrication System Capacity ____________________
Total Cooling System Capacity ________________________
Air Cleaner Element No. _________________________________
Fan Drive Belt No. ________________________________________
Alternator Belt No. ________________________________________
i01933748
Emissions Certification Film

Illustration 12
Typical serial number plate
(1)
(2)
(3)
(4)
Temporary Parts List number

Type
Serial number
List number
g00994966
A typical example is shown.
20
Product Identification Information
Illustration 13
g01002325
21
Operation Section
Lifting and Storage
Operation Section
i01942172
Engine Storage
Lifting and Storage

i01898037
Engine Lifting
If the engine will not be started for several weeks,

the lubricating oil will drain from the cylinder walls
and from the piston rings. Rust can form on the
cylinder walls. Rust on the cylinder walls will cause
increased engine wear and a reduction in engine
service life.
Lubrication System
To help prevent excessive engine wear, use the
following guidelines:
Complete all of the lubrication recommendations
that are listed in this Operation and Maintenance
Manual, Maintenance Interval Schedule
(Maintenance Section).
Illustration 14
g00103219
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle
between the supporting members and the object becomes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
If an engine is out of operation and if use of the

engine is not planned, special precautions should
be made. If the engine will be stored for more than
one month, a complete protection procedure is
recommended.
Use the following guidelines :
Completely clean the outside of the engine.

Drain the fuel system completely and refill
the system with preservative fuel.1772204
POWERPART Lay-Up 1 can be mixed with the
normal fuel in order to change the fuel into
preservative fuel.
If preservative fuel is not available, the fuel system

Use a hoist to remove heavy components. Use
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should
be parallel to each other. The chains and cables
should be perpendicular to the top of the object
that is being lifted.
Some removals require lifting the fixtures in order to
obtain proper balance and safety.
To remove the engine ONLY, use the lifting eyes that
are on the engine.
Lifting eyes are designed and installed for specific
engine arrangements. Alterations to the lifting 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 dealer for information
regarding fixtures for proper engine lifting.
can be filled with normal fuel. This fuel must

be discarded at the end of the storage period
together with the fuel filter elements.
Operate the engine until the engine reaches

normal operating temperature. Stop any leaks
from fuel, lubricating oil or air systems. Stop the
engine and drain the lubricating oil from the oil
pan.
Renew the canister(s) of the lubricating oil filter.
22
Operation Section
Lifting and Storage
Fill the oil pan to the Full Mark on the dipstick

with new, clean lubricating oil. Add 1762811
POWERPART Lay-Up 2 to the oil in order to
protect the engine against corrosion. If 1762811
POWERPART Lay-Up 2 is not available, use a
preservative of the correct specification instead
of the lubricating oil. If a preservative is used,
this must be drained completely at the end of the
storage period and the oil pan must be refilled to
the correct level with normal lubricating oil.
Cooling System
To help prevent excessive engine wear, use the
following guidelines:
NOTICE
Do not drain the coolant while the engine is still hot and
the system is under pressure because dangerous hot
coolant can be discharged.
If freezing temperatures are expected, check the
cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual, General Coolant Information (Maintenance
Section).
NOTICE
To prevent frost damage, ensure that all the coolant is
removed from the engine. This is important if the system is drained after it has been flushed with water, or if
an antifreeze solution too weak to protect the system
from frost has been used.
4. Open the tap or remove the drain plug at the

bottom of the radiator in order to drain the
radiator. If the radiator does not have a tap or a
drain plug, disconnect the hose at the bottom
of the radiator.
5. Flush the cooling system with clean water.
6. Fit the drain plugs and the filler cap. Close the
tap or connect the radiator hose.
7. Fill the cooling system with an approved
antifreeze mixture because this gives protection
against corrosion.
Note: Certain corrosion inhibitors could cause
damage to some engine components. Contact the
Service Department of Perkins for advice.
8. Operate the engine for a short period in order
to circulate the lubricating oil and the coolant
in the engine.
9. Disconnect the battery. Put the battery into safe
storage in a fully charged condition. Before the
battery is put into storage, protect the terminals
against corrosion.1734115 POWERPART Lay-Up
3 can be used on the terminals.
10. Clean the crankcase breather if one is installed.
Seal the end of the pipe.
11. Remove the fuel injector nozzles and spray
1762811 POWERPART Lay-Up 2 for one or two
seconds into each cylinder bore with the piston
at BDC.
12. Slowly rotate the crankshaft for one complete
revolution and then replace the fuel injector
nozzles.
Induction System
Remove the air filter assembly. If necessary,
Illustration 15
g00987502
remove the pipes that are installed between

the air filter assembly and the turbocharger.
Spray 1762811 POWERPART Lay-Up 2 into the
turbocharger. The duration of the spray is printed
on the container. Seal the turbocharger with
waterproof tape.
1. Ensure that the vehicle is on level ground.
Exhaust System
2. Remove the filler cap of the cooling system.
Remove the exhaust pipe. Spray 1762811
3. Remove the drain plug (1) from the side of the

cylinder block in order to drain the engine.
Ensure that the drain hole is not restricted.
POWERPART Lay-Up 2 into the turbocharger. The

duration of the spray is printed on the container.
Seal the turbocharger with waterproof tape.
23
Operation Section
Lifting and Storage
General Items
If the lubricating oil filler is installed on the rocker
cover, remove the filler cap. If the lubricating
oil filler cap is not installed on the rocker
cover, remove the rocker cover. Spray 1762811
POWERPART Lay-Up 2 around the rocker shaft
assembly. Replace the filler cap or the rocker
cover.
Seal the vent of the fuel tank or the fuel filler cap
with waterproof tape.
Remove the alternator drive belts and put the

drive belts into storage.
In order to prevent corrosion, spray the engine

with 1734115 POWERPART Lay-Up 3. Do not
spray the area inside the alternator.
When the engine protection has been completed in
accordance with these instructions, this ensures that
no corrosion will occur. Perkins are not responsible
for damage which may occur when an engine is in
storage after a period in service.
Your Perkins dealer or your Perkins distributor can
assist in preparing the engine for extended storage
periods.
24
Operation Section
Gauges and Indicators
1. Reduce the load and the engine rpm.

2. Inspect the cooling system for leaks.
i01930356

Your engine may not have the same gauges or all of
the gauges that are described. For more information
about the gauge package, see the OEM information.
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine the normal operating range by observing
the gauges over a period of time.
Noticeable changes in gauge readings indicate
potential gauge or engine problems. Problems may
also be indicated by gauge readings that change
even if the readings are within specifications.
Determine and correct the cause of any significant
change in the readings. Consult your Perkins dealer
or your Perkins distributor for assistance.
NOTICE
If no oil pressure is indicated, STOP the engine. If
maximum coolant temperature is exceeded, STOP the
engine. Engine damage can result.
Engine Oil Pressure The oil pressure
should be greatest after a cold engine is
started. The typical engine oil pressure
with SAE10W30 is 207 to 413 kPa (30 to 60 psi) at
rated rpm.
A lower oil pressure is normal at low idle. If the load
is stable and the gauge reading changes, perform
the following procedure:
1. Remove the load.
2. Reduce engine speed to low idle.
3. Check and maintain the oil level.
Jacket Water Coolant Temperature
Typical temperature range is 71 to 96C
(160 to 205F). The maximum allowable
temperature with the pressurized cooling system at
48 kPa (7 psi) is 110C (230F). Higher temperatures
may occur under certain conditions. The water
temperature reading may vary according to load.
The reading should never exceed the boiling point
for the pressurized system that is being used.
If the engine is operating above the normal range
and steam becomes apparent, perform the following
procedure:
3. Determine if the engine must be shut down

immediately or if the engine can be cooled by
reducing the load.
Tachometer This gauge indicates engine
speed (rpm). When the throttle control
lever is moved to the full throttle position
without load, the engine is running at high idle. The
engine is running at the full load rpm when the
throttle control lever is at the full throttle position
with maximum rated load.
NOTICE
To help prevent engine damage, never exceed the
high idle rpm. Overspeeding can result in serious
damage to the engine. The engine can be operated
at high idle without damage, but should never be
allowed to exceed high idle rpm.
Ammeter This gauge indicates the
amount of charge or discharge in the
battery charging circuit. Operation of the
indicator should be to the right side of 0(zero).
Fuel Level This gauge indicates the fuel
level in the fuel tank. The fuel level gauge
operates when the START/STOP switch
is in the on position.
Service Hour Meter The gauge indicates
operating time of the engine.
25
Operation Section
Engine Starting
Engine Starting
Do not start the engine or move any of the

i01903008
Before Starting Engine
controls if there is a DO NOT OPERATE warning

tag or similar warning tag attached to the start
switch or to the controls.
Ensure that the areas around the rotating parts

are clear.
Before the engine is started, perform the required

daily maintenance and any other periodic
maintenance that is due. Refer to the Operation
and Maintenance Manual, Maintenance Interval
Schedule for more information.
For the maximum service life of the engine,
All of the guards must be put in place. Check for

damaged guards or for missing guards. Repair
any damaged guards. Replace damaged guards
and/or missing guards.
Disconnect any battery chargers that are not

protected against the high current drain that
is created when the electric starting motor is
engaged. Check electrical cables and check the
battery for poor connections and for corrosion.
make a thorough inspection within the engine

compartment before the engine is started. Look
for the following items: oil leaks, coolant leaks,
loose bolts, and excessive dirt and/or grease.
Remove any excess dirt and/or grease buildup.
Repair any faults that were identified during the
inspection.
Reset all of the shutoffs or alarm components (if
Inspect the cooling system hoses for cracks and
the oil level between the ADD mark and the

FULL mark on the oil level dipstick.
equipped).
Check the engine lubrication oil level. Maintain
for loose clamps.
Inspect the alternator and accessory drive belts

for cracks, breaks, and other damage.
Inspect the wiring for loose connections and for

worn wires or frayed wires.
Check the fuel supply. Drain water from the water

separator (if equipped). Open the fuel supply
valve (if equipped).
NOTICE
All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage.
If the engine has not been started for several
weeks, fuel may have drained from the fuel system.
Air may have entered the filter housing. Also, when
fuel filters have been changed, some air pockets
will be trapped in the engine. In these instances,
prime the fuel system. Refer to the Operation and
Maintenance Manual, Fuel System - Prime for
more information on priming the fuel system.
Engine exhaust contains products of combustion

which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
Check the coolant level. Observe the coolant

level in the header tank (if equipped). Maintain
the coolant level to the FULL mark on the
header tank.
If the engine is not equipped with a header tank

maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level in the sight glass.
Observe the air cleaner service indicator (if

equipped). Service the air cleaner when the
yellow diaphragm enters the red zone, or when
the red piston locks in the visible position.
Ensure that any equipment that is driven by the

engine has been disengaged from the engine.
Minimize electrical loads or remove any electrical
loads.
26
Operation Section
Engine Starting
i01934161
Starting the Engine
i01929012
Starting with Jump Start

Cables

personal injury.
NOTICE
Do not crank the engine for more than 10 seconds.
Allow the starter motor to cool for 30 seconds before
cranking again. Do not engage the starter when the
flywheel is turning.
Refer to the OEM Manual for your type of controls.
1. Remove any load from the engine. Disengage
any driven equipment.
Improper jump start cable connections can cause

an explosion resulting in personal injury.
Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
Note: If it is possible, first diagnose the reason
for the starting failure. Make any necessary
repairs. If the engine will not start only due to
the condition of the battery, either charge the
battery, or start the engine with jump start cables.
The condition of the battery can be rechecked
after the engine has been switched OFF.
2. Crank the engine. Start the engine.

3. If the engine does not start, release the engine
start switch and allow the electric starting motor
to cool.
4. If the ambient temperature is low, activate the
glow plugs according to Table 3.
Do not reverse the battery cables. The alternator can

be damaged. Attach ground cable last and remove
first.
Table 3
Preheat Times
Temperature

Preheat Time
10 seconds
5 C (41 F)

5 C (23 F) to 4 C (40 F)

NOTICE
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.
20 seconds
Less than 5 C (23 F)
30 seconds
Continuous Preheat
60 seconds maximum
When using an external electrical source to start the

engine, turn the engine control switch to the OFF position. Turn all electrical accessories OFF before attaching the jump start cables.
Ensure that the main power switch is in the OFF position before attaching the jump start cables to the engine being started.
5. Crank the engine. Start the engine.

6. Allow the engine to idle for 5 to 10 minutes
before applying a load to the engine. Check
the oil pressure gauge. The oil pressure gauge
should be at the proper value.
1. Turn the start switch to the OFF position. Turn off

all the engines accessories.
2. Connect one positive end of the jump start cable
to the positive cable terminal of the discharged
battery. Connect the other positive end of the
jump start cable to the positive cable terminal
of the electrical source.
27
Operation Section
Engine Starting
3. Connect one negative end of the jump start cable

to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting the combustible
gases that are produced by some batteries.
4. Start the engine.
5. Immediately after the stalled engine is started,
disconnect the jump start cables in reverse order.
After jump starting, the alternator may not be
able to fully recharge batteries that are severely
discharged. The batteries must be replaced or
charged to the 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.
i01903609
After Starting Engine

Note: In temperatures from 0 to 60C (32 to 140F),
the warm-up time is approximately three minutes. In
temperatures below 0C (32F), additional warm-up
time may be required.
When the engine idles during warm-up, observe
the following conditions:
Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is
not possible in some applications.
Operate the engine at low idle until all systems

achieve operating temperatures. Check all
gauges during the warm-up period.
Note: Gauge readings should be observed and the
data should be recorded frequently while the engine
is operating. Comparing the data over time will
help to determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
28
Operation Section
Engine Operation
Engine Operation
i01934633
Fuel Conservation Practices

i01903587
Engine Operation
Proper operation and maintenance are key factors
in obtaining the maximum life and economy of
the engine. If the directions in the Operation and
Maintenance Manual are followed, costs can
be minimized and engine service life can be
maximized.
The engine can be operated at the rated rpm after
the engine reaches operating temperature. The
engine will reach normal operating temperature
sooner during a low engine speed (rpm) and
during a low power demand. This procedure is
more effective than idling the engine at no load.
The engine should reach operating temperature in
a few minutes.
Gauge readings should be observed and the data
should be recorded frequently while the engine is
operating. Comparing the data over time will help
to determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
The efficiency of the engine can affect the fuel

economy. Perkins design and technology in
manufacturing provides maximum fuel efficiency
in all applications. Follow the recommended
procedures 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.
Be aware of the properties of the different fuels.

Use only the recommended fuels.
Avoid unnecessary idling.

Shut off the engine rather than idle for long periods
of time.
Observe the service indicator frequently. Keep

the air cleaner elements clean.
Maintain a good electrical system.

One damaged battery cell will overwork the
alternator. This will consume excess power and
excess fuel.
Ensure that the belts are properly adjusted. The

belts should be in good condition.
Ensure that all of the connections of the hoses

are tight. The connections should not leak.
Ensure that the driven equipment is in good

working order.
Cold engines consume excess fuel. Utilize heat

from the jacket water system and the exhaust
system, when possible. Keep cooling system
components clean and keep cooling system
components in good repair. Never operate the
engine without water temperature regulators.
All of these items will help maintain operating
temperatures.
29
Operation Section
Engine Stopping
Engine Stopping
i01935215
After Stopping Engine

i01935195
Stopping the Engine
Note: Before you check the engine oil, do not

operate the engine for at least 10 minutes in order
to allow the engine oil to return to the oil pan.
NOTICE
Stopping the engine immediately after it has been
working under load, can result in overheating and accelerated wear of the engine components.
Check the crankcase oil level. Maintain the oil

level between the MIN mark and the MAX
mark on the oil level dipstick.
Avoid accelerating the engine prior to shutting it down.
If necessary, perform minor adjustments. Repair
Avoiding hot engine shutdowns will maximize turbocharger shaft and bearing life.
If the engine is equipped with a service hour
Note: Individual applications will have different

control systems. Ensure that the shutoff procedures
are understood. Use the following general
guidelines in order to stop the engine.
1. Remove the load from the engine. Reduce the
engine speed (rpm) to low idle. Perform this
procedure for five to six minutes in order to cool
the engine.
2. Stop the engine after the cool down period
according to the shutoff system on the engine
and turn the ignition key switch to the OFF
position. If necessary, refer to the instructions
that are provided by the OEM.
i01903586
Emergency Stopping
any leaks and tighten any loose bolts.

meter, note the reading. Perform the maintenance
that is in the Operation and Maintenance Manual,
Maintenance Interval Schedule.
Fill the fuel tank in order to help prevent

accumulation of moisture in the fuel. Do not
overfill the fuel tank.
NOTICE
Only use antifreeze/coolant mixtures recommended in
the Coolant Specifications that are in the Operation
and Maintenance Manual. Failure to do so can cause
engine damage.
Allow the engine to cool. Check the coolant level.

If freezing temperatures are expected, check
the coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the correct coolant/water mixture, if necessary.
Perform all required periodic maintenance on all

NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.
The OEM may have equipped the application with
an emergency stop button. For more information
about the emergency stop button, refer to the OEM
information.
Ensure that any components for the external system
that support the engine operation are secured after
the engine is stopped.
driven equipment. This maintenance is outlined in

the instructions from the OEM.
30
Operation Section
Cold Weather Operation

i01903584
Install the correct lubricant in each compartment

before the beginning of cold weather.
Check all rubber parts (hoses, fan drive belts,

etc) weekly.
Check all electrical wiring and connections for

any fraying or damaged insulation.
Perkins Diesel Engines can operate effectively in
cold weather. During cold weather, the starting and
the operation of the diesel engine is dependent on
the following items:
The type of fuel that is used

The viscosity of the oil
Keep all batteries fully charged and warm.

Fill the fuel tank at the end of each shift.
Check the air cleaners and the air intake daily.
Check the air intake more often when you operate
in snow.
The operation of the air inlet heater starting aid

Optional Cold starting aid
The purpose of this section will cover the following
information:
Explain potential problems that are caused by
Personal injury or property damage can result

from alcohol or starting fluids.
Alcohol or starting fluids are highly flammable and
toxic and if improperly stored could result in injury
or property damage.
cold weather operation.
Suggest steps which can be taken in order

to minimize starting problems and operating
problems when the ambient air temperature is
colder than 0 to 55 C (32 to 67 F).
The operation and maintenance of an engine in
freezing temperatures is complex. This is because
of the following conditions: the unlimited differences
in weather conditions, engine applications, and
the supplies that are available in your area. These
factors and recommendations from your Perkins
dealer are based on past proven practices. The
information that is contained in this section should
be combined in order to provide guidelines for cold
weather operations.
Hints for Cold Weather Operation

until a
If the engine will start, operate the engine

minimum operating temperature of 71 C (160 F)

is achieved. Achieving operating temperature will
help prevent the intake valves and exhaust valves
from sticking.
The cooling system and the lubrication system for

the engine do not lose heat immediately upon
shutdown. This means that an engine can be shut
down for a few hours and the engine can still have
the ability to start readily. If the engine is shut
down for at least eight hours, the engine should
be considered cooled to outside temperature.

personal injury.
For jump starting with cables in cold weather,

refer to the Operation and Maintenance Manual,
Starting with Jump Start Cables. for instructions.
Viscosity of the Engine Lubrication

Oil
Proper engine oil viscosity is essential. Oil viscosity
affects the amount of torque that is needed to
crank the engine. Refer to the Operation and
Maintenance Manual, Lubricant Specifications for
the recommended viscosity of oil.
Recommendations for the Coolant

Provide cooling system protection for the lowest
expected outside temperature. Refer to the
Operation and Maintenance Manual, General
Coolant Information for the recommended coolant
mixture.
In cold weather, check the coolant often for the
proper glycol concentration in order to ensure
adequate freeze protection.
31
Operation Section
Engine Block Heaters
Valves become stuck.
Engine block heaters (if equipped) heat the

engine jacket water that surrounds the combustion
chambers. This provides the following functions:
Pushrods are bent.

Other damage to valve train components can
result.
Startability is improved.
Warm up time is reduced.
An electric block heater can be activated once
the engine is stopped. An effective block heater
is typically a 1250/1500 W unit. Consult your
Perkins dealer or your Perkins distributor for more
information.
Idling the Engine

When idling after the engine is started in cold
weather, increase the engine rpm from 1000 to 1200
rpm. This will warm up the engine more quickly.
Maintaining an elevated low idle speed for extended
periods will be easier with the installation of a hand
throttle. The engine should not be raced in order
to speed up the warm up process.
While the engine is idling, the application of a light
load (parasitic load) will assist in maintaining the
minimum operating temperature. The minimum
operating temperature is 71 C (160 F).
Recommendations for Coolant

Warm Up
Warm up an engine that has cooled below normal
operating temperatures due to inactivity. This should
be performed before the engine is returned to full
operation. During operation in very cold temperature
conditions, damage to engine valve mechanisms
can result from engine operation for short intervals.
This can happen if the engine is started and
the engine is stopped many times without being
operated in order to warm up completely.
When the engine is operated below normal
operating temperatures, fuel and oil are not
completely burned in the combustion chamber.
This fuel and oil causes soft carbon deposits to
form on the valve stems. Generally, the deposits do
not cause problems and the deposits are burned
off during operation at normal engine operating
temperatures.
When the engine is started and the engine is
stopped many times without being operated in
order to warm up completely, the carbon deposits
become thicker. This will cause the following
problems:
Free operation of the valves is prevented.
For this reason, when the engine is started,

the engine must be operated until the coolant
temperature is 71 C (160 F) minimum. Carbon
deposits on the valve stems will be kept at a
minimum and the free operation of the valves and
the valve components will be maintained.
In addition, the engine must be thoroughly warmed
in order to keep other engine parts in better
condition and the service life of the engine will be
generally extended. Lubrication will be improved.
There will be less acid and less sludge in the oil.
This will provide longer service life for the engine
bearings, the piston rings, and other parts. However,
limit unnecessary idle time to ten minutes in order
to reduce wear and unnecessary fuel consumption.
Purge Valve and Insulated Heater Lines

The engine is equipped with a water temperature
regulator in order to allow the engine to reach the
correct operating temperature quickly. The water
temperature regulator remains in the closed position
until the jacket water coolant temperature has
reached the engines operating temperature. The
jacket water circulates from the top of the cylinder
block, to the water temperature regulator housing,
and back to the bottom of the cylinder block via
the bypass. The water temperature regulator allows
some flow of water and/or air to pass through the
water temperature regulator in order to ensure a
continuous flow of coolant within the cylinder block.
This is achieved via a small jiggle valve in the
water temperature regulator. The water temperature
regulator moves to the open position when the
jacket water coolant temperature has reached
the correct operating temperature. The water
temperature regulator moves to the open position in
order to allow the passage of the coolant through
the radiator to dissipate excess heat.
The above procedure is good for normal engine
operating conditions in temperate climates. During
periods of operations in a cold climate with a light
engine load, the coolant must bypass the radiator
in order to help prevent excessive cooling of the
engine. Coolant that passes through the radiator
must be minimized in order to maintain the engine
operating temperature in cold weather.
32
Operation Section
Excessive cooling of the engine can be prevented

by a valve that allows unnecessary coolant flow to
be diverted from the water temperature regulator
and back to the bottom of the engine block without
passing through the radiator.
Note: Group 3 fuels reduce the life of the engine.

The use of Group 3 fuels is not covered by the
Perkins warranty.
Note: Perkins discourages the use of all airflow

restriction devices such as radiator shutters.
Restriction of the airflow can result in the following:
high exhaust temperatures, power loss, excessive
fan usage, and reduction in fuel economy.
Group 1 fuels are the preferred Group of Fuels for

general use by Perkins. Group 1 fuels maximize
engine life and engine performance. Group 1
fuels are usually less available than Group 2 fuels.
Frequently, Group 1 fuels are not available in colder
climates during the winter.
Cab heater lines for very cold weather are also

beneficial. These lines provide more available heat
from the coolant to the cab. The feed from the
engine and the return lines from the cab should be
insulated in order to reduce heat loss to the outside
air.
Insulating the Air Inlet and Engine

Compartment

When temperatures below 18 C (0 F) will be

frequently encountered, an air cleaner inlet that
is located in the engine compartment may be
specified. An air cleaner that is located in the
engine compartment may also minimize the entry of
snow into the air cleaner. Also, heat that is rejected
by the engine helps to warm the intake air.
Additional heat can be retained around the engine
by insulating the engine compartment.
Special fuels include Biofuel.
Note: Group 2 fuels must have a maximum wear

scar of 650 micrometers (HFRR to ISO 12156-1).
Group 2 fuels are considered acceptable for issues
of warranty. This group of fuels may reduce the life
of the engine, the engines maximum power, and
the engines fuel efficiency.
When Group 2 diesel fuels are used the following
components provide a means of minimizing
problems in cold weather:
Glow plugs, which are standard equipment on

all 800 Series engines
Engine coolant heaters, which may be an OEM

option
Fuel heaters, which may be an OEM option

Fuel line insulation, which may be an OEM option
i01935225
Fuel and the Effect from Cold

Weather
There are three major differences between Group

1 fuels and Group 2 fuels. Group 1 fuels have the
following different characteristics to Group 2 fuels.
A lower cloud point

Note: Only use grades of fuel that are recommended
by Perkins. Refer to this Operation and Maintenance
Manual, Fuel Recommendations.
The following fuels can be used for the Perkins 800
Series engine.
Group 1
Group 2
Group 3
Special Fuels
Perkins prefer only Group 1 and Group 2 fuels for
use in 800 Series engines. Group 3 fuels include
Low Temperature Fuels and Aviation Kerosene
Fuels.
A lower pour point

A higher rating of kJ (BTU) per unit volume of fuel
The cloud point is the temperature when a cloud
of wax crystals begins to form in the fuel. These
crystals can cause the fuel filters to plug. The
pour point is the temperature when diesel fuel will
thicken. The diesel fuel becomes more resistant to
flow through fuel pumps and through the fuel lines.
Be aware of these values when diesel fuel is
purchased. Consider the average ambient air
temperature for the engines application. Engines
that are fueled in one climate may not operate well if
the engines are moved to another climate. Problems
can result due to changes in temperature.
33
Operation Section
Before troubleshooting for low power or for poor

performance in the winter, check the type of fuel
that is being used.
Low temperature fuels may be available for engine
operation at temperatures below 0 C (32 F). These
fuels limit the formation of wax in the fuel at low
temperatures. Wax in the fuel may prevent the flow
of the fuel through the fuel filters.
For more information on cold weather operation,
see Operation and Maintenance Manual, Cold
Weather Operation and Fuel Related Components
in Cold Weather.
i01903588
Fuel Related Components in

Cold Weather
Fuel Tanks
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after you operate the engine.
Fuel tanks should contain some provision for
draining water and sediment from the bottom of the
tanks. Some fuel tanks use supply pipes that allow
water and sediment to settle below the end of the
fuel supply pipe.
Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.
Drain the water and sediment from any fuel storage
tank at the following intervals: weekly, oil changes,
and refueling of the fuel tank. This will help prevent
water and/or sediment from being pumped from the
fuel storage tank and into the engine fuel tank.
Fuel Filters
It is possible that a primary fuel filter is installed
between the fuel tank and the engine fuel inlet. After
you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
system. Refer to the Operation and Maintenance
Manual in the Maintenance Section for more
information on priming the fuel system.
The micron rating and the location of a primary
fuel filter is important in cold weather operation.
The primary fuel filter and the fuel supply line are
the most common components that are affected by
cold fuel.
Fuel Heaters
Note: The OEM may equip the application with fuel
heaters. If this is the case, disconnect an electric
type of fuel heater in warm weather in order to
prevent overheating of the fuel. If the type of fuel
heater is a heat exchanger, the OEM should have
included a bypass for warm weather. Ensure that
the bypass is operational during warm weather in
order to prevent overheating of the fuel.
For more information about fuel heaters (if
equipped), refer to the OEM information.
34
Maintenance Section
Lubricant Specifications
Maintenance Section
Table 4
API Classifications
i01903582
Lubricant Information
(1)
Current
Obsolete
CF-4, CG-4, CH-4
CE
CF
CC, CD
CF-2(1)
CD-2(1)
The classifications CD-2 and American Petroleum Institute

CF-2 are for two-cycle diesel engines. Perkins does not sell
engines that utilize CD-2 and API CF-2 oils.
General Information
Terminology
Because of government regulations regarding

the certification of engine exhaust emissions, the
lubricant recommendations must be followed.
Certain abbreviations follow the nomenclature of

SAE J754. Some classifications follow SAE J183
abbreviations, and some classifications follow
the EMA Recommended Guideline on Diesel
Engine Oil. In addition to Perkins definitions, there
are other definitions that will be of assistance in
purchasing lubricants. Recommended oil viscosities
can be found in this publication, Engine Oil topic
Engine Manufacturers Association

