Manufacturing: Operation and Maintenance Manual Equipment Model: E28 - 560001

MANUFACTURING
PREPARED FOR: LASA S.A.
Operation and Maintenance Manual

Rev2013-01
Equipment Model:
e28 - 560001
Distributed by:
SERVICORE GS CORP
www.sgsequipment.com
Miami, FL
305-888-0189
M-1001
Model: e28
Rev. 2013-03 Operation and Maintenance Manual
MANUFACTURING
Page left blank intentionally.
For replacement parts and service contact:

Servicore GS Corp
Ph:305-888-0189 | www.sgsequipment.com
M-1001
Model: e28
Operation and Maintenance Manual Rev. 2013-03
MANUFACTURING
Introduction
This manual is to provide information and instructions about the unit to inexperienced or experienced
operators and mechanics. The intent of the manual is to guide and assist operators and maintenance
personnel in the proper use and care of the equipment. This manual contains functional descriptions,
operating instructions, maintenance information, troubleshooting and a parts list. The operation in-
structions describe step by step sequence. A set-up preparation section shows all necessary details on
how the unit is prepared for operation, and gives basic introduction to its controls. The maintenance
portion of this manual provides a maintenance schedule, a troubleshooting chart to solve problems
quickly, and a parts list that contains a complete breakdown of the unit’s replacement components.

Servicore GS Corp
M-1001
Model: e28
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Servicore GS Corp
M-1001
Model: e28
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Safety Warnings and Cautions
WARNING
CALIFORNIA PROPOSITION 65 – DIESEL ENGINES. Diesel engine exhaust and some of its constitu-
ents are known to the State of California to cause cancer, birth defects and other reproductive harm.
WARNING
ELECTRIC SHOCK CAN KILL. Do not touch live electrical parts.
ELECTRIC ARC FLASH can injure eyes, burn skin, cause equipment damage, and ignite combustible
material. DO NOT use power cables to break load and prevent tools from causing short circuits.
IMPROPER PHASE CONNECTION, PARALLELING, OR USE can damage the unit and attached equip-
ment.
IMPORTANT
Protect all operating personnel. Read, understand, and follow all instructions in the Operation/In-
struction Manual before installing, operating, or servicing the equipment. Keep the manual available
for future use by all operators.

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M-1001
Model: e28
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General
Equipment that supplies electrical power can cause serious injury, death, or damage to other equip-
ment or property. The operator must strictly follow all safety rules and take precautionary actions.
Safe practices have been developed from past experience in the use of power source equipment.
While certain practices below apply only to electrically-powered equipment, other practices apply to
engine-driven equipment, and some practices to both.
Shock Prevention
Bare conductors, terminals in the output circuit, or ungrounded, electrically live equipment can fatal-
ly shock a person. Have a certified electrician verify that the equipment is adequately grounded and
learn what terminals and parts are electrically HOT. Avoid hot spots on machine. Use proper safety
clothing, procedures, and test equipment. The electrical resistance of the body is decreased when
wet, permitting dangerous currents to flow through it. When inspecting or servicing equipment, do
not work in damp areas. Stand on a dry rubber mat or dry wood, and use insulating gloves when
dampness or sweat cannot be avoided. Keep clothing dry, and never work alone.
Installation and Grounding of Electrically Powered Equipment
Equipment driven or operated by facility electrical input or electric motors (rather than by diesel or
gasoline engines) must be installed and maintained in accordance with the National Electrical Code,
ANSI/NFPA 70E (most current version), or other applicable codes. A power disconnect switch or
circuit breaker must be located at the equipment. Check the nameplate for voltage, frequency, and
phase requirements. Always connect the grounding lead, if supplied in a power line cable, to the
grounded switch box or building ground. If not provided, use a separate grounding lead. Ensure that
the current (amperage) capacity of the grounding lead will be adequate for the worst fault current
situation. Refer to the National Electrical Code ANSI/NFPA 70E (most current version) for details. Do
not remove plug ground prongs and use correctly mating receptacles.
Output Cables and Terminals
Inspect cables frequently for damage to the insulation and the connectors. Replace or repair cracked
or worn cables immediately. Do not overload cables. Do not touch output terminal while equipment
is energized.

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M-1001
Model: e28
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Service and Maintenance
This equipment must be maintained in good electrical condition to avoid hazards stemming from
disrepair. Report any equipment defect or safety hazard to the supervisor and discontinue use of the
equipment until its safety has been assured. Repairs should be made by qualified personnel only.
Before inspecting or servicing this equipment, take the following precautions:
• A. Shut off all power at the disconnecting switch or line breaker, or by discon
necting battery, before inspecting or servicing the equipment.
• B. Lock switch OPEN (or remove line fuses) so that power cannot be turned on
accidentally.
• C. Disconnect power to equipment if it is out of service.
• D. If troubleshooting must be done with the unit energized, have another

person present who is trained in turning off the equipment and providing or
calling for first aid.
Fire and Explosion Prevention
Fire and explosion are caused by electrical short circuits, combustible material near engine exhaust
pipes, misuse of batteries and fuel, or unsafe operating or fueling conditions.
Electrical Short Circuits and Overloads
Overloaded or shorted equipment can become hot enough to cause fires by self-destruction or by
causing nearby combustibles to ignite. For electrically powered equipment, provide primary input
protection to remove short circuited or heavily overloaded equipment from the line.
Batteries
Batteries may explode and/or give off flammable hydrogen gas. Acid and arcing from a ruptured
battery can cause fires and additional failures. When servicing, do not smoke, cause sparking, or use
open flame near the battery.

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M-1001
Model: e28
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Engine Fuel
Use only approved fuel container or fueling system. Fires and explosions can occur if the fuel tank is
not grounded prior to or during fuel transfer. Shut unit DOWN before opening fuel tank cap. DO NOT
completely fill tank, because heat from the equipment may cause fuel expansion overflow. Remove
all spilled fuel IMMEDIATELY, including any that penetrates the unit. After clean-up, open equipment
doors and blow fumes away with compressed air.
Toxic Fume Prevention
Carbon monoxide - Engine exhaust fumes can kill and cause health problems. Pipe or vent the ex-
haust fumes to a suitable exhaust duct or outdoors. Never locate engine exhausts near intake ducts
of air conditioners.
Bodily Injury Prevention
Serious injury can result from contact with fans or hot spots inside some equipment. Shut DOWN
such equipment for inspection and routine maintenance. When equipment is in operation, use ex-
treme care in doing necessary trouble-shooting and adjustment. Do not remove guards while equip-
ment is operating.
Medical and First Aid Treatment
First aid facilities and a qualified first aid person should be available for each shift for immediate
treatment of all injury victims. Electric shock victims should be checked by a physician and taken to a
hospital immediately if any abnormal signs are observed. Call physician immediately. Seek additional
assistance. Use First Aid techniques recommended by American Red Cross until medical help arrives.
IF BREATHING IS DIFFICULT, give oxygen, if available, and have victim lie down. FOR ELECTRI-
CAL SHOCK, turn off power. Remove victim; if not breathing, begin artificial respiration, preferably
mouth-to-mouth. If no detectable pulse, begin external heart massage. CALL EMERGENCY RESCUE
SQUAD IMMEDIATELY.

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Model: e28
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Equipment Precautionary Labels
Inspect all precautionary labels on the equipment monthly. Order and replace all labels that cannot
be easily read.
Red AP Reflective Decal Tire Pressure Decal Electrical Hazard Decal
Diesel Fuel Only Decal Is the GPU Unplug Custom Decal Hot Exhaust Decal

Servicore GS Corp
M-1001
Model: e28
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Servicore GS Corp
M-1001
Model: e28
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Warranty
• Warranty is only available when a new e28 unit is bought directly from AP Manufacturing, Servi-
core G.S. Corp and/or an authorized dealer.
• The warranty covers parts for a 12-month period or 1200 hours, whichever comes first; the en-
gine warranty is provided directly by Perkins and has a 24-month period.
• The warranty expires exactly 1 year from the date the unit leaves our facilities.
• The unit should be installed and operated as stated in the manual.
• The unit should be used under the normal operation conditions it was designed for.
• Warranty does not cover damage by misuse, carelessness or accident.
• The unit should be maintained as stated in the manual.
• All parts exchanged would be subjected to full inspection.
• Continued use of the unit after discovery of a defect VOIDS ALL WARRANTIES.
• Any repair performed by an un-authorized person or company will void the warranty.

Servicore GS Corp
M-1001
Model: e28
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Servicore GS Corp
M-1001
Model: e28
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Table of Contents
Chapter 1 - Description & Operation............................................................ 1
General – Section 1................................................................................................ 1
Features – Section 2............................................................................................... 3
Identification & Orientation – Section 3..................................................................... 5
Engine, Generator, and Controls – Section 4.............................................................. 7
Engine – Section 4.1............................................................................................... 7
Generator – Section 4.2.........................................................................................11
Control Panel – Section 4.3.....................................................................................13
Inspection Before use on Aircraft – Section 5............................................................15
Chapter 2 - Maintenance ............................................................................ 1

General – Section 1................................................................................................ 1
Engine – Section 2................................................................................................. 3
Inspection – Section 2.1 ......................................................................................... 3
Lubrication – Section 2.1.1..................................................................................... 5
Air Filter – Section 2.1.2........................................................................................ 7
Fuel Filter – Section 2.1.3...................................................................................... 7
Drive Belts Service – Section 2.1.4.......................................................................... 7
Engine Cooling System – Section 2.1.5.................................................................... 9
Battery – Section 2.1.6.......................................................................................... 9
Procedures – Section 2.2........................................................................................11
Lubrication – Section 2.2.1....................................................................................11
Air Filter – Section 2.2.2.......................................................................................13
Fuel Filters – Section 2.2.3....................................................................................15
Drive Belt – Section 2.2.4.....................................................................................17
Battery – Section 2.2.5.........................................................................................19
Generator and Electrical System – Section 3.............................................................21
General - Section 3.1.............................................................................................21
Generator Gauges Calibration - Section 3.2..............................................................22

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Model: e28
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Chapter 3 - Overhaul................................................................................... 1
General – Section 1................................................................................................ 1
Disassembly – Section 2......................................................................................... 3
Assembly – Section 3............................................................................................. 7
Chapter 4 -Troubleshooting......................................................................... 1
General - Section 1................................................................................................ 1
Engine - Section 2.................................................................................................. 3
Electrical Parts - Section 3....................................................................................... 7
Chapter 6 - Electrical Diagrams................................................................... 1

Section 1 - e28 Wiring Schematic............................................................................. 3
Section 2 - Control Panel Tray Harness Diagram......................................................... 9
Section 3 - Voltage Regulator Diagram.....................................................................13
Section 4 - Electrical Tray Harness Diagram..............................................................15
Section 5 - Engine Wiring Harness Diagram..............................................................17
Chapter 7 – Manufacture’s Literature.......................................................... 1

Section 1 – Perkins 1104D Manual............................................................................ 1
Section 3 – Marathon Generator Manual.................................................................... 3

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M-1001
Model: e28
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Chapter 1 - Description & Operation
General – Section 1
The e28 is a diesel engine driven generator set manufactured by Servicore G.S. Corp.
The generator is set to deliver 28.5VDC with a drop of two to three volts with full load. It holds 800
amperes at continuous rating and 2000 amperes peak for aircraft engine starting. It has an adjust-
able current limiting and a voltage regulator with line drop compensation for proper voltage output.
Chapter 1 | Page 1 For replacement parts and service contact:

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Model: e28
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Designed by a former ground support mechanic, the e28 units were designed to be worked on with
ease. Easy access to the inside, an oil drain valve makes oil changes a breeze, and big fuel tank to
minimize down time.
The unit is powered by a Perking engine with a Marathon generator creating the heart and soul for a
reliable unit. With an easy to understand control panel you get faster setup time meaning less down
time.
With 3 simple steps, the generator can start working inmideatly:

1. Connect to airplane.
2. Start the e28.
3. Close contactor on the e28.
Here is the user friendly control panel of the e28. Simply easy.
For replacement parts and service contact: Chapter 1 | Page 2

Servicore GS Corp
M-1001
Model: e28
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Features – Section 2
Some of the features that make the AP Manufacturing e28 units different are the following:
• The e28 was designed with mechanics in mind, • Analog engine gauges gives the operator pre-
meaning that it is made with ease for repair- cise information about the engine.
ing any problems fast minimizing down time.
• Removable control panel makes electrical
• A single mechanic can disassemble the unit in troubleshooting and repairs simple.
just a couple of hours.
• It features a service engine switch which al-
• E28 have an operational noise level of less lows the unit to operate without generating
than 80 dB. any voltage making engine service safer.
• It has low operational costs by lower fuel and • All e28 units come with a cold start pre-heater
oil consumption. installed.
• Engine starts rapidly and the self generation • Check fuel level switch makes checking for
function makes it easy for operators to use. fuel easier, no need to turn on the unit.
• Adjustable current limiter inside the panel to • It features a 30 gallon fuel tank for less refu-
prevent misusage. eling time.
• Digital voltmeter and ammeter for easy read- • 5th wheel assembly for easy maneuverability
ings of the output voltage and load. and a heavy-duty trailer that will last a life-
time.

Servicore GS Corp
M-1001
Model: e28
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Servicore GS Corp
M-1001
Model: e28
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Identification & Orientation – Section 3
The e28 units come with a designated serial num-

ber that is located inside the control panel in a
placard and next to the air filter of the unit. The
image to the right shows how the placard looks
like.
Every unit comes with a Perkins engine and a Mar-

athon Electric generator. Each engine and gener-
ator have their unique serial numbers which are
located in the following spots.
The Serial Number Plate of the engine is located

on the left side of the cylinder block behind the
high pressure pipes of the Fuel injection pump.
The following information is stamped on the En-
gine Serial Number Plate: Engine serial number,
Model, and Arrangement number.
Typical engine serial number plate
(1) Temporary Parts List number

(2) Type
(3) Serial number
(4) List number

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The Serial Number Plate of the generator is located behind the air filter.
Record for Reference
e28 Serial Number ______________________

Engine Model ______________________
Engine Serial Number ______________________
Generator Model ______________________
Generator Serial Number ______________________

Servicore GS Corp
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Model: e28
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Engine, Generator, and Controls – Section 4
Engine – Section 4.1
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. This unit is not
equipped with any auxiliary oil filters.
1104D-44TG1 Engine
Compartment or System Liters Quarts

Maximum total system oil capacity (1) 8.4 8.9
Minimum oil capacity in sump 5.6 5.9
Maximum oil capacity in sump 6.9 7.3
(1) 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.

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Cooling System
To maintain the cooling system, the Total Cooling System capacity must be known. The approximate
capacity for the total cooling system is listed below.
1104D-44TG1 Engine
Compartment or System Liters Quarts

Total Cooling System Capacity 16.5 17.4
Engine capacity 7.0 7.4
Engine Specifications
Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right
sides of the engine are determined from the flywheel end. The number 1 cylinder is the front cylinder.
A typical example of the layout of the valves
(A) Inlet Valves (B) Exhaust Valves

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1104D-E44TG1 Specifications
Number of cylinders In-line 4

Bore 105 mm (4.134 inch)
Stroke 127 mm (5.0 inch)
Aspiration Turbocharged
Compression Ratios 16.2 : 1
Displacement 4.4 Liters
Firing Order 1342
Rotation (Flywheel end) Counterclockwise
Note: For more detailed information on the engine specifications, please refer to Manufactures Liter-
ature Section on this manual and look for Perkins Technical Data 1104D.

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Model: e28
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Servicore GS Corp
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Generator – Section 4.2
The E28 uses a MagnaPLUS 284PSL1748 generator manufactured by Marathon Electric. The Mag-
naPLUS generators are brushless, self excited, externally voltage regulated, and synchronous AC
generators. The generator’s exciter consists of a stationary field and a rotating armature.
The stationary field is designed to be the primary source of the generator’s residual magnetism. This
residual magnetism allows the exciter rotor to produce AC voltage even when the exciter stator is
not powered. This AC voltage is rectified to DC by the rotating rectifier assembly and fed directly to
main rotor. As the generator shaft continues to rotate, the main rotor induces a voltage into the gen-
erator’s main stator. At rated speed, the main stator’s voltage produced by the residual magnetism
of the exciter allows the automatic voltage regulator to function.
The regulator provides voltage to the exciter field resulting in a build-up of generator terminal volt-
age. This system of using residual magnetism eliminates the need for a special field flashing circuit in
the regulator. After the generator has established the initial residual voltage, the regulator provides
a controlled DC field voltage to the exciter stator resulting in a controlled generator terminal voltage.
The generator is also equipped with an optional PMG configuration. The regulator receives the input
power from the PMG. The regulator automatically monitors the generator’s output voltage against
an internal reference set point and provides the necessary DC output voltage to the exciter field re-
quired to maintain constant generator terminal voltage. The generator’s terminal voltage is changed
by adjusting the regulator’s reference set point.

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MagnaPLUS Generator Specifications
Volts 21 VAC
AMPS Continuous 859
KW 25
KVA 31
Hertz 60
RPM 1800
No. of Phases 3
Power Factor 0.8

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Control Panel – Section 4.3
The e28 consists of a very easy to operate con- The maintenance switch is used when a tech-
trol panel. Everything the operator needs is in the nician needs to work on the engine but doesn’t
control panel without the need to open the con- want the generator to build up voltage; the tech-
sole. In the control panel the operator will find nician would just move the maintenance switch
the RPM gauge, oil pressure gauge with a low oil
pressure fault light, a temperature gauge with a
high temp fault light, a voltmeter for the battery
with an alternator fault light, an hour meter so
that the hours can be recorded for the mainte-
nance schedule, and fuel gauge. On the right is
the check fuel push button to check the fuel level
when the unit is turned off and on the left is the
lights pushbutton for the clearance lights and the
control panel light. The start and stop push but-
tons are located under the engine gauges. The
to the on position and the unit will not generate

output voltage.
Next to maintenance switch is the glow plug
switch; this will engage the glow plugs for cold
start environments when it is switched to the on
position.
Behind these switches, to the left are the cur-

rent limiter rheostat and light, and the AVR reset
amp meter and the voltmeter for the DC output switch; to the right are the unit’s fuses.
voltage are located on the left side of the control
panel. Under those gauges are the contactor close
and open push buttons. These are the main con-
trols an operator will need to use the e28 unit.
Behind the control panel is the control panel tray

where the maintenance switch, glow plug switch,
current limiter rheostat and light, AVR reset
switch, fuses, and automatic voltage regulator
(AVR) are located. These other controls are not
necessary for daily use but are also important.

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The current limit rheostat is to limit the amount 3.1 for fuse values, Chapter 4, Section 3 for trou-
of current the generator will deliver; the light di- bleshooting, and Chapter 6, Section 3 for electri-
rectly on top of it is to indicate that the current cal schematics.
limiter is on.
The AVR’s function is to maintain the voltage sta-

The AVR reset switch is used to reset the AVR ble and compensate for any drop in voltage with
when a certain fault is indicated by the LED in the the load. The AVR has a LED that will blink if a
AVR (a label with the indicated faults is present fault is present. The LED will blink with the trouble
in the bottom portion where the AVR reset switch codes which are indicated below the AVR reset
is located); refer to Chapter 4, Section 3 for AVR switch.
trouble codes.
At the bottom of the control panel and above the

The unit’s fuses are marked F1, F2, F3, and F4; output cables, the emergency stop switch is locat-
each one has its unique purpose and should be ed. It is mounted by itself for easy access and fast
replaced if necessary. Refer to Chapter 2, Section use when necessary.
e28 Voltage Regulator. P/N: 560C016
DO NOT USE THE EMERGENCY SWITCH TO SHUT DOWN THE UNIT.

USE ONLY IN CASE OF EMERGENCY.
Note: The engie gauges (oil pres., water temp., voltmeter, and tach-meter) do not need
calibration since their reading can not be changed on the gauge. For the producedure on
how to calibrate the generator gauges please refer to Chapter 2 Section 3.2.

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Inspection Before use on Aircraft – Section 5
Before Starting the Unit:
• Before the engine is started, perform the required daily maintenance and any other periodic
maintenance that is due.
• For the maximum service life of the engine, make a thorough inspection within the engine bay
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.
• Inspect the cooling system hoses for cracks and for loose clamps.
• Inspect the alternator and accessory drive belt for cracks, breaks, and other damage.
• Inspect the wiring for loose connections and for worn wires or frayed wires.
• Check fuel supply. Drain water from the water separator.
• Do not start the unit if there is a “DO NOT OPERATE” warning tag or similar attached to the unit.
• Ensure that the areas around the rotating parts are clear.
• All of the guards must be put in place. Check for damaged guards or for missing guards. Repair
any damaged guards. Replace if necessary.
• Check the oil level. Maintain the oil level between the “ADD” mark and the “FULL” mark on the
oil dip stick.
• Check the coolant level. Fill to top if necessary.
• Observe the air cleaner indicator. Service the air cleaner when the red piston locks in the visible
position.
• Observe the fuses inside the control panel. Replace if damaged.

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Engine exhaust contains products of combustion which may be harmful

to your health. Always start and operate the unit in a well ventilated area
and, if in an enclosed area, vent the exhaust to the outside.

Servicore GS Corp
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Model: e28
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Servicore GS Corp
M-1001
Model: e28
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Chapter 2 - Maintenance
In order to guarantee your unit to be kept in correct operating condition, it must be well kept and
examined on a regular basis. Proper replacement of filters, lubricating oil, etc., at recommended in-
tervals would prevent damage or failure of unit, and grant most favorable performance.
WARNING
EXTREME CAUTION MUST BE USED WHILE MAKING SERVICE INSPECTIONS WITHIN THE UNIT WHILE
THE UNIT IS FUNCTIONING. WEAR NO LOOSE CLOTHING OR JEWELRY. NEVER EXAMINE THE UNIT
ALONE - A TRAINED TECHNICIAN SHOULD ALWAYS BE PRESENT DURING SERVICING OPERATIONS.
FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN SERIOUS INJURY OR DEATH.

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Servicore GS Corp
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Engine – Section 2
Inspection – Section 2.1
Precautionary Maintenance Inspection Schedule:
• A periodic inspection schedule should be established and well followed.
• The criteria listed below meets the minimum requirements necessary to ensure safe, reliable ser-
vice under normal working conditions. However, it may be modified as required to meet varying
operating and environmental conditions.
Use the folloring table to track you maintenance schedule
ENGINE PREVENTIVE MAINTENANCE SCHEDULE TABLE
PROCEDURE INTERVAL DATE SCHEDULED DATE DONE HOURS

OIL CHANGE 500 HOURS
OR EVERY 12
MONTHS
FUEL FILTER CHANGE 200 HOURS OR
AS REQUIRED
AIR FILTER CHANGE WHEN THE IN-
DICATOR TURNS
RED
DRIVE BELT CHECK 200 HOURS
COOLANT LEVEL EVERY DAY
CHECK
BATTERY CHECK 500 HOURS


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Maintenance Intervals
Procedure Daily 300 Hours 500 Hours

Coolant Level Check X
Air Filter Indicator Check X
Oil Level Check X
Fuel-Water Separator Filter Check/Drain X
Drive Belts Check X
Fuel Filters Change X
Air Filter Change X
Oil and Oil Filter Change X
Battery Test X

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Lubrication – Section 2.1.1
Lubrication schedule
Time schedules are based on average operating circumstances. It may be necessary to change oil
and air filters more frequently under strict operating conditions. It also, may be necessary to change
oil and air filters more repeatedly under severe operating situations such as operating in dry, boil-
ing, dusty climates (desert), areas of high humidity (tropical), and excessive period of heavy load or
frequent irregular operations.
Check the oil level after every 8-10 hours of being used, during the break-in period (first 50 hours).
Add oil as necessary.
• Before removing caps or plugs, always clean around oil filler openings.
• Do not over-lubricate or overfill the engine crankcase. Use the engine oil level dipstick to check
oil level.
• Prevent dust, dirt, or water from contaminating lubricants or lubricated equipment.
• Do not mix brands, weights, or types of oil when repairing unit.
• Check engine oil level daily, adding oil as required bringing level to "H" (full) mark on the oil level
dipstick.
Please refer to Chapter 1, Section 4.1 for Lubrication System Capacity.

