Preventive maintenance 4

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1 00 Series Preventive maintenance Preventive maintenance periods Use the procedures in this chapter to maintain your engine in accordance with the preventive maintenance schedule. Check the periods given by the manufacturer of the equipment in which the engine is installed. It is good preventive maintenance to check for leakage and loose fasteners at each service. These maintenance periods apply only to engines that are operated with fuel, lubricating oil and coolant that conform to the specifications given in this handbook. User s Handbook, TPD 77E, issue

2 Preventive maintenance schedules 00 Series The schedules which follow must be applied at the intervals (hours or months) which ever occur first. Every day or every 8 hours C Every 000 hours B Every 500 hours or months D Every 8000 hours B C D Operation Check the amount of coolant in the header tank Check the engine for leakage of oil and coolant Check the specific gravity of the coolant () () Check the tension and condition of the drive belt(s) Check for water in the pre-filter bowl (or earlier if your fuel supply is contaminated) Renew the element(s) of the fuel filter(s) Check the amount of lubricating oil in the sump Check the lubricating oil pressure at the gauge Renew the engine lubricating oil () (3) (6) Renew the closed crankcase breather element (5) Renew the closed breather assembly Renew the canister or element of the lubricating oil filter () (3) (6) Empty the dust bowl of the air filter: - Normal conditions - In extremely dusty conditions (7) Renew the air filter element Check all hoses and connections Check all electrical cables and connections Check the valve tip clearances of the engine and adjust, if necessary () () By a person who has had the correct training. () The oil service interval will change with the amount of sulphur in the fuel see, "Fuel specification" on page 39. The interval to change the canister or element of the lubricating oil filter is not affected. (3) See, "Lubricating oil specification" on page 0. () Renew the antifreeze every years. If a coolant inhibitor is used instead of antifreeze, it should be renewed every 6 months. If combustion gases are released into the coolant circuit, the coolant must be renewed. (5) For turbocharged and charge cooled engines only see,"how to renew the closed crankcase breather filter element" on page 33. (6) Engines with high load factor or high oil temperature will require a 50 hour or months service period, whichever occurs first. This would normally be determined between the customer and the Perkins applications engineer, but would typically be anything above 75% load factor (average) or 5 C oil temperature (more than hour in ). Load factors should be expressed in actual fuel used divided by fuel load rated speed used. For further information and advice, contact Perkins applications. (7) Check, and if necessary renew the air filter element. User s Handbook, TPD 77E, issue

3 00 Series How to drain the cooling system Warning! Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged. Caution: To prevent frost damage, ensure that all of 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 which is too weak to protect the system from frost has been used. Ensure that the machine is on level ground. Remove the filler cap of the coolant system. 3 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 drain plug, disconnect the hose at the bottom of the radiator. Remove the drain plug () from the side of the cylinder block in order to drain the engine. Ensure that the drain hole is not restricted. 5 Flush the coolant system with clean water. 6 Fit the drain plug () and tighten to 0 Nm (9,5 lbf ft),kgf m. 7 Fit the filler cap and close the radiator tap, or fit the bottom hose. R88/ How to fill the cooling system Warning! Refer to your equipment supplier's handbook for the application to fill the cooling system. If coolant is to be added to the system during service, allow the engine to cool before the coolant is added. Do not add coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged. Caution: If coolant is added to the circuit during service, it must consist of the same original mixture as used to fill the system. For details of the correct coolant to be used in the system, see "Coolant specification" on page 0. Ensure that the top and bottom hose connections are fitted correctly. Check that the drain plug () on the side of the cylinder block is fitted and tighten to 0 Nm (9,5 lbf ft),kgf m. Ensure that the radiator tap is closed, if one is fitted. 3 Remove filler cap. Fill the cooling system with coolant of the correct specification, see "Coolant specification" on page 0. Continue to slowly fill the cooling system to the correct level, refer to the user s handbook for the application. 5 Fit the filler cap, run the engine to normal operating temperature. Stop the engine. When the engine has cooled, check the coolant level. If necessary, fill again to the correct level. User s Handbook, TPD 77E, issue 3