(EMA) Oils
The Engine Manufacturers Association
Recommended Guideline on Diesel Engine Oil is
recognized by Perkins. For detailed information
about this guideline, see the latest edition of EMA
publication, EMA DHD -1.
i01903583
Engine Oil
API Oils
The Engine Oil Licensing and Certification System
by the American Petroleum Institute (API) is
recognized by Perkins. For detailed information
about this system, see the latest edition of the API
publication No. 1509. Engine oils that bear the API
symbol are authorized by API.
Commercial Oils
The performance of commercial diesel engine
oils is based on American Petroleum Institute
(API) classifications. These API classifications are
developed in order to provide commercial lubricants
for a broad range of diesel engines that operate at
various conditions.
Only use commercial oils that meet the following
classifications:
EMA DHD-1 multigrade oil (preferred oil)

API CH-4 multigrade oil (preferred oil)
ACEAE3
In order to make the proper choice of a commercial
oil, refer to the following explanations:
Illustration 16
g00546535
Typical API symbol
Diesel engine oils CC, CD, CD-2, and CE have

not been API authorized classifications since 1
January 1996. Table 4 summarizes the status of the
classifications.
35
Maintenance Section
EMA DHD-1 The Engine Manufacturers

Association (EMA) has developed lubricant
recommendations as an alternative to the API oil
classification system. DHD-1 is a Recommended
Guideline that defines a level of oil performance
for these types of diesel engines: high speed, four
stroke cycle, heavy-duty, and light duty. DHD-1 oils
may be used in Perkins engines when the following
oils are recommended: API CH-4, API CG-4, and
API CF-4. DHD-1 oils are intended to provide
superior performance in comparison to API CG-4
and API CF-4.
Three new engine tests were developed for the

API CH-4 oil. The first test specifically evaluates
deposits on pistons for engines with the two-piece
steel piston. This test (piston deposit) also measures
the control of oil consumption. A second test is
conducted with moderate oil soot. The second
test measures the following criteria: wear of piston
rings, wear of cylinder liners, and resistance to
corrosion. A third new test measures the following
characteristics with high levels of soot in the oil:
wear of the valve train, resistance of the oil in
plugging the oil filter, and control of sludge.
DHD-1 oils will meet the needs of high performance

Perkins diesel engines that are operating in many
applications. The tests and the test limits that
are used to define DHD-1 are similar to the new
API CH-4 classification. Therefore, these oils will
also meet the requirements of the low emissions
diesel engines. DHD-1 oils are designed to control
the harmful effects of soot with improved wear
resistance and improved resistance to plugging of
the oil filter. These oils will also provide superior
piston deposit control for engines with either
two-piece steel pistons or aluminum pistons.
In addition to the new tests, API CH-4 oils have

tougher limits for viscosity control in applications
that generate high soot. The oils also have improved
oxidation resistance. API CH-4 oils must pass an
additional test (piston deposit) for engines that use
aluminum pistons (single piece). Oil performance is
also established for engines that operate in areas
with high sulfur diesel fuel.
All DHD-1 oils must complete a full test program

with the base stock and with the viscosity grade of
the finished commercial oil. The use of API Base
Oil Interchange Guidelines are not appropriate for
DHD-1 oils. This feature reduces the variation in
performance that can occur when base stocks are
changed in commercial oil formulations.
DHD-1 oils are recommended for use in extended
oil change interval programs that optimize oil life.
These oil change interval programs are based
on oil analysis. DHD-1 oils are recommended for
conditions that demand a premium oil. Your Perkins
dealer or your Perkins distributor has the specific
guidelines for optimizing oil change intervals.
API CH-4 API CH-4 oils were developed in
order to meet the requirements of the new high
performance diesel engines. Also, the oil was
designed to meet the requirements of the low
emissions diesel engines. API CH-4 oils are also
acceptable for use in older diesel engines and
in diesel engines that use high sulfur diesel fuel.
API CH-4 oils may be used in Perkins engines that
use API CG-4 and API CF-4 oils. API CH-4 oils will
generally exceed the performance of API CG-4 oils
in the following criteria: deposits on pistons, control
of oil consumption, wear of piston rings, valve train
wear, viscosity control, and corrosion.
All of these improvements allow the API CH-4 oil to

achieve optimum oil change intervals. API CH-4 oils
are recommended for use in extended oil change
intervals. API CH-4 oils are recommended for
conditions that demand a premium oil. Your Perkins
dealer or your Perkins distributor has specific
guidelines for optimizing oil change intervals.
Some commercial oils that meet the API
classifications may require reduced oil change
intervals. To determine the oil change interval,
closely monitor the condition of the oil and perform
a wear metal analysis.
NOTICE
Failure to follow these oil recommendations can cause
shortened engine service life due to deposits and/or
excessive wear.
Total Base Number (TBN) and Fuel

Sulfur Levels for Direct Injection
(DI) Diesel Engines
The Total Base Number (TBN) for an oil depends on
the fuel sulfur level. For direct injection engines that
use distillate fuel, the minimum TBN of the new oil
must be 10 times the fuel sulfur level. The TBN is
defined by ASTM D2896. The minimum TBN of
the oil is 5 regardless of fuel sulfur level. Illustration
17 demonstrates the TBN.
36
Maintenance Section
Refer to Table 6 (minimum temperature) in order

to determine the required oil viscosity for starting
a cold engine.
Refer to Table 6 (maximum temperature) in order to
select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.
Generally, use the highest oil viscosity that
is available to meet the requirement for the
temperature at start-up.
Table 6
Engine Oil Viscosity

g00799818
Illustration 17
(Y) TBN by ASTM D2896

(X) Percentage of fuel sulfur by weight
(1) TBN of new oil
(2) Change the oil when the TBN deteriorates to 50 percent of
the original TBN.
EMA LRG-1
API CH-4
Viscosity Grade
Ambient Temperature
Minimum

Maximum
SAE 0W20
40 C (40 F)
10 C (50 F)
SAE 0W30
40 C (40 F)
30 C (86 F)
Use the following guidelines for fuel sulfur levels

that exceed 1.5 percent:
SAE 0W40
40 C (40 F)
40 C (104 F)
SAE 5W30
30 C (22 F)
30 C (86 F)
Choose an oil with the highest TBN that meets
SAE 5W40
30 C (22 F)
40 C (104 F)
SAE 10W30
20 C (4 F)
40 C (104 F)
SAE 15W40
10 C (14 F)
50 C (122 F)
one of these classifications: EMA DHD-1 and API

CH-4.
Reduce the oil change interval. Base the oil

change interval on the oil analysis. Ensure that
the oil analysis includes the condition of the oil
and a wear metal analysis.
Excessive piston deposits can be produced by an
oil with a high TBN. These deposits can lead to a
loss of control of the oil consumption and to the
polishing of the cylinder bore.
NOTICE
Operating Direct Injection (DI) diesel engines with fuel
sulphur levels over 0.5 percent will require shortened
oil change intervals in order to help maintain adequate
wear protection.
i01903738
Synthetic Base Stock Oils

Synthetic base oils are acceptable for use in
these engines if these oils meet the performance
requirements that are specified for the engine.
Synthetic base oils generally perform better than
conventional oils in the following two areas:
Synthetic base oils have improved flow at low

temperatures especially in arctic conditions.
Table 5
Percentage of Sulfur in the

fuel
Oil change interval
Synthetic base oils have improved oxidation
Lower than 0.5
Normal
0.5 to 1.0
0.75 of normal
Greater than 1.0
0.50 of normal
Some synthetic base oils have performance

characteristics that enhance the service life of the
oil. Perkins does not recommend the automatic
extending of the oil change intervals for any type
of oil.
Lubricant Viscosity Recommendations

for Direct Injection (DI) Diesel Engines
The proper SAE viscosity grade of oil is determined
by the minimum ambient temperature during
cold engine start-up, and the maximum ambient
temperature during engine operation.
stability especially at high operating temperatures.
37
Maintenance Section
i01903742
Re-refined Base Stock Oils

Re-refined base stock oils are acceptable for
use in Perkins engines if these oils meet the
performance requirements that are specified by
Perkins. Re-refined base stock oils can be used
exclusively in finished oil or in a combination with
new base stock oils. The US military specifications
and the specifications of other heavy equipment
manufacturers also allow the use of re-refined base
stock oils that meet the same criteria.
The process that is used to make re-refined base
stock oil should adequately remove all wear metals
that are in the used oil and all the additives that
are in the used oil. The process that is used to
make re-refined base stock oil generally involves
the process of vacuum distillation and hydrotreating
the used oil. Filtering is adequate for the production
of high quality, re-refined base stock oil.
i01903752
Cold Weather Lubricants

When an engine is started and an engine is
operated in ambient temperatures below 20 C
(4 F), use multigrade oils that are capable of
flowing in low temperatures.
NOTICE
Shortened engine service life could result if second
choice oils are used.
i01904027
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. This 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:
Select the proper oil, or a commercial oil that

These oils have lubricant viscosity grades of SAE
0W or SAE 5W.
When an engine is started and operated in ambient
temperatures below 30 C (22 F), use a synthetic
base stock multigrade oil with a 0W viscosity grade
or with a 5W viscosity grade. Use an oil with a pour
point that is lower than 50 C (58 F).
The number of acceptable lubricants is limited
in cold weather conditions. Perkins recommends
the following lubricants for use in cold weather
conditions:
First Choice Use oil with an EMA DHD-1
Recommended Guideline. Use a CH-4 oil that has
an API license. The oil should be either SAE 0W20,
SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40
lubricant viscosity grade.
Second Choice Use an oil that has a CH-4
additive package. Although the oil has not been
tested for the requirements of the API license, the oil
must be either SAE 0W20, SAE 0W30, SAE 0W40,
SAE 5W30, or SAE 5W40.
meets the EMA Recommended Guideline on

Diesel Engine Oil or the recommended API
classification.
See the appropriate Lubricant Viscosities table

in order to find the correct oil viscosity grade for
your engine.
At the specified interval, service the engine. Use

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

specified in the Operation and Maintenance
Manual, Maintenance Interval Schedule.
38
Maintenance Section
Fuel Specifications
Fuel Specifications
Diesel engines have the ability to burn a wide

variety of fuels. These fuels are divided into four
general groups:
i01904061
Fuel Recommendations
Group 1 (preferred fuels)

Group 2 (permissible fuels)
To get the correct power and performance from

the engine, use a fuel of the correct quality. The
recommended fuel specification for the Perkins
1106 engine is shown below:
Cetane number__________________________45 minimum

Viscosity___________2,0 to 4.5 cSt at 40 C (104 F)
Group 3 (aviation kerosene fuels)

Other fuels
Group 1 (preferred fuels): Specification
DERV to EN590
Distillation___________________85% at 350 C (662 F)
Note: Only use Arctic fuels when the temperature is

below 0 C (32 F). Do not use Arctic fuels when
the ambient temperature is above 0 C (32 F).
To ensure that the time period between cranking
the engine and first fire is kept to a minimum, only
use fuel of the correct viscosity and at the correct
temperature.
Lubricity______________________________460 micrometers
Gas oil to BS2869 Class A2
Density________________________0.835 to 0.855 Kg/liter

Sulfur_______________________0.2% of mass, maximum
maximum wear scar on ISO 12156 - 1

Cetane number
ASTM D975 - 91 Class 2D This can only be used

if the fuel has the correct specification of lubricity.
This indicates the properties of ignition of the fuel.

Fuel with a low cetane number can be the root
cause of problems during cold start. This will affect
combustion.
JIS K2204 (1992) Grades 1,2,3 and Special Grade

3 This can only be used if the fuel has the correct
specification of lubricity.
Viscosity
Note: If low sulfur or low sulfur aromatic fuels are

used, then fuel additives can be used to increase
lubricity.
This is the resistance to flow of a fluid. If this

resistance is outside the limits, the engine and the
engine starting performance in particular can be
affected.
Group 2 (permissible fuels): Specification
Sulfur
High sulfur content of the fuel is not normally found
in Europe, North America or Australasia. This can
cause engine wear. When only high sulfur fuels are
available, it will be necessary that high alkaline
lubricating oil is used in the engine or that the
lubricating oil change interval is reduced.
Distillation
This is an indication of the mixture of different
hydrocarbons in the fuel. A high ratio of light weight
hydrocarbons can affect the characteristics of
combustion.
These fuel specifications are considered acceptable

for issues of warranty. However,these fuels may
reduce the life of the engine, the engines maximum
power and the engines fuel efficiency.
ASTM D975 - 91 Class 1D
JP7, Mil T38219
NATO F63
NOTICE
These fuels should have a wear scar value of 650
micrometers maximum HFRR to ISO 12156 - 1 and
can only be used on VP30 24 volt specifications.
Group 3 (aviation kerosene fuels): Specification
Lubricity
This is the capability of the fuel to prevent pump
wear.
39
Maintenance Section
Fuel Specifications
These fuels need additives to achieve lubricity of

650 micrometers wear scar and the reliability of
the fuel injection pump will be reduced. The fuel
injection pump is not covered by a warranty, even
when the additives are included.
JP8 T83133 (Avtur FSII, NATO F34
Diesel fuels that meet the specifications in Table

7 will help to provide maximum engine service
life and performance. In North America, diesel
fuel that is identified as No. 2-D in ASTM D975
generally meets the specifications. Table 7 is for
diesel fuels that are distilled from crude oil. Diesel
fuels from other sources could exhibit detrimental
properties that are not defined or controlled by this
specification.
Jet A
Table 7
JP5 MIL T5624 (Avcat FSII, NATO F44
Jet A1, NATO F35, XF63
Perkins Specifications for Distillate Diesel Fuel

Specifications
Requirements
ASTM Test
Low temperature fuels
Aromatics
35% maximum
D1319
Special fuels for use in cold weather may be

available for engine operation at temperatures
below 0 C (32 F). These fuels limit the formation
of wax in the fuel oil at low temperatures. If wax
forms in the fuel oil, this could stop the flow of fuel
oil through the filter.
Ash
0.02% maximum
(weight)
D482
Carbon Residue
on 10% Bottoms
0.35% maximum
(weight)
D524
Cetane Number
40 minimum (DI
engines)
D613
Cloud Point
The cloud
point must not
exceed the
lowest expected
ambient
temperature.
Note: These fuels that lack lubricity may cause the

following problems:
Low engine power

Difficult starting in hot conditions or in cold
conditions
White smoke
Copper Strip
Corrosion
No. 3 maximum
Distillation
10% at 282 C
(540 F)
maximum
Deterioration of emissions and misfire at certain

operating conditions
90% at 360 C
(680 F)
maximum
Biofuel: Specification
Biofuel: A 5% mix of RME to EN14214 in
conventional fuel is permitted.
NOTICE
Water emulsion fuels: These fuels are not permitted
Flash Point
legal limit
API Gravity
30 minimum
45 maximum
Pour Point
Refer to the following fuel specifications for

North America.
The preferred fuels provide maximum engine
service life and performance. The preferred fuels
are distillate fuels. These fuels are commonly called
diesel fuel or gas oil.
The permissible fuels are crude oils or blended
fuels. Use of these fuels can result in higher
maintenance costs and in reduced engine service
life.
Sulfur
(1)
6 C (10 F)
minimum
below ambient
temperature
0.2% maximum
Kinematic
Viscosity (2)
2.0 cSt minimum

and 4.5 cSt
maximum at
40 C (104 F)
Water and
Sediment
0.1% maximum
Water
0.1% maximum
D130
D86
D93
D287
D97
D3605
or
D1552
D445
D1796
D1744
(continued)
40
Maintenance Section
Fuel Specifications
(Table 7, contd)
Table 8
Sediment
0.05% maximum
(weight)
D473
Gum and Resins
10 mg per 100
mL maximum
D381
(3)
Lubricity
(1)
(2)
(3)
(4)
(4)
0.38 mm
(0.015 inch)
maximum at
25 C (77 F)
Distillate Fuels
D6079
Perkins fuel systems and engine components can operate on

high sulfur fuels. Fuel sulfur levels affect exhaust emissions.
High sulfur fuels also increase the potential for corrosion of
internal components. Fuel sulfur levels above 0.5 percent
may significantly shorten the oil change interval. For
additional information, see this publication, Engine Oil topic
The values of the fuel viscosity are the values as the fuel
is delivered to the fuel injection pumps. If a fuel with a low
viscosity is used, cooling of the fuel may be required to maintain
a 1.4 cSt viscosity at the fuel injection pump. Fuels with a high
viscosity might require fuel heaters in order to bring down the
viscosity to a 20 cSt viscosity.
Follow the test conditions and procedures for gasoline (motor).
The lubricity of a fuel is a concern with low sulfur fuel. To
determine the lubricity of the fuel, use either the ASTM D6078
Scuffing Load Wear Test (SBOCLE) or the 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.
NOTICE
Operating with fuels that do not meet the Perkins recommendations can cause the following effects: Starting difficulty, poor combustion, deposits in the fuel injectors, reduced service life of the fuel system, deposits in the combustion chamber, and reduced service life of the engine.
NOTICE
Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel
must NOT be used in Perkins diesel engines. Severe
component wear and component failures will result if
HFO type fuels are used in engines that are configured
to use distillate fuel.
In extreme cold ambient conditions, you may
use the distillate fuels that are specified in Table
8. However, the fuel that is selected must meet
the requirements that are specified in Table 7.
These fuels are intended to be used in operating
temperatures that are down to 54 C (65 F).
(1)
(1)
Specification
Grade
MIL-T-5624R
JP-5
ASTM D1655
Jet-A-1
MIL-T-83133D
JP-8
The fuels that are listed in this Table may not meet the
requirements that are specified in the Perkins Specifications
for Distillate Diesel Fuel Table. Consult the supplier for the
recommended additives in order to maintain the proper fuel
lubricity.
These fuels are lighter than the No. 2 grades of fuel.

The cetane number of the fuels in Table 8 must be
at least 40. If the viscosity is below 1.4 cSt at 38 C
(100 F), use the fuel only in temperatures below
0 C (32 F). Do not use any fuels with a viscosity
of less than 1.2 cSt at 38 C (100 F). Fuel cooling
may be required in order to maintain the minimum
viscosity of 1.4 cSt at the fuel injection pump.
There are many other diesel fuel specifications that
are published by governments and by technological
societies. Usually, those specifications do not
review all the requirements that are addressed
in this specification. To ensure optimum engine
performance, a complete fuel analysis should be
obtained before engine operation. The fuel analysis
should include all of the properties that are listed
in Table 7.
41
Maintenance Section
Cooling System Specifications
Water
Cooling System
Specifications
Water is used in the cooling system in order to

transfer heat.
i01908149
General Coolant Information
Distilled water or deionized water is

recommended for use in engine cooling systems.
DO NOT use the following types of water in cooling
systems: Hard water, softened water that has been
conditioned with salt, and sea water.
NOTICE
Never add coolant to an overheated engine. Engine
damage could result. Allow the engine to cool first.
NOTICE
If the engine is to be stored in, or shipped to an area
with below freezing temperatures, the cooling system
must be either protected to the lowest outside temperature or drained completely to prevent damage.
NOTICE
Frequently check the specific gravity of the coolant for
proper freeze protection or for anti-boil protection.
If distilled water or deionized water is not available,

use water with the properties that are listed in Table
9.
Table 9
Perkins Minimum Acceptable Water Requirements

Property
Maximum Limit
Chloride (Cl)
40 mg/L
Sulfate (SO4)
100 mg/L
Total Hardness
170 mg/L
Total Solids
340 mg/L
Acidity
pH of 5.5 to 9.0
Clean the cooling system for the following reasons:
Contamination of the cooling system
For a water analysis, consult one of the following

sources:
Overheating of the engine
Local water utility company
Foaming of the coolant
Agricultural agent
NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system problems can develop without water temperature regulators.
Many engine failures are related to the cooling
system. The following problems are related to
cooling system failures: Overheating, leakage of
the water pump, and plugged radiators or heat
exchangers.
These failures can be avoided with proper cooling
system maintenance. Cooling system maintenance
is as important as maintenance of the fuel system
and 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.
Independent laboratory
Additives
Additives help to protect the metal surfaces of
the cooling system. A lack of coolant additives
or insufficient amounts of additives enable the
following conditions to occur:
Corrosion
Formation of mineral deposits
Rust
Scale
Foaming of the coolant
Many additives are depleted during engine
operation. These additives must be replaced
periodically. .
42
Maintenance Section
Additives must be added at the proper

concentration. Overconcentration of additives can
cause the inhibitors to drop out-of-solution. The
deposits can enable the following problems to
occur:
Formation of gel compounds
Table 11
Propylene Glycol
Concentration
Freeze
Protection
Anti-Boil
Protection
50 Percent
29 C (20 F)
106 C (223 F)
To check the concentration of glycol in the coolant,

measure the specific gravity of the coolant.
Reduction of heat transfer

Leakage of the water pump seal
Plugging of radiators, coolers, and small
passages
i01946006
Coolant Recommendations
Glycol
Glycol in the coolant helps to provide protection
against the following conditions:
The following two coolants are used in Perkins

diesel engines:
Boiling
Preferred Perkins Extended Life Coolant (ELC)
Freezing
Acceptable A commercial heavy-duty

coolant/antifreeze that meets ASTM D4985
specifications
Cavitation of the water pump

For optimum performance, Perkins recommends a
1:1 mixture of a water/glycol solution.
Note: Use a mixture that will provide protection
against the lowest ambient temperature.
Note: 100 percent pure glycol will freeze at a
temperature of 23 C (9 F).
Most conventional coolant/antifreezes use ethylene
glycol. Propylene glycol may also be used. In a 1:1
mixture with water, ethylene and propylene glycol
provide similar protection against freezing and
boiling. See Tables 10 and 11.
Table 10
Ethylene Glycol
Concentration
Freeze
Protection
Boil
Protection
50 Percent
36 C (33 F)
106 C (223 F)
60 Percent
51 C (60 F)
111 C (232 F)
NOTICE
Do not use propylene glycol in concentrations that exceed 50 percent glycol because of propylene glycols
reduced heat transfer capability. Use ethylene glycol
in conditions that require additional protection against
boiling or freezing.
NOTICE
Do not use a commercial coolant/antifreeze that only meets the ASTM D3306 specification. This type of
coolant/antifreeze is made for light automotive applications.
Perkins recommends a 1:1 mixture of water
and glycol. This mixture of water and glycol will
provide optimum heavy-duty performance as a
coolant/antifreeze. This ratio may be increased to
1:2 water to glycol if extra freezing protection is
required.
Note: A commercial heavy-duty coolant/antifreeze
that meets ASTM D4985 specifications MAY
require a treatment with an SCA at the initial fill.
Read the label or the instructions that are provided
by the OEM of the product.
In stationary engine applications and marine engine
applications that do not require anti-boil protection
or freeze protection, a mixture of SCA and water
is acceptable. Perkins recommends a six percent
to eight percent concentration of SCA in those
cooling systems. Distilled water or deionized water
is preferred. Water which has the recommended
properties may be used.
43
Maintenance Section
Engines that are operating in an ambient

temperature above 43 C (109.4 F) must use SCA
and water. Engines that operate in an ambient
temperature above 43 C (109.4 F) and below 0 C
(32 F) due to seasonal variations. Consult your
Perkins dealer or your Perkins distributor for the
correct level of protection.
ELC Concentrate is also available. ELC Concentrate

can be used to lower the freezing point to 51 C
(60 F) for arctic conditions.
Containers of several sizes are available. Consult
your Perkins dealer for the part numbers.
i01946026
Table 12
Extended Life Coolant (ELC)

Cooling System Maintenance
Coolant Service Life

Coolant Type
Service Life
Perkins ELC
12,000 Service Hours

or Six Years
Commercial Heavy-Duty
Coolant/Antifreeze that
meets ASTM D4985
3000 Service Hours or

Two Years
Perkins POWERPART
SCA

Two Years
Commercial SCA and

Water

Two Years
i01946021
Extended Life Coolant (ELC)

Perkins provides Extended Life Coolant (ELC) for
use in the following applications:
Heavy-duty spark ignited gas engines

Heavy-duty diesel engines
Automotive applications
The anti-corrosion package for ELC is different from
the anti-corrosion package for other coolants. ELC
is an ethylene glycol base coolant. However, ELC
contains organic corrosion inhibitors and antifoam
agents with low amounts of nitrite. Perkins ELC has
been formulated with the correct amount of these
additives in order to provide superior corrosion
protection for all metals in engine cooling systems.
ELC extends the service life of the coolant to 12000
service hours or six years. ELC does not require
a frequent addition of a Supplemental Coolant
Additive (SCA). An Extender is the only additional
maintenance that is needed at 6000 service hours
or one half of the ELC service life.
ELC is available in a 1:1 premixed cooling solution
with distilled water. The Premixed ELC provides
freeze protection to 36 C (33 F). The Premixed
ELC is recommended for the initial fill of the cooling
system. The Premixed ELC is also recommended
for topping off the cooling system.
Proper additions to the Extended

Life Coolant
NOTICE
Use only Perkins products for pre-mixed or concentrated coolants.
Use only Perkins Extender with Extended Life
Coolant.
Mixing Extended Life Coolant with other products reduces the Extended Life Coolant service life. Failure to
follow the recommendations can reduce cooling system components life unless appropriate corrective action is performed.
In order to maintain the correct balance between
the antifreeze and the additives, you must maintain
the recommended concentration of Extended Life
Coolant (ELC). Lowering the proportion of antifreeze
lowers the proportion of additive. This will lower
the ability of the coolant to protect the system from
pitting, from cavitation, from erosion, and from
deposits.
NOTICE
Do not use a conventional coolant to top-off a cooling
system that is filled with Extended Life Coolant (ELC).
Do not use standard supplemental coolant additive
(SCA). Only use ELC Extender in cooling systems that
are filled with ELC.
Perkins ELC Extender

ELC Extender is added to the cooling system
halfway through the ELC service life. Treat the
cooling system with ELC Extender at 6000 hours or
one half of the coolant service life. Use Table 13
in order to determine the proper amount of ELC
Extender that is required.
Containers of several sizes are available. Consult
your Perkins dealer for the part numbers.
44
Maintenance Section
Use the formula in Table 13 to determine the proper

amount of ELC Extender for your cooling system.
Refer to Operation and Maintenance Manual, Refill
Capacities in order to determine the capacity of
the cooling system.
Table 13
Formula For Adding ELC Extender To ELC

V 0.02 = X
V is the total capacity of the cooling system.
X is the amount of ELC Extender that is required.
Table 14 is an example for using the formula that

is in Table 13.
Table 14
Example Of The Equation For Adding ELC

Extender To ELC
Total Volume
of the Cooling
System (V)
Multiplication
Factor
Amount of ELC
Extender that is
Required (X)
9 L (2.4 US gal)
0.02
0.18 L
(0.05 US gal)
or (6 fl oz)
NOTICE
When using Perkins ELC, do not use standard SCAs
or SCA filters.
ELC Cooling System Cleaning

Note: If the cooling system is already using ELC,
cleaning agents are not required to be used at
the specified coolant change interval. Cleaning
agents are only required if the system has been
contaminated by the addition of some other type of
coolant or by cooling system damage.
Clean water is the only cleaning agent that is
required when ELC is drained from the cooling
system.
After the cooling system is drained and after the
cooling system is refilled, operate the engine while
the cooling system filler cap is removed. Operate
the engine until the coolant level reaches the normal
operating temperature and until the coolant level
stabilizes. As needed, add the coolant mixture in
order to fill the system to the specified level.
Changing to Perkins ELC

To change from heavy-duty coolant/antifreeze to the
Perkins ELC, perform the following steps:
NOTICE
Care must be taken to ensure that all fluids are
contained during performance of inspection, maintenance, testing, adjusting and the repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Drain the coolant into a suitable container.
2. Dispose of the coolant according to local
regulations.
3. Flush the system with clean water in order to
remove any debris.
4. Use Perkins cleaner to clean the system. Follow
the instruction on the label.
5. Drain the cleaner into a suitable container. Flush
the cooling system with clean water.
6. Fill the cooling system with clean water and
operate the engine until the engine is warmed to
49 to 66C (120 to 150F).
NOTICE
Improper or incomplete flushing of the cooling system
can result in damage to copper and other metal components.
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water.
Continue to flush the system until all the signs of the
cleaning agent are gone.
7. Drain the cooling system into a suitable container
and flush the cooling system with clean water.
Note: The cooling system cleaner must be
thoroughly flushed from the cooling system. Cooling
system cleaner that is left in the system will
contaminate the coolant. The cleaner may also
corrode the cooling system.
8. Repeat Steps 6 and 7 until the system is
completely clean.
9. Fill the cooling system with the Perkins premixed
ELC.
45
Maintenance Section
ELC Cooling System

Contamination
Perkins engine cooling systems should be tested

at 500 hour intervals for the concentration of
Supplemental Coolant Additive (SCA).
NOTICE
Mixing ELC with other products reduces the effectiveness of the ELC and shortens the ELC service life.
Use only Perkins Products for premixed or concentrate
coolants. Use only Perkins ELC extender with Perkins
ELC. Failure to follow these recommendations can result in shortened cooling system component life.
Additions of SCA are based on the results of the

test. An SCA that is liquid may be needed at 500
hour intervals.
Refer to Table 15 for part numbers and for quantities
of SCA.
Table 15
ELC cooling systems can withstand contamination

to a maximum of ten percent of conventional
heavy-duty coolant/antifreeze or SCA. If the
contamination exceeds ten percent of the total
system capacity, perform ONE of the following
procedures:
Drain the cooling system into a suitable container.