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Model: e28
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Servicore GS Corp
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Air Filter – Section 2.1.2
An exact time schedule to change the filter cartridge cannot be done

because of the unstable operating conditions. Change the filter car-
tridge when the red indicator flag locks into position and becomes
noticeable in the chamber located on the air filter housing.
The air filter housing is located inside the access panel located below
the control panel. To replace the air filter, there is screw that has to be
removed o that the housing can rotate and be able to open the filter
housing. The screw that has to be removed is labeled.
Fuel Filter – Section 2.1.3
The recommended period for a fuel filter is 300 hours, but depending of the quality of the fuel, the
fuel filter might be changed sooner.
Inspect daily the glass vase of the primary fuel filter (fuel/water sep-
arator) and drain as required; failure to do so might cause the unit to
malfunction.
Drive Belts Service – Section 2.1.4
Periodically inspect all drive belts and adjust if necessary each 300
hours. Replace when needed.

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Servicore GS Corp
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Engine Cooling System – Section 2.1.5
Throughout a warm climate when natural water is used as a coolant, the cooling system must be
protected against rust. During cold weather the cooling system must be protected from freezing. The
system should NEVER be operated on plain water, without a rust inhibitor or antifreeze.
Please refer to Chapter 1, Section 4.1 for Cooling System Capacity.
Battery – Section 2.1.6
The battery should be checked visually daily. If any moisture is on the outside of the case it desig-
nates possible damage. A battery test should be performed every 500 Hours or 12 months, which-
ever is sooner.
To inspect the battery, open the left-front door and release the battery holder by pressing the pin on
the latch, then swing the battey holder out to prevent a short circuit while testing the battery. Re-
menber to always disconect the neggative cablebefore disconecting the possitive cable.

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
Procedures – Section 2.2
Lubrication – Section 2.2.1
Changing engine oil
After the first 50 - 150 hours of use (break-in period), oil should be changed once. After the first 150
hours of use, the oil should just as well be changed every 500 hours or 12 months of engine opera-
tion. The generator set is equipped with an hour meter to record actual engine operating time. The
best time to change engine oil is right after a strong delivery run, when the engine is at operating
temperature. Remember to change the oil filter element each time the oil is changed.
Change oil as follows:
1. Place an open container for catching the old oil inspect it. Apply a light coating of lubricating
below the oil drain hose under the unit. oil to the gasket sealing surface and install the
new filter. DO NOT over tighten the filter.
2. Open the quick drain valve, to release oil. Al-
low adequate time for oil to drain before clos- 4. Close the valve when engine oil has complete-
ing the valve. ly drained.
5. Refill the engine with new clean oil that meets

engine manufacturer’s recommendations. For
oil weights and types please refer to Chapter
7, Section 1 in this manual.
6. Start engine and check oil pressure at once.

Allow engine to be with no load for 5 minutes,
check for leaks, and then stop the engine.
Quick oil release valve.
7. After the engine has been stopped for about
3. Change oil filter (P/N: 2654407) while oil is 5 minutes, recheck the oil level. Add oil, if re-
draining. Provide a container for catching quired, to bring the level up to the high bar on
spilled oil from the filter. Remember to remove the oil dipstick.
the oil filter by twisting counter-clockwise and

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
CAUTION
If bearing metal particles are found on the element or in the shell, the source should be
determined before a failure.
CAUTION
1.Always use clean containers, funnels, etc.
2. Don’t forget to close the drain valve and install the new oil before starting the engine.

Servicore GS Corp
M-1001
Model: e28
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Air Filter – Section 2.2.2
Replace air filter as follows:
1. Locate the Air filter housing. It is inside the 3. Rotate the housing towards the outside of the
access panel below the control panel (front- unit.
right of the unit).
4. Open the three (3) latches that hold the cap
2. Remove screw on the base of the air filter and remove it.
housing marked with a label.
5. Remove the filter elements and replace; out-
er element P/N: 26510342 and inner element
P/N: 26510343
6. Replace the cap back on the air filter housing

and close the three (3) latches.
7. Rotate the housing back to the original poti-

tion and place the screw that was removed
earlier.
Screw that holds air filter housing
CAUTION
DO NOT clean or re-use air filter cartridge.

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
Fuel Filters – Section 2.2.3
Changing the engine fuel filters:
• Replacement fuel filter part numbers.

Primary (water separator): 26550005. Secondary: 26560201
• The fuel filter must be change after every 300 hours or as requiered.
• Place a pan underneath the fuel filter to catch spilled fuel.
• Remove the fuel filter.
• Clean any dirt from the filter head.
• Apply a light film of oil or diesel on the rubber seal on the new filter.
• Fill new filter with diesel fuel.
• Screw in the new fuel filter “snug”. Check that the cartridge is seated correctly against the gasket
and tighten with a final half turn. DO NOT OVER TIGHTEN!
• Start the engine to check for leaks, make adjustments where necessary with the engine off.

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
Drive Belt – Section 2.2.4
To replace the drive belt:
1. Remove the alternator shroud.
2. Loosen the alternator tensioner.
3. Remove the belt from alternator.
4. Remove the belt from crankshaft.
5. Remove the belt from the fan drive pulley.
To install belt, just follow these steps in reverse.

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
Battery – Section 2.2.5
Caution
Disconnecting the positive cable first might cause injuries.
To replace the battery follow these steps:
1. Remove the battery door.
2. Swing out the battery holder by unlatching it from the right side.
Press pin down to unlatch the

battery holder.
3. Disconnect the negative cable first, then the positive
4. Remove the battery from the battery holder.
5. To install a battery, just follow these steps backwards.
CAUTION
Make sure the battery holder latches into position.
A loose battery may cause damage to the unit.
Battery Care
Never place a battery that has just been removed from a unit onto the concrete, metal, or ground, unless proper padding is
provided. A wooden platform or board is adequate insulation.
Maintain stored batteries in a charged condition.
Make sure batteries are fastened securely in their compartment to avoid damage from vibration.
Maintain battery fluid at proper level
Keep battery terminal posts and lead cable connectors clean.

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
Generator and Electrical System – Section 3
General - Section 3.1
The electrical system of the e28 is simple to understand and maintain. The following check list should
be done every 200 hours for better use of the unit.
• Check for loose and burned wires.
• Check for loose terminals.
• Check that all connections are tight and secure.
• Check for burned fuses and replace as necessary.
• Check for burned relays and replace as necessary.
• Check the output cable and plug, replace if necessary.
Power Console - Bridge Rectifier, Contactor, Capacitors

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
Generator Gauges Calibration - Section 3.2
The following procedure should be performed to calibrate the gauges on the panel for the generator
readings including volts and amperes.
Required Tools: D.C. Load Bank with 1400 AMP or more capacity, Calibrated volt meter with a range
of 0-50 VDC, and calibrated DC clamp Amp meter with a range of 0-2000 AMPS.
To calibrate the voltmeter:

• Start the unit and wait until it generates; voltage should be 28.5 +/- 0.5 D.C.
• Measure DC voltage on the voltmeter between wires 28(+) and E2(-). Voltage should be the same
on the measuring devide and the generator voltmeter +/- 3%.
• If the reading is off, use a small flat screwdriver to adjust the reading on the generator voltmeter
by turning the blue potentioneter located next to the terminal connection. See figure below.
Adjusting
Potentiometer
Back Side of Generator Volt Meter
• If the voltmeter does not meet the calibration requirements then it will need to be replaced.
To calibrate the Ampmeter:

• Connect the unit to the DC Load Bank, make sure the load switch is in the off possition.
• Start the unit and wait until it generates; voltage should be 28.5 +/- 0.5 D.C.

Servicore GS Corp
M-1001
Model: e28
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• Place the DC Clamp Amp meter into the possitive side of the output cable.
• Switch the load bank to 300 AMP and record the reading on the Clamp Amp Meter and the gen-
erator Amp Meter. The reading may have a 3% marging difference.
• If the reading on the generator ampmeter is off by more than 3% use the potentiometer to the
right to adjust. The potentiomete on the left is used to adjust the zero on the gauge when no load
is applied to the unit. See figure below.
Amp Reading Adjusting

Potentiometer
Zero reading adjusting

Potentiometer
Back Side of the generator Amp Meter.
• If the amp meter does not meet the calibration requirements then it will need to be replaced.

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
Chapter 3 - Overhaul
These instructions cover special and recommended procedures for overhaul of mechanical and elec-
trical components of the generator set. Check all wires and connections when the unit is being dis-
sembled and assembled. If a burned cable is found, replace it and follow its path to check the com-
ponents on each end of the cable. If a component is bad, have it replaced.
In the following sections, you will find the instructions on how to dissemble, assemble and replace
electrical components on the e28. To overhaul the engine, please refer to the Perkins Engine Manual.
To overhaul the generator, please refer to the Marathon Generator Manual.

Servicore GS Corp
M-1001
Model: e28
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Servicore GS Corp
M-1001
Model: e28
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Disassembly – Section 2
The e28 unit is a simple structure that can be disassembled in a couple of hours. The following in-
structions are provided as a guide to follow.
Use the following steps to disassemble the unit:
1. To disassemble the enclosure of the unit:
• Remove all the doors. • Remove the output cable from the unit by
disconnecting the leads from the contac-
• Disconnect the battery and remove it from tor (K1) and from the shunt. Release the
the unit. clamp from the side panel.
• Disconnect the plugs for the clearance • Remove the air ducts from the separator
lights (front and rear), control panel light panel on the right side of the unit.
(front) and beacon light if furnished (rear).
• Disconnect the plug for the engine harness
• Remove the top cover. Remove the shocks from the inside of the control panel P3.
before removing the hinges. Failure in fol-
lowing this step, may cause injury or dam- • Remove PR1, PR2 and P3 from the separa-
age to the unit. tor panel.
• Remove the rear top panel from the unit. • Remove the output plug holder.
• Remove the rear side panels and rear pan- • Remove the separator panel.
el.
• Remove the fuel supply tube from the left
• Remove the upper right door support. side panel and remove panel.
• Remove the upper left door support. • Disconnect the emergency stop pushbut-
ton and remove the right side panel.
• Remove the control panel support.
• Remove the enclosure base support.
• Remove the front panel.

Servicore GS Corp
M-1001
Model: e28
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2. To remove the control panel tray:
• Disconnect J2 and J3.
• Remove the 4 screws holding down the control panel tray and remove the tray.
3. To remove the electrical tray:
• Disconnect the generator leads from the diodes in the rectifier and remove the cables.
• Remove the PMG leads from T1 positions 0 and 220.
• Remove the generator exciter lead from TB2 positions 4 and 5.
• Remove the current sensing transformer from generator lead 3.
• Remove the 4 nuts holding the electrical tray to the shock absorbers.
• Lift the electrical tray with the help of someone or use a hoist.
Place the electrical tray on a leveled surface to prevent injury and/or

damage to the tray.
4. To remove the generator:
• Remove the air filter housing from the unit. and unbolt the generator from the fly-
wheel (inside of the generator, bolting into
• Remove the battery tray from the left elec- the engine flywheel).
trical tray support.
• While hoisting up the generator, start re-
• Remove both electrical tray supports. moving the housing bolts from the genera-
tor until the generator is completely loose.
• Remove the safety net on the generator
• Remove generator.
Do not place generator directly on the floor it may cause injury or damage
to the unit.

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M-1001
Model: e28
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5. To remove engine from trailer:
• Remove the whole exhaust system form the unit. Remove the tip from the muffler. Remove
the down pipe with the flex pipe (both ends) then remove the muffler from the trailer.
• Remove the noise control box from the radiator. Remove top panel, then remove the side
panels and lastly remove the bottom panel.
• Disconnect fuel lines from the fuel tank.
The engine can be removed with the genset frame or just the engine mounts.
• Remove the bolts holding the genset frame to the trailer on both sides, or remove the bolts
holding down the engine rubber mounts on all four engine mounts
• Hoist the engine and remove from the trailer.
Place the engine on firm floor or it may cause injury or damage to the unit.
6. To remove the fuel tank:
• Empty fuel from the tank. • Disconnect all lines and cables from the
fuel tank.
• Remove the bumper from the trailer.
• Slide tank toward the back of the unit until
• Remove the rear tank support bracket. the tank is completely out.
7. To disassemble the trailer:
• Remove fenders from both sides. wheels.
• Remove the brake from the front wheels. • Remove the wheel hubs
Remove the brake actuator link and the
brake actuator. • Remove fifth wheel assembly by removing
the top cover on the front the trailer and
• Remove tow bar by removing the locking unbolting the hub from the trailer.
bolt and pin.
• Remove wheel spindles.
• Place trailer on stands and remove the

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
8. Disassembling the electrical tray.
• If out-put cables are still connected, disconnect them and remove them from the unit.
• Disconnect all the wires from the electrical components.
• Remove the electrical components.
• If control panel it is still on the electrical tray, remove it and remove the vibration isolators.
9. Disassembling the control panel tray
• Disconnect the all the cables from control • Disconnect the AVR plugs J3 and J4.
panel coming from the control panel tray.
• Remove the relays from the tray. (CR1,
• Remove the screws holding the control CR2, and CR3)
panel hinges and remove the control panel
from the tray. • Remove the TD base from the tray.
• Remove the top inside wiring cover. • Disconnect the alternator interface. (A1)
• Remove the switches and front inside cov- • Remove the wiring harness from the tray
er including the back inside cover.
• Remove the back inside cover • After the wiring harness is out, remove the
rest of the components in the tray.
At this point, the e28 is completely disassembled.

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
Assembly – Section 3
The assembly of the e28 is fairly easy. No especial tools are needed for this job.
1. Assemble the trailer.
• Place the trailer frame on jack stands.
• Place the rear spindles in place. Insert screws and tighten them.
• Place the fifth wheel assembly in the front of the trailer and align the holes in the frame with the
bolts on the fifth wheel hub. Tighten bolts.
• Put the fenders in place.
• Insert the fuel tank into the trailer frame from the rear end.
• Place the rear tank support in the frame.
• Place the bumper on the trailer.
• Place the genset frame on top of the trailer and bolt down in place.
• Bolt the front engine support bases in place.
• Place the rear engine isolators on the genset frame.
• Place the front engine isolators in the rear bases.
2. Mounting the generator to the engine.
• Hoist the generator. Make sure it is leveled so that the process of installing it to the engine be-
comes easier.
• Align the holes of the generator housing with the bolts of the engine housing. Apply a thread
locker to the bolts used. Do not place any bolts on the two holes on each side of the generator.
Tighten 40 ft/lb of torque.
• Align the inside holes of the generator plate to match the holes on the flywheel. Use a thread
locker on the bolts used. Tighten to 45 ft/lb of torque.

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
Make sure everything is tight and secure before proceeding to the next step.
3. Mounting the engine with generator to the trailer.
• Hoist the engine and generator set. Make sure you are hoisting it by the engine and not the gen-
erator.
• Place engine/generator set on top of the trailer and align bolts of the engine mounts and the en-
gine isolators. (Make sure the engine is facing the rear of the trailer and the generator facing the
front of the trailer.)
• Tighten everything down.
• Install the engine wiring harness.
• Install the exhaust system.
• Install the noise control box, start by installing the bottom panel first and the top panel last.
4. Mounting the electrical tray.
• Place the electrical tray mounts on the 2 side holes on the generator housing. Make sure the left
one goes on the left side of the trailer and the right one goes on the right side of the trailer.
• The bolts to bolt up the mounts are longer than the ones used to bolt the generator to the engine
housing.
• Place the electrical tray angle supports on the mounts. Do not tighten all the way, just enough
to have the angles move so that the can be adjusted.
• Place the electrical tray isolators on the angle supports. Tighten just enough that they can be
adjusted.
• Place the electrical tray on the isolators and tighten.
• Measure 18 inches from the trailer to the inside of the electrical tray on each corner and tighten
the lower bolt of the angle supports. The other bolt has to be tighten later on, after placing the
enclosure on the unit so it can be squared out.
5. Assemble the electrical tray.
• The best way to do it is to start with the rectifier. It will make the process easer.

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
• Place the rectifier assembly over the big hole on the electrical tray and bolt it down.
• Place the capacitor clamps then insert the capacitors in place.
• Place the control panel isolators on the tray.
• Place the contactor (K1), Terminal Block (TB2) and drop down transformer (T1).
• Insert the generator leads into the main hole in the electrical tray connecting them to the rectifier.
Please see the connection schematic for proper connection.
• Place the current sensing transformer (T2) into one of the generator leads and connect it to TB2.
See diagram schematics for proper connection.
• Insert the PMG leads and Generator Exciter leads thru the main hole in the electrical tray.
• Connect exciter leads to TB2.
• Connect PMG leads to T1.
• Connect the Current Sensing wiring harness from TB2 to the electrical components.
• Connect the electrical tray wiring harness to the components in the electrical tray.
6. Assembling the control panel tray.
• Install the control panel wiring harness with back inside cover.
• Install and connect the alternator interface (A1), relays (CR1, CR2, CR3) and time delay base
(TD). See diagram schematics for proper connection.
• Place the back inside cover in its designed place and thiten screws.
• Install the AVR and connect J3 and J4.
• Install the switches in the front inside cover and place on the tray. See diagram for connections.
• Place the top inside cover in the tray.
• Attach the control panel to the tray. Align the hinges in their respectful place and tighten down.
• Connect the control panel accordingly to the schematics. Failure to do this step correct may cause
damage to the unit.

Servicore GS Corp
M-1001
Model: e28
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• Double-check the connections.
• Place assembled control panel tray on the electrical tray.
• Insert and tighten the four screws that hold the tray in place. The control panel tray has to be
aligned when the enclosure is placed.
7. Assembling the enclosure.
• Place the enclosure frame on the trailer
• Place the middle side panels on the enclosure frame.
• Place the control panel support. This panel requires two rubber isolators.
• Place the front panel on the sub frame and attach it to the control panel support.
• Install the control panel top support. It attaches to the front panel
• Place the rear cross member support.
• Place the rear side covers on the rear cross member and the enclosure frame.
• Place the right and left top door support. (Right one attaches to the right middle side panel and
the right rear side panel. The left one attaches to the front panel, the left middle side panel and
the left rear side panel).
• Place the rear panel attaching it to both rear side panels
• Place the rear top cover attaching it to the rear panel and rear side panels.
• Place the top cover on the unit. Install the hinges first then install the shock absorbers.
• Connect the clearance lights and beacon light (if furnished).
• Place all the doors on the unit.
These steps are basic and should be considered only as a guide. Actual
steps may vary.

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
Chapter 4 -Troubleshooting
General - Section 1
Troubleshooting procedures are done in a systematic format. When dealing with a problem, you must
check and eliminate all possible causes of trouble until the exact cause of trouble is found. The best
place to start looking for the cause of a trouble in a circuit is at the source of the power. Continue
testing and inspecting the circuit until the cause of trouble is located. See Diagram.
Troubleshooting Chart Description:
There are 3 headings:

1. Trouble, symptom and condition
2. Probable Causes
3. Test, check and remedy
Use of Troubleshooting Chart
Always read the first heading (Trouble, symptom and condition) before doing anything else. For
instance, the first and second symptoms in the chart both start out the same way. Since they both
start with the sentence “Engine will not start” you may be persuaded to just follow the first one you
see. However if you read on, one starter will crank the engine and one starter wont crank the engine.
Therefore it’s important to read the entire first heading to make sure it matches your exact problem.

Servicore GS Corp
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Model: e28
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Equipment for Troubleshooting
A good quality, multi-scale voltmeter will be required.
Diagrams
For each of the the generator sets covered by this manual an electrical schematic and connection dia-
gram is provided in the Manufacturers Literature chapter of this manual. These diagrams can be very
helpful in troubleshooting. Components shown in the diagram are identified by reference designators
(or item names in some instances). A legend appearing on the diagram identifies each reference
designator by its full item name. For example, the symbol K403 identifies the overvoltage relay, and
M406 identifies the voltmeter.
Illustrations
To aid maintenance personnel with troubleshooting, three illustrations are provided in this section,
showing the locations of various components of the generator set.
Connections and Wiring
Before condemning any electrical component, check all connections and wiring which could affect its
operation. In many instances a component may be non-functional simply because it is not receiving
power because of a loose connection or a poor ground. In most cases throughout the troubleshooting
chart, it will be assumed that connections and wiring have been checked.
WARNING
Loose garments, neckties, and other hanging items must not be worn by
personnel near the fan or other exposed moving parts of this equipment
while it is running. Also, avoid contact with live electrical parts. Death or
serious injury could result!

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
Engine - Section 2
Troubleshooting chart (Engine and Controls)
Trouble, Symptom and Probable Causes Test, Check and

Conditions Remedy
1. Engine will not start, starter a. Battery is discharged, battery Check battery voltage with the
will not crank engine. cables are loose, disconnected, voltmeter. If battery is com-
or bad. pletely discharged, charge and
test. Check battery connections,
on the battery and the engine.
Check battery cables and make
sure they are not broken.
b. Emergency switch failure. Make sure the E-Stop is dissen-
gaged. Test leads with voltme-
ter with respect to ground. re-
place if necesary.
c. Start Swich is difective. Check connections on the start
switch. Place a Jumper cable in
the hot side of the starter relay
(PR1) and the cable on the coil
of the relay (cable # 8). If star-
er cranks the engine
d. PR1 is defective. Use a jumper cable connect on
the hot side and the positive
lead. If engine does not turn
over, the solenoid needs re-
placement.
e. Defective starter. Use a jumper cable connect on
the positive lead from the bat-
tery and t
f. Internal engine siezure. Use a socket in front of the en-
gine drive pulley and try to turn
over the engine, if engine does
not turn, damage on the inside
of the engine is present.

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
Trouble, Symptom and Probable Causes Test, Check and

Conditions Remedy
2. Engine will not start, starter a. Defective start switch. Check the contact on the start
does crank engine. switch. The contact with the
numbers 13 and 14 should ac-
tivate before the other contact.
If this contact does not activate
before, replace contact block.
b. Engine fuse is burned. Check and replace if necesary
the fuses.
c. Defective time delay relay Make sure the setting on the
time delay are set properly.
the relay should always have a
green light on.
d. No fuel reaching the engine. Check the fuel level, fuel pump
and fuel filters. If air bubbles
are notable in the primary fuel
filter, purge the fuel lines. place
a jumper cable from the battery
to the fuel shut off valve (cable
# 19).

Servicore GS Corp
M-1001
Model: e28
MANUFACTURING
Chapter 6 - Electrical Diagrams
These are the connections diagrams, and schematics of the e28.