4 How to check the specific gravity of the coolant 00 Series For mixtures which contain inhibited ethylene glycol: Ensure that the machine is on level ground. Operate the engine until it is warm enough to open the thermostat. Continue to run the engine until the coolant has circulated the cooling system. 3 Stop the engine. llow the engine to cool until the temperature of the coolant is below 60 C (0 F). Warning! Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged. 5 Remove the filler cap of the cooling system. 6 Drain some coolant from the cooling system into a suitable container. 7 Use a special coolant hydrometer that will check the temperature and the specific gravity of the coolant, follow the manufacturer's instructions. Note: If a special coolant hydrometer is not available, put a hydrometer and a separate thermometer into the antifreeze mixture and check the readings on both instruments. Compare the readings with the chart (). 8 djust the strength of the mixture as necessary. Note: If it is necessary to fill or replenish the coolant system in service, mix the coolant to the correct strength before it is added to the coolant system. Perkins POWERPRT antifreeze with a concentration of 50% will give protection against frost to a temperature of -35 C (-3 F). It will also give protection against corrosion. This is especially important when there are aluminium components in the coolant circuit D B C Specific gravity chart = Percentage antifreeze by volume B = Mixture temperature in F C = Specific gravity D = Mixture temperature in C User s Handbook, TPD 77E, issue

5 00 Series How to check the drive belt(s) Renew a belt if it is worn or damaged. If twin belts are fitted, they must be renewed together. To ensure maximum belt life, it is recommended that a belt tensioner gauge is used to check the belt tension. Fit the gauge () at the centre of the longest free length and check the tension. If a Burroughs gauge is used, the correct tension is 355 N (80 lbf) 36 kgf. If the tension is 0 N (50 lbf) kgf or below, adjust the belt to 355 N (80 lbf) 36 kgf as indicated below: If a gauge is not available, press the belt with the thumb at the centre of the longest free length and check the deflection (B). With moderate thumb pressure, 5 N (0 lbf),5 kgf, the correct deflection of the belt is 0 mm (3/8 in). If twin belts are fitted, check and if necessary adjust the tension on both the belts. How to adjust the belt tension Loosen the pivot fastener (B) of the alternator and the adjustment link fasteners (B) and (C). Change the position of the alternator to give the correct tension. Tighten the pivot fastener of the alternator and the adjustment link fasteners to Nm (6 lbf), kgf m. 3 Check the belt tension again to ensure that it is still correct. If a new belt is fitted, the belt tension must be checked again after the first 0 hours of operation. 0 B R8 C R8 User s Handbook, TPD 77E, issue 5

6 Fuel pre-filter 00 Series pre-filter, if fitted, is installed between the fuel tank and the engine. Check the pre-filter bowl for water at regular intervals and drain as necessary, see "Preventive maintenance schedules" on page. How to renew the fuel filter element Warnings! The combustible material of some components of the engine (for example certain seals) can become extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with the eyes. Discard the used element and fuel oil in a safe place and in accordance with local regulations. Ensure that the starter switch is in the off position before servicing or repairs are made to the fuel system, because fuel will be released if the lift pump has power. If the fuel level in the tank is higher than the fuel lift pump, all the fuel line valves must be closed before maintenance or repairs are made to the fuel system, if this is not done, the fuel system will drain. Cautions: It is important that only genuine Perkins parts are used. The use of an element that is not a genuine Perkins part may damage the fuel injection pump and the warranty. The pre-filter canister and main filter elements must be renewed at the same time. Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area around the connection. fter a component has been disconnected, fit a suitable cover to all open connections. Place a suitable container below the fuel filter assembly to retain spilt fuel oil. Thoroughly clean the outside surfaces of the fuel filter assembly. Open the drain tap () at the bottom of the filter casing to drain the fuel from the filter. 3 Loosen the filter casing. Remove the casing and element from the fuel filter head. Continued 6 User s Handbook, TPD 77E, issue