Dispose of the coolant according to local
regulations. Flush the system with clean water. Fill
the system with the Perkins ELC.
Drain a portion of the cooling system into a

suitable container according to local regulations.
Then, fill the cooling system with premixed ELC.
This should lower the contamination to less than
10 percent.
Maintain the system as a conventional Heavy Duty

Coolant. Treat the system with an SCA. Change
the coolant at the interval that is recommended
for the conventional Heavy Duty Coolant.
Perkins Liquid SCA

Part Number
Quantity
21825755
Adding the SCA to Heavy-Duty

Coolant at the Initial Fill
Commercial heavy-duty coolant/antifreeze that
meets ASTM D4985 specifications MAY require
an addition of SCA at the initial fill. Read the label
or the instructions that are provided by the OEM
of the product.
Use the equation that is in Table 16 to determine
the amount of Perkins SCA that is required when
the cooling system is initially filled.
Table 16
Equation For Adding The SCA To Heavy-Duty

Coolant At The Initial Fill
V 0.045 = X
i01946221
Commercial Heavy-Duty
Coolant/Antifreeze and SCA
V is the total volume of the cooling system.

X is the amount of SCA that is required.
Table 17 is an example for using the equation that

is in Table 16.
NOTICE
Commercial Heavy-Duty Coolant which contains
Amine as part of the corrision protection system must
not be used.
NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system problems can develop without water temperature regulators.
Check the coolant/antifreeze (glycol concentration)
in order to ensure adequate protection against
boiling or freezing. Perkins recommends the use of a
refractometer for checking the glycol concentration.
Table 17
Example Of The Equation For Adding The SCA

To Heavy-Duty Coolant At The Initial Fill
Total Volume
of the Cooling
System (V)
Multiplication
Factor
Amount of SCA
that is Required
(X)
15 L (4 US gal)
0.045
0.7 L (24 oz)
Adding the SCA to Heavy-Duty

Coolant For Maintenance
Heavy duty coolant/antifreeze of all types REQUIRE
periodic additions of an SCA.
46
Maintenance Section
Test the coolant/antifreeze periodically for the

concentration of SCA. For the interval, see the
Operation and Maintenance Manual, Maintenance
Interval Schedule (Maintenance Section). Test the
concentration of SCA.
Additions of SCA are based on the results of the
test. The size of the cooling system determines the
amount of SCA that is needed.
Use the equation that is in Table 18 to determine the
amount of Perkins SCA that is required, if necessary:
Table 18
Equation For Adding The SCA To Heavy-Duty

Coolant For Maintenance
V 0.014 = X
V is the total volume of the cooling system.
X is the amount of SCA that is required.
Table 19 is an example for using the equation that

is in Table 18.
Table 19
Example Of The Equation For Adding The SCA To

Heavy-Duty Coolant For Maintenance
Total Volume
of the Cooling
System (V)
Multiplication
Factor
Amount of SCA
that is Required
(X)
15 L (4 US gal)
0.014
0.2 L (7 oz)
Cleaning the System of Heavy-Duty

Coolant/Antifreeze
Perkins cooling system cleaners are designed
to clean the cooling system of harmful scale
and corrosion. Perkins cooling system cleaners
dissolve mineral scale, corrosion products, light oil
contamination and sludge.
Clean the cooling system after used coolant is

drained or before the cooling system is filled with
new coolant.
Clean the cooling system whenever the coolant is

contaminated or whenever the coolant is foaming.
47
Maintenance Section
Refill Capacities
Refill Capacities
i01935403
Refill Capacities
Lubrication System
The refill capacities for the engine crankcase
reflect the approximate capacity of the crankcase
or sump plus standard oil filters. Auxiliary oil filter
systems will require additional oil. Refer to the
OEM specifications for the capacity of the auxiliary
oil filter. Refer to the Operation and Maintenance
Manual, Maintenance Section for more information
on Lubricant Specifications.
Table 20
Approximate Refill Capacity of the

Lubrication System
Compartment or System
Crankcase Oil Sump(1)
(1)
Liters
Pints
10
17.6
These values are the approximate capacities for the crankcase

oil sump which include the standard factory installed oil filters.
Engines with auxiliary oil filters will require additional oil. Refer
to the OEM specifications for the capacity of the auxiliary oil
filter.
Cooling System
To maintain the cooling system, the Total Cooling
System capacity must be known. The approximate
capacity for the engine cooling system is listed.
External System capacities will vary among
applications. Refer to the OEM specifications for the
External System capacity. This capacity information
will be needed in order to determine the amount
of coolant/antifreeze that is required for the Total
Cooling System.
Table 21
Approximate Refill Capacity of the Cooling System

Compartment or System
Engine Only
Liters
Pints
5.5
9.7
External Cooling System (OEM

Recommendation)(1)
Total Cooling System(2)
(1)
(2)
The external cooling system includes a radiator or an expansion

tank with the following components: The heat exchanger, the
aftercooler, and the piping Refer to the Perkins specifications
and/or the OEM specifications. Enter the value for the external
cooling system capacity in this row.
The Total Cooling System includes the capacity for the engine
cooling system plus the capacity for the external cooling
system. Enter the total in this row.
48
Maintenance Section
Maintenance Interval Schedule
i01949611
Maintenance Interval Schedule
Every 2000 Service Hours

Engine Mounts - Inspect ....................................... 58
Every 2 Years
Ensure that the Safety Information, Warnings,
and Instructions are read and understood
before operation or maintenance procedures are
performed.
Before each consecutive interval is performed, all
of the maintenance requirements from the previous
interval must also be performed.
When Required
Battery - Replace ..................................................
Battery or Battery Cable - Disconnect ..................
Engine - Clean ......................................................
Engine Air Cleaner Element (Single Element) Inspect/Replace ..................................................
Fuel System - Prime .............................................
Severe Service Application - Check ......................
57
60
65
54
56
57
58
62
67
Every 50 Service Hours or Weekly

Fuel Tank Water and Sediment - Drain ................. 62
Every 500 Service Hours or 6 Months

Alternator and Fan Belts - Inspect/Adjust/
Replace ............................................................... 49
Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check ..........................
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add .................................................
Engine Oil and Filter - Change .............................
Fuel System Filter - Replace ................................
Hoses and Clamps - Inspect/Replace ..................
Radiator - Clean ....................................................
50
55
58
61
63
64

Alternator - Inspect ...............................................
Engine Valve Lash - Inspect/Adjust ......................
Starting Motor - Inspect ........................................
Turbocharger - Inspect ..........................................

Water Pump - Inspect ........................................... 68
Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .... 54
Every 12 000 Service Hours or 6 Years

50
51
56
Daily
Cooling System Coolant Level - Check ................
Driven Equipment - Check ....................................
Engine Air Cleaner Service Indicator - Inspect .....
Engine Oil Level - Check ......................................
Fuel System Primary Filter/Water Separator Drain ...................................................................
Walk-Around Inspection ........................................
Cooling System Coolant - Change ....................... 52
49
60
65
66
Cooling System Coolant (ELC) - Change ............. 51
49
Maintenance Section
Alternator - Inspect
i01908658
Adjustment
Alternator - Inspect
Perkins recommends a scheduled inspection of
the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect
the ammeter (if equipped) during engine operation
in order to ensure proper battery performance
and/or proper performance of the electrical system.
Make repairs, as required.
Check the alternator and the battery charger for
proper operation. If the batteries are properly
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. When the
engine is not run for long periods of time or if the
engine is run for short periods, the batteries may
not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.
i01896863
Alternator and Fan Belts Inspect/Adjust/Replace

Inspection
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that
are worn or damaged.
For applications that require multiple drive belts,
replace the belts in matched sets. Replacing only
one belt of a matched set will cause the new belt to
carry more load because the older belt is stretched.
The additional load on the new belt could cause the
new belt to break.
If the belts are too loose, vibration causes
unnecessary wear on the belts and pulleys. Loose
belts may slip enough to cause overheating.
To check the belt tension, apply 45 N (10 lb ft)
of force midway between the pulleys. A correctly
adjusted belt will deflect 10 mm (0.39 inch).
Illustration 18
g00987404
Typical example
(1)
(2)
(3)
(4)
Mounting bolts
Alternator
Bracket
Belt
1. Loosen mounting bolts (1) .

2. Move the alternator (2) in order to increase or
decrease the belt tension. To check the belt
tension, apply 45 N (10 lb ft) of force midway
between the pulleys. A correctly adjusted belt
will deflect 10 mm (0.39 inch).
3. Tighten mounting bolts (1).
Replacement
1. Remove the tension from the belt by loosening
the mounting bolts (1).
2. Remove the belt (4).
3. Install the new belt.
4. Move the alternator (2) in order to increase or
decrease the belt tension. To check the belt
tension, apply 45 N (10 lb ft) of force midway
between the pulleys. A correctly adjusted belt
will deflect 10 mm (0.39 inch).
When new belts are installed, check the belt tension
again after 20 hours of engine operation.
50
Maintenance Section
Battery - Replace
i01878164
Battery - Replace
8. Connect the cable from the NEGATIVE -

terminal on the starter motor to the NEGATIVE
- battery terminal.
i01908638
Batteries give off combustible gases which can

explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
The battery cables or the batteries should not be

removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Switch the engine to the OFF position. Remove
all electrical loads.
Battery Electrolyte Level Check

When the engine is not run for long periods of
time or when the engine is run for short periods,
the batteries may not fully recharge. Ensure a full
charge in order to help prevent the battery from
freezing. If batteries are properly charged, ammeter
reading should be very near zero.
All lead-acid batteries contain sulfuric acid which

can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
1. Remove the filler caps. Maintain the electrolyte
level to the FULL mark on the battery.
If the addition of water is necessary, use distilled
water. If distilled water is not available use
clean water that is low in minerals. Do not use
artificially softened water.
2. Turn off any battery chargers. Disconnect any

battery chargers.
2. Check the condition of the electrolyte with a

suitable battery tester.
3. The NEGATIVE - cable connects the NEGATIVE

- battery terminal to the NEGATIVE - terminal
on the starter motor. Disconnect the cable from
the NEGATIVE - battery terminal.
3. Keep the batteries clean.
4. The POSITIVE + cable connects the POSITIVE

+ battery terminal to the POSITIVE + terminal
on the starting motor. Disconnect the cable from
the POSITIVE + battery terminal.
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
recycling facility.
5. Remove the used battery.
6. Install the new battery.
Note: Before the cables are connected, ensure that
the engine start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE + battery terminal.
Clean the battery case with one of the following

cleaning solutions:
A mixture of 0.1 kg (0.2 lb) of baking soda and

1 L (1 qt) of clean water
A mixture of 0.1 L (0.11 qt) of ammonia and

1 L (1 qt) of clean water
Thoroughly rinse the battery case with clean
water.
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
remove material excessively. Excessive removal
of material can cause the clamps to not fit
properly. Coat the clamps and the terminals with
a suitable silicone lubricant or petroleum jelly.
51
Maintenance Section
Battery or Battery Cable - Disconnect
i01492654
Battery or Battery Cable Disconnect
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
The battery cables or the batteries should not be

removed with the battery cover in place. The battery cover should be removed before any servicing 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
ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side
of two batteries must be disconnected.
3. Tape the leads in order to help prevent accidental
starting.
4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables.
i01946512
Cooling System Coolant (ELC)

- Change
coolant is contaminated.
The fuel has entered the cooling system and the

Note: When the cooling system is cleaned, only
clean water is needed when the ELC is drained
and replaced.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator
and the hoses, if necessary.
Drain
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap.
NOTICE
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 disassembling any component containing fluids.
Dispose of all fluids according to Local regulations and
mandates.
NOTICE
Keep all parts clean from contaminants.
Illustration 19
Contaminants may cause rapid wear and shortened

component life.
2. Open the drain cock or remove the drain plug (1)

on the engine. Open the drain cock or remove
the drain plug on the radiator.
g00987502
52
Maintenance Section
Cooling System Coolant - Change
Allow the coolant to drain.

NOTICE
Dispose of used engine coolant or recycle. Various
methods have been proposed to reclaim used coolant
for reuse in engine cooling systems. The full distillation
procedure is the only method acceptable by Perkins to
reclaim the coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Perkins
dealer or your Perkins distributor.
Flush
1. Flush the cooling system with clean water in
order to remove any debris.
2. Close the drain cock or install the drain plug in
the engine. Close the drain cock or install the
drain plug on the radiator.
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Cooling system air locks may result in engine damage.
3. Fill the cooling system with clean water. Install
the cooling system filler cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 C (120 to 150 F).
cooling system filler cap. Open the drain cock
or remove the drain plug on the engine. Open
the drain cock or remove the drain plug on
the radiator. Allow the water to drain. Flush the
cooling system with clean water.
Fill
1. Close the drain cock or install the drain plug on
NOTICE
2. Fill the cooling system with Extended Life Coolant

(ELC). Refer to the Operation and Maintenance
Manual, Cooling System Specifications topic
(Maintenance Section) for more information on
cooling system specifications. Do not install the
3. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
4. Check the coolant level. Maintain the coolant
level within 13 mm (0.5 inch) below the bottom
of the pipe for filling. Maintain the coolant level in
the expansion bottle (if equipped) at the proper
level.
5. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap.
If the gasket that is on the cooling system filler
cap is not damaged, use a suitable Pressurizing
Pump in order to pressure test the cooling
system filler cap. The correct pressure for the
cooling system filler cap is stamped on the face
of the cooling system filler cap. If the cooling
system filler cap does not retain the correct
pressure, install a new cooling system filler cap.
6. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
i01946911
Cooling System Coolant Change

(Commercial Heavy Duty)
NOTICE
Dispose of all fluids according to Local regulations and
mandates.
53
Maintenance Section
Cooling System Coolant - Change
NOTICE
component life.
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.
Illustration 20
The oil has entered the cooling system and the

The fuel has entered the cooling system and the
g00987502
2. Open the drain cock or remove the drain plug (1)

on the engine. Open the drain cock or remove
the drain plug on the radiator.
Allow the coolant to drain.
Note: When the cooling system is cleaned, only
clean water is needed.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator
and the hoses, if necessary.
Drain
NOTICE
Dispose of used engine coolant or recycle. Various
methods have been proposed to reclaim used coolant
for reuse in engine cooling systems. The full distillation
procedure is the only method acceptable by Perkins to
reclaim the coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Perkins
dealer or your Perkins distributor.
Flush
1. Flush the cooling system with clean water in
order to remove any debris.
2. Close the drain cock or install the drain plug in
NOTICE
3. Fill the cooling system with clean water. Install
the cooling system filler cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 C (120 to 150 F).
54
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

cooling system filler cap. Open the drain cock
or remove the drain plug on the engine. Open
the drain cock or remove the drain plug on
the radiator. Allow the water to drain. Flush the
cooling system with clean water.
Fill
1. Close the drain cock or install the drain plug on
i01946540
Cooling System Coolant

Extender (ELC) - Add
The Perkins Extended Life Coolant (ELC) does not
need the frequent addition of Supplemental Coolant
Additives (SCA) associated with conventional
coolants. The Extender only needs to be added
once.
Check the cooling system only when the engine is
stopped and cool.
NOTICE
1. Loosen the cooling system filler cap slowly in

order to relieve pressure. Remove the cooling
system filler cap.
2. It may be necessary to drain enough coolant

from the cooling system in order to add the
Extender.
2. Fill the cooling system with Commercial

Heavy-Duty Coolant. Add Supplemental Coolant
Additive to the coolant. For the correct amount,
refer to the Operation and Maintenance
Manual, Cooling System Specifications topic
(Maintenance Section) for more information on
cooling system specifications. Do not install the
3. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high
idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
4. Check the coolant level. Maintain the coolant
level within 13 mm (0.5 inch) below the bottom
of the pipe for filling. Maintain the coolant level in
the expansion bottle (if equipped) at the proper
level.
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap.
If the gasket that is on the cooling system filler
cap is not damaged, use a suitable Pressurizing
Pump in order to pressure test the cooling
system filler cap. The correct pressure for the
cooling system filler cap is stamped on the face
of the cooling system filler cap. If the cooling
system filler cap does not retain the correct
pressure, install a new cooling system filler cap.
leaks and for proper operating temperature.
3. Add Extender according to the requirements for

your engines cooling system capacity. Refer to
the Operation and Maintenance Manual, Refill
Capacities in the Maintenance Section for the
capacity of the cooling system for your engine.
Refer to the Operation and Maintenance Manual,
Cooling System Specifications information for
the Perkins ELC Extender.
gasket of the cooling system filler cap. If the
gasket is damaged then replace the cooling
system filler cap. Install the cooling system filler
cap.
i01935755
Cooling System Coolant Level

- Check
Engines With a Coolant Recovery
Tank
Note: The cooling system may not have been
provided by Perkins. The procedure that follows
is for typical cooling systems. Refer to the OEM
information for the correct procedures.
Check the coolant level when the engine is stopped
and cool.
55
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
1. Observe the coolant level in the coolant recovery

tank. Maintain the coolant level to COLD FULL
mark on the coolant recovery tank.
2. Loosen filler cap slowly in order to relieve any
pressure. Remove the filler cap.
Illustration 22
g00285520
Cooling system filler cap
3. Pour the proper coolant mixture into the tank.

Refer to the Operation and Maintenance Manual,
Cooling System Specifications for information
on the correct mixture and type of coolant. Refer
to the Operation and Maintenance Manual, Refill
Capacities for the cooling system capacity. Do
not fill the coolant recovery tank above COLD
FULL mark.
1. Remove the cooling system filler cap slowly in
order to relieve pressure.
2. Maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level to the proper level in the sight glass.
Illustration 21
g00103639
4. Clean filler cap and the receptacle. Reinstall the

filler cap and inspect the cooling system for
leaks.
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.
i01946566
Note: The coolant will expand as the coolant heats

up during normal engine operation. The additional
volume will be forced into the coolant recovery
tank during engine operation. When the engine is
stopped and cool, the coolant will return to the
engine.
Cooling System Supplemental

Coolant Additive (SCA) Test/Add
Engines Without a Coolant

Recovery Tank
Check the coolant level when the engine is stopped
and cool.
Cooling system coolant additive contains alkali.

To help prevent personal injury, avoid contact with
the skin and the eyes. Do not drink cooling system
coolant additive.
56
Maintenance Section
Driven Equipment - Check
Test for SCA Concentration

Heavy-Duty Coolant/Antifreeze and SCA
NOTICE
Do not exceed the recommended six percent supplemental coolant additive concentration.
Use a Coolant Conditioner Test Kit in order to check
the concentration of the SCA.
Add the SCA, If Necessary

NOTICE
Do not exceed the recommended amount of supplemental coolant additive concentration. Excessive
supplemental coolant additive concentration can form
deposits on the higher temperature surfaces of the
cooling system, reducing the engines heat transfer
characteristics. Reduced heat transfer could cause
cracking of the cylinder head and other high temperature components. Excessive supplemental coolant
additive concentration could also result in radiator
tube blockage, overheating, and/or accelerated water
pump seal wear. Never use both liquid supplemental
coolant additive and the spin-on element (if equipped)
at the same time. The use of those additives together
could result in supplemental coolant additive concentration exceeding the recommended maximum.
1. Slowly loosen the cooling system filler cap in
order to relieve the pressure. Remove the cooling
system filler cap.
Note: Always discard drained fluids according to
local regulations.
2. If necessary, drain some coolant from the cooling
system into a suitable container in order to allow
space for the extra SCA.
3. Add the proper amount of SCA. Refer to
the Operation and Maintenance Manual,
Commercial Heavy-Duty Antifreeze and SCA
for more information on SCA requirements.

gaskets of the cooling system filler cap. If the
gaskets are damaged, replace the old cooling
system filler cap with a new cooling system filler
cap. Install the cooling system filler cap.
i00174798
Driven Equipment - Check

Refer to the OEM specifications for more information
on the following maintenance recommendations for
the driven equipment:
Inspection
Adjustment
Lubrication
Other maintenance recommendations
Perform any maintenance for the driven equipment
which is recommended by the OEM.
i01936072
Engine - Clean
Personal injury or death can result from high voltage.

Moisture can create paths of electrical conductivity.
Make sure that the electrical system is OFF. Lock
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 accumulates 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
57
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 the engine is cleaned.
Pressure washers and steam cleaners should not
be directed at any electrical connectors or the
junction of cables into the rear of the connectors.
Avoid electrical components such as the alternator,
and the starter. Protect the fuel injection pump from
fluids in order to wash the engine.
Some engines are equipped with a differential

gauge for inlet air pressure. The differential gauge
for inlet air pressure displays the difference in the
pressure that is measured before the air cleaner
element and the pressure that is measured after
the air cleaner element. As the air cleaner element
becomes dirty, the pressure differential rises. If your
engine is equipped with a different type of service
indicator, follow the OEM recommendations in order
to service the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner element or in a remote location.
i01897734
Engine Air Cleaner

Element (Single Element) Inspect/Replace
Refer to Operation and Maintenance Manual,
Engine Air Cleaner Service Indicator-Inspect.
NOTICE
Never run the engine without an air cleaner element
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 prevent 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.
Illustration 23
g00103777
Typical service indicator
Observe the service indicator. The air cleaner

element should be cleaned or the air cleaner
element should be replaced when one of the
following conditions occur:
The yellow diaphragm enters the red zone.

The red piston locks in the visible position.
A wide variety of air cleaners may be installed for

use with this engine. Consult the OEM information
for the proper procedure to replace the air cleaner.
Test the Service Indicator

Service indicators are important instruments.
i01936073
Engine Air Cleaner Service

Indicator - Inspect
Check for ease of resetting. The service indicator

should reset in less than three pushes.
Check the movement of the yellow core when the

engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
greatest vacuum that is attained.
Some engines may be equipped with a different

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

yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the
new service indicator will not reset, the hole for the
service indicator may be restricted.
The service indicator may need to be replaced
frequently in environments that are severely dusty.
58
Maintenance Section
Engine Mounts - Inspect
i01908586
Engine Mounts - Inspect

Note: The engine mounts may not have been
supplied for this installation by Perkins. Refer to
the OEM information for further information on the
engine mounts and the correct bolt torque.
NOTICE
Operating your engine when the oil level is above the
FULL mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oils lubricating characteristics and could result in the loss of power.
2. Remove the oil filler cap and add oil, if necessary.
Clean the oil filler cap. Install the oil filler cap.
Inspect the engine mounts for deterioration and for

correct bolt torque. Engine vibration can be caused
by the following conditions:
i01936100
Engine Oil and Filter - Change
Improper mounting of the engine

Deterioration of the engine mounts
Any engine mount that shows deterioration should
be replaced. Refer to the OEM information for the
recommended torques.
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
i01897042
Engine Oil Level - Check

contact the skin.
NOTICE
mandates.
NOTICE
component life.
Illustration 24
g00986928
(Y) minimum MIN mark. (X) maximum MAX mark.
NOTICE
Perform this maintenance with the engine stopped.
1. Maintain the oil level between minimum MIN
mark (Y) and the maximum MAX mark (X) on
oil level gauge (1). Do not fill the crankcase
above MAX mark (X).
Do not drain the oil when the engine is cold. As

the oil cools, suspended waste particles settle
on the bottom of the oil pan. The waste particles
are not removed with the draining cold oil. Drain
the crankcase with the engine stopped. Drain the
crankcase with the oil warm. This draining method
allows the waste particles that are suspended in the
oil to be drained properly.
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
59
Maintenance Section
Engine Oil and Filter - Change
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:
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.
After the oil has drained, the oil drain plugs should
be cleaned and installed.
Replace the Oil Filter

NOTICE
Perkins oil filters are built to Perkins specifications.
Use of an oil filter not recommended by Perkins could
result in severe engine damage to the engine bearings, crankshaft, etc., as a result of the larger waste
particles from unfiltered oil entering the engine lubricating system. Only use oil filters recommended by
Perkins.
1. Remove the oil filter with a suitable chain wrench.
Note: The following actions can be carried out as
part of the preventive maintenance program.
2. Cut the oil filter open with a suitable tool. Break
apart the pleats and inspect the oil filter for metal
debris. An excessive amount of metal debris in
the oil filter may indicate early wear or a pending
failure.
Use a magnet to differentiate between the
ferrous metals and the nonferrous metals that
are found in the oil filter element. Ferrous metals
may indicate wear on the steel and cast iron
parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in
the oil filter. Consult your Perkins dealer or your
Perkins distributor in order to arrange for a
further analysis if an excessive amount of debris
is found in the oil filter.
Illustration 25
g00988564
(1) Filter mounting base

(2) Oil filter gasket
3. Clean the sealing surface of the filter mounting

base (1). Ensure that all of the old oil filter gasket
is removed.
4. Apply clean engine oil to the new oil filter gasket
(2).
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminated. Contaminated oil can cause accelerated wear to
engine components.
5. Install the oil filter. Tighten the oil filter until the
oil filter gasket contacts the base. Tighten the oil
filter by hand according to the instructions that
are shown on the oil filter. Do not overtighten the
oil filter.
Fill the Engine Crankcase

1. Remove the oil filler cap. Refer to the Operation
and Maintenance Manual for more information on
lubricant specifications. Fill the crankcase with
the proper amount of oil. Refer to the Operation
and Maintenance Manual for more information
on refill capacities.
NOTICE
If equipped with an auxiliary oil filter system or a remote oil filter system, follow the OEM or filter manufacturers recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.
60
Maintenance Section
Engine Valve Lash - Inspect/Adjust
NOTICE
To prevent crankshaft bearing damage, crank the engine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
2. Start the engine and run the engine at LOW
IDLE for two minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.
3. Stop the engine and allow the oil to drain back
to the sump for a minimum of ten minutes.
Ensure that the engine can not be started while

this maintenance is being performed. To help prevent 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.
Ensure that the engine is stopped before measuring
the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance
is performed.
Refer to the Service Manual for more information.
i01937717
Fuel System - Prime

Illustration 26
g00986928
4. Remove the oil level dipstick in order to check

the oil level. Maintain the oil level between the
MIN and MAX marks on the oil level dipstick.
i01937238
Engine Valve Lash Inspect/Adjust
If air enters the fuel system, the air must be purged

from the fuel system before the engine can be
started. Air can enter the fuel system when the
following events occur:
The fuel tank is empty or the fuel tank has been

partially drained.
The low pressure fuel lines are disconnected.

A leak exists in the low pressure fuel system.
The initial valve lash adjustment on new engines,

rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change.
The adjustment is necessary due to the initial wear
of the valve train components and to the seating of
the valve train components.
This maintenance is recommended by Perkins as
part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Perkins dealer or your Perkins distributor for the complete valve lash adjustment procedure.
Operation of Perkins engines with improper valve adjustments can reduce engine efficiency. This reduced
efficiency could result in excessive fuel usage and/or
shortened engine component life.
The fuel filter is replaced.

Use the following procedure in order to remove air
from the fuel system:
1. Turn the key switch to the RUN position. Leave
the key switch in the RUN position for 1 minutes.
2. Turn the key switch to the OFF position.
Note: Damage to the fuel injection pump, to the
battery, and to the starter motor can occur if the
starter motor is used excessively to purge the air
from the fuel system.
3. Loosen the flare nuts for the high pressure fuel
lines on all of the fuel injection nozzles.
61
Maintenance Section
Fuel System Filter - Replace
NOTICE
Do not crank the engine for more than 10 seconds.
Allow the starter motor to cool for 30 seconds before
cranking again.
Do not engage the starter when the flywheel is turning.
4. Observe the connection at the flare nut. Operate
the starting motor and crank the engine until the
fuel is free of air.
5. Tighten the flare nuts to a torque of 26.5 Nm
(19.5 lb ft) to 32.4 Nm (23.9 lb ft).
6. The engine is now ready to start. Operate the
engine at low idle for a minimum of five minutes
immediately after air has been removed from the
fuel system.
Note: Running the engine for this period of time will
help ensure that the pump is completely free of air.
i01905248
Fuel System Filter - Replace
Illustration 27
(1)
(2)
(3)
(4)
(5)
(6)
g00992025
Electric fuel priming pump

Fuel filter base
Quick release collar
Fuel filter
Sediment bowl
Drain valve for fuel filter
1. Close the fuel supply valve.
Fuel leaked or spilled onto hot surfaces or electrical 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
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.
Turn the fuel supply valve to the OFF position before
performing this maintenance. Place a tray under the
fuel filter in order to catch any fuel that might spill.
Clean up any spilled fuel immediately.
2. Clean the outside of the fuel filter assembly.

Open drain valve (6) and drain the fuel and water
from fuel filter (4) into a suitable container.
3. Remove sediment bowl (5).
NOTICE
Do not use a tool in order to remove the fuel filter.
Attempting to remove the fuel filter with a filter wrench
or a filter strap could damage the locking ring.
4. Hold fuel filter (4) and rotate quick release collar
(3) counterclockwise. Remove quick release
collar (3). The used element should be removed
and discarded.
NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.
5. Ensure that the fuel filter base is clean. Push a
new fuel filter fully into the fuel filter base.
6. Hold the fuel filter in place. Fit locking ring (3)
into position. Rotate the locking ring clockwise in
order to fasten the fuel filter to the fuel filter base.
62
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
7. Thoroughly clean sediment bowl (5). Inspect

the O-ring seals. Install new O-ring seals, if
necessary. Install the sediment bowl to the new
element. Hand tighten the sediment bowl. Hand
tightening is the only method that should be
used.
8. Prime the fuel system. Refer to Operation and
Maintenance Manual, Fuel System - Prime.
2. Close the drain valve (2).