Chapter 6 | Page 1 Servicore GS Corp
M-1001
Model: e28
MANUFACTURING

Servicore GS Corp
Chapter 6 | Page 2
M-1001
Model: e28
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P1-2 J1-2
E1 E2 E2
PB1
P1-8 J1-8
E1 2 2 DS2
15 CR1-87
1
3 E2
P1-13 J1-13
3
WHITE MR7
A1
5 ST E2
1
PR1
1 6 E2
P1-1
PR2
J1-1
GP PB5-11
E2 PB6 DS4
7B 15C E2A
1B 7A
DS5
F1 (20 AMP) 23 24
J1-7 P1-7
7B 8 8 PR1 E2A E2
CB1
7C 13 14
9 E2A
DS8 7E
P1-15
PB8 7F
J1-15
10 8
SW2
7D
E2B
1A
TD
J1-16
12 MR1-V
P1-16
PR2 E2B
11
15
E2
7C
13 J1-4
14
TB1
D3 D4
WHITE
30 87
RED
14 15
F2 (20 AMP) CR1 WHITE

15D
14 15 A1-P 15A
15B
15 CR3-85
15 F3
TITLE e28 WIRING SCHEMATIC

AUTHOR Karlos Medina
DATE 5/13/2013 SHEET 1 OF 5
REVISION 0001

M-1001
Model: e28
MANUFACTURING
WHITE 15B
WHITE
RED
15A 15D
15B
MR5 BLACK MR7

J1-8 2 15A
DS2 MR3
E2
J3-6 PB6-24 ORANGE
15D A1-S
C3 7GB
PB5 15D
WHITE
MR8
7G 14 13
DS7 MR6
O.S.
DS1 J1-6 25 17
MR4 ORANGE
J1-18,19,21
CB2 28
CR2-87 22 E2
28 1
2
1
2
26 J2-6 DS3
TD-8
E2 3 3 27 J2-9
7C
28
E2
12
L PB2
E2 E2 L
12 V
V DS6 30A J2-13
MR1 MR2 D5
14 14 13 30 J3-1
CR1-87 E2
PB4 17
J1-17 P1-14 17
15
16 17 CL1 CL1 CL2 CL2
F3 (5 AMP) E2
J2-5 P2-5
17 CL3 CL3 CL4 CL4
15 17
CONTROL 17
PANEL LIGHT TB2-10
OPTIONAL
J1-20 P1-20
18 18 BL E2
F4 (5 AMP)
85 86
15 E2
CR3 FSO
J1-10 P1-10
7C 30 87
19 19 E2
CR3
19 D6
FP E2

REVISION 0001

Servicore GS Corp
Chapter 6 | Page 4
M-1001
Model: e28
MANUFACTURING
PB7
J1-5 P1-5 J1-3 P1-3
30 87
14 12 20 20 21 22 DS3
CR2
PS2
21
J1-9 30 87a 85 86
23 E2
P1-9
CR2
CR1
21A
TS
P1-12 J1-12 85 86
24 24 E2
CR2
T1A T1B
T2A
T3A T2B
T3B
T2 T1C T1D
T3D
T2D
T2C
T3C
C1 K1 E2
31
GENERATOR 26
C2
EXITER PB3
J3-2 Q7 31
J2-11 P2-11
C3
27
P2-6 R2
T1 P2-9
0 R3
R4
J2-7 P2-7
CB2 28 28
220 K1
AUX
PMG P2-13 30A
P10A
J16A
I17A
Q9A
15B
14B
L1
L2
L3
CONTROL
17B PANEL K1
TB2 LIGHT
REAR
M13
15A
14A
O11
N12
P10
J16
I17
Q9
17
17ACLEARANCE TITLE e28 WIRING SCHEMATIC

LIGHTS

OUTPUT PLUG -+ REVISION 0001

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17 P2-5 J2-5
17 PB4-13
M13
15A
14A
N12
O11
P10
J16
I17
Q9
I17 P2-2 J2-2 J4-2 P4-2
I17
J4-2 P4-2 K1
PB8 J1
I
P2-1 J2-1 J4-1 P4-1
J16
J16 J J1
15A P2-8 J2-8 J4-4 P4-4
K15 K UH
14A P2-14 J2-14 SW1 J4-5 P4-5
L14 L VH
P2-10 J2-10 J4-7 P4-7
M13
M13 M U~
N12 P2-15 J2-15 J4-8 P4-8
N12 N V~
P2-16 J2-16 J4-9 P4-9
O11
O11 O W~
P10 P2-3 J2-3 J4-10 P4-10
P10 P K
CB2 Q9 P2-12 J2-12 J4-11 P4-11
Q9 Q L
J4-12 P4-12 AVR
28 R Bt+
28
J3-1 P3-1
28
PB2 30 H C
J3-2 P3-2
J2-7 PB3 Q7 G NO
R5 J3-3 P3-3
MR1-1 J4-6 F6 F RST
PB8 J3-4 P3-4
E T1
J3-5 P3-5
D T2
J3-6 P3-6
B2 C E0
D6
D4 J3-7 P3-7
E5 DS1 C3
D7
B E1
J3-8 P3-8
A 0
DS8 E2
R1
7E
CB1
P1-18,19,21 O.S. OIL SENDER
P1-6 25 FUEL SENDER
TEMPERATURE
P1-4 13
SENDER

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A - ALTERNATOR MR1 - VOLTMETER 28VDC

A1 - ALTERNATOR INTERFACE MR2 - AMMETER 0-2000
AVR - AUTOMATIC VOLTAGE REGULATOR MR3 - HOUR METER
BL - BEACON LIGHT (IF FURNISHED) MR4 - FUEL LEVEL GAUGE
C1 - CAPACITOR MR5 - VOLTMETER 12VDC
C2 - CAPACITOR MR6 - TEMPERATURE GAUGE
C3 - CAPACITOR MR7 - TACHOMETER
CB1 - CONTACT BLOCK 1 MR8 - OIL PRESSURE GAUGE
CB2 - CONTACT BLOCK 2 P1 - CONNECTOR MAIN PLUG
CL - CLEARANCE LIGHT P2 - CONNECTOR SECONDARY PLUG
CR1 - RELAY P3 - CONNECTOR AVR PLUG
CR2 - RELAY P4 - CONNECTOR AVR PLUG
CR3 - RELAY PB1 - PUSHBUTTON, E-STOP
D3 - DIODE ON TB1 PB2 - PUSHBUTTON , CONTACTOR CLOSE
D4 - DIODE ON TB1 PB3 - PUSHBUTTON, CONTACTOR OPEN
D5 - DIODE ON PB2 PB4 - PUSHBUTTON, LIGHTS
D6 - DIODE ON J3 PB5 - PUSHBUTTON, FUEL CHECK
D7 - DIODE ON J3 PB6 - PUSHBUTTON, ENGINE START
D8 - DIODE ON FSO PB7 - PUSHBUTTON, ENGINE STOP
DS1 - PILOT LIGHT, OVER VOLTAGE PB8 - PUSHBUTTON AVR RESET
DS2 - PILOT LIGHT, ALTERNATOR FAULT PMG - PERMANENT MAGNETIC GENERATOR
DS3 - PILOT LIGHT, OVER TEMPERATURE PR1 - AUXILIARY CONTACTOR , STARTER
DS4 - PILOT LIGHT, LOW OIL PRESSURE PR2 - AUXILIARY CONTACTOR , GLOW PLUG
DS5 - ILLUMINATED PB, ENGINE START PS1 - PRESSURE SWITCH 4LBS
DS6 - ILLUMINATED PB, CONTACTOR CLOSE PS2 - PRESSURE SWITCH 4LBS
DS7 - LIGHT, FUEL GAUGE R1 - REHOSTAT , CURRENT LIMITER
DS8 - LIGHT, CURRENT LIMITER ON R2 - RESISTOR
F1 - FUSE 20 AMP R3 - RESISTOR
F2 - FUSE 20 AMP R4 - RESISTOR
F3 - FUSE 5 AMP R5 - RESISTOR, 200K OHMS
F4 - FUSE 5 AMP ST - STARTER
FP - FUEL PUMP SW1 - SWITCH, DIAGNOSTICS
FSO - FUEL SHUT OFF SOLENOID SW2 - SWITCH, GLOW PLUG
GP - GLOW PLUG T1 - DROP DOWN TRANSFORMER
J1 - SOCKET MAIN PLUG T2 - CURRENT SENSING TRANSFORMER
J2 - SOCKET SECONDARY PLUG TB1 - TERMINAL BLOCK 1
J3 - SOCKET AVR TB2 - TERMINAL BLOCK 2
J4 - SOCKET AVR TD - TIME DELAY RELAY
K1 - 28VDC CONTACTOR TS - TEMPERATURE SWITCH

REVISION 0001

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Chapter 6 | Page 8
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P10 (J4-10)
M13 (J4-7)
J16 (J4-1)
I17 (J4-2)
J2 17 (PB4-13)
26 (MR2-1)
1 2 3
E2 28 (CB2)
4 5 6 7 31 (PB3-11)
15A (SW1)
8 9 10 11 12
27 (MR2-3)
13 14 15 16
30A (PB2-13)
17 18 19
O11 (J4-9)
Q9 (J4-11)
N12 (J4-8)
14A (SW1)
15 (CR1-87)
F1
1B (J1-1)
3 (J1-13)
7A (CB1)
WHITE (MR7)
1A (J1-1)
A1 F2
15 (CR1-87) 14 (CR1-30)
19 (J1-10) 15 (CR1-87)
E2 F3 TO PAGE 2
CR3
16 (PB4-14)
7C (CB1) F4
22 (DS3) 18 (J1-20)
23 (CR1-86)
87a
CR2
24 (J1-9) 21 (PB7-11)
30 (PB2-14)
67 (PB3-11)
F6 (PB8)
J3 D4 (R1-1) DS8
C3 (DS1) B2 (J3-7) 7E (CB1)
D7
D6 E2
E5 (J3-4)
E5 (R1-3)
B2 (DS8)
R1
I17 (J2-2)
J16 (J2-1)
K15 (SW1)
R5 D4 (J3-5)
J1 (PB8)
L14 (SW1)
M13 (J2-10) J1 (J4-6) F6 (J3-3)
PB8
J4
TITLE CONTROL PANEL TRAY HARNESS
7B (PB6-24)
7C (CR3-30)
7D (TD-10)
7E (DS8)
7A (J1)
28 (J2-7)
P10 (J2-3)
28 (J4-12)
28 (MR1-1)
Q9 (J2-12)
N12 (J2-15)
O11 (J2-16)
28 (CB2)
CB1 CB2 REVISION 0001

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MANUFACTURING
1A (F2), 1B (F1)
25 (MR4-S)
15C
14 (CR1-30) 20 (PB7-12)
13 (TB1-9) 8 (PB6-23)
21 (J1-9)
PB7 BLACK
24 (CR2-86) WHITE
2 1 3 21 (CR2-30) 20 (J1-3) ORANGE
2 (DS2) 11 12 MR6 RED MR8
BLACK BLACK
4 5 6 7 8 WHITE WHITE
21 (PB7-11) 17 (PB413) ORANGE ORANGE
RED RED
9 10 11 12 13 14
19 (CR3-87)
3 (A1- S)
PB6 O.S. (J1-18,19,21)
15 16 17 W
18 R 19
E2A (SW2) B
20 22
E2B (SW2) E2 22 (CR2-87)
O.S. (MR8) E2-C (SW2)
18 (F4) J1 DS5
15C (TB1-6)
DS3 DS4
10 (TD-6) 9(TD-5) BLACK
14 13 WHITE
ORANGE
7B (CB1) 8 (J1-7) MR5 RED
MR7
24 23 BLACK
WHITE
ORANGE
RED
7D (CB1) 12 (MR1-V)
7GB
15 (TB1-2) 10 (PB6-14)
PB5 15B (TB1-5)
TD 9 (PB6-13)
7D 2 (J1-8)
E2 11 (TB1-1)
7G (DS1)
15D (MR4-+)
14 13
DS2
TB1
11 (TD-3)
1
15 (TD-11) D3
15A (MR3-+)
2
WHITE (MR5) 3
FROM PAGE 1 15 (CR1-87)
4
15B (DS2)
5
15C (DS5)
SW2 6
15D (MR4-I) D4
7
E2A (J1-15)
E2C (DS4) E2B (J1-16) 17 (PB4-13) 8
ORANGE (MR5) 13 (J1-4)
WHITE (MR6) 9
MR3 15D (TB1-7)
14 (CR1-30)
RED (MR5) 10
15D (PB5)
SW1 E2 15A (TB1-3)

DS7 MR4
15A (J2-8) K15 (J4-4)
14A (J2-14) L14 (J4-5) 25 (J1-6)

E2
PB4
17 (DS7)
17 (J1-14) 16 (F3)
17 (J2-5) 13 14
28 (CB2)
28 (PB2-13) 1 1
26 (J2-6)
PB3
2 2
E2 3 3
27 (J2-9)
31 (J2-11) Q7 (J3-2)
CR1 11 12
L
E2 L
23 (CR2-87a) E2 12 (TD-8) 12 V
PB2 V
E2 30A (J2-13)
MR1 MR2
15 (A1-P) DS6 7G (PB5-14)
14 (F2)
14 (J1-5)
15 (CR3-85)
15 (F3)
D5
14 (TB1-10) 28 (MR1-1) C3 (J3-6)
15 (TB1-4)
13 14 30 (J3-1)
DS1

REVISION 0001

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Chapter 6 | Page 10
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MANUFACTURING
A1 - ALTERNATOR INTERFACE MR1 - VOLTMETER 28VDC

CB1 - CONTACT BLOCK 1 MR2 - AMMETER 0-2000
CB2 - CONTACT BLOCK 2 MR3 - HOUR METER
CR1 - RELAY MR4 - FUEL LEVEL GAUGE
CR2 - RELAY MR5 - VOLTMETER 12VDC
CR3 - RELAY MR6 - TEMPERATURE GAUGE
D3 - DIODE ON TB1 MR7 - TACHOMETER
D4 - DIODE ON TB1 MR8 - OIL PRESSURE GAUGE
D5 - DIODE ON PB2 PB1 - PUSHBUTTON, E-STOP
D6 - DIODE ON J3 PB2 - PUSHBUTTON , CONTACTOR CLOSE
D7 - DIODE ON J3 PB3 - PUSHBUTTON, CONTACTOR OPEN
DS1 - PILOT LIGHT, OVER VOLTAGE PB4 - PUSHBUTTON, LIGHTS
DS2 - PILOT LIGHT, ALTERNATOR FAULT PB5 - PUSHBUTTON, FUEL CHECK
DS3 - PILOT LIGHT, OVER TEMPERATURE PB6 - PUSHBUTTON, ENGINE START
DS4 - PILOT LIGHT, LOW OIL PRESSURE PB7 - PUSHBUTTON, ENGINE STOP
DS5 - ILLUMINATED PB, ENGINE START PB8 - PUSHBUTTON AVR RESET
DS6 - ILLUMINATED PB, CONTACTOR CLOSE R1 - REHOSTAT , CURRENT LIMITER
DS7 - LIGHT, FUEL GAUGE SW1 - SWITCH, DIAGNOSTICS
DS8 - LIGHT, CURRENT LIMITER ON SW2 - SWITCH, GLOW PLUG
F1 - FUSE 20 AMP TB1 - TERMINAL BLOCK 1
F2 - FUSE 20 AMP TD - TIME DELAY RELAY
F3 - FUSE 5 AMP
F4 - FUSE 5 AMP
J1 - SOCKET MAIN PLUG
J2 - SOCKET SECONDARY PLUG
J3 - SOCKET AVR
J4 - SOCKET AVR

REVISION 0001

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Chapter 6 | Page 12
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E1 E2 0
P3 J3 DS8
E0
B2 7E
CB1
A
B D7 DS1
0 RST T1 T2 C2 C1
C3 7G
C PB5-14
VOLTAGE REGULATOR D D6 E5
E D4
F F6 R1
G Q7 PB8
H 30
28 31
C NO
K1 J1 UH VH U~ V~ W~ K L Bt- Bt+ PB2 PB3
MR1-1
R5
I J1 J K L M N O P Q R
P4
2 6 1 4 5 7 8 9 10 11 12
J4
M13
O11
N12
K15
P10
I17
L14
J16
Q9
28
28
J1
SW1
CB2
15A 14A
P10 28
I17 J2
J16
1 2 3
4 5 6 7
15A Q9
8 9 10 11 12
13 14 15 16 31
14A
17 18 19
M13
N12
O11
CB1 - CONTACT BLOCK 1 MR1 - VOLTMETER 28 VDC

CB2 - CONTACT BLOCK 2 P3 - AVR PLUG, 9 PINS
D6 - DIODE P4 - AVR PLUG, 12 PINS
D7 - DIODE PB2 - PUSHBUTTON, CONTACTOR CLOSE
DS1 - PILOT LIGHT, O.V. PB3 - PUSHBUTTON, CONTACTOR OPEN TITLE VOLTAGE REGULATOR CONNECTION
DS8 - LIGHT, CURRENT LIMIT ON PB5 - PUSHBUTTON, FUEL CHECK
PB8 - PUSHBUTTON, AVR RESET AUTHOR Karlos Medina
J2 - SECONDARY MALE CONNECTOR
J3 - AVR CONNECTOR, 9 PINS R1 - CURRENT LIMIT REHOSTAT DATE 5/13/2013 SHEET 1 OF 1
J4 - AVR CONNECTOR, 12 PINS R5 - RESISTOR 200K OHMS
SW1 - SWITCH, DIAGNOSTIC REVISION 0001

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Chapter 6 | Page 14
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17
E2
P10
26
I17
J16 P2
1 2 3
26
4 5 6 7
15A
8 9 10 11 12
13 14 15 16
+
17 18 19
-
14A
M13
31
O11
N12
30A
28
Q9
27
++
27
- +
SHUNT
28
K1
31
++
K1
AUX
30A
TB2
M13
GENERATOR LINE 1
N12
GENERATOR LINE 2
+
- 28.5 VDC
O11
GENERATOR LINE 3
J16 J16A
I17 I17A C1 - CAPACITOR

C2 - CAPACITOR
P10 P10A C3 - CAPACITOR
P2 - SECONDARY PLUG
Q9 Q9A J5 - SINGLE LINE CONNECTOR
J6 - SINGLE LINE CONNECTOR
15A 15B K1 - CONTACTOR
P5 - SINGLE LINE PLUG
14A 14B P6 - SINGLE LINE PLUG
R1 - RESISTOR
17
R2 - RESISTOR
R3 - RESISTOR
T1 - TRANSFORMER, 220 TO 60
0 220 T2 T2 - TRANSFORMER SENSING
J5-1 P5-1 TB2 - TERMINAL BLOCK, 10 POSITIONS
CLEARANCE 17A
0 0
LIGHTS
TITLE ELECTRICAL TRAY HARNESS
60 220 AUTHOR Karlos Medina

J6-1 P6-1
TO PANEL 17B
LIGHT T1
REVISION 0001

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Chapter 6 | Page 16
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19
1 25
8
E2
20
TEMPERATURE 13 2 1 3 B+
SENDER 2
4 5 6 7 8 D
AW
9 10 11 12 13 14
E2
15 16 17 18 19
20 22 21
3
21A 12
P1
NO C
ST
E2 PS2 FUEL PUMP

5
E2
GP FUEL SHUT OFF

E2
C NO 24
6
TS
OS
PR1 18
OIL SENDER
E2-A
8 BEACON
(OPTIONAL) 17 FUEL SENDER
PR2
E2
E2-A NC C REAR CLEARANCE

LIGHTS
PS1
E2 E2
1
E2-B
8
+ _
E1
PB1
E2
A - ALTERNATOR PS1 - PRESS. SWITCH 1 4PSI TITLE ENGINE WIRING HARNESS

GP - GLOW PLUGS PS2 - PRESS. SWITCH 2 4PSI
P1 - PLUG CONNECTOR 1 ST - STARTER AUTHOR Karlos Medina
PB1 - E-STOP TS - TEMP. SWITCH DATE SHEET 1 OF 1
4/22/2013
PR1 - ST. POWER RELAY
PR2 - G.P. POWER RELAY REVISION 0001

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Servicore GS Corp
Chapter 6 | Page 18
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Chapter 7 - Manufacturer’s Literature
Section 1 - Perkins 1104D Manual

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Servicore GS Corp
Chapter 7 | Page 2
SEBU8325-01
July 2012
Operation and
Maintenance
Manual
1104D (Mech) Industrial Engine
NK (Engine)
NL (Engine)
NM (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions 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 prema-
ture failures, product damage, personal injury or
death.
SEBU8325-01 3
Table of Contents
Table of Contents
Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 5
General Hazard Information ................................... 6
Burn Prevention ...................................................... 8
Fire Prevention and Explosion Prevention .............. 8
Crushing Prevention and Cutting Prevention ........ 10
Before Starting Engine .......................................... 10
Engine Starting ..................................................... 10
Engine Stopping .................................................... 11
Electrical System ................................................... 11
Product Information Section

Model Views ......................................................... 13
Product Identi¿cation Information ........................ 18
Operation Section
Lifting and Storage ................................................ 20
Gauges and Indicators .......................................... 22
Features and Controls .......................................... 23
Engine Starting ..................................................... 24
Engine Operation .................................................. 27
Engine Stopping ................................................... 28
Cold Weather Operation ....................................... 29
Maintenance Section
Re¿ll Capacities .................................................... 33
Maintenance Interval Schedule ............................ 50
Warranty Section
Warranty Information ............................................ 79
Index Section
Index ..................................................................... 80
4 SEBU8325-01
Foreword
Foreword Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
Literature Information of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe,
This manual contains safety, operation instructions, dusty, wet or freezing cold operating conditions,
lubrication and maintenance information. This more frequent lubrication and maintenance than is
manual should be stored in or near the engine area speci¿ed in the Maintenance Interval Schedule may
in a literature holder or literature storage area. Read, be necessary.
study and keep it with the literature and engine
information. The maintenance schedule items are organized for
a preventive maintenance management program. If
English is the primary language for all Perkins the preventive maintenance program is followed, a
publications. The English used facilitates translation periodic tune-up is not required. The implementation
and consistency. of a preventive maintenance management program
should minimize operating costs through cost
Some photographs or illustrations in this manual avoidances resulting from reductions in unscheduled
show details or attachments that may be different downtime and failures.
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvement and advancement of product design Maintenance Intervals
may have caused changes to your engine which are
not included in this manual. Whenever a question Perform maintenance on items at multiples of
arises regarding your engine, or this manual, please the original requirement. We recommend that the
consult with your Perkins dealer or your Perkins maintenance schedules be reproduced and displayed
distributor for the latest available information. near the engine as a convenient reminder. We also
recommend that a maintenance record be maintained
as part of the engine's permanent record.
Safety
Your authorized Perkins dealer or your Perkins
This safety section lists basic safety precautions. distributor can assist you in adjusting your
In addition, this section identi¿es hazardous, maintenance schedule to meet the needs of your
warning situations. Read and understand the basic operating environment.
precautions listed in the safety section before
operating or performing lubrication, maintenance and
repair on this product. Overhaul
Major engine overhaul details are not covered in
Operation the Operation and Maintenance Manual except
for the interval and the maintenance items in that
Operating techniques outlined in this manual are interval. Major repairs should only be carried out by
basic. They assist with developing the skills and Perkins authorized personnel. Your Perkins dealer
techniques required to operate the engine more or your Perkins distributor offers a variety of options
ef¿ciently and economically. Skill and techniques regarding overhaul programs. If you experience
develop as the operator gains knowledge of the a major engine failure, there are also numerous
engine and its capabilities. after failure overhaul options available. Consult with
your Perkins dealer or your Perkins distributor for
The operation section is a reference for operators. information regarding these options.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and stopping the engine. This section also includes a California Proposition 65 Warning
discussion of electronic diagnostic information.
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
Maintenance birth defects, and other reproductive harm. Battery
posts, terminals and related accessories contain lead
The maintenance section is a guide to engine care. and lead compounds. Wash hands after handling.
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.
SEBU8325-01 5
Safety Section
Safety Messages
Safety Section The Universal Warning label (2) is located on the

rear end of the valve mechanism cover. Refer to
illustration 2.
i02690461
Safety Messages
There may be several speci¿c warning signs on your

engine. The exact location and a description of the
warning signs are reviewed in this section. Please
become familiar with all warning signs.
Ensure that all of the warning signs are legible. Clean

the warning signs or replace the warning signs if
the words cannot be read or if the illustrations are
not visible. Use a cloth, water, and soap to clean
the warning signs. Do not use solvents, gasoline, or
other harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
warning signs. The warning signs that are loosened
could drop off of the engine.
Replace any warning sign that is damaged or

missing. If a warning sign is attached to a part of the
engine that is replaced, install a new warning sign on
the replacement part. Your Perkins dealer or your
distributor can provide new warning signs.
(1) Universal Warning
Do not operate or work on this equipment unless

you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
heed the warnings could result in serious injury
or death.
g01154807
Illustration 1
Typical example
6 SEBU8325-01
Safety Section
General Hazard Information
g01353108
Illustration 2
(1) Ether Warning Label (2) Universal warning
(2) Ether i02677370
Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
personal injury.
g00104545
Illustration 4
Attach a “Do Not Operate” warning tag or a similar

Illustration 3
g01154809 warning tag to the start switch or to the controls
before you service the equipment or before you
Typical example
repair the equipment.
The ether warning label (1) is located on the inlet
manifold cover. Refer to illustration 2.
SEBU8325-01 7
Safety Section
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.
The maximum air pressure for cleaning purposes

must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
Illustration 5
g00702020 cause hydraulic Àuid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
Wear a hard hat, protective glasses, and other
protective equipment, as required. Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
Do not wear loose clothing or jewelry that can snag may occur. Do not disassemble any hydraulic
on controls or on other parts of the engine. components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
Make sure that all protective guards and all covers information for any procedures that are required to
are secured in place on the engine. relieve the hydraulic pressure.
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 Àuids into glass containers.