7 00 Series Remove the filter element from the casing. Press down on the filter element (B), against the spring pressure, and rotate it to the left to release it from the filter casing (B). 5 Put the new filter element inside the casing and press it down against the spring pressure, rotate it to the right to lock it into the casing. 6 Fit a new seal (B3) to the casing and lightly lubricate the seal face with clean fuel oil. 7 Check that the thread (B) on the inside of the element is not damaged. 8 Fit the filter assembly to the fuel filter head and tighten by hand until it contacts the filter head. Tighten the assembly a further / of a turn by hand. Do not use a strap wrench. 9 Close the drain tap () and remove the container. 0 Before the starter motor is engaged, operate the lift pump for one minute to eliminate air from the filter. Start the engine and check for leaks. 3 R85/ B R89/3 User s Handbook, TPD 77E, issue 7

8 How to eliminate air from the fuel system 00 Series Cautions: Do not operate the engine until the air is eliminated from the fuel injection pump. fter the air is eliminated, operate the engine at low idle for two minutes. The Delphi DP0 fuel injection pump will vent automatically when the start key is turned to the (R) position for three minutes. The Bosch VE and the VP30 fuel injection pumps will not vent automatically. Remove the atomiser cover, see "How to remove and to fit an atomiser" on page 30. Turn the start key to (R) position for three minutes, then return the key to the (0) position. 3 loosen the high pressure pipes () at the atomisers. Operate the starter motor until fuel free from air comes from the connections. 5 Tighten the union nuts to 30 Nm ( lbf ft) 3,0 kgf m. 6 Start the engine and check for leaks. 7 Fit the atomiser cover and tighten its setscrews. R8/ 8 User s Handbook, TPD 77E, issue

9 00 Series tomiser faults Caution: faulty atomiser must be renewed by a person who has had the correct training. Regular maintenance of the atomisers is not necessary. The atomiser nozzles should be renewed and not cleaned, and renewed only if an atomiser fault occurs. Some of the problems that may indicate that new nozzles are needed are listed below: Engine will not start or is difficult to start Not enough power Engine misfires or runs erratically High fuel consumption Black exhaust smoke Engine knocks or vibrates excessively Excessive engine temperature. Warnings! If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately. Keep away from moving parts during engine operation. Some moving parts cannot be seen clearly while the engine runs. Remove the atomiser cover setscrews () and remove the atomiser cover (). In order to find which atomiser is defective, operate the engine at fast idle speed. Loosen and tighten the union nuts (B) of the highpressure fuel pipe at each atomiser. Do not loosen the union nut more than half a turn. When the union nut of the defective atomiser is released, it has little or no effect on the engine speed. R83 B R8/ User s Handbook, TPD 77E, issue 9

10 How to remove and to fit an atomiser 00 Series How to remove Warning! The combustible material of some components of the engine (for example certain seals) can become extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with the eyes. Cautions: tomisers must be removed and fitted by a person with the correct training. Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area around the connection. fter a component has been disconnected, fit a suitable cover to all open connections. If necessary remove the crossover pipe from the turbocharger to the intake manifold. Note: There are different types of breather pipe for naturally aspirated engine and turbocharged engine. n outlet hose may need to be removed from the breather pipe on the turbocharged engines. Release the atomiser cover setscrews () and remove the atomiser cover (). 3 If necessary on a turbocharged engine release the breather hose clip and remove the hose. Release the fastener () and remove the breather pipe (3). 3 R83/ Continued 30 User s Handbook, TPD 77E, issue

11 00 Series Note: There are different types of atomiser fitted to 0 engines. Not all are designed with leak-off connections. 5 If fitted, remove the fuel leak-off hose from the connection (B). 6 Remove the union nuts of the high-pressure pipe from the atomiser (B) and from the fuel injection pump. Do not bend the pipe. If necessary, remove the pipe clamps. Fit a plastic cap to cover all open connections. 7 Remove the setscrew (B3) and remove the clamp (B) from the cylinder head. 8 Remove the atomiser and its seat washer (C) from its recess in the cylinder head. Caution: Remove and discard the seat washer (C). If the original seat washer remains in the recess, the nozzle protrusion will be incorrect when a new seat washer is added. 3 B R78/3 C R77/ User s Handbook, TPD 77E, issue 3