NOTICE
The water separator is under suction during normal
engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel
system.
i01938468
i01937818
Fuel System Primary

Filter/Water Separator - Drain
Fuel leaked or spilled onto hot surfaces or electrical 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
The water separator is not a filter. The water separator separates water from the fuel. The engine should
never be allowed to run with the water separator more
than half full. Engine damage may result.
Fuel Tank Water and Sediment

- Drain
NOTICE
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 disassembling any component containing fluids.
mandates.
Fuel Tank
Fuel quality is critical to the performance and to
the service life of the engine. Water in the fuel
can cause excessive wear to the fuel system.
Condensation occurs during the heating and
cooling of fuel. The condensation occurs as the fuel
passes through the fuel system and the fuel returns
to the fuel tank. This causes water to accumulate
in fuel tanks. Draining the fuel tank regularly and
obtaining fuel from reliable sources can help to
eliminate water in the fuel.
Drain the Water and the Sediment

Fuel tanks should contain some provision for
draining water and draining sediment from the
bottom of the fuel tanks.
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
the drain valve.
Illustration 28
g00992049
(1) Filter
(2) Drain
1. Open the drain valve (2). Catch the draining

water in a suitable container. Dispose of the
draining water properly.
Check the fuel daily. Drain the water and sediment

from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
63
Maintenance Section
Hoses and Clamps - Inspect/Replace
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.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
maintenance of the fuel system filter is important.
Fuel Storage Tanks
NOTICE
Do not bend or strike high pressure lines. Do not install 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.
Check for the following conditions:
End fittings that are damaged or leaking

Outer covering that is chafed or cut
Drain the water and the sediment from the fuel

storage tank during the following conditions:
Exposed wire that is used for reinforcement

Outer covering that is ballooning locally
Weekly
Flexible part of the hose that is kinked or crushed
Oil change
Armoring that is embedded in the outer covering
Refill of the tank

This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank.
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
i01907723
Hoses and Clamps Inspect/Replace
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.
Due to extreme temperature changes, the hose
will harden. Hardening of the hoses will cause
hose clamps to loosen. This can result in leaks. A
constant torque hose clamp will help to prevent
loose hose clamps.
Each installation application can be different. The
differences depend on the following factors:
Type of hose
Type of fitting material
Anticipated expansion and contraction of the
hose
Inspect all hoses for leaks that are caused by the

following conditions:
Cracking
Softness
Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
Anticipated expansion and contraction of the

fittings
Replace the Hoses and the Clamps

Refer to the Disassembly and Assembly Manual,
Oil Cooler - Remove and Oil Cooler - Install for
further information on removing and replacing the
oil cooler hoses. Refer to the Torque Specifications
Manual for further information on pipe fittings, hose
clamps, and constant torque hose clamps.
Refer to the OEM information for further information
on removing and replacing fuel hoses (if equipped).
64
Maintenance Section
Radiator - Clean
The coolant system and the hoses for the coolant

system are not usually supplied by Perkins.
The following text describes a typical method
of replacing coolant hoses. Refer to the OEM
information for further information on the coolant
system and the hoses for the coolant system.
i01907732
Radiator - Clean
The radiator is not usually supplied by Perkins.
The following text describes a typical cleaning
procedure for the radiator. Refer to the OEM
information for further information on cleaning the
radiator.
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
1. Stop the engine. Allow the engine to cool.
Inspect the radiator for these items: Damaged fins,

corrosion, dirt, grease, insects, leaves, oil, and
other debris. Clean the radiator, if necessary.
2. Loosen the cooling system filler cap slowly

Personal injury can result from air pressure.
Note: Drain the coolant into a suitable, clean

container. The coolant can be reused.
3. Drain the coolant from the cooling system to
a level that is below the hose that is being
replaced.
4. Remove the hose clamps.
5. Disconnect the old hose.
6. Replace the old hose with a new hose.
Note: For torques on hose clamps, see Torque
Specifications Manual, Torques for Standard Hose
Clamps and Torques for Constant Torque Hose
Clamps. Also refer to the OEM information for
further information on torques for hose clamps.
7. Install the hose clamps with a torque wrench.
Note: For the proper coolant, see Operation and
Maintenance Manual, General Coolant Information
and Coolant Recommendations.
8. Refill the cooling system. Refer to the OEM
information for further information on refilling the
cooling system.
9. Clean the cooling system filler cap. Inspect
the cooling system filler caps seals. Replace
the cooling system filler cap if the seals are
damaged. Install the cooling system filler cap.
leaks.
Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
to the fans air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the radiator fins. Slowly
move the air nozzle in a direction that is parallel
with the radiator tube assembly. This will remove
debris that is between the tubes.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
both sides.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
If the radiator is blocked internally, refer to the
OEM Manual for information regarding flushing the
cooling system.
After cleaning, start the engine and accelerate
the engine to high idle rpm. This will help in the
removal of debris and the drying of the core. Stop
the engine. Use a light bulb behind the core in
order to inspect the core for cleanliness. Repeat
the cleaning, if necessary.
65
Maintenance Section
Severe Service Application - Check
Inspect the fins for damage. Bent fins may be

opened with a comb. Inspect these items for
good condition: Welds, mounting brackets, air lines,
connections, clamps, and seals. Make repairs, if
necessary.
i01907735
Severe Service Application Check

Severe service is the application of an engine
that exceeds the current published standards for
that engine. Perkins maintains standards for the
following engine parameters:
Environmental Factors
Ambient temperatures The engine may be
exposed to extended operation in extremely
cold environments or hot environments. Valve
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
cold temperatures. Extremely hot intake air reduces
engine performance.
Quality of the air The engine may be exposed to
extended operation in an environment that is dirty
or dusty, unless the equipment is cleaned regularly.
Mud, dirt and dust can encase components.
Maintenance can be very difficult. The buildup can
contain corrosive chemicals.
Buildup Compounds, elements, corrosive
chemicals and salt can damage some components.
Performance such as power range, speed range,

and fuel consumption
Fuel quality
Altitude Problems can arise when the engine

is operated at altitudes that are higher than the
intended settings for that application. Necessary
adjustments should be made.
Operational Altitude
Maintenance intervals
Improper Operating Procedures
Oil selection and maintenance
Extended operation at low idle
Coolant type and maintenance
Frequent hot shutdowns
Environmental qualities
Operating at excessive loads
Installation
Operating at excessive speeds
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.
Operating outside the intended application
Improper Maintenance Procedures

Extending the maintenance intervals
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, improper operating
procedures and improper maintenance procedures
can be factors which contribute to a severe service
application.
Failure to use recommended fuel, lubricants and

coolant/antifreeze
i01907746
Starting Motor - Inspect

Perkins recommends a scheduled inspection of the
starting motor. If the starting motor fails, the engine
may not start in an emergency situation.
66
Maintenance Section
Turbocharger - Inspect
Check the starting motor for proper operation.

Check the electrical connections and clean the
electrical connections. Refer to the Systems
Operation, Testing and Adjusting Manual, Electric
Starting System - Test for more information on
the checking procedure and for specifications
or consult your Perkins dealer or your Perkins
distributor for assistance.
Note: Turbocharger components require precision

clearances. The turbocharger turbine and
compressor assembly must be accurately balanced
due to high operational rpm. Severe Service
Applications can accelerate component wear.
Severe Service Applications require more frequent
inspections of the compressor.
Removal and Installation

i01938674
(If Equipped)
Periodic inspection and cleaning is recommended
for the turbocharger compressor housing (inlet
side). Any fumes from the crankcase are filtered
through the air inlet system. Therefore, by-products
from oil and from combustion can collect in the
turbocharger compressor housing. Over time, this
buildup can contribute to loss of engine power,
increased black smoke and overall loss of engine
efficiency.
If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to
the turbocharger compressor wheel can cause
additional damage to the pistons, the valves, and
the cylinder head.
NOTICE
Turbocharger bearing failures can cause large quantities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.
For options regarding the removal, installation,

repair and replacement, consult your Perkins dealer
or your Perkins distributor. Refer to the Disassembly
and Assembly Manual, Turbocharger - Remove
and Turbocharger - Install for further information.
Cleaning and Inspecting

1. Remove the pipe from the turbocharger exhaust
outlet and remove the air intake pipe to the
turbocharger. Visually inspect the piping for the
presence of oil. Clean the interior of the pipes
in order to prevent dirt from entering during
reassembly.
2. Gently turn the compressor wheel and the turbine
wheel with a finger. The assembly should turn
freely. Inspect the compressor wheel and the
turbine wheel for contact with the turbocharger
housing. There should not be any visible signs of
contact between the turbine wheel or compressor
wheel and the turbocharger housing. If there is
any indication of contact between the rotating
turbine wheel or the compressor wheel and the
turbocharger housing, the turbocharger must
be renewed.
Minor leakage of a turbocharger housing under extended low idle operation should not cause problems
as long as a turbocharger bearing failure has not occurred.
3. Check the compressor wheel for cleanliness.

If only the blade side of the wheel is dirty,
dirt and/or moisture is passing through the air
filtering system. If oil is found only on the back
side of the wheel, there is a possibility of a failed
turbocharger oil seal.
When a turbocharger bearing failure is accompanied

by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.
The presence of oil may be the result of extended

engine operation at low idle. The presence of oil
may also be the result of a restriction of the line
for the inlet air (plugged air filters), which causes
the turbocharger to slobber.
An inspection of the turbocharger can minimize

unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for
potential damage to other engine parts.
4. Inspect the bore of the turbine housing for

corrosion.
5. Clean the turbocharger housing with standard
shop solvents and a soft bristle brush.
67
Maintenance Section
Walk-Around Inspection
6. Replace the compressor cover. Turn the

compressor gently in order to check that the
compressor turns freely and does not contact
the compressor cover. Fasten the air intake pipe
and the exhaust outlet pipe to the turbocharger
housing.
i01907741
Walk-Around Inspection
Inspect the Engine for Leaks and
for Loose Connections
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be
avoided.
For maximum engine service life, make a thorough
inspection of the engine compartment before
starting the engine. Look for items such as oil leaks
or coolant leaks, loose bolts, worn belts, loose
connections and trash buildup. Make repairs, as
needed:
The guards must be in the proper place. Repair

damaged guards or replace missing guards.
Wipe all caps and plugs before the engine is

serviced in order to reduce the chance of system
contamination.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.
Note: The water pump seal is lubricated by the

coolant in the cooling system. It is normal for a
small amount of leakage to occur as the engine
cools down and the parts contract.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For the removal of
the water pump and the installation of water pump
and/or seal, refer to the Disassembly and Assembly
Manual, Water Pump - Remove and Install for
more information or consult your Perkins dealer or
your Perkins distributor.
Inspect the lubrication system for leaks at the

front crankshaft seal, the rear crankshaft seal, the
oil pan, the oil filters and the rocker cover.
Inspect the fuel system for leaks. Look for loose

fuel line clamps and/or tie-wraps.
Inspect the piping for the air intake system and

the elbows for cracks and for loose clamps.
Ensure that hoses and tubes are not contacting
other hoses, tubes, wiring harnesses, etc.
Inspect the alternator belts and any 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 the fuel

tank 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.
NOTICE
Accumulated grease and/or oil on an engine is a fire
hazard. Remove the accumulated grease and oil. Refer to this Operation and Maintenance Manual, Engine - Clean for more information.
Ensure that the cooling system hoses are properly

clamped and that the cooling system hoses are
tight. Check for leaks. Check the condition of all
pipes.
Inspect the water pump for coolant leaks.
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.
68
Maintenance Section
Water Pump - Inspect
i01907756
Water Pump - Inspect

A failed water pump may cause severe engine
overheating problems that could result in the
following conditions:
Cracks in the cylinder head

A piston seizure
Other potential damage to the engine
Note: The water pump seal is lubricated by the
coolant in the cooling system. It is normal for a
small amount of leakage to occur as the engine
cools down and parts contract.
Visually inspect the water pump for leaks. Renew
the water pump seal or the water pump if there
is an excessive leakage of coolant. Refer to the
Disassembly and Assembly Manual, Water Pump
- Remove and Install for the disassembly and
assembly procedure.
69
Warranty Section
Warranty Information
Warranty Section
Warranty Information
i01903596
Emissions Warranty
Information
This engine may be certified to comply with
exhaust emission standards and gaseous emission
standards that are prescribed by the law at the
time of manufacture, and this engine may be
covered by an Emissions Warranty. Consult your
authorized Perkins dealer or your authorized Perkins
distributor in order to determine if your engine is
emissions certified and if your engine is subject to
an Emissions Warranty.
70
Index Section
Index
A
After Starting Engine .............................................
After Stopping Engine............................................
Aftermarket Oil Additives .......................................
Alternator - Inspect ................................................
Alternator and Fan Belts - Inspect/Adjust/
Replace................................................................
Adjustment .........................................................
Inspection...........................................................
Replacement......................................................
27
29
37
49
49
49
49
49
Cooling System Supplemental Coolant Additive

(SCA) - Test/Add..................................................
Add the SCA, If Necessary ................................
Test for SCA Concentration ...............................
Crushing Prevention and Cutting Prevention.........
55
56
56
12
D
Driven Equipment - Check..................................... 56
E
B
Battery - Replace................................................... 50
Battery Electrolyte Level - Check .......................... 50
Battery or Battery Cable - Disconnect ................... 51
Before Starting Engine .................................... 12, 25
Burn Prevention....................................................... 9
Batteries............................................................. 10
Coolant................................................................. 9
Oils..................................................................... 10
C
Cold Weather Lubricants .......................................
Cold Weather Operation ........................................
Hints for Cold Weather Operation ......................
Idling the Engine ................................................
Recommendations for Coolant Warm Up ..........
Recommendations for the Coolant ....................
Viscosity of the Engine Lubrication Oil ..............
Commercial Heavy-Duty Coolant/Antifreeze and
SCA .....................................................................
Adding the SCA to Heavy-Duty Coolant at the
Initial Fill ...........................................................
Adding the SCA to Heavy-Duty Coolant For
Maintenance.....................................................
Cleaning the System of Heavy-Duty
Coolant/Antifreeze ...........................................
Coolant Recommendations ...................................
Cooling System Coolant - Change (Commercial
Heavy Duty) .........................................................
Drain ..................................................................
Fill ......................................................................
Flush ..................................................................
Cooling System Coolant (ELC) - Change..............
Drain ..................................................................
Fill ......................................................................
Flush ..................................................................
Cooling System Coolant Extender (ELC) - Add.....
Cooling System Coolant Level - Check .................
Engines With a Coolant Recovery Tank.............
Engines Without a Coolant Recovery Tank........
Cooling System Specifications ..............................
37
30
30
31
31
30
30
45
45
45
46
42
52
53
54
53
51
51
52
52
54
54
54
55
41
Electrical System................................................... 13
Grounding Practices .......................................... 13
Emergency Stopping ............................................. 29
Emissions Certification Film .................................. 19
Emissions Warranty Information............................ 69
Engine - Clean....................................................... 56
Engine Air Cleaner Element (Single Element) Inspect/Replace ................................................... 57
Engine Air Cleaner Service Indicator - Inspect...... 57
Test the Service Indicator .................................. 57
Engine Description ................................................ 18
Engine Cooling and Lubrication......................... 18
Engine Service Life ............................................ 18
Engine Identification .............................................. 19
Engine Lifting......................................................... 21
Engine Mounts - Inspect........................................ 58
Engine Oil .............................................................. 34
Commercial Oils................................................. 34
Total Base Number (TBN) and Fuel Sulfur Levels
for Direct Injection (DI) Diesel Engines ............ 35
Engine Oil and Filter - Change .............................. 58
Drain the Engine Oil........................................... 59
Fill the Engine Crankcase .................................. 59
Replace the Oil Filter ......................................... 59
Engine Oil Level - Check ....................................... 58
Engine Operation................................................... 28
Engine Starting................................................ 12, 25
Engine Stopping .............................................. 13, 29
Engine Storage...................................................... 21
Cooling System.................................................. 22
Exhaust System ................................................. 22
General Items .................................................... 23
Induction System ............................................... 22
Lubrication System ............................................ 21
Engine Valve Lash - Inspect/Adjust ....................... 60
Extended Life Coolant (ELC)................................. 43
Extended Life Coolant (ELC) Cooling System
Maintenance ........................................................ 43
Changing to Perkins ELC................................... 44
ELC Cooling System Cleaning........................... 44
ELC Cooling System Contamination.................. 45
Perkins ELC Extender ....................................... 43
Proper additions to the Extended Life Coolant .. 43
71
Index Section
F
Fire Prevention and Explosion Prevention............. 10
Fire Extinguisher ................................................ 11
Lines, Tubes and Hoses..................................... 11
Foreword.................................................................. 5
California Proposition 65 Warning ....................... 5
Literature Information........................................... 4
Maintenance ........................................................ 4
Maintenance Intervals.......................................... 4
Operation ............................................................. 4
Overhaul .............................................................. 4
Safety................................................................... 4
Fuel and the Effect from Cold Weather ................. 32
Fuel Conservation Practices.................................. 28
Fuel Recommendations......................................... 38
Fuel Related Components in Cold Weather .......... 33
Fuel Filters ......................................................... 33
Fuel Heaters ...................................................... 33
Fuel Tanks.......................................................... 33
Fuel Specifications ................................................ 38
Fuel System - Prime.............................................. 60
Fuel System Filter - Replace ................................. 61
Fuel System Primary Filter/Water Separator Drain .................................................................... 62
Fuel Tank Water and Sediment - Drain.................. 62
Drain the Water and the Sediment..................... 62
Fuel Storage Tanks ............................................ 63
Fuel Tank ........................................................... 62
G
Gauges and Indicators .......................................... 24
General Coolant Information ................................. 41
Additives ............................................................ 41
Glycol ................................................................. 42
Water ................................................................. 41
General Hazard Information .................................... 8
Containing Fluid Spillage ..................................... 9
Fluid Penetration .................................................. 9
Pressure Air and Water........................................ 9
H
Hoses and Clamps - Inspect/Replace ................... 63
Replace the Hoses and the Clamps .................. 63
I
Lubricant Information.............................................
API Oils ..............................................................
Engine Manufacturers Association (EMA) Oils ..
General Information ...........................................
Lubricant Specifications ........................................
34
34
34
34
34
M
Maintenance Interval Schedule .............................
Maintenance Section .............................................
Model View Illustrations.........................................
Model Views ..........................................................
48
34
14
14
O
Operation Section.................................................. 21
P
Product Identification Information .......................... 19
Product Information Section .................................. 14
R
Radiator - Clean ....................................................
Re-refined Base Stock Oils ...................................
Reference Numbers ..............................................
Record for Reference.........................................
Refill Capacities.....................................................
Cooling System..................................................
Lubrication System ............................................
64
37
19
19
47
47
47
S
Safety Section ......................................................... 6
Safety Signs and Labels.......................................... 6
Serial Number Plate .............................................. 19
Severe Service Application - Check ...................... 65
Environmental Factors ....................................... 65
Improper Maintenance Procedures.................... 65
Improper Operating Procedures ........................ 65
Starting Motor - Inspect ......................................... 65
Starting the Engine................................................ 26
Starting with Jump Start Cables ............................ 26
Stopping the Engine .............................................. 29
Synthetic Base Stock Oils ..................................... 36
Important Safety Information ................................... 2

T
L
Lifting and Storage ................................................ 21
Table of Contents..................................................... 3
Turbocharger - Inspect (If Equipped) ..................... 66
Cleaning and Inspecting .................................... 66
Removal and Installation.................................... 66
72
Index Section
W
Walk-Around Inspection ........................................
Inspect the Engine for Leaks and for Loose
Connections .....................................................
Warranty Information .............................................
Warranty Section ...................................................
Water Pump - Inspect............................................
67
67
69
69
68


this publication.

replacement parts.
death.
3
Table of Contents
Table of Contents
Specifications Section
Engine Design .....................................................
Fuel Injection Lines ..............................................
Fuel Injection Pump .............................................
Fuel Injectors .......................................................
Fuel Transfer Pump ..............................................
Lifter Group ...........................................................
Rocker Shaft ........................................................
Valve Mechanism Cover ......................................
Cylinder Head Valves ............................................
Cylinder Head ......................................................
Exhaust Manifold .................................................
Camshaft .............................................................
Engine Oil Relief Valve ........................................
Engine Oil Pump ..................................................
Engine Oil Pressure .............................................
Engine Oil Bypass Valve ......................................
Engine Oil Pan .....................................................
Water Temperature Regulator ..............................
Cylinder Block ......................................................
Crankshaft ...........................................................
Crankshaft Seals .................................................
Connecting Rod Bearing Journal .........................
Main Bearing Journal ............................................
Connecting Rod ...................................................
Piston and Rings ..................................................
Front Housing and Covers ...................................
Gear Group (Front) ...............................................
Flywheel ...............................................................
Crankshaft Pulley .................................................
Belt Tension Chart ...............................................
Alternator and Regulator ......................................
Electric Starting Motor .........................................
Glow Plugs ...........................................................
4
4
4
5
6
6
7
7
7
9
9
9
11
11
12
12
13
13
14
15
16
16
17
17
17
19
20
20
21
21
22
22
23
Index Section
Index ..................................................................... 24
4
When the camshaft is viewed from the flywheel end

of the engine, the camshaft rotates in the following
direction: ....................................... Counterclockwise
i01955627
Note: The left side and the right side of the engine
are viewed from the flywheel end. The No. 1 cylinder
is the front cylinder.
Engine Design
i01891782
Fuel Injection Lines
Illustration 1
g01016767
Cylinder and valve location

(A) Inlet valve
(B) Exhaust valve
Bore ............................................ 94 mm (3.70 inch)

Stroke ........................................ 120 mm (4.72 inch)
Displacement ..................................... 3.3 L (203 in3)
Cylinder arrangement ..................................... In-line
Illustration 2
g00993243
Type of combustion
Naturally aspirated engines ..... Indirect injection
Turbocharged engines ............... Direct injection
(1) Tighten the nuts for the fuel injection lines to the
following torque. .... 27 to 32 Nm (20 to 24 lb ft)
Compression ratio
Naturally aspirated engines ........................ 22:1
Turbocharged engines ................................ 19:1
Number of cylinders ............................................... 4
Valves per cylinder ................................................. 2
Valve lash
Inlet valve ...................... 0.25 mm (0.0098 inch)
Exhaust valve ................ 0.25 mm (0.0098 inch)
Firing order ................................................. 1, 3, 4, 2
Fuel injection timing ...................................... 5 BTC
When the crankshaft is viewed from the flywheel
end of the engine, the crankshaft rotates in the
following direction: ....................... Counterclockwise
i01906880
Fuel Injection Pump

Note: The engine is equipped with an axial piston
distributor injection pump that is mechanically
governed. Parts that are inside of the fuel injection
pump are only serviceable by an authorized dealer.
5
i01959231
Fuel Injectors
Naturally Aspirated Engines
Illustration 3
g00993641
(1) Tighten the overflow valve for the fuel injection

pump to the following torque. ....... 22 to 31 Nm
(16 to 23 lb ft)
(2) Screw for adjusting the full load setting
(3) Tighten the nut for the fuel injection pump gear
to the following torque.
Naturally aspirated engines .......... 59 to 69 Nm
(43 to 51 lb ft)
Turbocharged engines .................. 83 to 98 Nm
(62 to 72 lb ft)
(4) Fuel shutoff solenoid
Illustration 4
g01010241
(1) Tighten the body in the retaining nut to the

Note: The fuel injector should only be disassembled
and assembled by personnel with the proper
training.
(5) Bolt for attaching to the gear case cover
(2) Tighten the fuel injector in the engine to the

(6) Delivery valves for the fuel
Type of fuel injector .............................. single orifice

Injection pressure
Standard at assembly ........ 11.77 to 12.75 MPa
(1707 to 1849 psi)
6
Turbocharged Engines
i01907139
Fuel Transfer Pump
Illustration 5
g00993511
(1) Tighten the retaining nut to the following

torque. ................... 25 to 34 Nm (18 to 25 lb ft)
Note: The fuel injector should only be disassembled
and assembled by personnel with the proper
training.
Tighten the clamp bolt that secures the fuel
injector in the cylinder head to the following
torque. ......................... 21 to 23 Nm (16 to 17 lb ft)
Illustration 6
g00993469
(1) Fuel transfer pump

(2) Torque for one fitting .. 6 to 8 Nm (53 to 71 lb in)
(3) Fuel filter/water separator
i01900860
Type of fuel injector ........................... multiple orifice
Lifter Group
Injection pressure
Standard at assembly ........ 18.14 to 19.12 MPa
(2631 to 2773 psi)
Illustration 7
g00988934
Clearance between the lifter and the bore in the

engine for the lifter
Standard at assembly .......... 0.016 to 0.052 mm
(0.0006 to 0.0020 inch)
7
Repair limit .................... 0.08 mm (0.0031 inch)

i01891826
Rocker Shaft
(5) Pushrods
Use a dial indicator to check all pushrods for
runout. Replace the pushrod if the runout exceeds
the following value. .............. 0.30 mm (0.0118 inch)
i01892068
Valve Mechanism Cover
Illustration 8
g00984738
(1) Rocker shaft

Diameter of the rocker
shaft .................................. 18.980 to 19.000 mm
(0.7472 to 0.7480 inch)
(2) Rocker arm
Inside diameter of the rocker arm
bushings ........................... 19.010 to 19.030 mm
(0.7484 to 0.7492 inch)
Clearance between the rocker arm bushing and
the rocker shaft .................... 0.010 to 0.050 mm
(0.0004 to 0.0020 inch)
Maximum permissible clearance between
the rocker arm bushing and the rocker
shaft ............................. 0.070 mm (0.0028 inch)
Illustration 10
g00984870
(1) Tighten the bolts for the valve mechanism cover

to the following torque. ................. 10 to 13 Nm
(7 to 10 lb ft)
i01892207
Cylinder Head Valves
(3) Spring
(4) Tighten the bolts evenly. Tighten the long
bolt first. Tighten the bolts to the following
torque. ..................... 10 to 20 Nm (7 to 15 lb ft)
Illustration 11
Illustration 9
g01014064
(1) Valve spring
g01010358
8
Free length of the valve springs ........ 48.85 mm

(1.92 inch)
Service limit for free length of the valve
springs ............................. 47.60 mm (1.87 inch)
Length of the valve springs under set
force ..................................... 43 mm (1.69 inch)
Set force of the valve springs ....... 176 to 196 N
(40 to 44 lb)
Service limit for set force of the valve
springs ........................................... 147 N (33 lb)
(6) Angle of the exhaust valve face from the

horizontal axis
Valve face angle ............................... 30 degrees
Valve seat angle ............................... 30 degrees
(7) Angle of the inlet valve face from the horizontal
axis
Valve face angle ............................... 30 degrees
Valve seat angle ............................... 30 degrees
(2) Valve spring recess

(3) Valve guides
Projection of the valve guide above the valve
spring recess ................................ 14 0.1 mm
(0.55 0.004 inch)
(4) Exhaust valve
Diameter of the exhaust valve
stem ...................................... 7.920 to 7.940 mm
(0.3118 to 0.3126 inch)
Service limit diameter of the exhaust valve
stem ............................. 7.850 mm (0.3091 inch)
Clearance of the exhaust valve stem in the
exhaust valve guide ............. 0.080 to 0.115 mm
(0.0031 to 0.0045 inch)
Maximum allowable clearance of the
exhaust valve stem in the exhaust valve
guide ........................... 0.200 mm (0.0079 inch)
Valve depth of the exhaust valve below the cylinder
head face
Standard at assembly .................. 0.4 to 0.6 mm
(0.016 to 0.024 inch)
Service limit ....................... 1.0 mm (0.039 inch)
(5) Inlet valve
Diameter of the inlet valve
stem ...................................... 7.940 to 7.955 mm
(0.3126 to 0.3132 inch)
Service limit diameter of the inlet valve
stem ............................. 7.900 mm (0.3110 inch)
Clearance of the inlet valve stem in the inlet
valve guide ........................... 0.065 to 0.095 mm
(0.0026 to 0.0037 inch)
Maximum allowable clearance of the inlet valve
stem in the inlet valve guide .............. 0.150 mm
(0.0059 inch)
Valve depth of the inlet valve below the cylinder
head face
Standard at assembly .................. 0.3 to 0.5 mm
(0.012 to 0.020 inch)
Service limit ....................... 1.0 mm (0.039 inch)
Illustration 12
g00985069
Bore in the cylinder head for the valve seats
Bore for the inlet valve seat

A
B
C
D
....................................................... 45 degrees
..... 46 to 46.0025 mm (1.8110 to 1.8111 inch)
.................... 2 0.1 mm (0.079 0.004 inch)
.................... 8 0.1 mm (0.315 0.004 inch)
Bore for the exhaust valve seat