Drain all liquids into a suitable container.
Obey all local regulations for the disposal of liquids.
Use all cleaning solutions with care.
Report all necessary repairs.
Do not allow unauthorized personnel on the g00687600

equipment. Illustration 6
Ensure that the power supply is disconnected before Always use a board or cardboard when you check
you work on the bus bar or the glow plugs. for a leak. Leaking Àuid that is under pressure can
penetrate body tissue. Fluid penetration can cause
Perform maintenance on the engine with the serious injury and possible death. A pin hole leak can
equipment in the servicing position. Refer to the cause severe injury. If Àuid is injected into your skin,
OEM information for the procedure for placing the you must get treatment immediately. Seek treatment
equipment in the servicing position. from a doctor that is familiar with this type of injury.
Pressure Air and Water Containing Fluid Spillage

Pressurized air and/or water can cause debris Care must be taken in order to ensure that Àuids
and/or hot water to be blown out. This could result in are contained during performance of inspection,
personal injury. maintenance, testing, adjusting and repair of the
engine. Make provision to collect the Àuid with a
The direct application of pressurized air or suitable container before any compartment is opened
pressurized water to the body could result in personal or before any component is disassembled.
injury.
• Only use the tools that are suitable for collecting
Àuids and equipment that is suitable for collecting
Àuids.
8 SEBU8325-01
Safety Section
Burn Prevention
• Only use the tools that are suitable for containing i02813488
Àuids and equipment that is suitable for containing
Àuids. Fire Prevention and Explosion
Obey all local regulations for the disposal of liquids.
Prevention
i02143195
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, ¿ttings or related
items are disconnected.
Coolant Illustration 7
g00704000
When the engine is at operating temperature, the All fuels, most lubricants, and some coolant mixtures
engine coolant is hot. The coolant is also under are Àammable.
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Flammable Àuids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
Any contact with hot coolant or with steam can cause a ¿re. Fire may cause personal injury and property
severe burns. Allow cooling system components to damage.
cool before the cooling system is drained.
A Àash ¿re may result if the covers for the engine
Check the coolant level after the engine has stopped crankcase are removed within ¿fteen minutes after
and the engine has been allowed to cool. an emergency shutdown.
Ensure that the ¿ller cap is cool before removing the Determine whether the engine will be operated in an
¿ller cap. The ¿ller cap must be cool enough to touch environment that allows combustible gases to be
with a bare hand. Remove the ¿ller cap slowly in drawn into the air inlet system. These gases could
order to relieve pressure. cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact If the application involves the presence of combustible
the skin, the eyes, or the mouth. gases, consult your Perkins dealer and/or your
Perkins distributor for additional information about
Oils suitable protection devices.
Hot oil and hot lubricating components can cause Remove all Àammable combustible materials or
personal injury. Do not allow hot oil to contact the conductive materials such as fuel, oil, and debris from
skin. Also, do not allow hot components to contact the engine. Do not allow any Àammable combustible
the skin. materials or conductive materials to accumulate on
the engine.
Batteries Store fuels and lubricants in correctly marked
containers away from unauthorized persons. Store
Electrolyte is an acid. Electrolyte can cause personal oily rags and any Àammable materials in protective
injury. Do not allow electrolyte to contact the skin or containers. Do not smoke in areas that are used for
the eyes. Always wear protective glasses for servicing storing Àammable materials.
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended. Do not expose the engine to any Àame.
SEBU8325-01 9
Safety Section
Fire Prevention and Explosion Prevention
Exhaust shields (if equipped) protect hot exhaust Use caution when you are refueling an engine. Do
components from oil or fuel spray in case of a line, not smoke while you are refueling an engine. Do not
a tube, or a seal failure. Exhaust shields must be refuel an engine near open Àames or sparks. Always
installed correctly. stop the engine before refueling.
Do not weld on lines or tanks that contain Àammable

Àuids. Do not Àame cut lines or tanks that contain
Àammable Àuid. Clean any such lines or tanks
thoroughly with a nonÀammable solvent prior to
welding or Àame cutting.
Wiring must be kept in good condition. All electrical

wires must be correctly 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.
Arcing or sparking could cause a ¿re. Secure

connections, recommended wiring, and correctly
maintained battery cables will help to prevent arcing g00704135
Illustration 9
or sparking.
Gases from a battery can explode. Keep any open
Inspect all lines and hoses for wear or for
Àames or sparks away from the top of a battery. Do
deterioration. The hoses must be correctly routed.
not smoke in battery charging areas.
The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the
Never check the battery charge by placing a metal
recommended torque. Leaks can cause ¿res.
object across the terminal posts. Use a voltmeter or
a hydrometer.
Oil ¿lters and fuel ¿lters must be correctly installed.
The ¿lter housings must be tightened to the correct
Incorrect jumper cable connections can cause
torque.
an explosion that can result in injury. Refer to
the Operation Section of this manual for speci¿c
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 ¿re extinguisher is available. Be
familiar with the operation of the ¿re extinguisher.
Inspect the ¿re extinguisher and service the ¿re
extinguisher regularly. Obey the recommendations
on the instruction plate.
g00704059
Illustration 8
10 SEBU8325-01
Safety Section
Crushing Prevention and Cutting Prevention
Lines, Tubes and Hoses When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent Chips or other debris may Ày off objects when objects
or damaged. Do not clip any other items to the high are struck. Before objects are struck, ensure that no
pressure lines. one will be injured by Àying debris.
Repair any lines that are loose or damaged. Leaks

i02675470
can cause ¿res. Consult your Perkins dealer or your
Perkins distributor for repair or for replacement parts. Before Starting Engine
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 The initial start-up of a new engine or a engine that
to the recommended torque. has been serviced or repaired make provision to shut
the engine off, in order to stop an overspeed. This
Replace the parts if any of the following conditions may be accomplished by shutting off the air and/or
are present: fuel supply to the engine.
• End ¿ttings are damaged or leaking. Overspeed shutdown should occur automatically for
engines that are controlled electronically. If automatic
• Outer coverings are chafed or cut. shutdown does not occur, press the emergency stop
button in order to cut the fuel and/or air to the engine.
• Wires are exposed.
Inspect the engine for potential hazards.
• Outer coverings are ballooning.
Before starting the engine, ensure that no one is on,
• Flexible part of the hoses are kinked. underneath, or close to the engine. Ensure that the
area is free of personnel.
• Outer covers have embedded armoring.
If equipped, ensure that the lighting system for the
• End ¿ttings are displaced. engine is suitable for the conditions. Ensure that all
lights work correctly, if equipped.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this All protective guards and all protective covers must
will help to prevent vibration, rubbing against other be installed if the engine must be started in order
parts, and excessive heat. to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
i02143194 around the parts carefully.
Crushing Prevention and Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
Cutting Prevention provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.
Support the component correctly when work beneath See the Service Manual for repairs and for
the component is performed. adjustments.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is i02678897
running.
Engine Starting
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan Do not use aerosol types of starting aids such as
blades will throw objects or cut objects. ether. Such use could result in an explosion and
personal injury.
SEBU8325-01 11
Safety Section
Engine Stopping
If a warning tag is attached to the engine start switch Use the Emergency Stop Button (if equipped) ONLY
or to the controls, DO NOT start the engine or move in an emergency situation. Do not use the Emergency
the controls. Consult with the person that attached Stop Button for normal engine stopping. After an
the warning tag before the engine is started. emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
All protective guards and all protective covers must corrected.
be installed if the engine must be started in order
to perform service procedures. To help prevent an Stop the engine if an overspeed condition occurs
accident that is caused by parts in rotation, work during the initial start-up of a new engine or an engine
around the parts carefully. that has been overhauled. This may be accomplished
by shutting off the fuel supply to the engine and/or
Start the engine from the operator's compartment or shutting off the air supply to the engine.
from the engine start switch.
i02176668
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation
Electrical System
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent Never disconnect any charging unit circuit or battery
personal injury. circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
To ensure that the jacket water heater (if equipped) gases that are produced by some batteries to ignite.
and/or the lube oil heater (if equipped) is working
correctly, check the water temperature gauge and the To help prevent sparks from igniting combustible
oil temperature gauge during the heater operation. gases that are produced by some batteries, the
negative “í” jump start cable should be connected
Engine exhaust contains products of combustion last from the external power source to the negative
which can be harmful to your health. Always start the “í” terminal of the starting motor. If the starting motor
engine and operate the engine in a well ventilated is not equipped with a negative “í” terminal, connect
area. If the engine is started in an enclosed area, the jump start cable to the engine block.
vent the engine exhaust to the outside.
Check the electrical wires daily for wires that are
Note: The engine is equipped with an automatic loose or frayed. Tighten all loose electrical wires
device for cold starting for normal conditions of before the engine is started. Repair all frayed
operation. If the engine will be operated in very cold electrical wires before the engine is started. See
conditions, then an extra cold starting aid may be the Operation and Maintenance Manual for speci¿c
required. Normally, the engine will be equipped with starting instructions.
the correct type of starting aid for your region of
operation.
Grounding Practices
The engines are equipped with a glow plug starting
aid in each individual cylinder that heats the intake Correct grounding for the engine electrical system
air in order to improve starting. is necessary for optimum engine performance
and reliability. Incorrect grounding will result in
uncontrolled electrical circuit paths and in unreliable
i02678838 electrical circuit paths.
Engine Stopping Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.
Stop the engine according to the procedure in
Engines that are installed without engine-to-frame
the Operation and Maintenance Manual, “Engine ground straps can be damaged by electrical
Stopping (Operation Section)” in order to avoid
discharge.
overheating of the engine and accelerated wear of
the engine components. To ensure that the engine and the engine electrical
systems function correctly, an engine-to-frame
ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct
engine ground to the frame.
12 SEBU8325-01
Safety Section
Electrical System
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.
SEBU8325-01 13
Model Views
Product Information
Section
Model Views
i02693072
Model View Illustrations

14 SEBU8325-01
Model Views
1104 Engine Model Views
g01351713
Illustration 10
Typical example
(1) Pulley (5) Valve Mechanism Cover (9) Fuel Injection Pump
(2) Alternator (6) Rear Lifting Eye (10) Oil Filter
(3) Front Lifting Eye (7) Air Intake (11) Crankshaft Pulley
(4) Water Outlet (8) Secondary Fuel Filter (12) Water Pump
SEBU8325-01 15
Model Views
g01352705
Illustration 11
(13) Flywheel (17) Turbocharger (21) Oil Drain Plug
(14) Flywheel Housing (18) Oil Gauge (22) Primary Fuel Filter
(15) Oil Filler Cap (19) Oil Pan
(16) Exhaust Manifold (20) Starting motor
Note: The primary fuel ¿lter may be mounted off the i04430909
engine.
Engine Description
The engines are available in the following types of

aspiration:
16 SEBU8325-01
Model Views
• Turbocharged aftercooled Table 1
• Turbocharged 1104D (Mech) Industrial Engine Speci¿cations
Number of Cylinders 4 In-Line

• Naturally aspirated
Bore 105 mm (4.134 inch)
Engine Speci¿cations Stroke 127 mm (5.0 inch)
Note: The front end of the engine is opposite the Aspiration Naturally aspirated
Àywheel end of the engine. The left and the right Turbocharged
Turbocharged aftercooled
sides of the engine are determined from the Àywheel
end. The number 1 cylinder is the front cylinder. Compression Ratio NA 19.3:1
T, TA 18.2:1
Displacement 4.4 L (268 in 3)
Firing Order 1 3 4 2
Rotation (Àywheel end) Counterclockwise
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
Valve Lash Setting
0.45 mm (0.018 inch)
(Exhaust)
Engine Cooling and Lubrication

The cooling system consists of the following
g00984281 components:
Illustration 12
A typical example of the layout of the valves • Gear-driven centrifugal water pump
(A) Inlet valves
(B) Exhaust valves • Water temperature regulator which regulates the
engine coolant temperature
Emissions Control Systems
• Gear-driven oil pump (gear type)
NK - Direct Diesel Injection
• Oil cooler
NL - Turbocharger, Direct Diesel Injection
The engine lubricating oil is supplied by a gear
NM - Turbocharger with Air to Air Charge Cooler, type pump. The engine lubricating oil is cooled and
Direct Diesel Injection the engine lubricating oil is ¿ltered. Bypass valves
provide unrestricted Àow of lubrication oil to the
engine parts when oil viscosity is high. Bypass valves
can also provide unrestricted Àow of lubrication oil
to the engine parts if the oil cooler should become
plugged or if the oil ¿lter element should become
plugged.
Engine ef¿ciency, ef¿ciency of emission controls, and

engine performance depend on adherence to proper
operation and maintenance recommendations.
Engine performance and ef¿ciency 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.
SEBU8325-01 17
Model Views
Engine Service Life

Engine ef¿ciency 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 time period. 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.
18 SEBU8325-01
Product Identi¿cation Information
Product Identi¿cation
Information
i02680910
Engine Identi¿cation
Perkins engines are identi¿ed 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 Illustration 14

g01347465
NK12345U090001P. Typical serial number plate
(2) Temporary Parts List number
NK __________________________________________Type of engine (3) List number
(4) Serial number
NK12345____________________________Engine List Number (5) Type
U ____________________________Built in the United Kingdom The Serial Number Plate (1) is located on the left side
of the cylinder block to the rear of the engine.
090001 ___________________________Engine Serial Number
The following information is stamped on the Serial
P _____________________________________Year of Manufacture Number Plate: Engine serial number, Model, and
Arrangement number.
Perkins dealers need these numbers in order to
determine the components that were included with
i02677372
the engine. This permits accurate identi¿cation of
replacement part numbers. Reference Numbers
i02681468
Serial Number Plate Information for the following items may be needed to
order parts. Locate the information for your engine.
Record the information in the appropriate space.
Make a copy of this list for a record. Keep the
information for future reference.
Record for Reference

Engine Model _______________________________________________
Engine Serial number _____________________________________
Engine Low Idle rpm ______________________________________
Engine Full Load rpm _____________________________________
Primary Fuel Filter _________________________________________
Water Separator Element ________________________________
Secondary Fuel Filter Element __________________________
Lubrication Oil Filter Element ___________________________

g01347087
Illustration 13 Auxiliary Oil Filter Element _______________________________
Location of serial number plate
SEBU8325-01 19
Product Identi¿cation Information
Total Lubrication System Capacity _____________________
Total Cooling System Capacity _________________________
Air Cleaner Element _______________________________________
Fan Drive Belt ______________________________________________
Alternator Belt ______________________________________________
i02690481
Emissions Certi¿cation Film
g01350379
Illustration 15
Typical example
20 SEBU8325-01
Operation Section
Lifting and Storage
Operation Section i04432996
Product Storage
Lifting and Storage
Perkins are not responsible for damage which may
i02677363 occur when an engine is in storage after a period in
service.
Product Lifting
Your Perkins dealer or your Perkins distributor can
assist in preparing the engine for extended storage
periods.
Condition for Storage

The engine must be stored in a water proof building.
The building must be kept at a constant temperature.
Engines that are ¿lled with Perkins ELC will have
coolant protection to an ambient temperature of
í36° C (í32.8° F). The engine must not be subjected
to extreme variations in temperature and humidity.
Storage Period
An engine can be stored for up to 6 months provided
g00103219
Illustration 16 all the recommendation are adhered to.
NOTICE Storage Procedure

Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem- Keep a record of the procedure that has been
ber that the capacity of an eyebolt is less as the angle completed on the engine.
between the supporting members and the object be-
comes less than 90 degrees. Note: Do not store an engine that has biodiesel in
the fuel system.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for 1. Ensure that the engine is clean and dry.
the weight.
a. If the engine has been operated using biodiesel,
the system must be drained and new ¿lters
Use a hoist to remove heavy components. Use installed. The fuel tank will require Àushing.
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be b. Fill the fuel system with an acceptable fuel. For
parallel to each other. The chains and cables should more information on acceptable fuels refer to
be perpendicular to the top of the object that is being this Operation and Maintenance Manual, “Fluid
lifted. recommendations”. Operate the engine for 15
minutes in order to remove all biodiesel from
Some removals require lifting the ¿xtures in order to the system.
obtain proper balance and safety.
2. Drain any water from the primary ¿lter water
To remove the engine ONLY, use the lifting eyes that separator. Ensure that the fuel tank is full.
are on the engine.
3. The engine oil will not need to be drained in
Lifting eyes are designed and installed for speci¿c order to store the engine. Provided the correct
engine arrangements. Alterations to the lifting eyes speci¿cation of engine oil is used the engine
and/or the engine make the lifting eyes and the lifting can be stored for up to 6 months. For the
¿xtures obsolete. If alterations are made, ensure correct speci¿cation of engine oil refer to this
that proper lifting devices are provided. Consult your Operation and Maintenance Manual, “Fluid
Perkins dealer for information regarding ¿xtures for recommendations”.
proper engine lifting.
4. Remove the drive belt from the engine.
SEBU8325-01 21
Operation Section
Lifting and Storage
Sealed Coolant System
Ensure that the cooling system is ¿lled with Perkins

ELC, or an antifreeze that meets “ASTM D6210”
speci¿cation.
Open Cooling System
Ensure that all cooling drain plugs have been

opened. Allow the coolant to drain. Install the drain
plugs. Place a vapor phase inhibitor into the system.
The coolant system must be sealed once the vapor
phase inhibitor has been introduced. The effect of the
vapor phase inhibitor will be lost if the cooling system
is open to the atmosphere.
For maintenance procedures refer to this Operation

and Maintenance Manual.
Monthly Checks
The crankshaft must be rotated in order to change
the spring loading on the valve train. Rotate the
crankshaft more than 180 degrees. Visibly check for
damage or corrosion to the engine.
Ensure that the engine is covered completely before

storage. Log the procedure in the record for the
engine.
22 SEBU8325-01
Operation Section
Gauges and Indicators
Gauges and Indicators 1. Reduce the load and the engine rpm.
2. Inspect the cooling system for leaks.

i02677374
3. Determine if the engine must be shut down
Gauges and Indicators immediately or if the engine can be cooled by
reducing the load.
Tachometer – This gauge indicates engine

Your engine may not have the same gauges or all of speed (rpm). When the throttle control lever
the gauges that are described. For more information is moved to the full throttle position without
about the gauge package, see the OEM information. load, the engine is running at high idle. The engine is
running at the full load rpm when the throttle control
Gauges provide indications of engine performance. lever is at the full throttle position with maximum
Ensure that the gauges are in good working order. rated load.
Determine the normal operating range by observing
the gauges over a period of time.
NOTICE
Noticeable changes in gauge readings indicate To help prevent engine damage, never exceed the
potential gauge or engine problems. Problems may high idle rpm. Overspeeding can result in serious
also be indicated by gauge readings that change damage to the engine. The engine can be operated
even if the readings are within speci¿cations. at high idle without damage, but should never be
Determine and correct the cause of any signi¿cant allowed to exceed high idle rpm.
change in the readings. Consult your Perkins dealer
or your Perkins distributor for assistance. Ammeter – This gauge indicates the
amount of charge or discharge in the
NOTICE battery charging circuit. Operation of the
If no oil pressure is indicated, STOP the engine. If indicator should be to the right side of “0” (zero).
maximum coolant temperature is exceeded, STOP
the engine. Engine damage can result. Fuel Level – This gauge indicates the fuel
level in the fuel tank. The fuel level gauge
Engine Oil Pressure – The oil pressure operates when the “START/STOP” switch
should be greatest after a cold engine is is in the “ON” position.
started. The typical engine oil pressure with
SAE10W30 is 207 to 413 kPa (30 to 60 psi) at rated Service Hour Meter – The gauge indicates
rpm. operating time of the engine.
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 96°C
(160 to 205°F). The maximum allowable
temperature with the pressurized cooling system at
48 kPa (7 psi) is 110°C (230°F). 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:
SEBU8325-01 23
Operation Section
Features and Controls
Features and Controls

i02690464
Fuel Shutoff
The fuel shutoff solenoid is located on the fuel

injection pump.
When the fuel shutoff solenoid is activated, the

solenoid moves to the “Open” position.
When the fuel shutoff solenoid is deactivated, the

solenoid moves to the “Closed” position.
24 SEBU8325-01
Operation Section
Engine Starting
Engine Starting • Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
i02675151 to the controls.
Before Starting Engine • Ensure that the areas around the rotating parts are
clear.
• All of the guards must be put in place. Check for

Before the engine is started, perform the required damaged guards or for missing guards. Repair
daily maintenance and any other periodic any damaged guards. Replace damaged guards
maintenance that is due. Refer to the Operation and/or missing guards.
and Maintenance Manual, “Maintenance Interval
Schedule” for more information. • Disconnect any battery chargers that are not
protected against the high current drain that
• For the maximum service life of the engine, make a is created when the electric starting motor is
thorough inspection within the engine compartment engaged. Check electrical cables and check the
before the engine is started. Look for the following battery for poor connections and for corrosion.
items: oil leaks, coolant leaks, loose bolts, and
excessive dirt and/or grease. Remove any excess • Reset all of the shutoffs or alarm components (if
dirt and/or grease buildup. Repair any faults that equipped).
were identi¿ed during the inspection.
• Check the engine lubrication oil level. Maintain the
• Inspect the cooling system hoses for cracks and oil level between the “MIN” mark and the “MAX”
for loose clamps. mark on the engine oil level gauge.
• Inspect the alternator and accessory drive belts for • Check the coolant level. Observe the coolant level
cracks, breaks, and other damage. in the header tank (if equipped). Maintain the
coolant level to the “FULL” mark on the header
• Inspect the wiring for loose connections and for tank.
worn wires or frayed wires.
• If the engine is not equipped with a header tank
• Check the fuel supply. Drain water from the water maintain the coolant level within 13 mm (0.5 inch)
separator (if equipped). Open the fuel supply valve of the bottom of the ¿ller pipe. If the engine is
(if equipped). equipped with a sight glass, maintain the coolant
level in the sight glass.
NOTICE
All valves in the fuel return line must be open before • Observe the air cleaner service indicator (if
and during engine operation to help prevent high fuel equipped). Service the air cleaner when the yellow
pressure. High fuel pressure may cause ¿lter housing diaphragm enters the red zone, or when the red
failure or other damage. piston locks in the visible position.
• Ensure that any equipment that is driven by the