12 How to fit 00 Series Remove all covers and caps from the component and connections. Put a new seat washer into the seat recess in the cylinder head. Note: Some new atomiser s have the seat washer (3) fitted on the atomiser. 3 Ensure that the atomiser seal () is not damaged. pply a small amount of clean fuel oil to the seal. Cautions: The atomiser must be fitted so that the pin or the union () faces away from the atomiser clamp (B). If fitted the leak-off hose is a push fit and will need replacing if the hose leaks. Put the atomiser (B) into its recess in the cylinder head. 5 Fit the clamp (B) and the setscrew (B3). Tighten the setscrew to 35 Nm (6 lbf ft) 3,5 kgf m. Caution: Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension. If there is a leakage from the union nut, ensure that the pipe is correctly aligned with the atomiser inlet. Do not tighten the atomiser union nut more, as this can cause a restriction at the end of the pipe. This can affect the fuel delivery. 6 Remove the plastic cap, fit the high-pressure fuel pipe and tighten the union nuts to 30 Nm ( lbf ft) 3,0 kgf m. 7 If removed earlier, fit the clamps to the high pressure fuel pipes. 8 Where necessary, fit the fuel leak-off hose to the connectors (B). 9 Check the O ring on the breather pipe and replace if necessary. pply a small amount of clean engine oil to the O ring and fit the breather pipe into the rocker cover. Tighten the fastener to 9 Nm (7 lbf ft) 0,9 kgf m. Fit the breather hose and clip if fitted. 0 If removed, fit the crossover pipe. Run the engine and check for leakage of fuel and air. Correct any leakage. Stop the engine. 3 Refit the atomiser cover and tighten the setscrews to 6 Nm ( lbf ft) 0,6 kgf m. 3 3 R77/ B R78/ 3 User s Handbook, TPD 77E, issue

13 00 Series How to renew the closed crankcase breather filter element Note: For details on how to change the closed crankcase breather element, contact Perkins applications for advice. How to renew the engine lubricating oil Warnings! Discard the used lubricating oil in a safe place and in accordance with local regulations. Do not exceed the correct level of lubricating oil in the sump. If there is too much lubricating oil, the excess must be drained to the correct level. n excess of lubricating oil could enter the breather valve. This could cause the engine speed to increase rapidly without control. Caution: Ensure that the machine is on a level surface to ensure an accurate reading on the dipstick. Operate the engine until it is warm. Stop the engine. Put a suitable container below the lubricating oil sump. 3 Remove the sump drain plug () and its O ring and drain the lubricating oil from the sump into the container. Ensure that the O ring is not damaged. Fit the drain plug and its O ring and tighten the plug to 3 Nm (5 lbf ft) 3,5 kgf m. 5 Fill the sump to the mark () on the dipstick with new and clean lubricating oil of an approved grade, see "Lubricating oil specification" on page 0. 6 Remove the container and discard old lubricating oil. R87/ User s Handbook, TPD 77E, issue 33

14 How to renew the canister type oil filter 00 Series Warning! Discard the used canister, and lubricating oil in a safe place and in accordance with local regulations. Cautions: Ensure that the machine is on a level surface to ensure an accurate reading on the dipstick It is important that only genuine Perkins parts are used. The use of an canister that is not a genuine Perkins part may damage the engine and the warranty. Note: The canister contains a valve and a special tube to ensure that lubricating oil does not drain from the filter, when the lubricating oil is changed. Put a suitable container below the lubricating oil filter. Remove the filter canister with a strap wrench. Ensure that the adaptor is secure in the filter head. Discard the canister. 3 Clean the filter head. Note: It is normally good procedure to fill the oil filter canister with clean engine lubricating oil. However this may not be possible on certain applications. Lubricate the top of the canister seal () with clean engine lubricating oil. 5 Fit the new canister and tighten it by hand only. Do not use a strap wrench. 6 Remove the container and discard the old lubricating oil. 7 Operate the engine and check for leakage from the filter. When the engine has cooled, check the oil level on the dipstick and add more oil into the sump, if necessary. R86/ 3 User s Handbook, TPD 77E, issue