A
B
C
D
....................................................... 45 degrees
......... 37 to 37.0025 mm (1.457 to 1.458 inch)
.................... 2 0.1 mm (0.079 0.004 inch)
.................... 8 0.1 mm (0.315 0.004 inch)
9
i01892090
Cylinder Head
Illustration 13
i01892688
Exhaust Manifold
g00984896
Tighten the cylinder head bolts in the sequence that

is shown to the following torque. .... 113 to 123 Nm
(83 to 91 lb ft)
Illustration 15
g00985166
(1) Bolt
Tighten the exhaust manifold bolts to the following
torque.
(11 to 16 lb ft)
(21 to 24 lb ft)
Maximum warpage of the flange for the exhaust
manifold ................................. 0.20 mm (0.008 inch)
i01892837
Camshaft
Illustration 14
g00984909
The permissible distortion of the cylinder head is

given below.
Maximum at assembly .. 0.05 mm (0.0020 inch)
Illustration 16
g00988290
(1) End play of a new camshaft .... 0.10 0.25 mm

(0.0039 0.0098 inch)
Maximum permissible end play of a worn
camshaft .............................. 0.30 mm (0.0118 inch)
10
(2) Tighten the thrust plate bolts to the following

(B) Camshaft lobe height

(C) Base circle
(3) The diameters of the camshaft journals are

given in the following table.
To determine the lobe lift, use the procedure that

follows:
Table 1
1. Measure the camshaft lobe height (B).
Diameters of Camshaft Journals

Camshaft
Journals
Standard
Diameter
Service Limit
2. Measure the base circle (C).
No. 1,2
53.94 to 53.96
mm (2.123 to
2.124 inch)
53.90 mm
(2.122 inch)
3. Subtract the base circle that is found in Step 2

from the camshaft lobe height that is found in
Step 1. The difference is the camshaft lobe lift.
No. 3
52.94 to 52.96
mm (2.084 to
2.085 inch)
52.90 mm
(2.083 inch)
If the camshaft lobe lift is less than the service limit,

replace the camshaft.
Illustration 18
g01014070
(4) Camshaft
Deflection over the full length of the camshaft
Illustration 17
g00987844
(A) Camshaft lobe lift

Naturally aspirated engines
Inlet lobe ...................... 6.722 mm (0.2646 inch)
Exhaust lobe ................ 6.720 mm (0.2645 inch)
Turbocharged engines
The service limit for camshaft lobe lift is given below:
Naturally aspirated engines
Turbocharged engines

11
i01893227
Service limit ................... 0.50 mm (0.0197 inch)
Engine Oil Relief Valve
Illustration 21
g00987861
g00987876
(2) Clearance between the outer rotor and the inner

rotor
(1) Tighten the engine oil relief valve to the following

Standard ................................... 0.13 to 0.15 mm

(0.0051 to 0.0059 inch)
Illustration 19
Opening pressure of engine oil relief

valve ............................... 350 50 kPa (50 7 psi)
Note: The engine oil relief valve is located on the
left side of the cylinder block.
i01893490
Engine Oil Pump

Type ............................. Gear-driven differential rotor
Illustration 22
Number of lobes
Inner rotor ......................................................... 4
Outer rotor ........................................................ 5
Illustration 20
g00987863
(3) Clearance between the rotors and the body

Standard ................................... 0.04 to 0.09 mm
(0.0016 to 0.0035 inch)
g00987857
(1) Clearance between the outer rotor and the body

Illustration 23
Standard ................................... 0.20 to 0.30 mm

(0.0079 to 0.0118 inch)
g00996150
12
(4) Diameter of main shaft (near

body) ................................ 15.985 to 16.000 mm
(0.6293 to 0.6299 inch)
i01935709
Engine Oil Bypass Valve
Clearance between the main shaft and the body

Standard ............................... 0.032 to 0.074 mm
(0.0013 to 0.0029 inch)
(5) Diameter of main shaft (near
bushing) ........................... 13.957 to 13.975 mm
(0.5495 to 0.5502 inch)
Clearance between the main shaft and the bushing
Standard ............................... 0.025 to 0.111 mm
(0.0010 to 0.0044 inch)
Service limit ................. 0.200 mm (0.0079 inch)
i01893585
Engine Oil Pressure

Table 2
Illustration 24
g00987878
Oil Pressure(1)
Oil Pressure at 1500 rpm
Oil pressure at idle
(1)
300 to 500 kPa

(44 to 73 psi)
100 kPa (14.5 psi)
or more
The oil temperature must be 70 to 90C (158 to 194F).
The minimum acceptable oil pressure at low

idle ..................................................... 50 kPa (7 psi)
Engine oil bypass valve

Tighten the engine oil bypass valve to the
Opening pressure of engine oil bypass
valve ...................................... 1.1 MPa (160 psi)
Note: The engine oil bypass valve is mounted on
the inside of the engine oil pan along the left side
oil pan rail.
13
i01959273
Engine Oil Pan
Illustration 27
g00987892
(3) Tighten the oil pan drain plug to the following

i01893737
Water Temperature Regulator

Illustration 25
g00987891
(1) Apply 21826038 or 21826051 POWERPART

silicon rubber to the flange of the oil pan. Refer
to illustration 26.
Illustration 28
g00877006
The water temperature regulator starts to open at

the following temperature. ..................... 82 1.5C
(180 2.7F)
The water temperature regulator has a lift of
more than 8 mm (0.3 inch) at the following
temperature. ...................................... 95 C (203 F)
Illustration 26
g01020644
Note: Apply 21820117 POWERPART threadlock

and nutlock in order to reuse the bolts for the
oil pan. Apply the sealant to the first 13 mm
(0.5118 inch) of the thread.
(2) Tighten the oil pan bolts to the following
14
i01959901
Cylinder Block
The permissible distortion of the contact surface of

the gasket is given below.
(2) Main bearing cap bolts
Use the following procedure in order to install the
main bearing cap bolts:
1. Apply engine oil to the bearings and install the
bearings to the caps.
Note: Apply a small amount of
21826038 or 21826051 POWERPART
silicone rubber to the corners of the cylinder block
for the rear main bearing cap. After the rear main
bearing cap is installed, remove any excess sealant
from the inside of the recess for the rear oil seal.
Excess sealant prevents the correct seating of the
rear oil seal.
2. Install the cap to the crankcase so that the rear
face of the cap is even with the rear face of the
crankcase.
g00987933
Illustration 29
3. Apply clean engine oil to the threads of the main

bearing cap bolts.
(1) Cylinder bore
Tighten the main bearing cap bolts to the

following torque. ... 98 to 108 Nm (72 to 80 lb ft)
Table 3
Tolerances of Cylinder Bores

Standard at
Assembly
Repair
Limit(1)
Service
Limit(2)
94.000 to
94.035 mm
(3.7008 to
3.7022 inch)
94.200 mm
(3.7087
inch)
94.700 mm
(3.7283
inch)
Out of
Round
0.010 mm
(0.0004
inch)
N/A
N/A
Taper
0.015 mm
(0.0006
inch)
N/A
N/A
Inside
Diameter
(1)
(2)
Bore the cylinder to the specified oversize dimension if the

repair limit has been reached.
Install a cylinder liner or replace the cylinder block if the service
limit has been reached.
Illustration 30
g01007113
(3) Rear main bearing cap
Bore the cylinder to the oversize dimension if the

cylinder has uneven wear. Refer to Table 4.
(4) Main bearing caps should have a marking that

indicates placement and orientation.
Table 4
(5) Front main bearing cap

Oversize Bore
Cylinder Bore Size
0.250 mm (0.0100 inch)
94.250 to 94.285 mm
(3.7106 to 3.7120 inch)
0.500 mm (0.0197 inch)
94.500 to 94.535 mm
(3.7205 to 3.7218 inch)
15
Illustration 31
g01007117
(6) Seal for the front and rear main bearing caps.
(7) The seals for the front and the rear main bearing
caps have a curve at one end. The curved side
must be installed toward the side of the engine.
The curved end is inserted first into the hole.
Note: Use the 27610013 Rubber plug replacer in
order to install the seal correctly.
Illustration 33
g00988954
(10) Inside diameter of the lifter bore

Standard at assembly ...... 14.000 to 14.018 mm
(0.5512 to 0.5519 inch)
Service limit ............... 14.100 mm (0.5551 inch)
i01894898
Crankshaft
(8) Before installing the seals, inject a small quantity

of 21826038 or 21826051 POWERPART
silicone rubber in the holes for the seals.
Illustration 32
g01007175
(9) Seal for the front main bearing cap.

Illustration 34
g00987940
(1) Crankshaft end play

(0.0039 to 0.0104 inch)
Repair limit .................. 0.300 mm (0.0118 inch)
16
Crankshaft deflection
i01059939

Crankshaft Seals
Clearance between crankshaft bearing and

crankshaft journal
(0.0020 to 0.0043 inch)
g00554030
Illustration 36
(1) Oil seal

(2) Oil seal sleeve
g00994009
Illustration 35
(A) Original width of the rear crankshaft

journal ............................... 31.000 to 31.039 mm
(1.2205 to 1.2220 inch)
Inspect the contact surface between the oil seal

and the crankshaft for wear. If the crankshaft is
worn, replace the oil seal with an oil seal and a
sleeve assembly.
Table 5
i01907581
Width of Crankshaft Journal for Oversize

Thrust Washers
Oversize Thrust
Washer
Oversize Width
for Front OR
Rear
Oversize Width
for Front AND
Rear
0.15 mm
(0.006 inch)
31.150 to 31.189
mm (1.2264 to
1.2279 inch)
31.300 to 31.339
mm (1.2323 to
1.2338 inch)
0.30 mm
(0.012 inch)
31.300 to 31.339
mm (1.2323 to
1.2338 inch)
31.450 to 31.489
mm (1.2382 to
1.2397 inch)
0.45 mm
(0.018 inch)
31.450 to 31.489
mm (1.2382 to
1.2397 inch)
31.600 to 31.639
mm (1.2441 to
1.2456 inch)
Refer to Specifications, Connecting Rod Bearing

Journal for information on the connecting rod
bearing journals.
Refer to Specifications, Main Bearing Journal for
information on the main bearing journals and the
main bearings.
Connecting Rod Bearing

Journal
Table 6
Diameter of Crankshaft Journal (Bearing Surface)

For Connecting Rod Bearings
(1)
Original Size Journal(1)
57.955 to 57.970 mm
(2.2817 to 2.2823 inch)
Undersize Journal
0.25 mm (0.010 inch)
57.705 to 57.720 mm
(2.2718 to 2.2724 inch)
Undersize Journal
0.50 mm (0.020 inch)
57.455 to 57.470 mm
(2.2620 to 2.2626 inch)
Undersize Journal
0.75 mm (0.030 inch)
57.205 to 57.220 mm
(2.2522 to 2.2528 inch)
Regrind the connecting rod bearing journals to the next

undersize dimension if the repair limit of 57.800 mm
(2.2756 inch) is exceeded.
The clearance between a new connecting rod

bearing and a new connecting rod bearing journal
is the following value. ................. 0.030 to 0.090 mm
(0.0012 to 0.0035 inch)
17
Service limit for clearance between a connecting

rod bearing and a connecting rod bearing
journal ................................ 0.200 mm (0.0079 inch)
i01907583
Clearance between the piston pin and the piston

pin bearing
Table 7
Diameter of Crankshaft Journal (Bearing

Surface) For Main Bearings
(2)
Inside diameter of the piston pin bearing

Nominal value ....................... 30 mm (1.18 inch)
(1.1819 to 1.1829 inch)
Main Bearing Journal
(1)
(1) Install the bearing cap to the connecting rod

and tighten the cap nuts to the following
Original Size Journal(1)
77.955 to 77.970 mm
(3.0691 to 3.0697 inch)
Undersize Journal
0.25 mm (0.010 inch)
77.705 to 77.720 mm
(3.0592 to 3.0598 inch)
Undersize Journal
0.50 mm (0.020 inch)
77.455 to 77.470 mm
(3.0494 to 3.0500 inch)
Undersize Journal
0.75 mm (0.030 inch)(2)
77.205 to 77.220 mm
(3.0396 to 3.0402 inch)
Regrind the main bearing journals to the next undersize

dimension if the repair limit of 77.850 mm (3.0650 inch) is
exceeded.
Service limit 77.100 mm (3.0354 inch)

(0.0008 to 0.0020 inch)
End play of the connecting rod that is attached to
the crankshaft.
Standard at assembly .............. 0.15 to 0.35 mm
(0.0059 to 0.0138 inch)
Service limit ..................... 0.50 mm (0.020 inch)
i01895761
Piston and Rings
The clearance between a new main bearing

and a new main bearing journal is the following
value. ... 0.050 to 0.110 mm (0.0020 to 0.0043 inch)
i01895665
Connecting Rod
Illustration 38
g00996359
(1) Diameter of the piston pin

Nominal value ....................... 30 mm (1.18 inch)
(1.1809 to 1.1811 inch)
Clearance between the piston pin and the bore
Illustration 37
g00987949
Prior to assembly, apply engine oil to the bearing.

(0.0000 to 0.0006 inch)
18
Refer to table 8 for the outside diameters of the

pistons.
Table 8
Item
Standard at
Assembly
Service Limit
Standard
93.955 to 93.985
mm (3.6990 to
3.7002 inch)
93.770 mm
(3.6917 inch)
0.25 mm
(0.0098 inch)
oversize
94.205 to 94.235
mm (3.7089 to
3.7100 inch)
94.020 mm
(3.7016 inch)
0.50 mm
(0.0197 inch)
oversize
94.455 to 94.485
mm (3.7187 to
3.7199 inch)
94.270 mm
(3.7114 inch)
Maximum difference in weight of the piston per

engine ...................................... 0.005 kg (0.0110 lb)
Illustration 40
g00987968
Clearance between the piston groove and a new

piston ring
No. 1 ring
(0.0028 to 0.0043 inch)
No. 2 ring
Illustration 39
g00987967
Piston ring end gap

(0.0118 to 0.0197 inch)

(0.0018 to 0.0033 inch)
Oil ring
(0.0010 to 0.0026 inch)
Illustration 41
(2) Protrusion of the piston
g00987974
19
Standard at Assembly
Naturally aspirated engines ... 0.25 to 0.15 mm
(0.0098 to 0.0059 inch)
Turbocharged engines ............. 0.05 to 0.45 mm
(0.0020 to 0.0177 inch)
Apply engine oil to the piston rings. Refer to

Illustration 43 for the assembled configuration of the
ends of the piston rings.
Note: Install the piston with the O mark toward
the front of the engine.
Compressed thickness of cylinder head

gasket ............... 1.2 0.05 mm (0.05 0.002 inch)
i01896193
Front Housing and Covers
Illustration 42
g00987977
(3) Piston from naturally aspirated engines

g00987995
(4) Piston from turbocharged engines
Illustration 44
(5) WEIGHT mark
(1) Tighten the bolts that fasten the front

plate to the cylinder block to the following
(6) MATCHING mark

Note: Assemble the piston and the connecting rod
with the WEIGHT mark on the piston and with the
MATCHING mark on the rod on the same side.
(2) Remove the excess gasket with a cutter.
Illustration 45
Illustration 43
(7) Camshaft side

(8) End gap of No. 1 compression ring
(9) End gap of No. 2 compression ring
(10) Side with the inlet valve
(11) End gap of oil ring
g00987981
g00987996
(3) Tighten the bolts that fasten the timing

gear case to the front plate to the following
20
i01960360
Gear Group (Front)
(7) Tighten the locknut for the oil pump gear to the
Backlash for gears
Helical gears at assembly ....... 0.03 to 0.18 mm
(0.0012 to 0.0071 inch)
Spur gears at assembly ............... .03 to .20 mm
(0.0012 to 0.0079 inch)
Service Limit .................. 0.25 mm (0.0098 inch)
i01896629
Flywheel
Flatness of friction surface of the flywheel
Repair limit ...................... 0.50 mm (0.020 inch)
Face and bore runouts of flywheel
Repair limit ...................... 0.50 mm (0.020 inch)
Illustration 46
g00988013
(1) Camshaft gear

(2) Idler gear
End play of idler gear
(0.0020 to 0.0079 inch)
Clearance between idler gear bushing and shaft
(0.0004 to 0.0020 inch)
(3) Fuel Injection pump gear
Tighten the bolts for the fuel injection pump
gear to the following torque.
(43 to 51 lb ft)
(62 to 72 lb ft)
(4) Crankshaft gear
(5) Oil pump gear
(6) Tighten the thrust plate bolts for the idler gear
to the following torque. ................. 29 to 39 Nm
(21 to 29 lb ft)
Illustration 47
g00988073
(1) Tighten the bolts for the flywheel to the following

21
i01963669
Crankshaft Pulley
i01948258
Belt Tension Chart

Note: Do not use the belt tension chart for belts with
tensioners that are spring loaded.
Illustration 48
g00988100
Note: Apply 21826038 POWERPART silicon

adhesive to the threads of the crankshaft before
the pulley nut is installed.
(1) Tighten the nut that fastens the crankshaft
pulley to the crankshaft to the following
torque. ........... 480 to 500 Nm (354 to 369 lb ft)
(2) Crankshaft pulley
Illustration 49
g00988022
(3) Maximum depth for the top of the V-belt in the

groove ................................. 1.6 mm (0.06 inch)
22
Table 9
Belt Tension Chart

Belt Type
Deflection
Applied Force for Specified Deflection
Type B
10 to 15 mm (0.4 to 0.6 inch)
98 to 147 N (22 to 33 lb)
i01961063
Alternator and Regulator
i01972534
Electric Starting Motor
Note: Apply a suitable Load to the battery in order

to get the maximum alternator output.
Illustration 51
g01024163
The starter motor

Illustration 50
g01014132
(1) Alternator and regulator

Voltage ...................................................... 13.5 V
Output current at 1500 rpm ... 20 amp or higher
(1) Electric starting motor

(2) Tighten the nut on the starter motor terminal to
the following torque. ...................... 18 to 25 Nm
(13.3 to 18.4 lb ft)
(3) Tighten the starter motor terminal to the following

torque. ................ 2.6 to 4.2 Nm (23 to 37 lb in)
No load conditions at 25 C (77 F)
Adjusting voltage of the regulator at 5000 rpm with

a load of 5 amp or lower ................ 14.2 V to 14.8 V
Speed .................................. 3000 rpm minimum

Current draw ....................... 200 amp maximum
Voltage ......................................................... 11 V
When the electric starting motor is viewed from
the drive end, the motor rotates in the following
direction. ................................................... Clockwise
23
i01899831
Glow Plugs
Naturally Aspirated Engines
Illustration 52
g00988137
(1) Tighten the glow plugs in the cylinder head to

(11 to 15 lb ft)
Type ............................................................... 12 Volt
Current (30 second rating) ................... 9.7 amperes
Turbocharged Engines
Illustration 53
g00988138
(1) Tighten the glow plugs in the cylinder head to

(15 to 22 lb ft)
Type .............................................................. 12 Volt
Current (30 second rating) ................... 5.5 amperes
Index
A
Alternator and Regulator ....................................... 22
Lifter Group............................................................ 6
Belt Tension Chart ................................................. 21
Main Bearing Journal ............................................ 17
Camshaft ...............................................................
Connecting Rod.....................................................
Connecting Rod Bearing Journal ..........................
Crankshaft ............................................................
Crankshaft Pulley ..................................................
Crankshaft Seals ...................................................
Cylinder Block........................................................
Cylinder Head........................................................
Cylinder Head Valves ............................................
9
17
16
15
21
16
14
9
7
Piston and Rings ................................................... 17

R
Rocker Shaft.......................................................... 7
S
Specifications Section ........................................... 4
E
Electric Starting Motor ...........................................
Engine Design .......................................................
Engine Oil Bypass Valve .......................................
Engine Oil Pan.......................................................
Engine Oil Pressure...............................................
Engine Oil Pump....................................................
Engine Oil Relief Valve ..........................................
Exhaust Manifold ...................................................
22
4
12
13
12
11
11
9
20
19
4
4
5
5
6
6
G
Gear Group (Front) ................................................
Glow Plugs ............................................................
Naturally Aspirated Engines...............................
Turbocharged Engines .......................................
Table of Contents................................................... 3
V
Valve Mechanism Cover ........................................ 7
W
F
Flywheel ................................................................
Front Housing and Covers.....................................
Fuel Injection Lines................................................
Fuel Injection Pump...............................................
Fuel Injectors.........................................................
Naturally Aspirated Engines...............................
Turbocharged Engines .......................................
Fuel Transfer Pump ...............................................
20
23
23
23
I
Important Safety Information ................................. 2
Water Temperature Regulator ............................... 13


this publication.

replacement parts.
death.
3
Table of Contents
Table of Contents
Battery - Test .........................................................

Belt Tension Chart ................................................
Electric Starting System - Test ..............................
Glow Plugs - Test ..................................................
Systems Operation Section

Engine Design ....................................................... 4
General Information ................................................ 4
Fuel System ........................................................... 9
Air Inlet and Exhaust System ............................... 14
Lubrication System .............................................. 17
Cooling System .................................................... 19
Basic Engine ......................................................... 20
Electrical System ................................................. 23
Testing and Adjusting Section

Fuel System
Fuel System - Inspect ...........................................
Air in Fuel - Test ....................................................
Finding Top Center Position for No. 1 Piston ........
Fuel Injection Timing - Check ...............................
Fuel Injector - Test ................................................
Fuel Quality - Test .................................................
Fuel System - Prime .............................................
25
25
26
26
28
30
31
Air Inlet and Exhaust System

Air Inlet and Exhaust System - Inspect .................
Turbocharger - Inspect ..........................................
Exhaust Temperature - Test ..................................
Compression - Test ...............................................
Engine Valve Lash - Inspect/Adjust ......................
Valve Depth - Inspect ............................................
Valve Guide - Inspect ............................................
32
32
34
34
35
36
37
Lubrication System
Engine Oil Pressure - Test ....................................
Engine Oil Pump - Inspect ....................................
Excessive Bearing Wear - Inspect ........................
Excessive Engine Oil Consumption - Inspect .......
Increased Engine Oil Temperature - Inspect ........
38
38
39
39
40
Cooling System
Cooling System - Check (Overheating) ................
Cooling System - Inspect ......................................
Cooling System - Test ...........................................
Engine Oil Cooler - Inspect ...................................
Water Temperature Regulator - Test .....................
41
42
42
44
45
Basic Engine
Piston Ring Groove - Inspect ................................
Connecting Rod - Inspect .....................................
Connecting Rod Bearings - Inspect ......................
Main Bearings - Inspect ........................................
Cylinder Block - Inspect ........................................
Cylinder Head - Inspect ........................................
Piston Height - Inspect ..........................................
Flywheel - Inspect .................................................
Flywheel Housing - Inspect ...................................
Gear Group - Inspect ............................................
46
46
47
47
47
47
48
49
50
51
Electrical System
Alternator - Test .................................................... 53
54
54
55
55
Index Section
Index ..................................................................... 57
4
When the camshaft is viewed from the flywheel end

of the engine, the camshaft rotates in the following
direction: ....................................... Counterclockwise
i01959147
Note: The front of the engine is opposite the

flywheel end. The left side and the right side of the
engine are viewed from the flywheel end. The No. 1
cylinder is the front cylinder.
Engine Design
i01959148
General Information
Note: When you are ordering new parts, refer
to the engine identification number in order to
receive the correct parts. Refer to the Operation
and Maintenance Manual, Product Identification
Information for the correct numbers for your engine.
Illustration 1
g01016767
Cylinder and valve location

(A) Inlet valve
(B) Exhaust valve
The 800 Series engines are in-line four cylinder

engines. The engines are controlled by a
mechanically governed fuel injection pump.
Bore ............................................ 94 mm (3.70 inch)
The engines have been designed for many different

applications. These engines are available in two
different types of aspiration:
Stroke ........................................ 120 mm (4.72 inch)
Naturally aspirated
Displacement ..................................... 3.3 L (203 in3)
Turbocharged
Cylinder arrangement ..................................... In-line
Lifting the Engine
Type of combustion
Naturally aspirated engines ..... Indirect injection
Turbocharged engines ............... Direct injection
Compression ratio
Naturally aspirated engines ........................ 22:1
Turbocharged engines ................................ 19:1
Number of cylinders ............................................... 4
Valves per cylinder ................................................. 2
Valve lash
Firing order ................................................. 1, 3, 4, 2
When the crankshaft is viewed from the flywheel
end of the engine, the crankshaft rotates in the
following direction: ....................... Counterclockwise
NOTICE
Failure to follow recommended procedures for handling or transporting engines can lead to engine damage.
To avoid possible engine damage, use the following
procedure.
When you are lifting or moving the engine, use the
following procedures in order to prevent engine
damage.
1. Do not tilt the engine to an extreme angle unless
the lubricating oil is first drained from the oil pan.
2. Do not turn the engine onto a side or an end
surface unless the lubricating oil is first drained
from the oil pan.
5
3. If the oil is not drained prior to tilting the engine

or turning the engine onto a side or an end
surface, the lubricating oil from the oil pan can
flow into the intake manifold and the cylinder
bores. This situation could cause a hydraulic
lock in the engine. Hydraulic lock can severely
damage the engine.
4. The engine oil should be refilled to the correct
level before the engine is started.
Naturally Aspirated Engine Views
Illustration 2
Left side view of the naturally aspirated engine
g01023045
6
(1) Fuel injector

(2) Bus bar with glow plugs
(3) Oil filler cap (top)
(4) Engine lifting bracket
(5) Intake manifold
(6) Coolant drain plug
(8) Flywheel
(9) Dipstick
(10) Engine oil filter
(11) Engine oil relief valve
(12) Oil drain plug
(13) Engine oil pan
(14) Engine oil pressure switch
Fuel injection pump

Fan
Oil filler cap (front)
Engine oil cooler
Water pump
g01023254
Illustration 3
Right side view of the naturally aspirated engine
(20) Valve mechanism cover
(21) Water temperature regulator housing
(22) Engine lifting bracket
(23) Alternator
(15)
(16)
(17)
(18)
(19)
(24) V-Belt
7
Turbocharged Engine Views
g01023339
Illustration 4
Left side view of the turbocharged engine
(1) Fuel injector
(2) Bus bar with glow plugs
(3) Intake manifold
(4) Closed crankcase breather
(5) Coolant drain plug
(7) Flywheel
(8) Dipstick
(10) Engine oil relief valve
(11) Oil drain plug
(12) Engine oil pan
(13) Engine oil pressure switch

(14) Fuel injection pump
(15) Oil filler cap (front)
(16) Fan
(17) Water pump
8
g01023266
Illustration 5
Right side view of the turbocharged engine
(20) Alternator
(21) V-Belt

(24) Oil supply line for turbocharger
(25) Oil drain line for turbocharger
(26)
(27)
(28)
(29)
Exhaust manifold
Shut off valve
Turbocharger
Oil filler cap (top)
9
i01959149
Fuel System
g00987171
Illustration 6
Flow diagram of the fuel system
(1) Fuel injectors
(2) High pressure fuel lines
(3) Fuel return lines
(4) Fuel injection pump

(5) Fuel supply line
(6) Return line to the fuel tank
The engine is equipped with a Bosch or a Denso

axial piston distributor injection pump that is
mechanically governed.
The axial piston distributor injection pump generates
injection pressure for all cylinders in a single
pump. The injection pump is responsible for the
distribution of fuel to the fuel injectors. The injection
pressure is generated by an axially moving piston.
The movement of the piston is parallel to the fuel
injection pump shaft.
(7) Fuel transfer pump

(8) Fuel filter/water separator
(9) Fuel tank
When the engine is cranking, the fuel is pulled from

fuel tank (9) through the primary fuel filter/water
separator (8) by fuel transfer pump (7). When the
fuel passes through the water separator, any water
in the fuel will go to the bottom of the bowl. From
the fuel transfer pump, the fuel passes through fuel
supply line (5) to fuel injection pump (4).
10
The fuel is drawn by an internal fuel transfer pump

into the fuel injection pump. A portion of the fuel
is routed through the pressure regulator assembly
to the suction side of the fuel injection pump. The
fuel that is under pressure from the fuel transfer
pump flows to the interior of the pump housing.
The pressurized fuel is routed to the pumping
chamber. As the plunger rotates and as the plunger
reciprocates, high pressure fuel is routed through
high pressure fuel lines (2) to fuel injectors (1).
The fuel injectors spray atomized fuel into the
cylinder. Excess fuel is routed through fuel return
lines (3) and (6) and returned to the fuel tank.
Routing excess fuel back to the fuel tank allows air
in the fuel to flow back to the fuel tank through the
fuel return line. The fuel that flows into the housing
of the fuel injection pump performs the following
functions:
Lubricate the internal components.