If the engine has not been started for several weeks, engine has been disengaged from the engine.
fuel may have drained from the fuel system. Air Minimize electrical loads or remove any electrical
may have entered the ¿lter housing. Also, when fuel loads.
¿lters 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.
SEBU8325-01 25
Operation Section
Engine Starting
i02678840 Note: If it is possible, ¿rst diagnose the reason for the

starting failure. Make any necessary repairs. If the
Starting the Engine 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.
Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and NOTICE
personal injury. 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
Refer to the OEM for your type of controls. Use the the electrical system.
following procedure to start the engine.
Do not reverse the battery cables. The alternator can
1. If equipped, move the throttle lever to the full be damaged. Attach ground cable last and remove
throttle position before you start the engine. ¿rst.
NOTICE When using an external electrical source to start the

Do not crank the engine for more than 30 seconds. engine, turn the generator set control switch to the
Allow the electric starting motor to cool for two minutes “OFF” position. Turn all electrical accessories OFF be-
before cranking the engine again. fore attaching the jump start cables.
Ensure that the main power switch is in the OFF posi-

2. Turn the engine start switch to the START position. tion before attaching the jump start cables to the en-
Hold the engine start switch in the START position gine being started.
and crank the engine.
3. When the engine starts, release the engine start 1. Turn the start switch to the OFF position. Turn off
switch. all the engine's accessories.
4. If equipped, slowly move the throttle lever to the 2. Connect one positive end of the jump start cable
low idle position and allow the engine to idle. Refer to the positive cable terminal of the discharged
to the Operation and Maintenance Manual, “After battery. Connect the other positive end of the jump
Starting Engine” topic. start cable to the positive cable terminal of the
electrical source.
5. If the engine does not start, release the engine
start switch and allow the electric starting motor to 3. Connect one negative end of the jump start cable
cool. Then, repeat steps 2 through step 4. to the negative cable terminal of the electrical
source. Connect the other negative end of the
6. Turn the engine start switch to the OFF position in jump start cable to the engine block or to the
order to stop the engine. chassis ground. This procedure helps to prevent
potential sparks from igniting the combustible
gases that are produced by some batteries.
i02678837
Starting with Jump Start 4. Start the engine.
Cables 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
correct voltage with a battery charger after the engine
Improper jump start cable connections can cause
is stopped. Many batteries which are considered
an explosion resulting in personal injury.
unusable are still rechargeable. Refer to Operation
and Maintenance Manual, “Battery - Replace” and
Prevent sparks near the batteries. Sparks could
Testing and Adjusting Manual, “Battery - Test”.
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
26 SEBU8325-01
Operation Section
Engine Starting
i02674934
After Starting Engine
Note: In temperatures from 0 to 60°C (32 to 140°F),

the warm-up time is approximately three minutes. In
temperatures below 0°C (32°F), additional warm-up
time may be required.
When the engine idles during warm-up, observe the

following conditions:
• Check for any Àuid 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. Signi¿cant
changes in the readings should be investigated.
SEBU8325-01 27
Operation Section
Engine Operation
Engine Operation i02678851
Fuel Conservation Practices

i02678894
Engine Operation
The ef¿ciency of the engine can affect the fuel
economy. Perkins design and technology in
manufacturing provides maximum fuel ef¿ciency in
Correct operation and maintenance are key factors all applications. Follow the recommended procedures
in obtaining the maximum life and economy of in order to attain optimum performance for the life
the engine. If the directions in the Operation and of the engine.
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized. • Avoid spilling fuel.
The engine can be operated at the rated rpm after the Fuel expands when the fuel is warmed up. The fuel
engine reaches operating temperature. The engine may overÀow from the fuel tank. Inspect fuel lines for
will reach normal operating temperature sooner leaks. Repair the fuel lines, as needed.
during a low engine speed (rpm) and during a low
power demand. This procedure is more effective than • Be aware of the properties of the different fuels.
idling the engine at no load. The engine should reach Use only the recommended fuels.
operating temperature in a few minutes.
• Avoid unnecessary idling.
Gauge readings should be observed and the data
should be recorded frequently while the engine Shut off the engine rather than idle for long periods of
is operating. Comparing the data over time will time.
help to determine normal readings for each gauge.
Comparing data over time will also help detect • Observe the air cleaner service indicator frequently.
abnormal operating developments. Signi¿cant Keep the air cleaner elements clean.
changes in the readings should be investigated.
• Maintain the electrical systems.
One damaged battery cell will overwork the alternator.
This will consume excess power and excess fuel.
• Ensure that the drive belts are correctly adjusted.

The drive 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.
28 SEBU8325-01
Operation Section
Engine Stopping
Engine Stopping i02678906
After Stopping Engine

i02677379
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 • Check the crankcase oil level. Maintain the oil level
working under load can result in overheating and ac- between the “MIN” mark and the “MAX” mark on
celerated wear of the engine components. the oil level dipstick.
If the engine has been operating at high rpm and/or • If necessary, perform minor adjustments. Repair
high loads, run at low idle for at least three minutes any leaks and tighten any loose bolts.
to reduce and stabilize internal engine temperature
before stopping the engine. • Note the required service interval. Perform
the maintenance that is in the Operation and
Avoiding hot engine shutdowns will maximize tur- Maintenance Manual, “Maintenance Interval
bocharger shaft and bearing life. Schedule”.
• Fill the fuel tank in order to help prevent

Prior to stopping an engine that is being operated accumulation of moisture in the fuel. Do not over¿ll
at low loads, operate the engine at low idle for 30 the fuel tank.
seconds before stopping. If the engine has been
operating at highway speeds and/or at high loads, NOTICE
operate the engine at low idle for at least three Only use antifreeze/coolant mixtures recommended in
minutes. This procedure will cause the internal the Re¿ll Capacities and Recommendations topic that
engine temperature to be reduced and stabilized. is in this Operation and Maintenance Manual. Failure
to do so can cause engine damage.
Ensure that the engine stopping procedure is
understood. Stop the engine according to the shutoff
system on the engine or refer to the instructions that • Allow the engine to cool. Check the coolant level.
are provided by the OEM.
• If freezing temperatures are expected, check the
• To stop the engine, turn the key to the OFF position. coolant for the correct antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
i01903586 the correct coolant/water mixture, if necessary.
Emergency Stopping • Perform all required periodic maintenance on all
driven equipment. This maintenance is outlined in
the instructions from the OEM.
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.
SEBU8325-01 29
Operation Section
Cold Weather Operation
Cold Weather Operation • Install the correct speci¿cation of engine lubricant

before the beginning of cold weather.
i02680008 • 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 • Keep all batteries fully charged and warm.
cold weather. During cold weather, the starting and
the operation of the diesel engine is dependent on • Fill the fuel tank at the end of each shift.
the following items:
• Check the air cleaners and the air intake daily.
• The type of fuel that is used Check the air intake more often when you operate
in snow.
• The viscosity of the engine oil
• Ensure that the glow plugs are in working order.
• The operation of the glow plugs Refer to Testing and Adjusting Manual, “Glow Plug
- Test”.
• Optional Cold starting aid
• Battery condition
This section will cover the following information: Personal injury or property damage can result
from alcohol or starting Àuids.
• Potential problems that are caused by cold weather Alcohol or starting Àuids are highly Àammable and
operation
toxic and if improperly stored could result in injury
or property damage.
• Suggest steps which can be taken in order to
minimize starting problems and operating problems
when the ambient air temperature is between
0° toí40 °C (32° to 40 °F).
The operation and maintenance of an engine in Do not use aerosol types of starting aids such as
freezing temperatures is complex. This is because of ether. Such use could result in an explosion and
the following conditions: personal injury.
• Weather conditions • For jump starting with cables in cold weather,

refer to the Operation and Maintenance Manual,
• Engine applications “Starting with Jump Start Cables.” for instructions.
Recommendations from your Perkins dealer or

your Perkins distributor are based on past proven Viscosity of the Engine Lubrication
practices. The information that is contained in Oil
this section provides guidelines for cold weather
operation. Correct engine oil viscosity is essential. Oil viscosity
affects the amount of torque that is needed to
Hints for Cold Weather Operation crank the engine. Refer to this Operation and
Maintenance Manual, “Fluid Recommendations” for
the recommended viscosity of oil.
• If the engine will start, operate the engine until a
minimum operating temperature of 81 °C (177.8 °F)
is achieved. Achieving operating temperature will Recommendations for the Coolant
help prevent the intake valves and exhaust valves
from sticking. Provide cooling system protection for the lowest
expected outside temperature. Refer to this Operation
• The cooling system and the lubrication system and Maintenance Manual, “Fluid Recommendations”
for the engine do not lose heat immediately upon for the recommended coolant mixture.
shutdown. This means that an engine can be shut
down for a period of time and the engine can still
have the ability to start readily.
30 SEBU8325-01
Operation Section
In cold weather, check the coolant often for the • Free operation of the valves is prevented.
correct glycol concentration in order to ensure
adequate freeze protection. • Valves become stuck.
Engine Block Heaters • Pushrods are bent.
Engine block heaters (if equipped) heat the • Other damage to valve train components can
engine jacket water that surrounds the combustion result.
chambers. This provides the following functions:
For this reason, when the engine is started,
• Startability is improved. the engine must be operated until the coolant
temperature is 71 °C (160 °F) minimum. Carbon
• Warm up time is reduced. deposits on the valve stems will be kept at a minimum
and the free operation of the valves and the valve
An electric block heater can be activated once components will be maintained.
the engine is stopped. An effective block heater
is typically a 1250/1500 W unit. Consult your In addition, the engine must be thoroughly warmed in
Perkins dealer or your Perkins distributor for more order to keep other engine parts in better condition
information. 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
Idling the Engine longer service life for the engine bearings, the piston
rings, and other parts. However, limit unnecessary
When idling after the engine is started in cold idle time to ten minutes in order to reduce wear and
weather, increase the engine rpm from 1000 to 1200 unnecessary fuel consumption.
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
The Water Temperature Regulator and
throttle. The engine should not be “raced” in order to Insulated Heater Lines
speed up the warm up process.
The engine is equipped with a water temperature
While the engine is idling, the application of a light regulator. When the engine coolant is below the
load (parasitic load) will assist in achieving the correct operating temperature jacket water circulates
minimum operating temperature. The minimum through the engine cylinder block and into the
operating temperature is 82 °C (179.6 °F). engine cylinder head. The coolant then returns to the
cylinder block via an internal passage that bypasses
the valve of the coolant temperature regulator. This
Recommendations for Coolant ensures that coolant Àows around the engine under
Warm Up cold operating conditions. The water temperature
regulator begins to open when the engine jacket
Warm up an engine that has cooled below normal water has reached the correct minimum operating
operating temperatures due to inactivity. This should temperature. As the jacket water coolant temperature
be performed before the engine is returned to full rises above the minimum operating temperature the
operation. During operation in very cold temperature water temperature regulator opens further allowing
conditions, damage to engine valve mechanisms can more coolant through the radiator to dissipate excess
result from engine operation for short intervals. This heat.
can happen if the engine is started and the engine is
stopped many times without being operated in order The progressive opening of the water temperature
to warm up completely. regulator operates the progressive closing of the
bypass passage between the cylinder block and
When the engine is operated below normal operating head. This ensures maximum coolant Àow to
temperatures, fuel and oil are not completely burned the radiator in order to achieve maximum heat
in the combustion chamber. This fuel and oil causes dissipation.
soft carbon deposits to form on the valve stems.
Generally, the deposits do not cause problems and Note: Perkins discourages the use of all air Àow
the deposits are burned off during operation at restriction devices such as radiator shutters.
normal engine operating temperatures. Restriction of the air Àow can result in the following:
high exhaust temperatures, power loss, excessive
When the engine is started and the engine is stopped fan usage, and reduction in fuel economy.
many times without being operated in order to warm
up completely, the carbon deposits become thicker.
This will cause the following problems:
SEBU8325-01 31
Operation Section
A cab heater is bene¿cial in very cold weather. The When Group 2 diesel fuels are used the following
feed from the engine and the return lines from the components provide a means of minimizing problems
cab should be insulated in order to reduce heat loss in cold weather:
to the outside air.
• Glow plugs (if equipped)
Insulating the Air Inlet and Engine
Compartment • Engine coolant heaters, which may be an OEM
option
When temperatures below í18 °C (í0 °F) will be
frequently encountered, an air cleaner inlet that • Fuel heaters, which may be an OEM option
is located in the engine compartment may be
speci¿ed. An air cleaner that is located in the engine • Fuel line insulation, which may be an OEM option
compartment may also minimize the entry of snow There are three major differences between Group
into the air cleaner. Also, heat that is rejected by the
1 fuels and Group 2 fuels. Group 1 fuels have the
engine helps to warm the intake air.
following different characteristics to Group 2 fuels.
Additional heat can be retained around the engine by
insulating the engine compartment. • A lower cloud point
• A lower pour point
i02683046
• A higher energy per unit volume of fuel
Fuel and the Effect from Cold
Weather Note: Group 3 fuels reduce the life of the engine. The
use of Group 3 fuels is not covered by the Perkins
warranty.
Group 3 fuels include Low Temperature Fuels and

Note: Only use grades of fuel that are recommended
Aviation Kerosene Fuels.
by Perkins. Refer to this Operation and Maintenance
Manual, “Fluid Recommendations”.
Special fuels include Biofuel.
The following fuels can be used in this series of
The cloud point is a temperature that allows wax
engine.
crystals to form in the fuel. These crystals can cause
the fuel ¿lters to plug.
• Group 1
The pour point is the temperature when diesel fuel
• Group 2 will thicken. The diesel fuel becomes more resistant
to Àow through fuel lines, fuel ¿lters,and fuel pumps.
• Group 3
Be aware of these facts when diesel fuel is
• Special Fuels purchased. Consider the average ambient air
temperature for the engine's application. Engines that
Perkins prefer only Group 1 and Group 2 fuels for
are fueled in one climate may not operate well if the
use in this series of engines.
engines are moved to another climate. Problems can
result due to changes in temperature.
Group 1 fuels are the preferred Group of Fuels for
general use by Perkins. Group 1 fuels maximize
Before troubleshooting for low power or for poor
engine life and engine performance. Group 1 fuels
performance in the winter, check the fuel for waxing.
are usually less available than Group 2 fuels.
Frequently, Group 1 fuels are not available in colder
Low temperature fuels may be available for engine
climates during the winter.
operation at temperatures below 0 °C (32 °F). These
fuels limit the formation of wax in the fuel at low
Note: Group 2 fuels must have a maximum wear
temperatures.
scar of 650 micrometers (HFRR to ISO 12156-1).
For more information on cold weather operation, refer
Group 2 fuels are considered acceptable for issues
to the Operation and Maintenance Manual, “Cold
of warranty. This group of fuels may reduce the life
Weather Operation and Fuel Related Components in
of the engine, the engine's maximum power, and the
Cold Weather”.
engine's fuel ef¿ciency.
32 SEBU8325-01
Operation Section
i02678858
Fuel Related Components in

Cold Weather
Fuel Tanks
Condensation can form in partially ¿lled 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 ¿lter is important.
Drain the water and sediment from any fuel storage

tank at the following intervals: weekly, service
intervals, 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
A primary fuel ¿lter is installed between the fuel
tank and the engine fuel inlet. After you change
the fuel ¿lter, 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 location of a primary fuel ¿lter is important in cold

weather operation. The primary fuel ¿lter 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, the temperature of the fuel
must not exceed 73 °C (163 °F) at the fuel transfer
pump.
For more information about fuel heaters (if equipped),

refer to the OEM information.
SEBU8325-01 33
Maintenance Section
Re¿ll Capacities
Maintenance Section i04478615
Fluid Recommendations
Re¿ll Capacities
General Lubricant Information
i02682592
Re¿ll Capacities Because of government regulations regarding the

certi¿cation of exhaust emissions from the engine,
the lubricant recommendations must be followed.
Engine Manufacturers Association (EMA)

Lubrication System
Oils
The re¿ll capacities for the engine crankcase
reÀect the approximate capacity of the crankcase The “Engine Manufacturers Association
or sump plus standard oil ¿lters. Auxiliary oil ¿lter Recommended Guideline on Diesel Engine Oil” is
systems will require additional oil. Refer to the OEM recognized by Perkins. For detailed information
speci¿cations for the capacity of the auxiliary oil ¿lter. about this guideline, see the latest edition of EMA
Refer to the Operation and Maintenance Manual, publication, “EMA DHD -1”.
“Maintenance Section” for more information on
Lubricant Speci¿cations. API Oils
Table 2 The Engine Oil Licensing and Certi¿cation System by
Engine the American Petroleum Institute (API) is recognized
Re¿ll Capacities by Perkins. For detailed information about this
system, see the latest edition of the “API publication
Compartment or System Minimum Maximum No. 1509”. Engine oils that bear the API symbol are
7 L authorized by API.
5 L (1.1658
Oil Pan(1) (1.5398
Imp gal)
Imp gal)
(1) These values are the approximate capacities for the oil pan
(aluminum) which includes the standard factory installed oil
¿lters. Engines with auxiliary oil ¿lters and alternative oil pans
will require additional oil. Refer to the OEM speci¿cations for
the capacity of the auxiliary oil ¿lter and the engine oil pan.
Cooling System
Refer to the OEM speci¿cations 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. g00546535
Illustration 17
Table 3 Typical API symbol
Engine
Re¿ll Capacities Diesel engine oils CC, CD, CD-2, and CE have
not been API authorized classi¿cations since 1
Compartment or System Liters January 1996. Table 4 summarizes the status of the
7 L (1.5398 classi¿cations.
Engine Only
Imp gal)
Table 4
External System Per OEM(1)
API Classi¿cations
(1) The External System includes a radiator or an expansion
tank with the following components: heat exchanger and Current Obsolete
piping. Refer to the OEM speci¿cations. Enter the value for the
capacity of the External System in this row. CH-4, , CI-4 CE, CC, CD
- CD-2 (1)
(1) The oil CD-2 is for a two-cycle diesel engine. Perkins does not
sell engines that utilize CD-2 oil.
34 SEBU8325-01
Maintenance Section
Re¿ll Capacities
Terminology All DHD-1 oils must complete a full test program

with the base stock and with the viscosity grade of
Certain abbreviations follow the nomenclature of the ¿nished commercial oil. The use of “API Base
“SAE J754”. Some classi¿cations follow “SAE J183” Oil Interchange Guidelines” are not appropriate for
abbreviations, and some classi¿cations follow the DHD-1 oils. This feature reduces the variation in
“EMA Recommended Guideline on Diesel Engine performance that can occur when base stocks are
Oil”. In addition to Perkins de¿nitions, there are other changed in commercial oil formulations.
de¿nitions that will be of assistance in purchasing
lubricants. Recommended oil viscosities can be found DHD-1 oils are recommended for use in extended oil
in this publication, “Fluid Recommendations/Engine change interval programs that optimize the life of the
Oil” topic (Maintenance Section). oil. These oil change interval programs are based
on oil analysis. DHD-1 oils are recommended for
conditions that demand a premium oil. Your Perkins
Engine Oil dealer or your Perkins distributor has the speci¿c
guidelines for optimizing oil change intervals.
Commercial Oils
API CH-4 – API CH-4 oils were developed in order to
The performance of commercial diesel engine meet the requirements of the new high performance
oils is based on American Petroleum Institute diesel engines. Also, the oil was designed to
(API) classi¿cations. These API classi¿cations are meet the requirements of the low emissions diesel
developed in order to provide commercial lubricants engines. API CH-4 oils are also acceptable for use
for a broad range of diesel engines that operate at in older diesel engines and in diesel engines that
various conditions. use high sulfur diesel fuel. API CH-4 oils may be
used in Perkins engines that use API CG-4 and API
Only use commercial oils that meet the following CF-4 oils. API CH-4 oils will generally exceed the
classi¿cations: performance of API CG-4 oils in the following criteria:
deposits on pistons, control of oil consumption, wear
• API CH-4 CI-4 of piston rings, valve train wear, viscosity control,
and corrosion.
In order to make the correct choice of a commercial
oil, refer to the following explanations: Three new engine tests were developed for the API
CH-4 oil. The ¿rst test speci¿cally evaluates deposits
EMA DHD-1 – The Engine Manufacturers on pistons for engines with the two-piece steel piston.
Association (EMA) has developed lubricant This test (piston deposit) also measures the control
recommendations as an alternative to the API oil of oil consumption. A second test is conducted
classi¿cation system. DHD-1 is a Recommended with moderate oil soot. The second test measures
Guideline that de¿nes a level of oil performance for the following criteria: wear of piston rings, wear of
these types of diesel engines: high speed, four stroke cylinder liners, and resistance to corrosion. A third
cycle, heavy-duty, and light duty. DHD-1 oils may new test measures the following characteristics with
be used in Perkins engines when the following oils high levels of soot in the oil: wear of the valve train,
are recommended: API CH-4, API CG-4, and API resistance of the oil in plugging the oil ¿lter, and
CF-4. DHD-1 oils are intended to provide superior control of sludge.
performance in comparison to API CG-4 and API
CF-4. In addition to the new tests, API CH-4 oils have
tougher limits for viscosity control in applications that
DHD-1 oils will meet the needs of high performance generate high soot. The oils also have improved
Perkins diesel engines that are operating in many oxidation resistance. API CH-4 oils must pass an
applications. The tests and the test limits that are additional test (piston deposit) for engines that use
used to de¿ne DHD-1 are similar to the new API aluminum pistons (single piece). Oil performance is
CH-4 classi¿cation. Therefore, these oils will also also established for engines that operate in areas
meet the requirements for diesel engines that require with high sulfur diesel fuel.
low emissions. DHD-1 oils are designed to control the
harmful effects of soot with improved wear resistance All of these improvements allow the API CH-4
and improved resistance to plugging of the oil ¿lter. oil to achieve optimum oil change intervals. API
These oils will also provide superior piston deposit CH-4 oils are recommended for use in extended oil
control for engines with either two-piece steel pistons change intervals. API CH-4 oils are recommended
or aluminum pistons. for conditions that demand a premium oil. Your
Perkins dealer or your Perkins distributor has speci¿c
guidelines for optimizing oil change intervals.
SEBU8325-01 35
Maintenance Section
Re¿ll Capacities
Some commercial oils that meet the API

classi¿cations may require reduced oil change NOTICE
intervals. To determine the oil change interval, closely Operating Direct Injection (DI) diesel engines with fuel
monitor the condition of the oil and perform a wear sulphur levels over 0.5 percent will require shortened
metal analysis. oil change intervals in order to help maintain adequate
wear protection.
NOTICE
Failure to follow these oil recommendations can cause Table 5
shortened engine service life due to deposits and/or
Percentage of Sulfur in Oil change interval
excessive wear.
the fuel
Lower than 0.5 Normal
Total Base Number (TBN) and Fuel Sulfur
0.5 to 1.0 0.75 of normal
Levels for Direct Injection (DI) Diesel
Engines Greater than 1.0 0.50 of normal
The Total Base Number (TBN) for an oil depends on