15 00 Series How to renew the element type oil filter Warning! Discard the used element and lubricating oil in a safe place and in accordance with local regulations. Cautions: Ensure that the machine is on a level surface to ensure an accurate reading on the dipstick. It is important that only genuine Perkins parts are used. The use of an element that is not a genuine Perkins part may damage the engine and the warranty. Put a suitable container below the lubricating oil filter. Remove the plug together with the seal () and drain the lubricating oil. 3 Fit a / square drive ratchet into the recess () and remove the filter bowl (3). Discard the old filter element. Clean the filter bowl and replace the seal (B). 5 Fit the new filter element (B) into the bowl and rotate element to locate it into position. Note: It is normally good procedure to fill the oil filter bowl with clean engine lubricating oil. However, this may not be possible on certain applications. 6 Lubricate the seal (B) with clean engine lubricating oil. Fit the bowl (3) into the filter head (). 7 Tighten the bowl (3) to Nm (6 lbf ft), kgf m. 8 Fit a new seal to the drain plug and tighten the drain plug to Nm (9 lbf ft), kgf m. 9 Remove the container and discard the old lubricating oil. 0 Operate the engine and check for leakage from the filter. When the engine has cooled, check the oil level on the dipstick and add more lubricating oil into the sump, if necessary. 3 R339/ B R30/ User s Handbook, TPD 77E, issue 35

16 ir filter 00 Series Caution: Do not operate the engine if there is a blockage in the air filter or the induction hose. This can cause lubricating oil to enter the cylinders through the breather valve. Environmental conditions have an important effect on the frequency at which the air filter needs service. Certain air filters have a separate dust bowl () which must be cleaned at intervals. The amount of dust in the bowl shows if it has been removed at the correct time for the conditions of operation. Do not let dust completely fill the bowl, because this will reduce the life of the filter element (). Certain air filters have automatic dust valves (B) through which dust is expelled from the filter. The rubber dust valve must be kept clean. Ensure that the sides of the valves close completely together and that they can separate freely. If a restriction indicator (C) is fitted, it will indicate precisely when the air filter element needs service. This prevents the premature removal of the filter element which causes extra cost or late removal of the element which can cause loss of engine power. The filter element must be cleaned or renewed according to the manufacturers recommendations. B User s Handbook, TPD 77E, issue

17 00 Series Restriction indicator The restriction indicator is fitted on the air filter outlet or between the air filter and the induction manifold. When the red warning indicator () is seen through the clear panel () after the engine has stopped, the air filter element must be removed for service. fter a clean element has been fitted, press the rubber bottom (3) or the button () of the restriction indicator to reset the red warning indicator. 3 User s Handbook, TPD 77E, issue 37

18 How to check the valve tip clearances 00 Series The valve tip clearances are checked between the top of the valve stem and the rocker lever (), with the engine cold. The correct clearance for inlet valves is 0,0 mm (0.008 in) and 0,5 mm (0.08 in) for exhaust valves. The valve positions are shown at (B). The sequence of valves from number cylinder is shown in the table below. Note: Number cylinder is the furthest cylinder from the flywheel end of the engine. Rotate the crankshaft in the normal direction of rotation until the inlet valve (B7) of number cylinder has just opened and the exhaust valve (B8) of the same cylinder has not closed completely. Check the clearances of the valves (B and B) of number cylinder and adjust them, if necessary. Set the valves (B3 and B) of number cylinder as indicated above for number cylinder. Then check / adjust the clearances of the valves (B5 and B6) of number 3 cylinder. 3 Set the valves (B and B) of number cylinder. Then check / adjust the clearances of the valves (B7 and B8) of number cylinder. Set the valves (B5 and B6) of number 3 cylinder. Then check / adjust the clearances of the valves (B3 and B) of number cylinder. Cylinder and valve number Valve I = Inlet E = Exhaust I E I E I E I E R80/ B R8 38 User s Handbook, TPD 77E, issue

TPD1352E, Issue 4 November User s Handbook Series EDi WK WL WM WN WP WQ WR WS

TPD1352E, Issue 4 November User s Handbook Series EDi WK WL WM WN WP WQ WR WS TPD1352E, Issue 4 November 2011 User s Handbook 1300 Series EDi WK WL WM WN WP WQ WR WS Thispublication iswritten in PerkinsApproved Clear English This publication is divided into six chapters: 1 General