Cool the internal components.
Remove small air bubbles.
The fuel injection pump needs fuel for lubrication.
The precision parts of the pump are easily
damaged. The engine must not be started until the
fuel injection pump is full of fuel. The system must
be primed when any part of the system is drained
of fuel. The fuel system needs priming when a fuel
filter is changed, and/or when a fuel line is removed,
and/or when the fuel injection pump is replaced.
11
Fuel Injection Pump
g00992842
Illustration 7
Components of the fuel injection pump (typical example)
(1) Control lever
(2) Flyweights
(3) Screw for adjusting the full load setting
(4) Drive shaft
(5) Governor lever

(7) Head of the distributor
(8) Control sleeve
(9) Transfer pump
(10) Holder for the rollers
The fuel injection pump is a pressurized system

that is totally enclosed. The pump sends the correct
amount of fuel under high pressure at the correct
time through the fuel injectors to the individual
cylinders. The correct timing occurs near the end
of the compression stroke. The fuel injection pump
regulates the amount of fuel that is delivered to the
fuel injectors. This action controls the engine rpm
by the governor setting or the position of the throttle
control.
(11)
(12)
(13)
(14)
(15)
Plunger
Cam
Timer
Plunger spring
Delivery valve
Fuel Delivery
The fuel lines to the fuel injectors are equal lengths.

This ensures even pressure and correct injection
timing at each fuel injector.
During operation, extra fuel is used as coolant and
lubricant for pump parts that move. The extra fuel is
circulated through the pump housing. The extra fuel
is then returned to the fuel tank. Fuel return lines
also carry away any air that is trapped in the fuel
injectors or in the fuel injection pump housing.
Illustration 8
g00531644
Cross section view of the fuel injection pump (typical example)

(4) Drive shaft
(8) Control sleeve
(12) Cam
(14) Plunger spring
(15) Delivery valve
(16) Gear
12
The fuel injection pump transfers fuel to the fuel

injectors at high pressure. Cam (12) is driven from
the engine by drive shaft (4). The drive shaft is
driven from the front gear group. Lobes on the cam
cause the plunger to reciprocate. The reciprocating
motion first draws the fuel into the pump. The
reciprocating motion then pressurizes the fuel.
Fuel Injectors
Naturally Aspirated Engines (Indirect
Injection)
The plunger also rotates with the cam in order to

sequentially align the discharge groove of the cam
with each of the ports on the fuel injection pump.
The plunger moves a distance which is established
by the lobes of the cam.
The effective stroke is established by the position of
the control sleeve. When control sleeve (8) is moved
to the left prior to the injection of fuel, the spill port
is uncovered. Uncovering the spill port reduces
the amount of fuel that is delivered to the cylinder.
When the control sleeve is moved to the right prior
to the injection of fuel, the spill port is covered.
Covering the spill port increases the amount of fuel
that is delivered to the fuel injector.
The pump also includes an internal timer (not
shown). The timer allows early fuel injection by
advancing the plunger. The plunger is advanced in
relation to the camshaft. Fuel shutoff solenoid (6)
is normally closed. When a voltage is applied, the
plunger in the solenoid moves up in order to allow
the fuel delivery which allows the engine to run.
Timing Control System (if equipped)

The timing control system deactivates the load
sensing timer when the engine coolant temperature
is below 60 C (140 F).
Illustration 9
g00993073
Cross section of the fuel injector

(1)
(2)
(3)
(4)
(5)
(6)
Fuel inlet
Body
Fuel return
Retaining nut
Pressure spring
Nozzle tip assembly
The fuel injection pump forces the fuel to flow

under high pressure to the hole in fuel inlet (1).
The fuel then flows down through body (2) to the
underside of the needle in nozzle tip assembly (6).
The pressure of the fuel pushes the needle valve
and pressure spring (5). When the force of the fuel
pressure is greater than the force of the pressure
spring, the needle valve will lift up.
When the needle valve opens, fuel under high
pressure will flow through the single orifice and into
the cylinder. The fuel is injected into the cylinder
as a very fine spray. When the fuel is injected into
the cylinder, the force of the fuel pressure in the
nozzle body will decrease. The force of the pressure
spring will then be greater than the force of the
fuel pressure that is in the nozzle body. The needle
valve will move quickly to the closed position.
The seat of the needle valve has a close fit with
the inside of the nozzle. This makes a positive seal
when the valve is closed.
13
When the fuel is injected into the cylinder, a small

quantity of fuel will leak into the chamber that
contains the pressure spring. This fuel lubricates
the moving parts of the fuel injector. This fuel then
goes through a passage in the body of the fuel
injector to fuel return (3). This excess fuel is then
returned to the fuel tank.
Turbocharged Engines (Direct Injection)
Illustration 10
g00993074
Cross section of the fuel injector

(1)
(2)
(3)
(4)
(5)
(6)
Fuel inlet
Fuel return
Body
Pressure spring
Retaining nut
Nozzle tip
The fuel injection pump forces the fuel to flow under

high pressure to the hole in fuel inlet (1). The fuel
then flows down through body (3) to the underside
of the needle in nozzle tip (6). The pressure of the
fuel pushes the needle valve and pressure spring
(4). When the force of the fuel pressure is greater
than the force of the pressure spring, the needle
valve will lift up.
When the needle valve opens, fuel under high
pressure will flow through the multiple orifices in the
nozzle tip and into the cylinder. The fuel is injected
into the cylinder as a very fine spray. When the fuel
is injected into the cylinder, the force of the fuel
pressure in the nozzle body will decrease. The force
of the pressure spring will then be greater than the
force of the fuel pressure that is in the nozzle body.
The needle valve will move quickly to the closed
position.
The seat of the needle valve has a close fit with
the inside of the nozzle. This makes a positive seal
when the valve is closed.
When the fuel is injected into the cylinder, a small

quantity of fuel will leak into the chamber that
contains the pressure spring. This fuel lubricates
the moving parts of the fuel injector. This fuel then
goes through a passage in the body of the fuel
injector to fuel return (2). This excess fuel is then
returned to the fuel tank.
14
i01959150
g00987178
Illustration 11
Flow diagram of the air inlet and exhaust system
(1) Turbocharger
(2) Exhaust
The components of the air inlet and exhaust system

control the quality of air and the amount of air that
is available for combustion.
Naturally aspirated engines pull outside air through
air inlet (3) of an air cleaner directly into the intake
manifold. The air flows through the intake manifold
which directs an even distribution of the air to each
engine cylinder. The air is pulled into the engine
cylinder during the intake stroke of the piston. Fuel
is mixed with the air in the engine cylinders during
the compression stroke. After the fuel combustion
occurs in the engine cylinder, the exhaust gases
flow directly to the outside air through the exhaust
(2).
(3) Air inlet
15
Turbocharged engines pull outside air through

air inlet (3) of an air cleaner into the air inlet
of turbocharger (1). The suction is caused by
the turbocharger compressor wheel. Then, the
turbocharger compressor wheel compresses the
air. The air flows through the intake manifold which
directs an even distribution of the air to each
engine cylinder. The air is pulled into the engine
cylinder during the intake stroke of the piston. Fuel
is mixed with the air in the engine cylinders during
the compression stroke. After the fuel combustion
occurs in the engine cylinder, the exhaust gases
flow to the exhaust manifold. The exhaust gases
from the exhaust manifold enter the turbine side of
the turbocharger in order to turn the turbocharger
turbine wheel. The turbine wheel is connected to
the same shaft that drives the compressor wheel.
Exhaust gases from the turbocharger pass through
the exhaust outlet and to exhaust (2).
Turbocharger (if equipped)
Each piston makes four strokes for one complete

cycle in two revolutions of the crankshaft.
1. Intake
Illustration 12
g00302786
Components of a turbocharger (typical example)
During the intake stroke, the piston moves down

and air is drawn into the cylinder through the
open inlet valve.
2. Compression
During the compression stroke, the valves are
closed and the piston moves up in the cylinder
in order to compress the air. As the air is
compressed, the temperature increases. As the
piston nears the top of the stroke, fuel is injected
into the combustion chamber on top of the
piston. The fuel mixes with the hot compressed
air in order to cause combustion.
3. Power
During the power stroke, the valves are closed
as the forces from combustion push the piston
and connecting rod down turning the crankshaft.
4. Exhaust
During the exhaust stroke, the inertial force of
the turning flywheel helps continue the rotation of
the crankshaft in order to push up the piston in
the cylinder. This action forces the burned gases
out of the exhaust valve. This completes the four
strokes of the piston.
(1) Air inlet

(2) Compressor housing
(3) Compressor wheel
(4) Bearing
(5) Oil inlet port
(6) Bearing
(7) Turbine housing
(8) Turbine wheel
(9) Exhaust outlet
(10) Oil outlet port
(11) Exhaust inlet
The turbocharger is mounted on the exhaust

manifold. All the exhaust gases from the engine go
through the turbocharger. The exhaust gases enter
the turbine housing (7) through the exhaust inlet
(11). The exhaust gases then push the blades of the
turbine wheel (8). The turbine wheel is connected
by a shaft to the compressor wheel (3).
When the load on the engine increases, more fuel
is injected into the cylinders. The combustion of
this additional fuel produces more exhaust gases.
The additional exhaust gases cause the turbine
and the compressor wheels of the turbocharger to
turn faster. As the compressor wheel turns faster,
more air is forced into the cylinders. The increased
flow of air gives the engine more power by allowing
the engine to burn the additional fuel with greater
efficiency.
Bearings (4) and (6) for the turbocharger use engine
oil under pressure for lubrication and cooling. The
oil comes in through the oil inlet port (5). The oil
then goes through passages in the center section
in order to lubricate the bearings. This oil also cools
the bearings. Oil from the turbocharger passes
through the oil outlet port (10) in the bottom of the
center section. The oil then returns to the engine
oil pan.
16
Valve System Components
Illustration 13
g00986774
Valve system components

(1)
(2)
(3)
(4)
(5)
Rocker arm
Valve spring
Pushrod
Valve
Lifter
The valve system components control the flow of

inlet air into the cylinders during engine operation.
The valve system components also control the flow
of exhaust gases out of the cylinders during engine
operation.
The crankshaft gear drives the camshaft gear
through an upper idler gear. The camshaft must be
timed to the crankshaft in order to get the correct
relationship between the piston movement and the
valve movement.
The camshaft has two camshaft lobes for each
cylinder. The lobes operate the inlet and exhaust
valves. Each cylinder has one inlet valve and one
exhaust valve. As the camshaft rotates, the lobes
cause the lifter (5) to move the pushrod (3) up
and down. The upward movement of the pushrod
against the rocker arm (1) results in downward
movement (opening) of the valve (4). The valve
spring (2) closes the valves when the lifters move
down.
17
i01964001
Lubrication System
g00987199
Illustration 14
Flow diagram of the lubrication system
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Piston cooling jets

Rocker arm shaft
Camshaft
Main oil gallery
Engine oil cooler
Idler gear
Engine oil relief valve
(8) Crankshaft
(9) Engine oil pump
(11) Engine oil pan
(12) Engine oil bypass valve
(13) External line (supply)
(14) Turbocharger
Pressure for the lubrication system is supplied by

an engine oil pump (9). The gerotor type pump has
an inner rotor and an outer rotor. The axis of rotation
of the rotors are off-center relative to each other.
The inner rotor has four lobes which mesh with the
five lobes of the outer rotor. When the pump rotates,
the distance increases between the lobes of the
outer rotor and the lobes of the inner rotor in order
to create suction. When the distance decreases
between the lobes, pressure is created.
Lubricating oil from the engine oil pan (11) flows

through a strainer and a pipe to the suction side of
the engine oil pump. The lubricating oil flows from
the outlet side of the pump through a passage to
the engine oil filter (10).
The oil then flows from the filter head through a
pipe to the engine oil cooler (5). The plate type oil
cooler is located on the left side of the cylinder
block. From the engine oil cooler, the oil then flows
to the main oil gallery (4) that is located along the
left side of the cylinder block.
18
Lubricating oil from the main oil gallery flows through

high pressure passages to the main bearings of
the crankshaft (8). The oil then flows through the
passages in the crankshaft to the connecting rod
bearing journals.
The pistons and the cylinder bores are lubricated
by the splash of oil from piston cooling jets (1),
which are connected to the main oil gallery.
Lubricating oil from the main oil gallery flows through
passages in the cylinder block to the journals of the
camshaft (3). The oil then flows from the camshaft
at a reduced pressure to the cylinder head. The
oil flows into the rocker arm shaft (2) at a reduced
pressure to the bearings of the rocker arm levers.
The valve stems, the valve springs and the valve
lifters are lubricated by the splash and the oil mist.
The hub of the idler gear (6) is lubricated by oil from
the main oil gallery. The timing gears are lubricated
by the splash from the oil.
Turbochargers (14) are lubricated by oil from a
connection on the right hand side of the cylinder
block. An external line (13) that is connected
from the main oil gallery supplies oil to the top of
the turbocharger. The oil then flows through the
turbocharger. An external line that is connected to
the bottom of the turbocharger returns the oil to the
engine oil pan.
Engine oil relief valve (7) is installed in order to
prevent damage to the lubricating system. The
engine oil relief valve helps keep a constant oil
pressure throughout the engine. If the main system
relief valve fails to open, the high engine oil pressure
can cause damage to engine components. In order
to limit the possibility of engine damage due to a
malfunctioning relief valve, the lubrication system
contains a backup system for engine oil relief valve
(7). Engine oil bypass valve (12) is located inside
engine oil pan (11) on the bottom of the cylinder
block.
19
i01964002
Cooling System
g00987289
Illustration 15
Flow diagram of the cooling system
(1) Radiator
(3) Cylinder head
(4) Bypass tube

(5) Water pump
(6) Water jacket in the cylinder block
The coolant flows from the bottom of radiator (1)

to a centrifugal water pump (5). The water pump
assists in the flow of the coolant through the system.
The water pump is installed on the front of the
timing case and the pump is driven by a belt from
the crankshaft pulley.
The water pump forces the coolant through a
passage in the front of the water jacket in the
cylinder block (6).
Some of the coolant passes into the engine oil
cooler (7). The coolant flows around the element of
the oil cooler back into the cylinder block.
(7) Engine oil cooler
The coolant then passes from the entire length of

the cylinder block through passages and into the
cylinder head (3).
The coolant flows forward through the cylinder head
and into the water temperature regulator housing
(2). If the water temperature regulator is closed,
the coolant goes directly through the bypass tube
(4) to the inlet side of the water pump. If the water
temperature regulator is open, the bypass is closed
and the coolant flows to the top of the radiator.
20
i01959151
Basic Engine
The basic engine components are described in this
section.
The journals of the camshaft run directly in the

bores of the cylinder block. Thrust washer (2) is
located at the rear of the block in order to control
the end play of the crankshaft.
Cylinder Head
Cylinder block
Cylinder head
Pistons and connecting rods
Crankshaft
Camshaft
Timing case and gears
Flywheel and flywheel housing
Cylinder Block
Illustration 17
g00987347
Exploded view of the cylinder head
Illustration 16
g00987345
Exploded view of the cylinder block

(1) Cylinder block
(2) Thrust washer
Cylinder block (1) is made of cast iron with an

integral crankcase. The four cylinders are arranged
in-line. The sides of the block extend below the
centerline of the crankshaft in order to provide
added strength. The cylinder block provides full
support for the length of the cylinder bores. The
cylinder sleeves are integral with the cylinder block.

(2) Rocker shaft assembly
(3) Valve keepers
(4) Valve spring retainer
(5) Valve seal
(6) Valve spring
(7) Valve guide
(8) Cylinder head
(9) Cylinder head gasket
(10) Valve seat insert
(11) Valve
The cast iron cylinder head (8) is fastened to the

top of the cylinder block by seventeen setscrews.
A cylinder head gasket (9) is used between the
engine block and the cylinder head in order to seal
combustion gases, coolant, and oil. The inlet and
exhaust ports are designed to improve the air flow.
21
The cylinder head assembly has two overhead

valves (11) for each cylinder. Each valve is held in
place by a single valve spring (6), a valve spring
retainer (4), and two valve keepers (3). The cylinder
head has steel valve seat inserts (10) for both the
inlet and exhaust valves. The valves move in steel
valve guides (7). Each valve guide is equipped
with a synthetic rubber valve seal (5). The exhaust
valve guides have a counterbore in order to prevent
seizure of the valve stem that is caused by a
buildup of carbon underneath the head of the valve.
Both the valve seat inserts and the valve guides
can be renewed.
Pistons (2) have a combustion chamber in the top

of the piston. The bowl in the piston head ensures
an efficient mix of fuel and air.
The overhead valves are operated by a rocker

shaft assembly (2) that is installed under a valve
mechanism cover (1). The rocker arms are operated
by cold drawn pushrods with hardened heads.
The rocker shaft is supported by four brackets
that support the rocker shaft between each pair
of valves. The rocker shaft assembly and valve
components are lubricated by an oil flow from the
hollow rocker shaft. The rocker shaft receives a
reduced oil flow from the oil feed of the camshaft.
All engines are equipped with piston cooling jets.

The piston cooling jets spray lubricating oil onto
the inner surface of the piston in order to cool the
piston.
Valve lash is adjusted by adjustment screws and

locknuts at the pushrod end of each rocker arm.
The connecting rod and the connecting rod cap

are machined on the surfaces in order to provide a
smooth mating surface. The cap is held in position
by a pair of bolts with nuts.
The valve mechanism cover also contains an oil

filler cap and breather pipe.
Pistons and Connecting Rods
Piston rings (1) consist of two compression rings

and an oil control ring. The groove in the piston
for the top ring has a hard metal insert that
reduces wear of the groove. The piston skirt has
a layer of graphite in order to improve the wear
characteristics. The fully floating piston pin (3) is
held in an axial location by retaining rings (4). The
piston pin is placed off-center in order to reduce
the noise level.
The correct piston height is important in order to

ensure that the piston does not contact the cylinder
head and that the fuel has efficient combustion. The
pistons and connecting rods (6) are matched to
each cylinder.
Crankshaft
Illustration 19
Illustration 18
Exploded view of the piston and connecting rod
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Piston rings
Piston
Piston pin
Retaining rings
Piston pin bearing
Connecting rod
Connecting rod bearing
g00987348
Exploded view of the crankshaft

(1)
(2)
(3)
(4)
(5)
Main bearings
Crankshaft
Crankshaft gear
Main bearing cap
Thrust washers
g00987351
22
Crankshaft (2) is forged from chrome molybdenum

steel. The crankshaft has five main bearing journals
and four connecting rod bearing journals. The
flywheel is attached to the large flange at the rear
of the crankshaft.
End play of the crankshaft is controlled by three
thrust washers (5). Two thrust washers are located
on both sides of the rear main bearing. The third
thrust washer is located on the rear face of the
cylinder block (Illustration 16).
End play of the camshaft is controlled by thrust

washer (1) that is mounted in front of the camshaft.
The thrust washer is held in place by two bolts in
the cylinder block.
Timing Case and Gears
Main bearings (1) have steel backs with an

aluminum and tin bearing material. Main bearing
caps (4) are made of cast iron.
Crankshaft gear (3) is held on the tapered shaft
of the crankshaft by a pair of woodruff keys. The
crankshaft pulley is held in position by a nut on the
front of the crankshaft.
Camshaft
Illustration 21
g00987354
Exploded view of the timing case and gears

(1)
(2)
(3)
(4)
Camshaft gear
Fuel injection pump gear
Upper idler gear
Crankshaft front seal
The timing case is constructed of either aluminum

or cast iron. The timing case cover contains the
crankshaft front seal (4).
Illustration 20
g00994980
There are two different types of timing gears, helical

gears and spur gears if a PTO is installed. The
crankshaft gear (not shown) drives an upper idler
gear (3). The upper idler gear drives the camshaft
gear (1), the fuel injection pump gear (2), and the
oil pump gear (not shown).
Exploded view of the camshaft

(1) Thrust washer
(2) Camshaft
The engine has a single camshaft (2) that is made

of cast iron. The camshaft has four sets of lobes.
Each set of lobes controls the movement of the inlet
and exhaust valves for each cylinder.
The camshaft is driven at the front end by the
camshaft gear. As the camshaft rotates, the
camshaft lobes move the valve system components.
The valve system components move the cylinder
valves.
The camshaft gear must be timed to the crankshaft
gear. The relationship between the lobes of the
camshaft and the camshaft gear causes the valves
in each cylinder to open at the correct time. The
camshaft gear is held on the tapered shaft of the
camshaft by a woodruff key.
The camshaft and the fuel injection pump run at half

the speed of the crankshaft. The oil pump runs at
three quarters of the speed of the crankshaft.
23
Flywheel and Flywheel Housing
Electric Starting Motor
Illustration 23
g00986944
Illustration 22
g00988009
Exploded view of the flywheel and flywheel housing

(1)
(2)
(3)
(4)
Gasket
Flywheel housing
Crankshaft rear seal
Flywheel
Flywheel (4) and the flywheel housing (2) are made

of cast iron. The flywheel housing contains the
crankshaft rear seal (3).
i01892119
Electrical System
The electrical system is a negative ground system.
The charging circuit operates when the engine
is running. The alternator in the charging circuit
produces direct current for the electrical system.
The components of the electrical system for the
engine are described in this section.
Electric starting motor (1) turns the engine flywheel.

The rpm must be high enough in order to initiate
a sustained operation of the fuel ignition in the
cylinders.
The starting motor has a solenoid. When the ignition
switch is activated, voltage from the electrical
system will cause the solenoid to move the pinion
toward the flywheel ring gear of the engine. The
electrical contacts in the solenoid close the circuit
between the battery and the starting motor barely
before the pinion engages the ring gear. This
causes the starting motor to rotate. This type of
activation is called a positive shift.
When the engine begins to run, the overrunning
clutch of the pinion drive prevents damage to the
armature. Damage to the armature is caused by
excessive speeds. The clutch prevents damage
by stopping the mechanical connection. However,
the pinion will stay meshed with the ring gear until
the ignition switch is released. A spring in the
overrunning clutch returns the clutch to the rest
position.
Alternator
Electric starting motor

Alternator
Glow plugs
Illustration 24
(1) Alternator
g00995007
24
Alternator (1) is an electro-mechanical component

that is driven by a belt from the crankshaft pulley.
The alternator charges the storage battery during
the engine operation.
The alternator converts the mechanical energy
and the magnetic energy into alternating current
and voltage. This conversion is done by rotating a
direct current electromagnetic field on the inside of
a three-phase stator. The electromagnetic field is
generated by electrical current flowing through a
rotor. The stator generates alternating current and
voltage.
The alternating current is changed to direct current
by a three-phase, full-wave rectifier. Direct current
flows to the output terminal of the alternator. The
rectifier has three exciter diodes. The direct current
is used for the charging process.
A solid-state regulator is installed on the rear end of
the alternator. Two brushes conduct current through
two slip rings. The current then flows to the rotor
field. A capacitor protects the rectifier from high
voltages. The regulators are sealed and repair is
not possible.
The alternator is cooled by an internal fan which
is covered by the alternator housing. The fan pulls
air through the holes in the front of the alternator.
The air exits through the holes in the back of the
alternator.
The diodes, the resistors, and the brushes are also
covered by the alternator housing in order to protect
the components from dirt and moisture.
The alternator is connected to the battery through
the ignition switch. Therefore, alternator excitation
occurs when the switch is in the ON position.
Glow Plugs
Illustration 25
Typical example
g00986945
The electrically operated glow plugs are installed in

the cylinder head near the fuel injection nozzles.
The glow plugs are connected by a bus bar.
On naturally aspirated engines (indirect injection),
the tips of the glow plugs reach into the
precombustion chamber in the cylinder head.
On turbocharged engines (direct injection), the
tips of the glow plugs reach into the combustion
chamber in the piston crown.
When the glow plugs are energized, the tips
become very hot in order to improve the combustion
during cold start conditions.
25
Testing and Adjusting

Section
2. Install a suitable fuel flow tube with a visual sight

gauge in the fuel return line. When possible,
install the sight gauge in a straight section of the
fuel line that is at least 304.8 mm (12 inches)
long. Do not install the sight gauge near the
following devices that create turbulence:
Fuel System
Elbows
i01804057
Fuel System - Inspect
Relief valves
Check valves
A problem with the components that send fuel to

the engine can cause low fuel pressure. This can
decrease engine performance.
1. Check the fuel level in the fuel tank. Ensure that
the vent in the fuel cap is not filled with dirt.
2. Check all fuel lines for fuel leakage. The fuel lines
must be free from restrictions and faulty bends.
Verify that the fuel return line is not collapsed.
Observe the fuel flow during engine cranking.

Look for air bubbles in the fuel. If there is no
fuel that is present in the sight gauge, prime
the fuel system. Refer to Testing and Adjusting,
Fuel System - Prime for more information. If the
engine starts, check for air in the fuel at varying
engine speeds. When possible, operate the
engine under the conditions which have been
suspect.
3. Inspect the fuel filter for excess contamination. If

necessary, install a new fuel filter. Determine the
source of the contamination. Make the necessary
repairs.
4. Service the primary fuel filter (if equipped).
5. Remove any air that may be in the fuel system.
Refer to Testing and Adjusting, Fuel System Prime.
i01854200
Air in Fuel - Test

This procedure checks for air in the fuel system.
This procedure also assists in finding the source
of the air.
1. Examine the fuel system for leaks. Ensure that
the fuel line fittings are properly tightened. Check
the fuel level in the fuel tank. Air can enter the
fuel system on the suction side between the fuel
transfer pump and the fuel tank.
Work carefully around an engine that is running.

Engine parts that are hot, or parts that are moving,
can cause personal injury.
Illustration 26
g00578151
(1) A steady stream of small bubbles with a diameter of

approximately 1.60 mm (0.063 inch) is an acceptable amount
of air in the fuel.
(2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch)
are also acceptable if there is two seconds to three seconds
intervals between bubbles.
(3) Excessive air bubbles in the fuel are not acceptable.
3. If excessive air is seen in the sight gauge in the

fuel return line, install a second sight gauge at
the inlet to the fuel transfer pump. If a second
sight gauge is not available, move the sight
gauge from the fuel return line and install the
sight gauge at the inlet to the fuel transfer pump.
Observe the fuel flow during engine cranking.
Look for air bubbles in the fuel. If the engine
starts, check for air in the fuel at varying engine
speeds.
26
If excessive air is not seen at the inlet to the fuel

transfer pump, the air is entering the system after
the fuel transfer pump. Refer to the Testing and
Adjusting, Fuel System - Prime.
If excessive air is seen at the inlet to the fuel
transfer pump, air is entering through the suction
side of the fuel system.
To avoid personal injury, always wear eye and face

protection when using pressurized air.
NOTICE
To avoid damage, do not use more than 55 kPa (8 psi)
to pressurize the fuel tank.
4. Pressurize the fuel tank to 35 kPa (5 psi). Do not
use more than 55 kPa (8 psi) in order to avoid
damage to the fuel tank. Check for leaks in the
fuel lines between the fuel tank and the fuel
transfer pump. Repair any leaks that are found.
Check the fuel pressure in order to ensure that
the fuel transfer pump is operating properly. For
information about checking the fuel pressure, see
Testing and Adjusting, Fuel System Pressure
- Test.
5. If the source of the air is not found, disconnect
the supply line from the fuel tank and connect an
external fuel supply to the inlet of the fuel transfer
pump. If this corrects the problem, repair the fuel
tank or the stand pipe in the fuel tank.
i01959152
Finding Top Center Position

for No. 1 Piston
3. Rotate the crankshaft further by 1/8 of a turn

in a clockwise direction. Insert a suitable lever
between the rocker lever and the valve spring
cap of the No. 1 inlet valve. Open the inlet
valve. Put a spacer that is approximately 5 mm
(0.2 inch) thick between the valve stem and the
rocker lever.
4. Slowly rotate the crankshaft in a counterclockwise
direction until the piston makes contact with
the open valve. Make a temporary mark on the
damper or the pulley in order to align accurately
with the tip of the pointer.
5. Rotate the crankshaft in a clockwise direction
by one or two degrees. Remove the spacer
that is between the valve stem and the rocker
lever. Rotate the crankshaft by 1/4 of a turn in
a counterclockwise direction. Put a spacer that
is approximately 5 mm (0.2 inch) thick between
the valve stem and the rocker lever of the No.
1 inlet valve.
6. Slowly rotate the crankshaft clockwise until the
piston makes contact with the open valve. Make
another temporary mark on the damper or the
pulley in order to align accurately with the tip
of the pointer.
7. Make a temporary mark at the center point
between the two marks on the damper or the
pulley. Remove the other two marks. Rotate the
crankshaft by 1/8 of a turn in a counterclockwise
direction. Remove the spacer between the valve
stem and the rocker lever.
8. Slowly rotate the crankshaft in a clockwise
direction until the mark on the damper or the
pulley, which was made in Step 7, aligns with the
tip of the pointer. The No. 1 piston is now at the
top center on the compression stroke.
i01963608
Note: The crankshaft may be turned by using a

socket wrench on the setscrew in the crankshaft
pulley.
1. Remove the valve mechanism cover.
2. Rotate the crankshaft clockwise when you face
the front of the engine. Rotate the crankshaft
until the pushrod for the inlet valve of the rear
cylinder begins to tighten.
Fuel Injection Timing - Check

Table 1
Required Tools
Part
Number
Part Description
Qty
27610272
Dial gauge
27610273
Timing pin for fuel injection pump
Incorrect fuel injection timing can cause poor

engine performance.
27
1. Remove the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install. Rotate the
crankshaft in the normal direction of the engine
until the inlet valve of the No. 4 cylinder has
just opened and the exhaust valve of the No. 4
cylinder has not completely closed.
Illustration 29
Illustration 27
g00565561
Turning the engine
2. Align the TC mark on the crankshaft pulley with

the pointer on the timing case.
Illustration 28
g01025444
3. Remove the plug (1) that is located at the center

of the rear face of the fuel injection pump. Install
the timing pin for the fuel injection with the dial
indicator in order to measure the cam lift.
4. Rotate the crankshaft in the opposite direction of
the engine until the reading on the dial gauge
stabilizes at the bottom of the lift of the plunger
in the pump. Set the dial indicator to zero.
g00994700
(1) Plug
Illustration 30
g01011407
5. Rotate the crankshaft in the normal direction of

the engine until the 5 mark on the crankshaft
pulley is aligned with the pointer on the timing
case.
6. Record the reading on the dial indicator. The
reading should be 0.5 mm (0.020 inch).
28
Bench test the fuel injectors at a temperature of

18 to 20 C (64 to 70 F).
Illustration 31
g01024431
Positioning the fuel injection pump

Illustration 32
7. To adjust the timing of the fuel injection pump,

loosen the flange nuts and move the pump
in order to achieve a reading of 0.5 mm
(0.020 inch).
8. With the cam lift at 0.5 mm (0.020 inch), secure
the pump in position.
9. Remove the tooling from the rear of the fuel
injection pump. Install the plug (1) into the
rear of the fuel injection pump and tighten to
1.4 to 2.0 Nm (12.3910 to 17.7015 lb in).
10. Install the valve mechanism cover. Refer to
Disassembly and Assembly, Valve Mechanism
Cover - Remove and Install.
11. Eliminate all air from the fuel system. Refer to
Testing and Adjusting, Fuel System - Prime.
g00994438
(1) Connections for the high pressure fuel lines
1. Run the engine at low idle.