the fuel sulfur level. For direct injection engines that
Lubricant Viscosity Recommendations
use distillate fuel, the minimum TBN of the new oil for Direct Injection (DI) Diesel Engines
must be ten times the fuel sulfur level. The TBN is
de¿ned by “ASTM D2896”. The minimum TBN of the The correct SAE viscosity grade of oil is determined
oil is 5 regardless of fuel sulfur level. Illustration 18 by the minimum ambient temperature during
demonstrates the TBN. cold engine start-up, and the maximum ambient
temperature during engine operation.
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
g00799818
Illustration 18 Engine Oil Viscosity
(Y) TBN by “ASTM D2896”
(X) Percentage of fuel sulfur by weight EMA LRG-1 Ambient Temperature
(1) TBN of new oil API CH-4
(2) Change the oil when the TBN deteriorates to 50 percent of Viscosity Grade Minimum Maximum
the original TBN.
SAE 0W20 í40 °C (í40 °F) 10 °C (50 °F)
Use the following guidelines for fuel sulfur levels that SAE 0W30 í40 °C (í40 °F) 30 °C (86 °F)
exceed 1.5 percent:
SAE 0W40 í40 °C (í40 °F) 40 °C (104 °F)
• Choose an oil with the highest TBN that meets one SAE 5W30 í30 °C (í22 °F) 30 °C (86 °F)
of these classi¿cations: EMA DHD-1 and API CH-4.
SAE 5W40 í30 °C (í22 °F) 40 °C (104 °F)
• Reduce the oil change interval. Base the oil SAE 10W30 í20 °C (í4 °F) 40 °C (104 °F)
change interval on the oil analysis. Ensure that the
oil analysis includes the condition of the oil and a SAE 15W40 í10 °C (14 °F) 50 °C (122 °F)
wear metal analysis.
Synthetic Base Stock Oils
Excessive piston deposits can be produced by an oil
with a high TBN. These deposits can lead to a loss Synthetic base oils are acceptable for use in
of control of the oil consumption and to the polishing these engines if these oils meet the performance
of the cylinder bore. requirements that are speci¿ed for the engine.
36 SEBU8325-01
Maintenance Section
Re¿ll Capacities
Synthetic base oils generally perform better than First Choice – Use oil with an EMA DHD-1
conventional oils in the following two areas: Recommended Guideline. Use a CH-4 oil that has
an API license. The oil should be either SAE 0W20,
• Synthetic base oils have improved Àow at low SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40
temperatures especially in arctic conditions. lubricant viscosity grade.
• Synthetic base oils have improved oxidation Second Choice – Use an oil that has a CH-4
stability especially at high operating temperatures. additive package. Although the oil has not been
tested for the requirements of the API license, the oil
Some synthetic base oils have performance must be either SAE 0W20, SAE 0W30, SAE 0W40,
characteristics that enhance the service life of the SAE 5W30, or SAE 5W40.
oil. Perkins does not recommend the automatic
extending of the oil change intervals for any type of NOTICE
oil. Shortened engine service life could result if second
choice oils are used.
Re-re¿ned Base Stock Oils
Re-re¿ned base stock oils are acceptable for Aftermarket Oil Additives
use in Perkins engines if these oils meet the
performance requirements that are speci¿ed by Perkins does not recommend the use of aftermarket
Perkins. Re-re¿ned base stock oils can be used additives in oil. It is not necessary to use aftermarket
exclusively in ¿nished oil or in a combination with additives in order to achieve the engine's maximum
new base stock oils. The US military speci¿cations service life or rated performance. Fully formulated,
and the speci¿cations of other heavy equipment ¿nished oils consist of base oils and of commercial
manufacturers also allow the use of re-re¿ned base additive packages. These additive packages are
stock oils that meet the same criteria. blended into the base oils at precise percentages in
order to help provide ¿nished oils with performance
The process that is used to make re-re¿ned base characteristics that meet industry standards.
stock oil should adequately remove all wear metals
that are in the used oil and all the additives that There are no industry standard tests that evaluate
are in the used oil. The process that is used to the performance or the compatibility of aftermarket
make re-re¿ned base stock oil generally involves the additives in ¿nished oil. Aftermarket additives may
process of vacuum distillation and hydrotreating the not be compatible with the ¿nished oil's additive
used oil. Filtering is adequate for the production of package, which could lower the performance of the
high quality, re-re¿ned base stock oil. ¿nished oil. The aftermarket additive could fail to
mix with the ¿nished oil. This could produce sludge
in the crankcase. Perkins discourages the use of
Lubricants for Cold Weather aftermarket additives in ¿nished oils.
When an engine is started and an engine is operated
To achieve the best performance from a Perkins
in ambient temperatures below í20 °C (í4 °F), use
engine, conform to the following guidelines:
multigrade oils that are capable of Àowing in low
temperatures.
• Select the correct oil, or a commercial oil that meets
the “EMA Recommended Guideline on Diesel
These oils have lubricant viscosity grades of SAE
Engine Oil” or the recommended API classi¿cation.
0W or SAE 5W.
When an engine is started and operated in ambient • See the appropriate “Lubricant Viscosities” table in
order to ¿nd the correct oil viscosity grade for your
temperatures below í30 °C (í22 °F), use a synthetic
engine.
base stock multigrade oil with an 0W viscosity grade
or with a 5W viscosity grade. Use an oil with a pour
point that is lower than í50 °C (í58 °F). • At the speci¿ed interval, service the engine. Use
new oil and install a new oil ¿lter.
The number of acceptable lubricants is limited
in cold-weather conditions. Perkins recommends • Perform maintenance at the intervals that are
speci¿ed in the Operation and Maintenance
the following lubricants for use in cold-weather
Manual, “Maintenance Interval Schedule”.
conditions:
SEBU8325-01 37
Maintenance Section
Re¿ll Capacities
Oil analysis
NOTICE
Some engines may be equipped with an oil sampling Frequently check the speci¿c gravity of the coolant for
valve. If oil analysis is required the oil sampling valve proper freeze protection or for anti-boil protection.
is used to obtain samples of the engine oil. The oil
analysis will complement the preventive maintenance
program. Clean the cooling system for the following reasons:
The oil analysis is a diagnostic tool that is used to • Contamination of the cooling system
determine oil performance and component wear
rates. Contamination can be identi¿ed and measured • Overheating of the engine
by using the oil analysis. The oil analysis includes
the following tests: • Foaming of the coolant
• The Wear Rate Analysis monitors the wear of the NOTICE

engine's metals. The amount of wear metal and Never operate an engine without water temperature
type of wear metal that is in the oil is analyzed. The regulators in the cooling system. Water temperature
increase in the rate of engine wear metal in the regulators help to maintain the engine coolant at the
oil is as important as the quantity of engine wear proper operating temperature. Cooling system prob-
metal in the oil. lems can develop without water temperature regula-
tors.
• Tests are conducted in order to detect
contamination of the oil by water, glycol, or fuel.
Many engine failures are related to the cooling
system. The following problems are related to cooling
• The Oil Condition Analysis determines the loss of system failures: Overheating, leakage of the water
the oil's lubricating properties. An infrared analysis
is used to compare the properties of new oil to the pump, and plugged radiators or heat exchangers.
properties of the used oil sample. This analysis
allows technicians to determine the amount of These failures can be avoided with correct cooling
deterioration of the oil during use. This analysis system maintenance. Cooling system maintenance is
also allows technicians to verify the performance as important as maintenance of the fuel system and
of the oil according to the speci¿cation during the the lubrication system. Quality of the coolant is as
entire oil change interval. important as the quality of the fuel and the lubricating
oil.
i04478616 Coolant is normally composed of three elements:

Water, additives, and glycol.
Fluid Recommendations
(Coolant Information) Water
Water is used in the cooling system in order to
transfer heat.
Cooling System Speci¿cations Distilled water or deionized water is
recommended for use in engine cooling systems.
General Coolant Information
DO NOT use the following types of water in cooling
NOTICE systems: Hard water, softened water that has been
Never add coolant to an overheated engine. Engine conditioned with salt, and sea water.
damage could result. Allow the engine to cool ¿rst.
If distilled water or deionized water is not available,
use water with the properties that are listed in Table 7.
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 temper-
ature or drained completely to prevent damage.
38 SEBU8325-01
Maintenance Section
Re¿ll Capacities
Table 7 • Freezing
Acceptable Water
• Cavitation of the water pump
Property Maximum Limit
Chloride (Cl) 40 mg/L
For optimum performance, Perkins recommends a
1:1 mixture of a water/glycol solution.
Sulfate (SO4) 100 mg/L
Total Hardness 170 mg/L
Note: Use a mixture that will provide protection
against the lowest ambient temperature.
Total Solids 340 mg/L
Acidity pH of 5.5 to 9.0
Note: 100 percent pure glycol will freeze at a
temperature of í23 °C (í9 °F).
For a water analysis, consult one of the following Most conventional antifreezes use ethylene glycol.
sources: Propylene glycol may also be used. In a 1:1 mixture
with water, ethylene and propylene glycol provide
• Local water utility company similar protection against freezing and boiling. See
Tables 8 and 9.
• Agricultural agent
Table 8
• Independent laboratory Ethylene Glycol
Freeze Boil
Additives Concentration
Protection Protection
Additives help to protect the metal surfaces of 50 Percent í36 °C (í33 °F) 106 °C (223 °F)
the cooling system. A lack of coolant additives or
60 Percent í51 °C (í60 °F) 111 °C (232 °F)
insuf¿cient amounts of additives enable the following
conditions to occur:
NOTICE
• Corrosion Do not use propylene glycol in concentrations that ex-
ceed 50 percent glycol because of the reduced heat
• Formation of mineral deposits transfer capability of propylene glycol. Use ethylene
glycol in conditions that require additional protection
• Rust against boiling or freezing.
• Scale Table 9
• Foaming of the coolant Propylene Glycol

Freeze Anti-Boil
Many additives are depleted during engine operation. Concentration
Protection Protection
These additives must be replaced periodically.
50 Percent í29 °C (í20 °F) 106 °C (223 °F)
Additives must be added at the correct concentration.
Overconcentration of additives can cause the To check the concentration of glycol in the coolant,
inhibitors to drop out-of-solution. The deposits can measure the speci¿c gravity of the coolant.
enable the following problems to occur:
• Formation of gel compounds Coolant Recommendations

The following two coolants are used in Perkins diesel
• Reduction of heat transfer engines:
• Leakage of the water pump seal Preferred – Perkins Extended Life Coolant (ELC)
• Plugging of radiators, coolers, and small passages Acceptable – A commercial heavy-duty antifreeze
that meets “ASTM D4985” speci¿cations
Glycol
Glycol in the coolant helps to provide protection
against the following conditions:
• Boiling
SEBU8325-01 39
Maintenance Section
Re¿ll Capacities
• Automotive applications
NOTICE
Do not use a commercial coolant/antifreeze that on- The anti-corrosion package for ELC is different from
ly meets the ASTM D3306 speci¿cation. This type of the anti-corrosion package for other coolants. ELC
coolant/antifreeze is made for light automotive appli- is an ethylene glycol base coolant. However, ELC
cations. contains organic corrosion inhibitors and antifoam
agents with low amounts of nitrite. Perkins ELC
has been formulated with the correct amount of
Perkins recommends a 1:1 mixture of water and these additives in order to provide superior corrosion
glycol. This mixture of water and glycol will provide protection for all metals in engine cooling systems.
optimum heavy-duty performance as an antifreeze.
This ratio may be increased to 1:2 water to glycol if ELC is available in a 1:1 premixed cooling solution
extra freezing protection is required. with distilled water. The Premixed ELC provides
freeze protection to í36 °C (í33 °F). The Premixed
Note: A commercial heavy-duty antifreeze that ELC is recommended for the initial ¿ll of the cooling
meets “ASTM D4985” speci¿cations MAY require a system. The Premixed ELC is also recommended for
treatment with an SCA at the initial ¿ll. Read the label topping off the cooling system.
or the instructions that are provided by the OEM of
the product. ELC Concentrate is also available. ELC Concentrate
can be used to lower the freezing point to í51 °C
In stationary engine applications and marine engine (í60 °F) for arctic conditions.
applications that do not require anti-boil protection
or freeze protection, a mixture of SCA and water Containers of several sizes are available. Consult
is acceptable. Perkins recommends a 6 percent to your Perkins dealer or your Perkins distributor for the
8 percent concentration of SCA in those cooling part numbers.
systems. Distilled water or deionized water is
preferred. Water which has the recommended
properties may be used. ELC Cooling System Maintenance
Engines that are operating in an ambient temperature Correct additions to the Extended Life
above 43 °C (109.4 °F) must use SCA and water. Coolant
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 NOTICE
or your Perkins distributor for the correct level of Use only Perkins products for pre-mixed or concen-
protection. trated coolants.
Table 10 Mixing Extended Life Coolant with other products re-

duces the Extended Life Coolant service life. Failure to
Coolant Service Life follow the recommendations can reduce cooling sys-
Coolant Type Service Life tem components life unless appropriate corrective ac-
tion is performed.
6,000 Service Hours or
Perkins ELC
Three Years
Commercial Heavy-Duty
In order to maintain the correct balance between
3000 Service Hours or the antifreeze and the additives, you must maintain
Antifreeze that meets
Two Years the recommended concentration of Extended Life
“ASTM D4985”
Coolant (ELC). Lowering the proportion of antifreeze
Perkins POWERPART 3000 Service Hours or lowers the proportion of additive. This will lower the
SCA Two Years ability of the coolant to protect the system from pitting,
Commercial SCA and 3000 Service Hours or from cavitation, from erosion, and from deposits.
Water Two Years
NOTICE
Extended Life Coolant (ELC) Do not use a conventional coolant to top-off a cooling
system that is ¿lled with Extended Life Coolant (ELC).
Perkins provides Extended Life Coolant (ELC) for
use in the following applications: Do not use standard supplemental coolant additive
(SCA).
• Heavy-duty spark ignited gas engines When using Perkins ELC, do not use standard SCA's
or SCA ¿lters.
• Heavy-duty diesel engines
40 SEBU8325-01
Maintenance Section
Re¿ll Capacities
ELC Cooling System Cleaning

NOTICE
Note: If the cooling system is already using ELC, Incorrect or incomplete Àushing of the cooling system
cleaning agents are not required to be used at can result in damage to copper and other metal com-
the speci¿ed coolant change interval. Cleaning ponents.
agents are only required if the system has been
contaminated by the addition of some other type of To avoid damage to the cooling system, make sure to
coolant or by cooling system damage. completely Àush the cooling system with clear water.
Continue to Àush the system until all the signs of the
Clean water is the only cleaning agent that is required cleaning agent are gone.
when ELC is drained from the cooling system.
After the cooling system is drained and after the 7. Drain the cooling system into a suitable container
cooling system is re¿lled, operate the engine while and Àush the cooling system with clean water.
the cooling system ¿ller cap is removed. Operate
the engine until the coolant level reaches the normal Note: The cooling system cleaner must be thoroughly
operating temperature and until the coolant level Àushed from the cooling system. Cooling system
stabilizes. As needed, add the coolant mixture in cleaner that is left in the system will contaminate the
order to ¿ll the system to the speci¿ed level. coolant. The cleaner may also corrode the cooling
system.
Changing to Perkins ELC 8. Repeat Steps 6 and 7 until the system is
completely clean.
To change from heavy-duty antifreeze to the Perkins
ELC, perform the following steps:
9. Fill the cooling system with the Perkins Premixed
ELC.
NOTICE
Care must be taken to ensure that all Àuids are ELC Cooling System Contamination
contained during performance of inspection, main-
tenance, testing, adjusting and the repair of the
product. Be prepared to collect the Àuid with suitable NOTICE
containers before opening any compartment or dis- Mixing ELC with other products reduces the effective-
assembling any component containing Àuids. ness of the ELC and shortens the ELC service life.
Use only Perkins Products for premixed or concen-
Dispose of all Àuids according to local regulations and trate coolants. Failure to follow these recommenda-
mandates. tions can result in shortened cooling system compo-
nent life.
1. Drain the coolant into a suitable container.
ELC cooling systems can withstand contamination to
2. Dispose of the coolant according to local a maximum of ten percent of conventional heavy-duty
regulations. antifreeze or SCA. If the contamination exceeds ten
percent of the total system capacity, perform ONE of
3. Flush the system with clean water in order to the following procedures:
remove any debris.
• Drain the cooling system into a suitable container.
4. Use Perkins cleaner to clean the system. Follow Dispose of the coolant according to local
the instruction on the label. regulations. Flush the system with clean water. Fill
the system with the Perkins ELC.
5. Drain the cleaner into a suitable container. Flush
the cooling system with clean water. • Drain a portion of the cooling system into a suitable
container according to local regulations. Then, ¿ll
6. Fill the cooling system with clean water and the cooling system with premixed ELC. This should
operate the engine until the engine is warmed to lower the contamination to less than 10 percent.
49° to 66°C (120° to 150°F).
• 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.
SEBU8325-01 41
Maintenance Section
Re¿ll Capacities
Commercial Heavy-Duty Antifreeze and Table 13 is an example for using the equation that
SCA is in Table 12.
Table 13
NOTICE
Commercial Heavy-Duty Coolant which contains Example Of The Equation For Adding The SCA To
Amine as part of the corrosion protection system must The Heavy-Duty Coolant At The Initial Fill
not be used. Total Volume Multiplication Amount of SCA
of the Cooling Factor that is Required
System (V) (X)
NOTICE
Never operate an engine without water temperature 15 L (4 US gal) × 0.045 0.7 L (24 oz)
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
correct operating temperature. Cooling system prob-
Adding The SCA to The Heavy-Duty
lems can develop without water temperature regula- Coolant For Maintenance
tors.
Heavy-duty antifreeze of all types REQUIRE periodic
additions of an SCA.
Check the antifreeze (glycol concentration) in
order to ensure adequate protection against boiling Test the antifreeze periodically for the concentration
or freezing. Perkins recommends the use of a of SCA. For the interval, refer to the Operation
refractometer for checking the glycol concentration. and Maintenance Manual, “Maintenance Interval
Schedule” (Maintenance Section). Test the
Perkins engine cooling systems should be tested concentration of SCA.
at 500 hour intervals for the concentration of
Supplemental Coolant Additive (SCA). Additions of SCA are based on the results of the
test. The size of the cooling system determines the
Additions of SCA are based on the results of the test. amount of SCA that is needed.
An SCA that is liquid may be needed at 500 hour
intervals. Use the equation that is in Table 14 to determine the
amount of Perkins SCA that is required, if necessary:
Refer to Table 11 for part numbers and for quantities
of SCA. Table 14
Table 11 Equation For Adding The SCA To The Heavy-Duty

Coolant For Maintenance
Perkins Liquid SCA
V × 0.014 = X
Part Number Quantity
V is the total volume of the cooling system.
21825735 10
X is the amount of SCA that is required.
Adding the SCA to Heavy-Duty Coolant Table 15 is an example for using the equation that
at the Initial Fill is in Table 14.
Commercial heavy-duty antifreeze that meets “ASTM Table 15
D4985” speci¿cations MAY require an addition of
Example Of The Equation For Adding The SCA To
SCA at the initial ¿ll. Read the label or the instructions The Heavy-Duty Coolant For Maintenance
that are provided by the OEM of the product.
Total Volume Multiplication Amount of SCA
Use the equation that is in Table 12 to determine the of the Cooling Factor that is Required
amount of Perkins SCA that is required when the System (V) (X)
cooling system is initially ¿lled. 15 L (4 US gal) × 0.014 0.2 L (7 oz)
Table 12
Equation For Adding The SCA To The Heavy-Duty

Coolant At The Initial Fill
V × 0.045 = X
V is the total volume of the cooling system.
X is the amount of SCA that is required.
42 SEBU8325-01
Maintenance Section
Re¿ll Capacities
Cleaning the System of Heavy-Duty

Antifreeze NOTICE
These recommendations are subject to change with-
Perkins cooling system cleaners are designed out notice. Contact your local Perkins distributor for
to clean the cooling system of harmful scale the most up-to-date recommendations.
and corrosion. Perkins cooling system cleaners
dissolve mineral scale, corrosion products, light oil
contamination, and sludge. Diesel Fuel Requirements
• Clean the cooling system after used coolant is Perkins is not in a position to continuously evaluate
drained or before the cooling system is ¿lled with and monitor all worldwide distillate diesel fuel
new coolant. speci¿cations that are published by governments and
technological societies.
• Clean the cooling system whenever the coolant is
contaminated or whenever the coolant is foaming. Table 16 provides a known reliable baseline in order
to judge the expected performance of distillate diesel
fuels that are derived from conventional sources.
i04478614
Fluid Recommendations Satisfactory engine performance is dependent on

the use of a good quality fuel. The use of a good
(Fuel Recommendations) quality fuel will give the following results: long engine
life and acceptable exhaust emissions levels. The
fuel must meet the minimum requirements that are
stated in table 16.
• Glossary
NOTICE
• ISO International Standards Organization The footnotes are a key part of the Perkins Speci¿ca-
tion for Distillate Diesel Fuel Table. Read ALL of the
• ASTM American Society for Testing and Materials footnotes.
• HFRR High Frequency Reciprocating Rig for

Lubricity testing of diesel fuels
• FAME Fatty Acid Methyl Esters

• CFR Co-ordinating Fuel Research
• LSD Low Sulfur Diesel
• ULSD Ultra Low Sulfur Diesel
• RME Rape Methyl Ester
• SME Soy Methyl Ester
• EPA Environmental Protection Agency of the
United States
General Information
NOTICE
Every attempt is made to provide accurate, up-to-date
information. By use of this document you agree that
Perkins Engines Company Limited is not responsible
for errors or omissions.
SEBU8325-01 43
Maintenance Section
Re¿ll Capacities
Table 16
Perkins Speci¿cation for Distillate Diesel Fuel (1)
Property UNITS Requirements “ASTM”Test “ISO”Test

Aromatics %Volume 35% maximum D1319 “ISO”3837
Ash %Weight 0.01% maximum D482 “ISO”6245
Carbon Residue on %Weight 0.35% maximum D524 “ISO”4262
10% Bottoms
Cetane Number (2) - 40 minimum D613/D6890 “ISO”5165
Cloud Point °C The cloud point must D2500 “ISO”3015
not exceed the lowest
expected ambient
temperature.
Copper Strip - No. 3 maximum D130 “ISO”2160
Corrosion
Density at 15 °C Kg / M 3
801 minimum and 876 No equivalent test “ISO 3675 ”“ISO 12185”
(59 °F) (3) maximum
Distillation °C 10% at 282 °C D86 “ISO”3405
(539.6 °F) maximum
90% at 360 °C (680 °F)
maximum
Flash Point °C legal limit D93 “ISO”2719
Thermal Stability - Minimum of 80% D6468 No equivalent test
reÀectance after aging
for 180 minutes at
150 °C (302 °F)
Pour Point °C 6 °C (42.8 °F) minimum D97 “ISO”3016
below ambient
temperature
Sulfur (1)(4) %mass 1% maximum D5453/D26222 “ISO 20846 ”“ISO 20884”
Kinematic Viscosity (5) “MM” “/S (cSt)”
2
The viscosity of the D445 “ISO”3405
fuel that is delivered to
the fuel injection pump.
“1.4 minimum/4.5
maximum”
Water and sediment % weight 0.1% maximum D1796 “ISO”3734
Water % weight 0.1% maximum D6304 No equivalent test
Sediment % weight 0.05% maximum D473 “ISO”3735
Gums and Resins (6) mg/100mL 10 mg per 100 mL D381 “ISO”6246
maximum
(continued)
44 SEBU8325-01
Maintenance Section
Re¿ll Capacities
(Table 16, contd)