2. Loosen the connection for the high pressure fuel
line (1) at the fuel injector on No. 1 cylinder. Do
not loosen the nut more than half of a turn. Listen
for the low idle to decrease or become rough.
Tighten the nut for the fuel supply line on No. 1
cylinder. Perform this test on each cylinder.
3. The fuel injector is faulty when the nut for the
fuel supply line is loosened and the following
events occur:
The engine rpm does not decrease.

The engine does not idle roughly.
4. Remove the fuel injector for additional testing.
i01963609
Fuel Injector - Test

Test the Fuel Injectors
Note: If leakage occurs at the nut for the fuel supply

line, make sure that the fuel supply line and the nut
are correctly aligned with the inlet connection of fuel
injector. Do not tighten the nut for the fuel supply
line on the high pressure fuel line more than the
recommended torque. If the nut is tightened more,
the fuel line may become restricted or the threads
of the fuel injector and the nut may be damaged.
Cleaning of the fuel injectors

Ensure that you wear eye protection at all times
during testing. When fuel injectors are tested, test
fluids travel through the orifices of the nozzle tip
with high pressure. Under this amount of pressure, the test fluid can pierce the skin and cause
serious injury to the operator. Always keep the tip
of the fuel injector pointed away from the operator
and into the fuel collector and extension.
Perform the following procedures in order to
determine if a fuel injector does not work correctly.
Before a fuel injector is tested, remove any loose

carbon from the tip of the fuel injector. Do not use
abrasive material or a wire brush in order to clean
the nozzle.
The fuel injector is not a serviceable part.
Disassembling or adjusting the nozzle will violate
the standards for emissions.
29
Note: Extra care should be used in handling the fuel

injector in order to prevent damage to the nozzle
tip. A scratch or a burr could cause needle leakage
or spray distortion. Dirt in the orifices of the nozzle
tip can damage engine components. Dirt can also
distort the spray pattern of the nozzle.
Pressure Test

Position the fuel injector so that the fuel spray

is directed into the extension (4) and the fuel
collector (5).
Use clean calibration fluid when the fuel injectors
are tested. The calibration fluid should be
equivalent to SAE J-967 (ISO 4113) oil.
2. Close the gauge protector valve. Close the
shutoff valve. Open the pump isolator valve.
In order to flush the fuel injector, operate the
nozzle tester for 10 to 15 strokes at a rate of
approximately 60 strokes per minute.
3. Open the gauge protector valve. Slowly increase
the pressure until the valve in the fuel injector
opens. Note the highest pressure indication on
the dial indicator before the pointer moves to
0 kPa (0 psi). This highest pressure indication
is the opening pressure of the fuel injector. The
opening pressure is defined when the valve
needle is lifted from the valve seat.
4. Refer to Specifications, Fuel Injectors for the
correct pressure settings.
If the opening pressure is not within the range of
the setting that is given, the fuel injector must
be replaced.
Back Leakage Test

1. Connect the fuel injector (2) to suitable tooling
that is similar to the Illustration 33.
collector (5).
2. Pump the pressure to about 1030 kPa (150 psi)
below the opening pressure of the fuel injector.
Illustration 33
g00804566
Test equipment
(1)
(2)
(3)
(4)
(5)
(6)
Adapter
Fuel injector
Tube assembly
Extension
Fuel collector
Filter
NOTICE
Do not use dirty test fluids when you test fuel injectors.
Also, do not test fuel injectors unless you have the
correct service tools.The use of dirty test fluids and
the use of incorrect service tools will result in damage
to the fuel injectors.
Refer to Specifications, Fuel Injectors for the

correct setting of the opening pressure.
Release the handle. When the pressure begins
to decrease, note the time that is required for
the pressure to decrease to approximately 0 kPa
(0 psi). If the fuel injector is not faulty, the time
will not be less than 5 seconds or more than
45 seconds.
3. When the test in Step 2 is done, look for any
leakage from the pressure faces of the holder
and the retaining nut of the fuel injector. If leaks
are visible, make sure that the components
are tightened to the correct torque. Do not
overtighten the components in order to stop the
leakage. Instead, a pressure test on the fuel
injector must be conducted. This test may force
any foreign particles out of the nozzle. Replace
the fuel injector if there is excessive fuel leakage.
30
4. If the pressure decreases to 0 kPa (0 psi) in less

than 5 seconds, too much fuel is leaking around
the valve needle. The valve needle or the fuel
injector must be replaced in order to correct the
problem.
Fuel Injector and Seat Test

collector (5).
2. Pump the pressure of the injector tester to
approximately 1030 kPa (150 psi) below the
opening pressure of the fuel injector.
Refer to Specifications, Fuel Injectors for the
correct setting of the opening pressure.
A drop of fuel should not form on the tip of the
fuel injector for at least ten seconds. A light
dampness is acceptable. If the results of the
tests are not acceptable, clean the fuel injector.
After you clean the fuel injector and the fuel
leakage still occurs, the nozzle must be replaced.
Test the Spray Pattern

The pressure adjustment must be correct before the
spray pattern is tested.

Illustration 34
g01007931
Spray patterns of the fuel injectors

(A) Spray pattern for indirect injection
(B) Spray pattern for direct injection

collector (5).
2. Close the gauge protector valve and the shutoff
valve. Open the pump isolator valve.
3. Quickly pump the injector tester and look at
the spray pattern when the fluid begins to flow
through the orifices of the fuel injector.
The spray, which flows from all of the orifices,
must have the same pattern. The fuel injector
is faulty if there is a difference in the vertical
patterns or a difference in the horizontal patterns.
Refer to the correct spray pattern in Illustration
34.
Note: Be sure that the gauge protector valve is
closed before the fuel injector is removed from
the injector tester. Closing the valve will prevent
damage to the pressure gauge.
i01944302
Fuel Quality - Test

Use the following procedure to test for problems
regarding fuel quality:
1. Determine if water and/or contaminants are
present in the fuel. Check the water separator (if
equipped). If a water separator is not present,
proceed to Step 2. Drain the water separator, if
necessary. A full fuel tank minimizes the potential
for overnight condensation.
31
Note: A water separator can appear to be full of fuel

when the water separator is actually full of water.
2. Determine if contaminants are present in the
fuel. Remove a sample of fuel from the bottom
of the fuel tank. Visually inspect the fuel sample
for contaminants. The color of the fuel is not
necessarily an indication of fuel quality. However,
fuel that is black, brown, and/or similar to sludge
can be an indication of the growth of bacteria or
oil contamination. In cold temperatures, cloudy
fuel indicates that the fuel may not be suitable for
the operating conditions. Refer to Operation and
Maintenance Manual, Fuel Recommendations
for more information.
3. If fuel quality is still suspected as a possible
cause of problems regarding engine
performance, disconnect the fuel inlet line, and
temporarily operate the engine from a separate
source of fuel that is known to be good. This
will determine if the problem is caused by fuel
quality. If fuel quality is determined to be the
problem, drain the fuel system and replace the
fuel filters. Engine performance can be affected
by the following characteristics:
Cetane number of the fuel
Other fuel characteristics

i01977628
Fuel System - Prime

If air enters the fuel system, the air must be purged
before the engine can be started. Air can enter the
fuel system when the following events occur:
The fuel tank is empty or the tank has been

partially drained during normal operation.
The low pressure fuel lines are disconnected.

A leak exists in the low pressure fuel system
during engine operation.
The fuel filter or the fuel pump is replaced.

The high pressure fuel lines are disconnected.
Use the following procedure in order to remove air
from the fuel system:
1. Turn the ignition key to the RUN position for three
minutes in order to energize the electric fuel
transfer pump. Do not start the engine.
g00994438
(1) Connections for the high pressure fuel lines
3. Loosen the connections for the high pressure

fuel lines (1).
4. Operate the electric starting motor until fuel that
is free of air comes from the connections.
5. Tighten the connections for the high pressure
fuel lines. Refer to Specifications, Fuel Injection
lines for the correct torque.
6. Start the engine and check for leaks.
Air in the fuel
2. Turn the ignition key to the OFF position.
Illustration 35
32
Air Inlet and Exhaust

System
i01959154
i01822825

- Inspect
A general visual inspection should be made to the
air inlet and exhaust system. Make sure that there
are no signs of leaks in the system.
There will be a reduction in the performance of the
engine if there is a restriction in the air inlet system
or the exhaust system.
Hot engine components can cause injury from

burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
Hot engine components can cause injury from

burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
NOTICE
component life.
NOTICE
mandates.
Making contact with a running engine can cause

burns from hot parts and can cause injury from
rotating parts.
When working on an engine that is running, avoid
contact with hot parts and rotating parts.
1. Inspect the engine air cleaner inlet and ducting
in order to ensure that the passageway is not
blocked or collapsed.
2. Inspect the engine air cleaner element. Replace
a dirty element with a clean element.
Before you begin inspection of the turbocharger,

be sure that the inlet air restriction is within the
specifications for your engine. Be sure that the
exhaust system restriction is within the specifications
for your engine. Refer to Testing and Adjusting, Air
Inlet and Exhaust System - Inspect.
The condition of the turbocharger will have definite
effects on engine performance. Use the following
inspections and procedures to determine the
condition of the turbocharger.
Inspection of the compressor wheel and the

3. Check for dirt tracks on the clean side of the
engine air cleaner element. If dirt tracks are
observed, contaminants are flowing past the
element.
compressor housing
Inspection of the turbine wheel and the turbine

housing
33
Inspection of the Compressor

Wheel and the Compressor
Housing
c. Inspect the engine crankcase breather. Clean

the breather or replace the breather if the
breather is plugged.
d. Remove the oil drain tube. Inspect the oil
drain hole and the oil drain tube for oil sludge.
Inspect the area between the bearings of the
rotating assembly shaft. If necessary, clean
the rotating assembly shaft, the oil drain hole,
and the oil drain tube.
e. If Steps 5.a through 5.d did not reveal the
source of the oil leakage, the turbocharger has
internal damage. Replace the turbocharger.
Inspection of the Turbine Wheel

and the Turbine Housing
Illustration 36
g00922408
Typical example of a turbocharger

(1) Compressor housing
(2) Compressor wheel
1. Remove the air cleaner from the compressor

inlet.
2. Inspect the compressor wheel (2) for damage
from a foreign object. If there is damage,
determine the source of the foreign object. As
required, clean the inlet system and repair the
intake system. Replace the turbocharger. If there
is no damage, go to Step 3.
Illustration 37
3. Clean the compressor wheel (2) and the

compressor housing (1) if you find buildup of
foreign material. If there is no buildup of foreign
material, go to Step 4.
g00922420
Typical example of a turbocharger

(1) Turbine housing
(2) Turbine wheel
1. Remove the air piping from the turbine housing.

4. Turn the rotating assembly by hand. While you
turn the assembly, push the assembly sideways.
The assembly should turn freely. Compressor
wheel (2) should not rub the compressor housing
(1). The turbocharger must be replaced if the
compressor wheel rubs the compressor housing.
If there is no rubbing or scraping, go to Step 5.
5. Inspect the compressor wheel (2) and the
compressor housing (1) for oil leakage.
a. Check the oil level in the crankcase. If the oil
level is too high, adjust the oil level.
b. Inspect the air cleaner element for restriction.
If restriction is found, correct the problem.
2. Inspect the turbine wheel (2) for damage by a

foreign object. If there is damage, determine
the source of the foreign object. Replace the
turbocharger. If there is no damage, go to Step 3.
3. Clean the turbine wheel (2) and the turbine
housing (1) if you find buildup of carbon or
foreign material. If there is no buildup of carbon
or foreign material, go to Step 4.
34
4. Turn the rotating assembly by hand. While you

turn the assembly, push the assembly sideways.
The assembly should turn freely. Turbine wheel
(2) should not rub the turbine housing (1).
Replace the turbocharger if the turbine wheel
rubs the turbine housing. If there is no rubbing
or scraping, go to Step 5.
A very high temperature can indicate that too much

fuel is flowing to the cylinder. A malfunctioning fuel
injector could cause this very high temperature.
5. Inspect the turbine wheel (2) and the turbine

housing (1) for oil leakage and oil coking. Some
oil coking may be cleaned. Heavy oil coking may
require replacement of the turbocharger. If the oil
is coming from the turbocharger center housing
go to Steps 5.a through 5.e.
i01959155
a. Remove the oil drain tube. Inspect the oil

drain hole and the oil drain tube for oil sludge.
Inspect the area between the bearings of the
rotating assembly shaft. If necessary, clean
the rotating assembly shaft, the oil drain hole,
and the oil drain tube.
b. If the crankcase pressure is high, or if the
oil drain is restricted, pressure in the center
housing may be greater than the pressure
of the turbine housing (1). Oil flow may be
forced in the wrong direction and the oil may
not drain. Check the crankcase pressure and
correct any problems.
Use a suitable laser infrared thermometer to check

this exhaust temperature.
Compression - Test
Compression
The following conditions can affect the results of the
cylinder compression test:
Battery
Condition of the starter motor
Ambient conditions
Quality of the compression gauge
c. If the oil drain tube is damaged, replace the

oil drain tube.
d. Check the routing of the oil drain tube.
Eliminate any sharp restrictive bends. Make
sure that the oil drain tube is not too close to
the engine exhaust manifold.
e. If Steps 5.a through 5.d did not reveal the
source of the oil leakage, the turbocharger has
internal damage. Replace the turbocharger.
i01962244
Exhaust Temperature - Test

Illustration 38
g00564993
Measure the Exhaust Temperature
Checking compression of the engine
When the engine runs at low idle, the temperature of

an exhaust manifold port can indicate the condition
of a fuel injector.
1. Remove the fuel injector from the cylinder in

order to measure the compression for that
cylinder.
A low temperature indicates that no fuel is flowing

to the cylinder. An inoperative fuel injector or a
problem with the fuel injection pump could cause
this low temperature.
2. Connect a suitable compression gauge to the

cylinder.
3. Disconnect the fuel shutoff solenoid.
35
4. Operate the starter motor and record the

pressure on the compression gauge.
Valves become damaged due to the following

causes:
5. Repeat for each cylinder.
The fuel injectors do not operate correctly.
Note: Compression tests should only be used to

compare pressures between cylinders of an engine.
If one or more cylinders vary more than 350 kPa
(51 psi) then those cylinders may be damaged.
Excessive dirt and oil are present on the filters
Note: The cylinder compression test should not be

the only test for determining the condition of an
engine.
The load capacity of the engine is frequently
Table 2
Compression
Pressure(1)
(1)
Standard at
Assembly
Repair Limit
2940 kPa
(426 psi)
2450 kPa
(355 psi)
for the air inlet.
Incorrect fuel settings on the fuel injection pump.

exceeded.
Too much valve lash can cause broken valve stems,
springs, and spring retainers. Too much valve lash
can be an indication of the following problems:
Worn camshaft and valve lifters

Worn rocker arms
The compression pressure is taken at 250 rpm.
6. Repair procedures must be taken if the

compression is lower than the repair limit.
NOTICE
Be sure to measure the compression on all of the cylinders. If all of the cylinders are not checked an improper
diagnosis may result. The compression pressure will
vary with the change in engine rpm. It is necessary to
keep the engine rpm constant for all cylinders when
you are taking a compression reading.
i01959156
Engine Valve Lash Inspect/Adjust
Bent pushrods
Broken socket on the upper end of a pushrod
Loose adjustment screw for the valve lash
If the camshaft and valve lifters show rapid wear,
look for fuel in the lubrication oil or dirty lubrication
oil as a possible cause.
Valve Lash Check

The valve lash is measured between the top of the
valve stem and the rocker arm lever.
Valve Lash Setting (cold engine)
If the measurement is not within the acceptable
clearance, adjustment is necessary. Refer to Valve
Lash Adjustment.
To prevent possible injury, do not use the starter

to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before measuring valve clearance.
If the valve lash requires adjustment several times
in a short period of time, excessive wear exists in a
different part of the engine. Repair the problem in
order to prevent more damage to the engine.
Not enough valve lash can be the cause of rapid
wear of the camshaft and valve lifters. Not enough
valve lash can indicate that the seats for the valves
are damaged.
Valve Lash Adjustment

Note: The No. 1 cylinder is at the front of the engine.
36
2. Rotate the crankshaft in the normal rotation of the

engine. When the inlet valve of the No. 2 cylinder
has opened and the exhaust valve of the No.
2 cylinder has not completely closed measure
the valve lash of the inlet valve and the exhaust
valve of No. 3 cylinder.
If adjustment is necessary, refer to Steps 1.a,
1.b, and 1.c.
Illustration 39
g00987161

Setting the valve lash

(1) Adjustment screw
(2) Feeler gauge
Accidental engine starting can cause injury or

death to personnel.
To prevent accidental engine starting, turn the ignition switch to the OFF position and place a do
not operate tag at the ignition switch location.
Remove the valve mechanism cover and perform
the following procedure in order to adjust the valve
lash:
has opened and the exhaust valve of the No. 4
cylinder has not completely closed measure the
valve lash of the inlet valve and the exhaust valve
of No. 1 cylinder. If necessary, make adjustment.

1.b, and 1.c.
1.b, and 1.c.
Note: Lubricate the rocker shaft assembly with clean
engine oil after the valves have been adjusted.
Lubricate the bearing surfaces on the rocker shaft,
the tips of the valves, the pushrod sockets, and
the pushrods so that the oil will drain in order to
lubricate the lobes of the cam.
i01962713
Valve Depth - Inspect
a. Loosen the valve adjustment screw locknut

that is on adjustment screw (1).
b. Place the appropriate feeler gauge (2)
between the rocker arm and the valve stem.
Turn adjustment screw (1) while the valve
adjustment screw locknut is being held from
turning. Adjust the valve lash until the correct
specification is achieved.
c. After each adjustment, tighten the valve
adjustment screw locknut to the correct torque
while adjustment screw (1) is being held from
turning.
Table 3
Required Tools
Part
Number
Part Description
Qty
27610272
Dial gauge
21825496
Dial gauge holder
37
i01962876
Valve Guide - Inspect

Perform this test in order to determine if a valve
guide should be replaced.
Illustration 40
g00953530
(1) Dial gauge

(2) Dial gauge holder
1. Use the dial gauge (1) with the dial gauge holder
(2) to check the depths of the inlet valves and
the exhaust valves below the face of the cylinder
head. Use the cylinder head face (3) to zero the
dial gauge (1).
2. Position the dial gauge holder (2) and the dial
gauge (1) in order to measure the valve depth.
Measure the depth of the inlet valve and the
exhaust valve before the valve springs are
removed.
Refer to Specifications, Cylinder Head Valves
for the minimum, the maximum, and the service
wear limits for the valve depth below the cylinder
head face.
If the valve depth below the cylinder head
face exceeds the service limit, use a new
valve to check the valve depth. If the valve
depth still exceeds the service limit, renew the
cylinder head or renew the valve seat inserts (if
equipped). If the valve depth is within the service
limit, renew the valves.
3. Inspect the valves for cracks and other damage.
Check the valve stems for wear. Check that
the valve springs are the correct length under
the test force. Refer to Specifications, Cylinder
Head Valves for the dimensions and tolerances
of the valves and valve springs.
Illustration 41
g00314806
(1) Valve guide

(2) Radial movement of the valve in the valve guide
(3) Valve stem
(4) Dial indicator
(5) Valve head
1. Place a new valve in the valve guide.

2. Place the dial indicator with the magnetic base
on the face of the cylinder head.
3. Lift the edge of the valve head to a distance of
15.0 mm (0.60 inch).
4. Move the valve in a radial direction away from
the dial indicator. Make sure that the valve moves
away from the dial indicator as far as possible.
Position the contact point of the dial indicator on
the edge of the valve head. Set the position of
the needle of the dial indicator to zero.
5. Move the valve in a radial direction toward
the dial indicator as far as possible. Note the
distance of movement which is indicated on
the dial indicator. If the distance is greater than
the maximum clearance of the valve in the
valve guide, replace the valve guide. Refer to
Specifications, Cylinder Head Valves for the
maximum clearance of the valve in the valve
guide.
38
Lubrication System
i01897292
Engine Oil Pump - Inspect

i01962248
Engine Oil Pressure - Test

An oil pressure gauge that has a defect can indicate
low oil pressure.
Use a suitable gauge that measures the oil pressure
in the engine.
If any part of the oil pump is worn enough in order

to affect the performance of the pump, the oil pump
must be replaced.
Perform the following procedures in order to inspect
the oil pump. Refer to Specifications, Engine Oil
Pump for clearances.
1. Ensure that the engine is filled to the correct oil

level.
2. Connect the gauge to a pressure tap location
for engine oil.
3. Operate the engine. Allow the engine to obtain
normal operating temperature.
4. Keep the oil temperature constant with the engine
at the rated rpm. Read the pressure gauge.
5. Refer to Table 4 in order to determine if the
engine oil pressure is in tolerance.
Illustration 42
g00987624
Exploded view of the oil pump

Table 4
Oil Pressure(1)
Oil Pressure at 1500 rpm
Oil Pressure at Idle
(1)
300 to 500 kPa

(44 to 73 psi)
100 kPa (14.5 psi)
or more
The oil temperature must be 70 to 90C (158 to 194F).
(1)
(2)
(3)
(4)
(5)
O-ring
Inner rotor
Shaft
Outer rotor
Body
1. Remove the oil pump from the engine.

2. Remove all of the parts. Clean all of the parts.
Look for cracks in the metal or other damage.
Find the cause of the problem and correct the

problem if the results of the test do not fall within
the pressure range in Table 4. Engine failure or a
reduction in engine life can be the result if engine
operation is continued with oil pressure outside this
range.
Note: A record of engine oil pressure at regular
intervals can be used as an indication of possible
problems of the engine. A record of engine oil
pressure at regular intervals can also be used as an
indication of possible damage to the engine. The
engine should be inspected and the problem should
be corrected if there is a sudden increase or a
sudden decrease of 70 kPa (10 psi) in oil pressure.
Illustration 43
g00987626
Clearance of outer rotor to body
3. Install the outer rotor. Measure the clearance of

the outer rotor to the body.
39
i01794028
Excessive Engine Oil

Consumption - Inspect
Engine Oil Leaks on the Outside of
the Engine
Illustration 44
g00987627
Clearance of inner rotor to outer rotor
4. Install the inner rotor. Measure the clearance of

the inner rotor to the outer rotor.
Check for leakage at the seals at each end of

the crankshaft. Look for leakage at the gasket
for the engine oil pan and all lubrication system
connections. Look for any engine oil that may be
leaking from the crankcase breather. This can
be caused by combustion gas leakage around
the pistons. A dirty crankcase breather will cause
high pressure in the crankcase. A dirty crankcase
breather will cause the gaskets and the seals to
leak.
Engine Oil Leaks into the

Combustion Area of the Cylinders
Engine oil that is leaking into the combustion area
of the cylinders can be the cause of blue smoke.
There are several possible ways for engine oil to
leak into the combustion area of the cylinders:
Leaks between worn valve guides and valve

stems
Illustration 45
g00987628
Worn components or damaged components

(pistons, piston rings, or dirty return holes for the
engine oil)
End play of rotors
5. Measure the end play of the rotors with a straight

edge and a feeler gauge.
Incorrect installation of the compression ring
6. Clean the top face of the oil pump. Replace the

O-ring and install the oil pump on the engine.
Leaks past the seal rings in the turbocharger shaft
and/or the intermediate ring
Overfilling of the crankcase

i01126690
Excessive Bearing Wear Inspect

When some components of the engine show
bearing wear in a short time, the cause can be a
restriction in an oil passage.
An engine oil pressure indicator may show that there
is enough oil pressure, but a component is worn
due to a lack of lubrication. In such a case, look at
the passage for the oil supply to the component. A
restriction in an oil supply passage will not allow
enough lubrication to reach a component. This will
result in early wear.
Wrong dipstick or guide tube

Sustained operation at light loads
Excessive consumption of engine oil can also result
if engine oil with the wrong viscosity is used. Engine
oil with a thin viscosity can be caused by fuel
leakage into the crankcase or by increased engine
temperature.
40
i01462628
Increased Engine Oil

Temperature - Inspect
Look for a restriction in the oil passages of the oil
cooler. The oil temperature may be higher than
normal when the engine is operating. In such
a case, the oil cooler may have a restriction. A
restriction in the oil cooler will not cause low oil
pressure in the engine.
Determine if the oil cooler bypass valve is held in
the open position. This condition will allow the oil to
pass through the valve instead of the oil cooler. The
oil temperature will increase.
41
Cooling System
i01962683
Cooling System - Check

(Overheating)
Above normal coolant temperatures can be caused
by many conditions. Use the following procedure
to determine the cause of above normal coolant
temperatures:
1. Check the coolant level in the cooling system. If
the coolant level is too low, air will get into the
cooling system. Air in the cooling system will
cause a reduction in coolant flow and bubbles
in the coolant. Air bubbles will keep the coolant
away from the engine parts, which will prevent
the transfer of heat to the coolant. Low coolant
level is caused by leaks or incorrectly filling the
expansion tank.
2. Check the mixture of ELC. Refer to Operation
and Maintenance, Extended Life Coolant (ELC).
3. Check for air in the cooling system. Air can enter
the cooling system in different ways. The most
common causes of air in the cooling system
are not filling the cooling system correctly and
combustion gas leakage into the cooling system.
Combustion gas can get into the system through
inside cracks, a damaged cylinder head, or a
damaged cylinder head gasket. Air in the cooling
system causes a reduction in coolant flow and
bubbles in the coolant. Air bubbles keep the
coolant away from the engine parts, which
prevents the transfer of heat to the coolant.
4. Check the sending unit. In some conditions, the
temperature sensor in the engine sends signals
to a sending unit. The sending unit converts
these signals to an electrical impulse which is
used by a mounted gauge. If the sending unit
malfunctions, the gauge can show an incorrect
reading. Also if the electric wire breaks or if the
electric wire shorts out, the gauge can show an
incorrect reading.
5. Check the radiator for a restriction to coolant flow.
Check the radiator for debris, dirt, or deposits on
the inside of the core. Debris, dirt, or deposits will
restrict the flow of coolant through the radiator.
6. Check the filler cap. A pressure drop in the
cooling system can cause the boiling point to be
lower. This can cause the cooling system to boil.
Refer to Testing and Adjusting, Cooling System
- Test.
7. Check the cooling system hoses and clamps.

Damaged hoses with leaks can normally be
seen. Hoses that have no visual leaks can soften
during operation. The soft areas of the hose can
become kinked or crushed during operation.
These areas of the hose can cause a restriction
in the coolant flow. Hoses become soft and/or
get cracks after a period of time. The inside of a
hose can deteriorate, and the loose particles of
the hose can cause a restriction of the coolant
flow.
8. Check for a restriction in the air inlet system.
A restriction of the air that is coming into the
engine can cause high cylinder temperatures.
High cylinder temperatures require higher than
normal temperatures in the cooling system.
9. Check for a restriction in the exhaust system.
A restriction of the air that is coming out of the
engine can cause high cylinder temperatures.
a. Make a visual inspection of the exhaust
system.
b. Check for damage to exhaust piping. Check
for damage to the exhaust elbow. If no
damage is found, check the exhaust system
for a restriction.
10. Check the water temperature regulator. A water
temperature regulator that does not open, or
a water temperature regulator that only opens
part of the way can cause overheating. Refer
to Testing and Adjusting, Water Temperature
Regulator - Test.
11. Check the water pump. A water pump with
a damaged impeller does not pump enough
coolant for correct engine cooling. Remove
the water pump and check for damage to the
impeller.
12. Consider high outside temperatures. When
outside temperatures are too high for the rating
of the cooling system, there is not enough of
a temperature difference between the outside
air and coolant temperatures. The maximum
temperature of the ambient air that enters the
engine should not exceed 50 C (120 F).
13. When a load that is applied to the engine is too
large, the engine rpm does not increase with an
increase of fuel. This lower engine rpm causes
a reduction in coolant flow through the system.
This combination of less air and less coolant flow
during high input of fuel will cause above normal
heating.
42
i01626003
Cooling System - Inspect
9. Shrouds that are loose or missing cause poor

air flow for cooling.
i01964006
This engine has a pressure type cooling system. A

pressure type cooling system gives two advantages:
The pressure type cooling system can operate

safely at a higher temperature than the boiling
point of water at a range of atmospheric
pressures.
The pressure type cooling system prevents

cavitation in the water pump.
Cavitation is the sudden generation of low pressure
bubbles in liquids by mechanical forces. The
generation of an air or steam pocket is much more
difficult in a pressure type cooling system.
Cooling System - Test

Remember that temperature and pressure work
together. When a diagnosis is made of a cooling
system problem, temperature and pressure must
be checked. The cooling system pressure will have
an effect on the cooling system temperature. For
an example, refer to Illustration 46. This will show
the effect of pressure on the boiling point (steam)
of water. This will also show the effect of height
above sea level.
Regular inspections of the cooling system should be

made in order to identify problems before damage
can occur. Visually inspect the cooling system
before tests are made with the test equipment.
Visual Inspection Of The Cooling

System
1. Check the coolant level in the cooling system.
2. Look for leaks in the system.
Note: A small amount of coolant leakage across
the surface of the water pump seals is normal.
This leakage is required in order to provide
lubrication for this type of seal. A hole is provided
in the water pump housing in order to allow this
coolant/seal lubricant to drain from the pump
housing. Intermittent leakage of small amounts of
coolant from this hole is not an indication of water
pump seal failure.
3. Inspect the radiator for bent fins and other
restriction to the flow of air through the radiator.
4. Inspect the drive belt for the fan.
5. Inspect the blades of the fan for damage.
6. Look for air or combustion gas in the cooling
system.
7. Inspect the radiator cap for damage. The sealing
surface must be clean.
8. Look for large amounts of dirt in the radiator core.
Look for large amounts of dirt on the engine.
Illustration 46
g00286266
Cooling system pressure at specific altitudes and boiling points

of water
Personal injury can result from hot coolant, steam

and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
The coolant level must be to the correct level in
order to check the coolant system. The engine must
be cold and the engine must not be running.
After the engine is cool, loosen the pressure cap
in order to relieve the pressure out of the cooling
system. Then remove the pressure cap.
43
The level of the coolant should not be more than

13 mm (0.5 inch) from the bottom of the filler pipe.
If the cooling system is equipped with a sight glass,
the coolant should be to the correct level in the
sight glass.
Checking the Filler Cap

One cause for a pressure loss in the cooling system
can be a faulty seal on the radiator pressure cap.
Seal
Surface for seal
Remove any deposits that are found on these
items, and remove any material that is found on
these items.
3. Install the pressure cap onto a suitable
pressurizing Pump.
4. Observe the exact pressure that opens the filler
cap.
5. Compare the pressure to the pressure rating that
is found on the top of the filler cap.
6. If the filler cap is damaged, replace the filler cap.
Testing The Radiator And Cooling

System For Leaks
Use the following procedure to test the radiator and
the cooling system for leaks.
Illustration 47
g00296067
Typical schematic of filler cap

(1) Sealing surface between the pressure cap and the radiator

and alkali.
To check for the amount of pressure that opens the
filler cap, use the following procedure:
1. After the engine cools, carefully loosen the filler
cap. Slowly release the pressure from the cooling
system. Then, remove the filler cap.
2. Inspect the pressure cap carefully. Look for
damage to the seal. Look for damage to the
surface that seals. Remove any debris on the
cap, the seal, or the sealing surface.
Carefully inspect the filler cap. Look for any
damage to the seals and to the sealing surface.
Inspect the following components for any foreign
substances:
Filler cap

and alkali.
1. When the engine has cooled, loosen the filler cap
to the first stop. Allow the pressure to release
from the cooling system. Then remove the filler
cap.
2. Make sure that the coolant covers the top of the
radiator core.
3. Put a suitable pressurizing Pump onto the
radiator.
4. Use the pressurizing pump to increase the
pressure to an amount of 20 kPa (3 psi) more
than the operating pressure of the filler cap.
5. Check the radiator for leakage on the outside.
6. Check all connections and hoses of the cooling
system for leaks.
The radiator and the cooling system do not have
leakage if all of the following conditions exist:
44
You do NOT observe any leakage after five

minutes.
1. Place a container under the oil cooler in order to

collect any engine oil or coolant that drains from
the oil cooler.
The dial indicator remains constant beyond

five minutes.
The inside of the cooling system has leakage
only if the following conditions exist:
2. Remove the cover (4). Refer to Disassembly and

Assembly, Engine Oil Cooler - Remove for
removal of the engine oil cooler.
3. Thoroughly clean the flange face of the cover
and the cylinder block.
The reading on the gauge goes down.

You do NOT observe any outside leakage.
Make any repairs, as required.
Personal injury can result from air pressure.

i01959183
Engine Oil Cooler - Inspect
Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.

contact the skin.
4. Inspect the cooling plates (2) for cracks and

dents. Replace the cooling plates if cracks or
dents exist.
If necessary, clean the outside and clean the
inside of the cooling plates. Use a solvent
that is not corrosive on copper. Ensure that no
restrictions for the flow of lubricating oil exist in
the cooling plates.
Dry the cooling plates with low pressure air.
Flush the inside of the cooling plates with clean
lubricating oil.
5. Replace the O-rings (3) and the gasket (1).
Install the engine oil cooler. Refer to Disassembly
and Assembly, Engine Oil Cooler - Install for
installation of the engine oil cooler.
6. Ensure that the cooling system of the engine is
filled to the correct level. Operate the engine.
Check for oil or coolant leakage.
Illustration 48
g00987668
Exploded view of the engine oil cooler

(1)
(2)
(3)
(4)
Gasket
Cooling plates
O-rings
Cover
Perform the following procedure in order to inspect

the engine oil cooler:
45
i01666401
Water Temperature Regulator

- Test
Personal injury can result from escaping fluid under pressure.

If a pressure indication is shown on the indicator,
push the release valve in order to relieve pressure
before removing any hose from the radiator.
1. Remove the water temperature regulator from
the engine.
2. Heat water in a pan until the temperature of the
water is equal to the fully open temperature
of the water temperature regulator. Refer to
Specifications, Water Temperature Regulator
for the fully open temperature of the water
temperature regulator. Stir the water in the pan.
This will distribute the temperature throughout
the pan.
3. Hang the water temperature regulator in the pan
of water. The water temperature regulator must
be below the surface of the water. The water
temperature regulator must be away from the
sides and the bottom of the pan.
4. Keep the water at the correct temperature for
ten minutes.
5. After ten minutes, remove the water temperature
regulator. Immediately measure the opening
of the water temperature regulator. Refer to
Specifications, Water Temperature Regulator
for the minimum opening distance of the
water temperature regulator at the fully open
temperature.
If the distance is less than the amount listed in the
manual, replace the water temperature regulator.
46
Basic Engine
i01853436
Piston Ring Groove - Inspect
Note: Some pistons have a tapered top groove and

the piston ring is wedged. The clearance for the
top piston ring cannot be checked by the above
method when this occurs.
Inspect the Piston Ring End Gap
Inspect the Piston and the Piston

Rings
1. Check the piston for wear and other damage.
2. Check that the piston rings are free to move in
the grooves and that the rings are not broken.
Inspect the Clearance of the Piston

Ring
1. Remove the piston rings and clean the grooves
and the piston rings.
Illustration 50
g00782363
(1) Piston ring

(2) Cylinder ring ridge
(3) Feeler gauge
1. Clean all carbon from the top of the cylinder

bores.
2. Place each piston ring (1) in the cylinder bore
just below the cylinder ring ridge (2).
3. Use a suitable feeler gauge (3) to measure
piston ring end gap. Refer to Specifications,
Piston and Rings for the dimensions.
Note: The coil spring must be removed from the oil
control ring before the gap of the oil control ring is
measured.
i01962707
Connecting Rod - Inspect

Illustration 49
g00905732
(1) Feeler gauge

(2) Piston ring
(3) Piston grooves
Inspect the Connecting Rod

1. Inspect the connecting rod for wear or cracking.
2. Fit new piston rings (2) in the piston grooves (3).

3. Check the clearance for the piston ring by
placing a suitable feeler gauge (1) between
piston groove (3) and the top of piston ring (2).
Refer to Specifications, Piston and Rings for
the dimensions.
2. Inspect the piston pin bearing and the piston pin

for wear and other damage. Check the piston
pin bearing for a clogged oil hole.
Note: Be sure that the oil holes of the piston pin
bearing and the small end of the connecting rod
are lined up.
3. Inspect the connecting rod bolts for stripped
threads.
47
Measure Clearances and End Play
i01748792
Main Bearings - Inspect

Check the main bearings for wear or other damage.
Replace both halves of the bearings and check the
condition of the other bearings if a main bearing is
worn or damaged.
Main bearings are available with a smaller inside
diameter than the original size bearings. These
bearings are for main bearing journals that have
been ground.
Illustration 51
g00994326
i01962706
1. Measure the clearance of the piston pin in

the piston pin bearing. Refer to Specifications,
Connecting Rod for clearance dimensions.
Cylinder Block - Inspect

Inspect the top of the cylinder block for cracks
and warpage. Refer to the Specifications Module,
Cylinder Block topic for the tolerances.
Inspect each cylinder bore. There should be no
scoring, rust or corrosion. Use a suitable dial bore
gauge in order to measure each cylinder bore.
Each cylinder bore should be measured at the top,
middle and bottom.
Illustration 52
g00994330
2. Install the connecting rod to the connecting rod

journal. Tighten the bolts to the correct torque.
If the cylinder bores are out of the service limit, the

cylinder block must be bored oversize. Refer to the
Specifications Module, Cylinder Block topic for
the tolerances.
i01962703
Cylinder Head - Inspect
3. Measure the end play. Refer to Specifications,

Connecting Rod for end play values.
4. If the end play exceeds the service limit, replace
the connecting rod.
i01748770
Connecting Rod Bearings Inspect

Check the connecting rod bearings and the
connecting rod bearing journal for wear or other
damage.
Connecting rod bearings are available with a
smaller inside diameter than the original size
bearings. These bearings are for crankshafts that
have been ground.
1. Remove the cylinder head from the engine.

2. Clean the cylinder head thoroughly. Make sure
that the contact surfaces of the cylinder head
and the cylinder block are clean, smooth and flat.
3. Inspect the bottom surface of the cylinder head
for pitting, corrosion, and cracks. Inspect the
area around the valve seat inserts and the holes
for the fuel injectors.
48
5. Measure the cylinder head for flatness. Measure

the flatness with straight edge (3) and with feeler
gauge (4).
Measure the cylinder head from one side to

the other side (A).
Measure the cylinder head from one end to

the other end (B).
Measure the cylinder head from one corner to

the other corner (C).
Illustration 53
g00876690
Refer to Specifications , Cylinder Head for the

requirements of flatness.
Typical example
i01964003
(1) Cylinder head

(2) Cylinder head repair stand
Piston Height - Inspect
4. Place cylinder head (1) on a suitable cylinder

head repair stand (2).
Table 5
Required Tools
Illustration 54
g00987700
Measuring points on cylinder head

(A) Side to side
(B) End to end
(C) Corner to corner
Part
Number
Part Description
Qty
27610272
Dial gauge
21825496
Dial gauge holder
If the height of the piston above the cylinder block

is not within the tolerance that is given in the
Specifications Module, Piston and Rings, the
bearing for the piston pin must be checked. Refer to
Testing and Adjusting, Connecting Rod - Inspect.
If any of the following components are replaced or
remachined, the piston height above the cylinder
block must be measured:
Crankshaft
Cylinder head
Connecting rod
Bearing for the piston pin
The correct piston height must be maintained in
order to ensure that the engine conforms to the
standards for emissions.
Illustration 55
Measuring flatness
(3) Straight edge
(4) Feeler gauge
g00987701
Note: The top of the piston should not be machined.

If the original piston is installed, be sure that
the original piston is assembled to the correct
connecting rod and installed in the original cylinder.
49
i01962689
Flywheel - Inspect
Inspect the Flywheel
Illustration 56
g00953648
(1) Dial gauge

(2) Dial gauge holder
1. Use the dial gauge (1) and the dial gauge holder
(2) in order to measure the piston height above
the cylinder block. Use the cylinder block face to
zero the dial gauge (1).
2. Rotate the crankshaft until the piston is at the
approximate top center. Ensure that the flame
ring of the cylinder liner does not interfere with
the dial gauge holder (2) or the dial gauge (1).
3. Position the dial gauge holder (2) and the dial
gauge (1) in order to measure the piston height
above the cylinder block. Slowly rotate the
crankshaft in order to determine when the piston
is at the highest position. Record this dimension.
Compare this dimension with the dimensions that
are given in Specifications, Piston and Rings.
Illustration 57
g00987873
Exploded view of flywheel and flywheel housing

(1)
(2)
(3)
(4)
(5)
(6)
Gasket
Flywheel housing
Bolt
Rear oil seal
Flywheel
Setscrew
1. Check for cracks or a damaged dowel hole.

2. Check the ring gear on flywheel (5) for teeth that
are worn or damaged.
3. Inspect the setscrews for the flywheel (6) for
stripped threads.
Flatness of the Flywheel

Note: The flywheel must be removed from the
engine in order to check the flatness.
50
4. Calculate the difference between the lower

measurements and the higher measurements
that are performed at all four points. Refer to
Specifications, Flywheel for the correct values
of the runout.
i01961097
Flywheel Housing - Inspect
Illustration 58
g00987717
Flatness of flywheel
1. Place the flywheel on a surface plate.

2. Set a suitable dial indicator at one side of the
surface plate and move the dial indicator to the
opposite side. Refer to Illustration 58.
3. Refer to Specifications, Flywheel for the correct
values of the flatness.
Face Runout (Radial Eccentricity)

of the Flywheel
Illustration 60
g00987862
Exploded view of flywheel housing

(1)
(2)
(3)
(4)
Setscrew
Gasket
Flywheel housing
Rear oil seal
1. Check for cracks or a damaged dowel hole.

2. Inspect the setscrews (1) that hold the flywheel
housing in place for stripped threads.
Illustration 59
g00987720
Runout of flywheel
1. Refer to Illustration 59 and install a suitable dial

indicator. Always put a force on the crankshaft
in the same direction before the dial indicator
is read. This will remove any crankshaft end
clearance.
2. Set the dial indicator to read 0.0 mm (0.00 inch).
3. Turn the flywheel at intervals of 90 degrees and
read the dial indicator.
3. Inspect rear oil seal (4) for leaks or damage.
51
i01962698
Gear Group - Inspect
Note: If one or more of the gears need to be

removed for repair, refer to Disassembly and
Assembly in order to correctly remove the gears.
Measure Backlash and End Play

Inspect the Gear Group
Illustration 63
g00987788
Measuring backlash
1. Install a suitable dial indicator in Illustration 63,

as shown.
Illustration 61
g01023896
2. Measure the backlash of the gears. Refer to

Specifications, Gear Group (Front) for the
values of the backlash.
Illustration 64
g00987800
Measuring end play of the idler gear
1. Install the dial indicator in Illustration 64, as

shown.
Illustration 62
g00987777
Exploded view of the front timing group

(1)
(2)
(3)
(4)
(5)
Camshaft gear
Upper idler gear
Oil pump gear
Crankshaft gear
Fuel injection pump gear
Inspect the gears for wear or for damage. If the

gears are worn or damaged, use new parts for
replacement.
2. Measure the end play of the idler gear. Refer

to Specifications, Gear Group (Front) for the
values of the end play.
52
Illustration 65
g00996060
Measuring end play of the camshaft
1. Install the dial indicator in Illustration 65, as

shown.
2. Measure the end play of the camshaft. Refer to
Specifications, Camshaft for the values of the
end play.
Note: The end play is controlled by the camshaft
thrust washer. If the end play is not within
specifications, replace the thrust washer.
53
Electrical System
i01964004
Alternator - Test
1. Put the positive lead + of a suitable multimeter
on the Bat terminal of the alternator. Put the
negative - lead on the ground terminal or on the
frame of the alternator. Put a suitable ammeter
around the positive output wire of the alternator.
2. Turn off all electrical accessories. Turn off the fuel
to the engine. Crank the engine for 30 seconds.
Wait for two minutes in order to cool the starting
motor. If the electrical system appears to operate
correctly, crank the engine again for 30 seconds.
Note: Cranking the engine for 30 seconds partially
discharges the batteries in order to do a charging
test. If the battery has a low charge, do not perform
this step. Jump start the engine or charge the
battery before the engine is started.
3. Start the engine and run the engine at high idle.
4. Check the output current of the alternator.
The initial charging current should be equal
to the minimum full load current or greater
than the minimum full load current. Refer to
Specifications, Alternator and Regulator for the
correct minimum full load current.
Table 6
Fault Conditions And Possible Causes

Current At Start-up
The Voltage Is Below

Specifications After 10
Minutes.
The Voltage Is Within

Minutes.
The Voltage Is Above

Minutes.
Less than the

specifications
Replace the alternator.

Check the circuit of the
ignition switch.
Turn on all accessories. If the

voltage decreases below the
specifications, replace the
alternator.
Decreases after matching

specifications
The alternator and the battery

match the specifications. Turn
on all accessories in order to
verify that the voltage stays
within specifications.
The voltage consistently

exceeds specifications.
Test the battery. Test the

alternator again.
The alternator operates

within the specifications. Test
the battery.

Inspect the battery for
damage.
5. After approximately ten minutes of operating the

engine at high idle, the output voltage of the
alternator should be 14.0 0.5 volts. Refer to the
Fault Conditions And Possible Causes in Table 6.
6. After ten minutes of engine operation,

the charging current should decrease to
approximately 10 amperes. The actual length of
time for the decrease to 10 amperes depends on
the following conditions:
The battery charge
54
The ambient temperature

The rpm of the engine
Refer to the Fault Conditions And Possible
Causes in Table 6.
i01899136
Battery - Test
Most of the tests of the electrical system can be
done on the engine. The wiring insulation must be
in good condition. The wire and cable connections
must be clean, and both components must be tight.
Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operated. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Injury to personnel can be the result.
The battery circuit is an electrical load on the
charging unit. The load is variable because of the
condition of the charge in the battery.
NOTICE
The charging unit will be damaged if the connections
between the battery and the charging unit are broken
while the battery is being charged. Damage occurs
because the load from the battery is lost and because
there is an increase in charging voltage. High voltage
will damage the charging unit, the regulator, and other
electrical components.
The correct procedures to test the battery can be
found in the manual that is supplied by the OEM.
i01940506
Belt Tension Chart

Note: Do not use the belt tension chart for belts with
tensioners that are spring loaded.
55
Table 7
Belt Tension Chart

Belt Type
Deflection
Applied Force for Specified Deflection
Type B
10 to 15 mm (0.4 to 0.6 inch)
98 to 147 N (22 to 33 lb)
i01964005
Electric Starting System - Test
Starting motors that operate too slowly can have

an overload due to excessive friction in the engine
that is being started. Slow operation of the starting
motors can also be caused by a short circuit, loose
connections, and/or dirt in the motor.
Use the multimeter in the DCV range to find starting

system components which do not function.
Move the start control switch in order to activate the
starting solenoids. The starting solenoids operation
can be heard as the pinion of the starting motor is
engaged with the ring gear on the engine flywheel.
If a solenoid for a starting motor will not operate,
it is possible that the current from the battery
did not reach the solenoid. Fasten one lead of
the multimeter to the connection (terminal) for the
battery cable on the solenoid. Connect the other
lead to a good ground. A zero reading indicates
that there is a broken circuit from the battery. More
testing is necessary when there is a voltage reading
on the multimeter.
The solenoid operation also closes the electric
circuit to the motor. Connect one lead of the
multimeter to the solenoid connection (terminal) that
is fastened to the motor. Connect the other lead to
a good ground. Activate the starting solenoid and
look at the multimeter. A voltage reading of the
battery shows that the problem is in the motor. The
motor must be removed for further testing. A zero
reading on the multimeter shows that the solenoid
contacts do not close. This indicates the need for
repair to the solenoid, or to the clearance for the
starter motor pinion.
Perform a test. Fasten one multimeter lead to the
connection (terminal) for the small wire at the
solenoid and fasten the other lead to the ground.
Look at the multimeter and activate the starting
solenoid. A voltage reading shows that the problem
is in the solenoid. A zero reading indicates that the
problem is in the start switch or the wires for the
start switch.
Fasten one multimeter lead to the start switch at the
connection (terminal) for the wire from the battery.
Fasten the other lead to a good ground. A zero
reading indicates a broken circuit from the battery.
Check of the circuit breaker and wiring. If there is a
voltage reading, the problem is in the start switch
or in the wires for the start switch.
i01962219
Glow Plugs - Test

Continuity Check of the Glow Plugs
The following test will check the continuity of the
glow plugs.
1. Disconnect the power supply and the bus bar.
2. Set a suitable digital multimeter to check
continuity (resistance). Turn the audible signal on
the digital multimeter ON.
3. Place one probe on the connection for the glow
plug and the other probe to a suitable ground.
The digital multimeter should make an audible
sound. Replace the glow plug if there is no
continuity.
4. Check the continuity on all the glow plugs.
Checking the Operation of the Glow

Plug
The following test will check the operation of the
glow plugs.
1. Disconnect the power supply and the bus bar.
2. Connect the power supply to only one glow plug.
3. Place a ammeter on the power supply wire.
4. Connect the digital multimeter to the terminal on
the glow plug and to a suitable ground.
5. Turn the switch to the ON position in order to
activate the glow plugs.
6. Check the reading on all of the glow plugs. Refer
to Specifications, Glow Plugs for the values of
the current for each glow plug.
56
7. If there is no reading on the ammeter check the

electrical connections. If the readings on the
ammeter are low replace the glow plugs. If there
is still no reading replace the glow plugs.
57
Index Section
Index
A
Air in Fuel - Test..................................................... 25
Air Inlet and Exhaust System .......................... 14, 32
Turbocharger (if equipped)................................. 15
Valve System Components................................ 16
Air Inlet and Exhaust System - Inspect.................. 32
Alternator - Test ..................................................... 53
Excessive Engine Oil Consumption - Inspect........ 39

Engine Oil Leaks into the Combustion Area of the
Cylinders .......................................................... 39
Engine Oil Leaks on the Outside of the Engine.. 39
Exhaust Temperature - Test................................... 34
Measure the Exhaust Temperature.................... 34
F
B
Basic Engine.................................................... 20, 46
Camshaft............................................................ 22
Crankshaft.......................................................... 21
Cylinder Block .................................................... 20
Cylinder Head .................................................... 20
Flywheel and Flywheel Housing ........................ 23
Pistons and Connecting Rods............................ 21
Timing Case and Gears ..................................... 22
Battery - Test ......................................................... 54
Belt Tension Chart ................................................. 54
C
Compression - Test................................................ 34
Compression...................................................... 34
Connecting Rod - Inspect ...................................... 46
Inspect the Connecting Rod............................... 46
Measure Clearances and End Play ................... 47
Connecting Rod Bearings - Inspect....................... 47
Cooling System ............................................... 19, 41
Cooling System - Check (Overheating) ................. 41
Cooling System - Inspect....................................... 42
Visual Inspection Of The Cooling System.......... 42
Cooling System - Test............................................ 42
Checking the Filler Cap...................................... 43
Testing The Radiator And Cooling System For
Leaks................................................................ 43
Cylinder Block - Inspect......................................... 47
Cylinder Head - Inspect ......................................... 47
E
Electric Starting System - Test .............................. 55
Electrical System............................................. 23, 53
Alternator ........................................................... 23
Electric Starting Motor ....................................... 23
Glow Plugs......................................................... 24
Engine Design ......................................................... 4
Engine Oil Cooler - Inspect.................................... 44
Engine Oil Pressure - Test..................................... 38
Engine Oil Pump - Inspect..................................... 38
Engine Valve Lash - Inspect/Adjust ....................... 35
Valve Lash Adjustment ...................................... 35
Valve Lash Check .............................................. 35
Excessive Bearing Wear - Inspect......................... 39
Finding Top Center Position for No. 1 Piston ......... 26

Flywheel - Inspect.................................................. 49
Face Runout (Radial Eccentricity) of the
Flywheel ........................................................... 50
Flatness of the Flywheel .................................... 49
Inspect the Flywheel .......................................... 49
Flywheel Housing - Inspect ................................... 50
Fuel Injection Timing - Check ................................ 26
Fuel Injector - Test ................................................. 28
Back Leakage Test............................................. 29
Cleaning of the fuel injectors.............................. 28
Fuel Injector and Seat Test ................................ 30
Pressure Test ..................................................... 29
Test the Fuel Injectors........................................ 28
Test the Spray Pattern........................................ 30
Fuel Quality - Test.................................................. 30
Fuel System....................................................... 9, 25
Fuel Injection Pump ........................................... 11
Fuel Injectors ..................................................... 12
Fuel System - Inspect............................................ 25
Fuel System - Prime.............................................. 31
G
Gear Group - Inspect............................................. 51
Inspect the Gear Group ..................................... 51
Measure Backlash and End Play ....................... 51
General Information................................................. 4
Lifting the Engine ................................................. 4
Naturally Aspirated Engine Views ........................ 5
Turbocharged Engine Views ................................ 7
Glow Plugs - Test................................................... 55
Checking the Operation of the Glow Plug .......... 55
Continuity Check of the Glow Plugs................... 55
I
Important Safety Information ................................... 2
Increased Engine Oil Temperature - Inspect ......... 40
L
Lubrication System.......................................... 17, 38
58
Index Section
M
Main Bearings - Inspect......................................... 47
P
Piston Height - Inspect ..........................................
Piston Ring Groove - Inspect.................................
Inspect the Clearance of the Piston Ring...........
Inspect the Piston and the Piston Rings ............
Inspect the Piston Ring End Gap.......................
48
46
46
46
46
S
Systems Operation Section ..................................... 4
T
Table of Contents..................................................... 3
Testing and Adjusting Section ............................... 25
Turbocharger - Inspect........................................... 32
Inspection of the Compressor Wheel and the
Compressor Housing ....................................... 33
Inspection of the Turbine Wheel and the Turbine
Housing ............................................................ 33
V
Valve Depth - Inspect ............................................ 36
Valve Guide - Inspect ............................................ 37
W
Water Temperature Regulator - Test...................... 45

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Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Product Information Section

Recommended service should be per formed

This safety section lists basic safety precautions.

Perform maintenance on items at multiples

Your authorized Perkins dealer or your Perkins

California Proposition 65 Warning

Safety Signs and Labels

Do Not Operate Before Reading the

General Hazard Information

This message is located on the side of the valve

Do not operate or work on this engine unless you

Attach a Do Not Operate warning tag or a similar

Starting Aid (2)

Wear a hard hat, protective glasses, and other

If equipped with an air inlet heater (AIH) for cold

Keep the engine free from foreign material. Remove

Use all cleaning solutions with care. Report all

Pressure Air and Water

Always use a board or cardboard when you check

Containing Fluid Spillage

Only use the tools that are suitable for collecting

Only use the tools that are suitable for containing

fluids and equipment that is suitable for containing

Pressure can be trapped in the hydraulic circuit

Ensure that the filler cap is cool before removing

Fire Prevention and Explosion

Determine whether the engine will be operated in

All fuels, most lubricants, and some coolant mixtures

Arcing or sparking could cause a fire. Secure

Improper jumper cable connections can cause

Use caution when you are refueling an engine. Do

Lines, Tubes and Hoses

End fittings are damaged or leaking.

Gases from a battery can explode. Keep any open

Flexible part of the hoses are kinked.

Crushing Prevention and

All protective guards and all protective covers must

Support the component properly when work

Do not bypass the automatic shutoff circuits. Do not

Unless other maintenance instructions are provided,

See the Service Manual for repairs and for

Keep objects away from moving fan blades. The

Before Starting Engine

Do not use aerosol types of starting aids such as

Engine exhaust contains products of combustion

Check the electrical wires daily for wires that are

Engines that are installed without engine-to-frame

To ensure that the engine and the engine electrical

Model View Illustrations

Left side view of naturally aspirated 800 Series engine

(6) Oil drain plug

Water drain plug

(9) Oil filter

(20) Crankshaft vibration damper

Naturally Aspirated 800 Series Specifications

Four Stroke Cycle

120 mm (4.72 inch)

3.33 L (203 in3)

Valve Lash Setting (Inlet)

0.25 mm (0.0098 inch)

Valve Lash Setting