Lubricity corrected mm 0.46 maximum D6079 “ISO”12156-1
wear scar diameter at
60 °C (140 °F). (7)
(1) This speci¿cation includes the requirements for Ultra Low Sulfur Diesel (ULSD). ULSD fuel will have 15 ppm (0.0015%) sulfur. Refer to
“ASTM D5453”, “ASTM D2622”, or “ISO 20846, ISO 20884” test methods. This speci¿cation includes the requirements for Low Sulfur
Diesel (LSD). LSD fuel will have 500 ppm (0.05%) sulfur. Refer to following:“ASTM 5453, ASTM D2622”, “ISO 20846”, and “ISO 20884
test methods”.
(2) A fuel with a higher cetane number is recommended in order to operate at a higher altitude or in cold weather.
(3) “Via standards tables, the equivalent API gravity for the minimum density of 801 kg / m 3 (kilograms per cubic meter) is 45 and for the
maximum density of 876 kg / m 3 is 30”.
(4) Regional regulations, national regulations, or international regulations can require a fuel with a speci¿c sulfur limit. Consult all applicable
regulations before selecting a fuel for a given engine application. 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% may signi¿cantly shorten the oil change interval. For additional information, refer to this manual, “Fluid
recommendations (General lubricant Information)”.
(5) The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum
viscosity requirement and the fuel should meet the maximum viscosity requirements at 40 °C (104 °F) of either the “ASTM D445” test
method or the “ISO 3104” test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain 1.4 cSt or
greater viscosity at the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to lower the viscosity to 4.5
cSt at the fuel injection pump.
(6) Follow the test conditions and procedures for gasoline (motor).
(7) The lubricity of a fuel is a concern with low sulfur and ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1
or ASTM D6079 High Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum requirements,
consult your fuel supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives
can cause problems in the fuel system.
Cetane numbers in excess of 45 are normally

NOTICE expected from current diesel fuel. However, a cetane
Operating with fuels that do not meet the Perkins rec- number of 40 may be experienced in some territories.
ommendations can cause the following effects: Start- The United States of America is one of the territories
ing dif¿culty, poor combustion, deposits in the fuel in- that can have a low cetane value. A minimum cetane
jectors, reduced service life of the fuel system, de- value of 40 is required during average starting
posits in the combustion chamber, and reduced ser- conditions. A higher cetane value may be required
vice life of the engine. for operations at high altitudes or in cold-weather
operations.
Engines that are manufactured by Perkins are certi¿ed
with the fuel that is prescribed by the United States En- Fuel with a low cetane number can be the root cause
vironmental Protection Agency. Engines that are man- of problems during cold start.
ufactured by Perkins are certi¿ed with the fuel that
is prescribed by the European Certi¿cation and oth- Viscosity
er regulatory agencies. Perkins does not certify diesel
engines on any other fuel. Viscosity is the property of a liquid of offering
resistance to shear or Àow. Viscosity decreases with
increasing temperature. This decrease in viscosity
Note: The owner and the operator of the engine has
follows a logarithmic relationship for normal fossil
the responsibility of using the fuel that is prescribed
fuel. The common reference is to kinematic viscosity.
by the Environmental Protection Agency (EPA) and
This is the quotient of the dynamic viscosity that is
other appropriate regulatory agencies.
divided by the density. The determination of kinematic
viscosity is normally by readings from gravity Àow
Diesel Fuel Characteristics viscometers at standard temperatures. Refer to “ISO
3104” for the test method.
Perkins Recommendations
The viscosity of the fuel is signi¿cant because fuel
Cetane Number serves as a lubricant for the fuel system components.
Fuel must have suf¿cient viscosity in order to
Fuel that has a high cetane number will give a shorter lubricate the fuel system in both cold temperatures
ignition delay. This will produce a better ignition and hot temperatures. If the kinematic viscosity of the
quality. Cetane numbers are derived for fuels against fuel is lower than 1.4 cSt at the fuel injection pump
proportions of cetane and heptamethylnonane in the damage to the fuel injection pump can occur. This
standard CFR engine. Refer to “ISO 5165” for the damage can be excessive scuf¿ng and seizure. Low
test method. viscosity may lead to dif¿cult hot restarting, stalling,
and loss of performance. High viscosity may result in
seizure of the pump.
SEBU8325-01 45
Maintenance Section
Re¿ll Capacities
Perkins recommends kinematic viscosities of 1.4 and The lubricity has particular signi¿cance to the current
4.5 cSt that is delivered to the fuel injection pump. low viscosity fuel, low sulfur fuel, and low aromatic
If a fuel with a low viscosity is used, cooling of the fossil fuel. These fuels are made in order to meet
fuel may be required to maintain 1.4 cSt or greater stringent exhaust emissions.
viscosity at the fuel injection pump. Fuels with a high
viscosity might require fuel heaters in order to lower The lubricity of these fuels must not exceed wear scar
the viscosity to 4.5 cSt at the fuel injection pump. diameter of 0.46 mm (0.01811 inch). The fuel lubricity
test must be performed on an HFRR, operated at
Density 60 °C (140 °F). Refer to “ISO 12156-1 ”.
Density is the mass of the fuel per unit volume NOTICE

at a speci¿c temperature. This parameter has a The fuels system has been quali¿ed with fuel hav-
direct inÀuence on engine performance and a direct ing lubricity up to 0.46 mm (0.01811 inch) wear scar
inÀuence on emissions. This determines the heat diameter as tested by “ISO 12156-1 ”. Fuel with higher
output from a given injected volume of fuel. This is wear scar diameter than 0.46 mm (0.01811 inch) will
quoted in the following kg/m3 at 15 °C (59 °F). lead to reduced service life and premature failure of
the fuel system.
Perkins recommends a value of density of 841 kg/m3
in order to obtain the correct power output. Lighter
fuels are acceptable but these fuels will not produce In case of the fuels which do not meet speci¿ed
the rated power. lubricity requirement appropriate lubricity additive can
be used to enhance the lubricity of the fuel.
Sulfur Contact your fuel supplier for those circumstances
when fuel additives are required. Your fuel supplier
The level of sulfur is governed by emissions
can make recommendations for additives to use and
legislations. Regional regulation, national regulations,
for the proper level of treatment.
or international regulations can require a fuel with
a speci¿c sulfur limit. The sulfur content of the fuel
and the fuel quality must comply with all existing local Distillation
regulations for emissions.
This is an indication of the mixture of different
In some parts of the world and for some applications, hydrocarbons in the fuel. A high ratio of light weight
high sulfur fuels above 0.5% by mass might only be hydrocarbons can affect the characteristics of
available. Fuel with a high sulfur content can cause combustion.
engine wear. High sulfur fuel will have a negative
impact on emissions of particulates. High sulfur Classi¿cation of the Fuels
fuel can be used if the local emissions legislation
will allow the use. High sulfur fuel can be used in Diesel engines have the ability to burn wide variety
countries that do not regulate emissions. of fuels. Below is a list of typically encountered
fuel speci¿cations that have been assessed as to
When only high sulfur fuels are available, it will be their acceptability and are divided into following
necessary that high alkaline lubricating oil is used in categories:
the engine or that the lubricating oil change interval
is reduced. Refer to Operation and Maintenance Group 1: Preferred Fuels
Manual, “Fluid Recommendations (Lubricant
Information)” for information on sulfur in fuel. The following fuel speci¿cations are considered
acceptable.
Lubricity
Fuels meeting the requirements that are listed in the
This is the capability of the fuel to prevent pump table 16.
wear. The lubricity of the Àuid describes the ability of
the Àuid to reduce the friction between surfaces that “EN590 - Grades A to F and class 0 to 4”
are under load. This ability reduces the damage that
is caused by friction. Fuel injection systems rely on “ASTM D975 Grade No. 1-D and 2-D”
the lubricating properties of the fuel. Until fuel sulfur
limits were mandated, the lubricity of the fuel was “JIS K2204 Grades 1, 2 & 3 & Special Grade 3”
believed to be a function of fuel viscosity. acceptable provided lubricity ware scar diameter
does not exceed of 0.46 mm (0.01811 inch) as per
“ISO 12156-1”.
“BS2869 - Class A2 Off Highway Gas Oil, Red Diesel”

46 SEBU8325-01
Maintenance Section
Re¿ll Capacities
Note: The lubricity of these fuels must not exceed Biodiesel Fuel
wear scar diameter of 0.46 mm (0.01811 inch) as per
“ISO 12156-1”. Refer to “Lubricity”. Biodiesel is a fuel that can be de¿ned as mono-alkyl
esters of fatty acids. Biodiesel is a fuel that can be
Group 2: Aviation Kerosene Fuels made from various feedstock. The most commonly
available biodiesel in Europe is Rape Methyl Ester
Following kerosene and jet fuel speci¿cations are (REM). This biodiesel is derived from rapeseed
acceptable alternative fuels and may be used on a oil. Soy Methyl Ester (SME) is the most common
contingency bases for emergency or continuous use, biodiesel in the United States. This biodiesel is
where standard diesel fuel is not available and where derived from soybean oil. Soybean oil or rapeseed oil
legislation allows their use: are the primary feedstocks. These fuels are together
known as Fatty Acid Methyl Esters (FAME).
“MIL-DTL-83133 NATO F34 (JP-8)”
Raw pressed vegetable oils are NOT acceptable for
“MIL-DTL-83133 NATO F35” use as a fuel in any concentration in compression
engines. Without esteri¿cation, these oils gel in the
“MIL-DTL-5624 NATO F44 (JP-5)” crankcase and the fuel tank. These fuels may not be
compatible with many of the elastomers that are used
“MIL-DTL-38219 (USAF) (JP7)” in engines that are manufactured today. In original
forms, these oils are not suitable for use as a fuel
“NATO XF63” in compression engines. Alternate base stocks for
biodiesel may include animal tallow, waste cooking
“ASTM D1655 JET A” oils, or various other feedstocks. In order to use any
of the products that are listed as fuel, the oil must
“ASTM D1655 JET A1” be esteri¿ed.
NOTICE Fuel made of 100 percent FAME is generally referred

These fuels are only acceptable when used with ap- to as B100 biodiesel or neat biodiesel.
propriate lubricity additive and must meet minimum
requirements that are listed in table 16. The lubricity Biodiesel can be blended with distillate diesel fuel.
of these fuels must not exceed wear scar diameter of The blends can be used as fuel. The most commonly
0.46 mm (0.01811 inch) as per “ISO 12156-1”. Refer available biodiesel blends are B5, which is 5 percent
to “Lubricity”. biodiesel and 95 percent distillate diesel fuel. B20,
which is 20 percent biodiesel and 80 percent distillate
diesel fuel.
Note: Minimum cetane number of 40 is recommended
otherwise cold starting problems or light load mis¿re Note: The percentages given are volume-based.
might occur. Since jet fuel speci¿cations do not The U.S. distillate diesel fuel speci¿cation “ASTM
mention cetane requirements, Perkins recommends D975-09a” includes up to B5 (5 percent) biodiesel.
that a fuel sample is taken to determine the cetane
number. European distillate diesel fuel speci¿cation
“EN590:2010” includes up B7 (7 percent) biodiesel.
Note: Fuels must have minimum viscosity of 1.4
cSt delivered to the fuel injection pump. Cooling Note: Engines that are manufactured by Perkins
of the fuel may be required to maintain 1.4 cSt or are certi¿ed by use of the prescribed Environmental
greater viscosity at the fuel injection pump. Perkins Protection Agency (EPA) and European Certi¿cation
recommends that the actual viscosity of the fuel be fuels. Perkins does not certify engines on any other
measured in order to determine if a fuel cooler is fuel. The user of the engine has the responsibility
needed. Refer to “Viscosity”. of using the correct fuel that is recommended by
the manufacturer and allowed by the EPA and other
Note: Rated power loss of up to 10 percent is appropriate regulatory agencies.
possible due to lower density and lower viscosity of
jet fuels compared to diesel fuels. Speci¿cation Requirements
The neat biodiesel must conform to “EN14214”

or “ASTM D6751” (in the USA) and can only be
blended in mixture of up to 20 percent by volume in
acceptable mineral diesel fuel meeting requirements
that are listed in table 16 or the latest edition of
“EN590” and “ASTM D 975” commercial standards.
This blend is commonly known as B20.
SEBU8325-01 47
Maintenance Section
Re¿ll Capacities
Biodiesel blends are denoted as “BXX” with “XX” Performance Related Issues with B20
representing the content of neat biodiesel contained
in the blend with mineral diesel fuel (for example B5, Due to the lower energy content than the standard
B10, B20). distillate fuel B20 will cause a power loss in order
of 2 to 4 percent. In addition, over time the power
In United States Biodiesel blends of B6 to B20 must may deteriorate further due to deposits in the fuel
meet the requirements listed in the latest edition of injectors.
“ASTM D7467” (B6 to B20) and must be of an API
gravity of 30-45. Biodiesel and biodiesel blends are known to cause
an increase in fuel system deposits, most signi¿cant
In North America biodiesel and biodiesel blends of which are deposits within the fuel injector. These
must be purchased from the BQ-9000 accredited deposits can cause a loss in power due to restricted
producers and BQ-9000 certi¿ed distributors. or modi¿ed fuel injection or cause other functional
issues associated with these deposits.
In other areas of the world, the use of biodiesel
that is BQ-9000 accredited and certi¿ed, or that is Note: Perkins T400012 Fuel Cleaner is most
accredited and certi¿ed by a comparable biodiesel effective in cleaning and preventing the formation
quality body to meet similar biodiesel quality of deposits. Perkins Diesel Fuel Conditioner helps
standards is required. to limit deposit issues by improving the stability of
biodiesel and biodiesel blends. Refer to “Perkins
Engine Service Requirements with B20 Diesel Fuel System Cleaner” for more information.
Aggressive properties of biodiesel fuel may cause General Requirements

debris in the fuel tank and fuel lines. The aggressive
properties of biodiesel will clean the fuel tank Biodiesel has poor oxidation stability, which can result
and fuel lines. This cleaning of the fuel system in long-term problems in the storage of biodiesel.
can prematurely block of the fuel ¿lters. Perkins Biodiesel fuel should be used within 6 months of
recommends that after the initial usage of B20 manufacture. Equipment should not be stored with
biodiesel blended fuel the fuel ¿lters must be replaced the B20 biodiesel blends in the fuel system for longer
at 50 hours. than 3 months.
Glycerides present in biodiesel fuel will also cause Due to poor oxidation stability and other potential
fuel ¿lters to become blocked more quickly. Therefore issues, it is strongly recommended that engines with
the regular service interval should be reduced to 250 limited operational time either not use B20 biodiesel
hours. blends or, while accepting some risk, limit biodiesel
blend to a maximum of B5. Examples of applications
When biodiesel fuel is used, crank case oil and that should limit the use of biodiesel are the following:
aftertreatment systems may be inÀuenced. This Standby generator sets and certain emergency
inÀuence is due to the chemical composition and vehicles.
characteristics of biodiesel fuel, such as density and
volatility, and to chemical contaminants that can be Perkins strongly recommends that seasonally
present in this fuel, such as alkali and alkaline metals operated engines have the fuel systems, including
(sodium, potassium, calcium, and magnesium). fuel tanks, Àashed with conventional diesel fuel
before prolonged shutdown periods. An example of
• Crankcase oil fuel dilution can be higher when an application that should seasonally Àush the fuel
biodiesel or biodiesel blends are used. This system is a combine harvester.
increased level of fuel dilution when using biodiesel
or biodiesel blends is related to the typically Microbial contamination and growth can cause
lower volatility of biodiesel. In-cylinder emissions corrosion in the fuel system and premature plugging
control strategies utilized in many of the industrial of the fuel ¿lter. Consult your supplier of fuel for
latest engine designs may lead to a higher level assistance in selecting appropriate antimicrobial
of biodiesel concentration in the engine oil pan. additive.
The long-term effect of biodiesel concentration in
crankcase oil is currently unknown. Water accelerates microbial contamination and
growth. When biodiesel is compared to distillate
• Perkins recommends the use of oil analysis in order fuels, water is naturally more likely to exist in the
to check the quality of the engine oil if biodiesel biodiesel. It is therefore essential to check frequently
fuel is used. Ensure that the level of biodiesel in and if necessary, drain the water separator.
the fuel is noted when the oil sample is taken.
48 SEBU8325-01
Maintenance Section
Re¿ll Capacities
Materials such as brass, bronze, copper, led, tin, and Aftermarket Fuel Additives
zinc accelerate the oxidation process of the biodiesel
fuel. The oxidation process can cause deposits NOTICE
formation therefore these materials must not be used Perkins does not warrant the quality or performance
for fuel tanks and fuel lines. of non Perkins Àuids and ¿lters.
Fuel for Cold Weather Operation When auxiliary devices, accessories, or consumables
(¿lters, additives) which are made by other manufac-
The European standard “EN590” contains climate turers are used on Perkins products, the Perkins war-
dependant requirements and a range of options. The ranty is not affected simply because of such use.
options can be applied differently in each country.
There are ¿ve classes that are given to arctic climates However, failures that result from the installation
and severe winter climates. 0, 1, 2, 3, and 4. or use of other manufacturers devices, acces-
sories, or consumables are NOT Perkins defects.
Fuel that complies with “EN590 ” CLASS 4 can be Therefore, the defects are NOT covered under the
used at temperatures as low as í44 °C (í47.2 °F). Perkins warranty.
Refer to “EN590” for a detailed discretion of the
physical properties of the fuel.
Supplemental diesel fuel additives are not
The diesel fuel “ASTM D975 1-D” that is used in recommended. This is due to potential damage to
the United States of America may be used in cold the fuel system or the engine. Your fuel supplier
temperatures that are below í18 °C (í0.4 °F). or the fuel manufacturer will add the appropriate
supplemental diesel fuel additives.
In extreme cold ambient conditions, you may use
the aviation kerosene fuels that are speci¿ed in Perkins recognizes the fact that additives may
“Classi¿cation of the Fuels”. These fuels are intended be required in some special circumstances. Fuel
to be used in temperatures that can be as low as additives need to be used with caution. Contact
í54 °C (í65.2 °F). Refer to “Classi¿cation of the your fuel supplier for those circumstances when
Fuels” for detail and conditions of use of the aviation fuel additives are required. Your fuel supplier can
kerosene fuels. recommend the appropriate fuel additive and the
correct level of treatment.
Note: For the best results, your fuel supplier should

treat the fuel when additives are required. The treated
Mixing alcohol or gasoline with diesel fuel can pro- fuel must meet the requirements that are stated in
duce an explosive mixture in the engine crankcase table 16.
or the fuel tank. Alcohol or gasoline must not be
used in order to dilute diesel fuel. Failure to follow Perkins Diesel Fuel System Cleaner
this instruction may result in death or personal in-
jury. Perkins T400012 Fuel Cleaner is the only fuel cleaner
that is recommended by Perkins.
There are many other diesel fuel speci¿cations that
are published by governments and by technological If biodiesel or biodiesel blends of fuel are to be
societies. Usually, those speci¿cations do not review used, Perkins require the use of Perkins fuel cleaner.
all the requirements that are addressed in table 16. For more information on the use of biodiesel and
To ensure optimum engine performance, a complete biodiesel blends refer to “Biodiesel Fuel”.
fuel analysis should be obtained before engine
operation. The fuel analysis should include all of the Perkins fuel cleaner will remove deposits that can
properties that are stated in the table 16. form in the fuel system with the use of biodiesel and
biodiesel blends. These deposits can create a loss
of power and engine performance.
Once the fuel cleaner has been added to the fuel,

the deposits within the fuel system are removed
after 30 hours of engine operation. For maximum
results, continue to use the fuel cleaner for up to
80 hours. Perkins fuel cleaner can be used on an
on-going basis with no adverse impact on engine or
fuel system durability.
SEBU8325-01 49
Maintenance Section
Re¿ll Capacities
Detailed instructions on the rate of which the fuel

cleaner must be use are on the container.
50 SEBU8325-01
Maintenance Section
Maintenance Interval Schedule
i04431375 Turbocharger - Inspect .......................................... 75

Water Pump - Inspect ........................................... 78
Maintenance Interval Schedule
Every 3000 Service Hours
Alternator Belt - Inspect/Adjust/Replace ............... 52
When Required Fuel Injector - Test/Change ................................... 67
Battery - Replace .................................................. 52 Every 3000 Service Hours or 2 Years
Battery or Battery Cable - Disconnect .................. 53
Engine - Clean ...................................................... 59 Cooling System Coolant (Commercial Heavy-Duty) -
Engine Air Cleaner Element (Dual Element) - Change ............................................................... 54
Clean/Replace .................................................... 60
Engine Air Cleaner Element (Single Element) - Every 4000 Service Hours
Inspect/Replace .................................................. 62
Fuel System - Prime ............................................. 68 Aftercooler Core - Clean/Test ............................... 51
Severe Service Application - Check ..................... 74
Every 12 000 Service Hours or 6 Years
Daily
Cooling System Coolant (ELC) - Change ............. 55
Cooling System Coolant Level - Check ................ 57
Driven Equipment - Check .................................... 59
Engine Air Cleaner Service Indicator - Inspect ..... 62
Engine Air Precleaner - Check/Clean ................... 63
Engine Oil Level - Check ...................................... 64
Fuel System Primary Filter/Water Separator -
Drain ................................................................... 69
V-Belts - Inspect/Adjust/Replace .......................... 76
Walk-Around Inspection ........................................ 77
Every 50 Service Hours or Weekly

Fuel Tank Water and Sediment - Drain ................. 72

V-Belts - Inspect/Adjust/Replace .......................... 76
Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check .......................... 53
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 58
Crankcase Breather (Canister) - Replace ............. 59
Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................... 60
Engine Oil and Filter - Change ............................. 64
Fuel System Primary Filter (Water Separator)
Element - Replace .............................................. 68
Fuel System Secondary Filter - Replace .............. 70
Hoses and Clamps - Inspect/Replace .................. 73
Radiator - Clean .................................................... 74

Engine Valve Lash - Inspect/Adjust ...................... 66

Aftercooler Core - Inspect ..................................... 51
Alternator - Inspect ............................................... 52
Engine Mounts - Inspect ....................................... 63
Starting Motor - Inspect ........................................ 75
SEBU8325-01 51
Maintenance Section
Aftercooler Core - Clean/Test
i02690449
Aftercooler Core - Clean/Test

Personal injury can result from air pressure.
Personal injury can result without following prop-

1. Remove the core. Refer to the OEM information er procedure. When using pressure air, wear a pro-
for the correct procedure. tective face shield and protective clothing.
2. Turn the aftercooler core upside-down in order to Maximum air pressure at the nozzle must be less
remove debris. than 205 kPa (30 psi) for cleaning purposes.
8. Dry the core with compressed air. Direct the air in

the reverse direction of the normal Àow.
9. Inspect the core in order to ensure cleanliness.
Personal injury can result without following prop- Pressure test the core. If necessary, repair the
er procedure. When using pressure air, wear a pro- core.
tective face shield and protective clothing.
10. Install the core. Refer to the OEM information for
Maximum air pressure at the nozzle must be less the correct procedure.
than 205 kPa (30 psi) for cleaning purposes.
11. After cleaning, start the engine and accelerate
the engine to high idle rpm. This will help in the
3. Pressurized air is the preferred method for removal of debris and drying of the core. Stop the
removing loose debris. Direct the air in the engine. Use a light bulb behind the core in order
opposite direction of the fan's air Àow. Hold the to inspect the core for cleanliness. Repeat the
nozzle approximately 6 mm (.25 inch) away from cleaning, if necessary.
the ¿ns. Slowly move the air nozzle in a direction
that is parallel with the tubes. This will remove
debris that is between the tubes. i02690450
4. Pressurized water may also be used for cleaning. Aftercooler Core - Inspect
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. Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
NOTICE
Inspect the aftercooler for these items: damaged ¿ns,
Do not use a high concentration of caustic cleaner to
corrosion, dirt, grease, insects, leaves, oil, and other
clean the core. A high concentration of caustic cleaner
debris. Clean the aftercooler, if necessary.
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
For air-to-air aftercoolers, use the same methods that
cleaner.
are used for cleaning radiators.
5. Back Àush the core with a suitable cleaner.
6. Steam clean the core in order to remove any

residue. Flush the ¿ns of the aftercooler core. Personal injury can result from air pressure.
Remove any other trapped debris.
7. Wash the core with hot, soapy water. Rinse the er procedure. When using pressure air, wear a pro-
core thoroughly with clean water. tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.
52 SEBU8325-01
Maintenance Section
Alternator - Inspect
After cleaning, start the engine and accelerate the • Check the belt of cracks, splits, glazing, grease,
engine to high idle rpm. This will help in the removal and splitting.
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.
Inspect the ¿ns for damage. Bent ¿ns may be opened

with a “comb”.
Note: If parts of the aftercooler system are repaired

or replaced, a leak test is highly recommended.
Inspect these items for good condition: Welds,

mounting brackets, air lines, connections, clamps,
and seals. Make repairs, if necessary.
i02674959
Alternator - Inspect
Perkins recommends a scheduled inspection of Illustration 19

g01251375
the alternator. Inspect the alternator for loose Typical example
connections and correct battery charging. Inspect the
ammeter (if equipped) during engine operation in
order to ensure correct battery performance and/or Adjustment
correct performance of the electrical system. Make
repairs, as required. This type of belt has an automatic belt tensioner.
Check the alternator and the battery charger for Replace

correct operation. If the batteries are correctly
charged, the ammeter reading should be very near Refer to Disassembly and Assembly manual,
zero. All batteries should be kept charged. The “Alternator Belt - Remove and Install”.
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 i02675026
engine is not run for long periods of time or if the
engine is run for short periods, the batteries may not Battery - Replace
fully charge. A battery with a low charge will freeze
more easily than a battery with a full charge.
i02690445
Alternator Belt - Batteries give off combustible gases which can

explode. A spark can cause the combustible gas-
Inspect/Adjust/Replace es to ignite. This can result in severe personal in-
(Poly V-Belt) jury or death.
Ensure proper ventilation for batteries that are in

an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
Inspection near batteries. Do not smoke when batteries are
serviced.
To maximize the engine performance, inspect the belt
(1) for wear and for cracking. Replace the belt if the
belt is worn or damaged.
• If the belt (1) has more than four cracks per

25.4000 mm (1 inch) the belt must be replaced.
SEBU8325-01 53
Maintenance Section
Battery Electrolyte Level - Check
The battery cables or the batteries should not be All lead-acid batteries contain sulfuric acid which
removed with the battery cover in place. The bat- can burn the skin and clothing. Always wear a face
tery cover should be removed before any servic- shield and protective clothing when working on or
ing is attempted. near batteries.
Removing the battery cables or the batteries with

1. Remove the ¿ller caps. Maintain the electrolyte
the cover in place may cause a battery explosion
resulting in personal injury. level to the “FULL” mark on the battery.
If the addition of water is necessary, use distilled

1. Switch the engine to the OFF position. Remove water. If distilled water is not available use clean
all electrical loads. water that is low in minerals. Do not use arti¿cially
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 3. Install the caps.
on the starting motor. Disconnect the cable from
the NEGATIVE “-” battery terminal. 4. Keep the batteries clean.
4. The POSITIVE “+” cable connects the POSITIVE Clean the battery case with one of the following
“+” battery terminal to the POSITIVE “+” terminal cleaning solutions:
on the starting motor. Disconnect the cable from
the POSITIVE “+” battery terminal. • A mixture of 0.1 kg (0.2 lb) of washing soda or
baking soda and 1 L (1 qt) of clean water
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate • A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
recycling facility. (1 qt) of clean water
5. Remove the used battery. Thoroughly rinse the battery case with clean water.
6. Install the new battery.

i02675127
Note: Before the cables are connected, ensure that

the engine start switch is OFF.
Battery or Battery Cable -
Disconnect
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
8. Connect the cable from the NEGATIVE “-” terminal

on the starting motor to the NEGATIVE “-” battery
terminal. The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
i02674900 tery cover should be removed before any servic-
ing is attempted.
Battery Electrolyte Level -
Removing the battery cables or the batteries with
Check the cover in place may cause a battery explosion
resulting in personal injury.
When the engine is not run for long periods of time or 1. Turn the start switch to the OFF position. Turn the
when the engine is run for short periods, the batteries ignition switch (if equipped) to the OFF position
may not fully recharge. Ensure a full charge in order and remove the key and all electrical loads.
to help prevent the battery from freezing. If batteries
are correctly charged, the ammeter reading should 2. Disconnect the negative battery terminal. Ensure
be very near zero, when the engine is in operation. that the cable cannot contact the terminal. When
four 12 volt batteries are involved, two negative
connection must be disconnected.
54 SEBU8325-01
Maintenance Section
Cooling System Coolant (Commercial Heavy-Duty) - Change
3. Remove the positive connection. • The fuel has entered the cooling system and the
coolant is contaminated.
4. Clean all disconnected connection and battery
terminals. Note: When the cooling system is cleaned, only
clean water is needed.
5. Use a ¿ne grade of sandpaper to clean the
terminals and the cable clamps. Clean the items Note: Inspect the water pump and the water
until the surfaces are bright or shiny. DO NOT temperature regulator after the cooling system has
remove material excessively. Excessive removal been drained. This is a good opportunity to replace
of material can cause the clamps to not ¿t the water pump, the water temperature regulator and
correctly. Coat the clamps and the terminals with the hoses, if necessary.
a suitable silicone lubricant or petroleum jelly.
6. Tape the cable connections in order to help

Drain
prevent accidental starting.
7. Proceed with necessary system repairs.

Pressurized System: Hot coolant can cause seri-
8. In order to connect the battery, connect the ous burns. To open the cooling system ¿ller cap,
positive connection before the negative connector. stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
i02675519 sure.
Cooling System Coolant
1. Stop the engine and allow the engine to cool.
(Commercial Heavy-Duty) - Loosen the cooling system ¿ller cap slowly in
Change order to relieve any pressure. Remove the cooling
system ¿ller cap.
NOTICE
Care must be taken to ensure that Àuids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the Àuid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing Àuids.
Dispose of all Àuids according to Local regulations and

mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened

component life.
Clean the cooling system and Àush the cooling

g01356026
system before the recommended maintenance Illustration 20
interval if the following conditions exist:
2. Open the drain cock or remove the drain plug (1)
• The engine overheats frequently. on the engine. Open the drain cock or remove the
drain plug on the radiator.
• Foaming is observed.
Allow the coolant to drain.
• The oil has entered the cooling system and the
SEBU8325-01 55
Maintenance Section
Cooling System Coolant (ELC) - Change
2. Fill the cooling system with Commercial

NOTICE Heavy-Duty Coolant. Add Supplemental Coolant
Dispose of used engine coolant or recycle. Various Additive to the coolant. For the correct amount,
methods have been proposed to reclaim used coolant refer to the Operation and Maintenance Manual,
for reuse in engine cooling systems. The full distillation “Fluid Recommendations” topic (Maintenance
procedure is the only method acceptable by Perkins to Section) for more information on cooling system
reclaim the coolant. speci¿cations. Do not install the cooling system
¿ller cap.
For information regarding the disposal and the 3. Start and run the engine at low idle. Increase the
recycling of used coolant, consult your Perkins dealer engine rpm to high idle. Run the engine at high
or your Perkins distributor. idle for one minute in order to purge the air from
the cavities of the engine block. Stop the engine.
Flush
4. Check the coolant level. Maintain the coolant level
1. Flush the cooling system with clean water in order within 13 mm (0.5 inch) below the bottom of the
to remove any debris. pipe for ¿lling. Maintain the coolant level in the
expansion bottle (if equipped) at the correct level.
2. Close the drain cock or install the drain plug in the
engine. Close the drain cock or install the drain 5. Clean the cooling system ¿ller cap. Inspect the
plug on the radiator. gasket that is on the cooling system ¿ller cap. If
the gasket that is on the cooling system ¿ller cap
is damaged, discard the old cooling system ¿ller
NOTICE
cap and install a new cooling system ¿ller cap. If
Do not ¿ll the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
is not damaged, use a suitable pressurizing pump
in order to pressure test the cooling system ¿ller
Cooling system air locks may result in engine damage.
cap. The correct pressure for the cooling system
¿ller cap is stamped on the face of the cooling
3. Fill the cooling system with clean water. Install the system ¿ller cap. If the cooling system ¿ller cap
cooling system ¿ller cap. does not retain the correct pressure, install a new
cooling system ¿ller cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F). 6. Start the engine. Inspect the cooling system for
leaks and for correct operating temperature.
Loosen the cooling system ¿ller cap slowly in
i02675568
order to relieve any pressure. Remove the cooling
system ¿ller cap. Open the drain cock or remove
the drain plug on the engine. Open the drain cock
Cooling System Coolant (ELC)
or remove the drain plug on the radiator. Allow - Change
the water to drain. Flush the cooling system with
clean water.
Fill NOTICE
Care must be taken to ensure that Àuids are contained
1. Close the drain cock or install the drain plug on the during performance of inspection, maintenance, test-
engine. Close the drain cock or install the drain ing, adjusting and repair of the product. Be prepared to
plug on the radiator. collect the Àuid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing Àuids.
NOTICE
Do not ¿ll the cooling system faster than 5 L Dispose of all Àuids according to Local regulations and
(1.3 US gal) per minute to avoid air locks. mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened

component life.
56 SEBU8325-01
Maintenance Section
Cooling System Coolant (ELC) - Change
Clean the cooling system and Àush 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 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 Illustration 21
g01356026
the hoses, if necessary. Typical example
Drain 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.
Pressurized System: Hot coolant can cause seri- Allow the coolant to drain.
ous burns. To open the cooling system ¿ller cap,
stop the engine and wait until the cooling system NOTICE
components are cool. Loosen the cooling system Dispose of used engine coolant or recycle. Various
pressure cap slowly in order to relieve the pres- methods have been proposed to reclaim used coolant
sure. for reuse in engine cooling systems. The full distillation
procedure is the only method acceptable by Perkins to
reclaim the coolant.
order to relieve any pressure. Remove the cooling For information regarding the disposal and the
system ¿ller cap. 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 ¿ll the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
3. Fill the cooling system with clean water. Install the

SEBU8325-01 57
Maintenance Section
Cooling System Coolant Level - Check
4. Start and run the engine at low idle until the i02675588
temperature reaches 49 to 66 °C (120 to 150 °F).
Cooling System Coolant Level
- Check
system ¿ller 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 Engines With a Coolant Recovery
the water to drain. Flush the cooling system with Tank
clean water.
Note: The cooling system may not have been
Fill provided by Perkins. The procedure that follows
is for typical cooling systems. Refer to the OEM
1. Close the drain cock or install the drain plug on the information for the correct procedures.
engine. Close the drain cock or install the drain
plug on the radiator. Check the coolant level when the engine is stopped
and cool.
NOTICE 1. Observe the coolant level in the coolant recovery
Do not ¿ll the cooling system faster than 5 L tank. Maintain the coolant level to “COLD FULL”
(1.3 US gal) per minute to avoid air locks. mark on the coolant recovery tank.
2. Fill the cooling system with Extended Life Pressurized System: Hot coolant can cause seri-
Coolant (ELC). Refer to the Operation and ous burns. To open the cooling system ¿ller cap,
Maintenance Manual, “Fluid Recommendations” stop the engine and wait until the cooling system
topic (Maintenance Section) for more information components are cool. Loosen the cooling system
on cooling system speci¿cations. Do not install the pressure cap slowly in order to relieve the pres-
cooling system ¿ller cap. sure.
3. Start and run the engine at low idle. Increase the
engine rpm to high idle. Run the engine at high 2. Loosen ¿ller cap slowly in order to relieve any
idle for one minute in order to purge the air from pressure. Remove the ¿ller cap.
the cavities of the engine block. Stop the engine.
3. Pour the correct coolant mixture into the tank.
4. Check the coolant level. Maintain the coolant level Refer to the Operation and Maintenance Manual,
within 13 mm (0.5 inch) below the bottom of the “Re¿ll Capacities and Recommendations” for
pipe for ¿lling. Maintain the coolant level in the information on the correct mixture and type of
expansion bottle (if equipped) at the correct level. coolant. Refer to the Operation and Maintenance
Manual, “Re¿ll Capacities and Recommendations”
5. Clean the cooling system ¿ller cap. Inspect the for the cooling system capacity. Do not ¿ll the
gasket that is on the cooling system ¿ller cap. If coolant recovery tank above “COLD FULL” mark.
is damaged, discard the old cooling system ¿ller
cap and install a new cooling system ¿ller cap. If
in order to pressure test the cooling system ¿ller
cap. The correct pressure for the cooling system
¿ller cap is stamped on the face of the cooling
system ¿ller cap. If the cooling system ¿ller cap
does not retain the correct pressure, install a new
6. Start the engine. Inspect the cooling system for

leaks and for correct operating temperature.
g00103639
Illustration 22
58 SEBU8325-01
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
4. Clean ¿ller cap and the receptacle. Reinstall the i02675604

¿ller cap and inspect the cooling system for leaks.
Cooling System Supplemental
Note: The coolant will expand as the coolant heats
up during normal engine operation. The additional
Coolant Additive (SCA) -
volume will be forced into the coolant recovery tank Test/Add
during engine operation. When the engine is stopped
and cool, the coolant will return to the engine.
Engines Without a Coolant

Recovery Tank Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact with
Check the coolant level when the engine is stopped the skin and the eyes. Do not drink cooling system
and cool. coolant additive.
Test for SCA Concentration

Heavy-Duty Coolant/Antifreeze and SCA
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
Use a Coolant Conditioner Test Kit in order to check

the concentration of the SCA.
g00285520
Illustration 23 Add the SCA, If Necessary
Cooling system ¿ller cap
NOTICE
Do not exceed the recommended amount of sup-
plemental coolant additive concentration. Excessive
Pressurized System: Hot coolant can cause seri- supplemental coolant additive concentration can form
ous burns. To open the cooling system ¿ller cap, deposits on the higher temperature surfaces of the
stop the engine and wait until the cooling system cooling system, reducing the engine's heat transfer
components are cool. Loosen the cooling system characteristics. Reduced heat transfer could cause
pressure cap slowly in order to relieve the pres- cracking of the cylinder head and other high temper-
sure. ature components. Excessive supplemental coolant
additive concentration could also result in radiator
tube blockage, overheating, and/or accelerated water
1. Remove the cooling system ¿ller cap slowly in
pump seal wear. Never use both liquid supplemental
order to relieve pressure.
coolant additive and the spin-on element (if equipped)
at the same time. The use of those additives together
2. Maintain the coolant level within 13 mm (0.5 inch)
could result in supplemental coolant additive concen-
of the bottom of the ¿ller pipe. If the engine is
tration exceeding the recommended maximum.
equipped with a sight glass, maintain the coolant
level to the correct level in the sight glass.
3. Clean the cooling system ¿ller cap and inspect the

gasket. If the gasket is damaged, discard the old
¿ller cap and install a new ¿ller cap. If the gasket
ous burns. To open the cooling system ¿ller cap,
stop the engine and wait until the cooling system
in order to pressure test the ¿ller cap. The correct
components are cool. Loosen the cooling system
pressure is stamped on the face of the ¿ller cap. If
pressure cap slowly in order to relieve the pres-
the ¿ller cap does not retain the correct pressure,
sure.
install a new ¿ller cap.
4. Inspect the cooling system for leaks.

SEBU8325-01 59
Maintenance Section
Crankcase Breather (Canister) - Replace
1. Slowly loosen the cooling system ¿ller cap in 3. Lubricate the O ring seal (2) on the new canister
order to relieve the pressure. Remove the cooling with clean engine lubricating oil. Install the new
system ¿ller cap. canister. Tighten the canister to 12 N·m (8 lb ft).
Do not overtighten the canister.
Note: Always discard drained Àuids according to
local regulations. 4. Remove the container. Dispose of the old canister
and any split oil in a safe place.
2. If necessary, drain some coolant from the cooling
system into a suitable container in order to allow
i02676008
space for the extra SCA.
3. Add the correct amount of SCA. Refer to the

Driven Equipment - Check
Operation and Maintenance Manual, “Re¿ll
Capacities and Recommendations” for more
information on SCA requirements. Refer to the OEM speci¿cations for more information
on the following maintenance recommendations for
4. Clean the cooling system ¿ller cap and inspect the the driven equipment:
gasket. If the gasket is damaged, discard the old
¿ller cap and install a new ¿ller cap. If the gasket
• Inspection
in order to pressure test the ¿ller cap. The correct
pressure is stamped on the face of the ¿ller cap. If
• Adjustment
the ¿ller cap does not retain the correct pressure,
install a new ¿ller cap.
• Lubrication
• Other maintenance recommendations
i02690442
Perform any maintenance for the driven equipment
Crankcase Breather (Canister) which is recommended by the OEM.
- Replace
i02683047
Engine - Clean
NOTICE
Ensure that the engine is stopped before any servicing
or repair is performed.
Note: The breather assembly is not installed on all Personal injury or death can result from high volt-
engines. age.
Moisture can create paths of electrical conductiv-

ity.
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 ¿re haz-
ard. Keep the engine clean. Remove debris and Àuid
spills whenever a signi¿cant quantity accumulates on
the engine.
g01350307
Illustration 24
Typical example NOTICE
Failure to protect some engine components from
1. Place a container under the canister (1). washing may make your engine warranty invalid.
Allow the engine to cool for one hour before washing
2. Clean the outside of the canister. Use a suitable the engine.
tool in order to remove the canister.
60 SEBU8325-01
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
Periodic cleaning of the engine is recommended. • Check the precleaner (if equipped) and the dust
Steam cleaning the engine will remove accumulated bowl daily for accumulation of dirt and debris.
oil and grease. A clean engine provides the following Remove any dirt and debris, as needed.
bene¿ts:
• Operating in dirty conditions may require more
• Easy detection of Àuid leaks frequent service of the air cleaner element.
• Maximum heat transfer characteristics • The air cleaner element should be replaced at least
one time per year. This replacement should be
• Ease of maintenance performed regardless of the number of cleanings.
Note: Caution must be used in order to prevent Replace the dirty air cleaner elements with clean air
electrical components from being damaged by cleaner elements. Before installation, the air cleaner
excessive water when the engine is cleaned. When a elements should be thoroughly checked for tears
pressure washer or steam cleaner is used to clean and/or holes in the ¿lter material. Inspect the gasket
the engine, a minimum distance of 300 mm (12 inch) or the seal of the air cleaner element for damage.
must be maintained between the components of the Maintain a supply of suitable air cleaner elements
engine and the jet nozzle of the pressure washer for replacement purposes.
or steam cleaner. Pressure washers and steam
cleaners should not be directed at any electrical Dual Element Air Cleaners
connectors or the junction of cables into the rear of
the connectors. Avoid electrical components such as The dual element air cleaner contains a primary air
the alternator and the starter. Protect the fuel injection cleaner element and a secondary air cleaner element.
pump from Àuids in order to wash the engine.
The primary air cleaner element can be used up
i02690459
to six times if the element is properly cleaned and
properly inspected. The primary air cleaner element
Engine Air Cleaner Element should be replaced at least one time per year. This
replacement should be performed regardless of the
(Dual Element) - Clean/Replace number of cleanings.
The secondary air cleaner element is not serviceable.

Refer to the OEM information for instructions in order
NOTICE to replace the secondary air cleaner element.
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air When the engine is operating in environments that
cleaner element. Do not use air cleaner elements with are dusty or dirty, air cleaner elements may require
damaged pleats, gaskets or seals. Dirt entering the more frequent replacement.
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne 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.
Servicing the Air Cleaner Elements

Note: The air ¿lter system may not have been
provided by Perkins. The procedure that follows
is for a typical air ¿lter system. Refer to the OEM
g00736431
information for the correct procedure. Illustration 25
(1) Cover
If the air cleaner element becomes plugged, the air (2) Primary air cleaner element
can split the material of the air cleaner element. (3) Secondary air cleaner element
Un¿ltered air will drastically accelerate internal (4) Air inlet
engine wear. Refer to the OEM information for the
correct air cleaner elements for your application. 1. Remove the cover. Remove the primary air
cleaner element.
SEBU8325-01 61
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
2. The secondary air cleaner element should be Visually inspect the primary air cleaner element
removed and discarded for every three cleanings before cleaning. Inspect air cleaner elements for
of the primary air cleaner element. damage to the pleats, the seals, the gaskets and
the outer cover. Discard any damaged air cleaner
Note: Refer to “Cleaning the Primary Air Cleaner element.
Elements”.
Two methods may be used in order to clean the
3. Cover the air inlet with tape in order to keep dirt primary air cleaner element:
out.
• pressurized air
4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth. • Vacuum cleaning
5. Remove the tapefrom the air inlet. Install the Pressurized Air
secondary air cleaner element. Install a primary
air cleaner element that is new or cleaned.
6. Install the air cleaner cover.

7. Reset the air cleaner service indicator.
er procedure. When using pressure air, wear a pro-
Cleaning the Primary Air Cleaner tective face shield and protective clothing.
Elements
Refer to the OEM information in order to determine than 205 kPa (30 psi) for cleaning purposes.
the number of times that the primary ¿lter element can
be cleaned. When the primary air cleaner element is Pressurized air can be used to clean primary air
cleaned, check for rips or tears in the ¿lter material. cleaner elements that have not been cleaned more
The primary air cleaner element should be replaced than three times. Use ¿ltered, dry air with a maximum
at least one time per year. This replacement should pressure of 207 kPa (30 psi). Pressurized air will not
be performed regardless of the number of cleanings. remove deposits of carbon and oil.
NOTICE
Do not tap or strike the air cleaner element.
Do not wash the primary air cleaner element.
Use low pressure (207 kPa; 30 psi maximum) pres-

surised air or vacuum cleaning to clean the primary
air cleaner element.
Take extreme care in order to avoid damage to the air

cleaner elements.
Do not use air cleaner elements that have damaged

pleats, gaskets or seals.
g00281692
Illustration 26
Refer to the OEM information in order to determine Note: When the primary air cleaner elements are
the number of times that the primary air cleaner cleaned, always begin with the clean side (inside)
element can be cleaned. Do not clean the primary in order to force dirt particles toward the dirty side
air ¿lter element more than three times. The primary (outside).
air cleaner element must be replaced at least one
time per year. Aim the air hose so that air Àows along the length of
the ¿lter. Follow the direction of the paper pleats in
Cleaning the air ¿lter element will not extend the life order to prevent damage to the pleats. Do not aim
of the air ¿lter element. the air directly at the face of the paper pleats.
Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.
62 SEBU8325-01
Maintenance Section
Engine Air Cleaner Element (Single Element) - Inspect/Replace
Vacuum Cleaning i02676010
Vacuum cleaning is a good method for removing Engine Air Cleaner

accumulated dirt from the dirty side (outside) of a
primary air cleaner element. Vacuum cleaning is
Element (Single Element) -
especially useful for cleaning primary air cleaner Inspect/Replace
elements which require daily cleaning because of a
dry, dusty environment.
Cleaning from the clean side (inside) with pressurized Refer to Operation and Maintenance Manual, “Engine
air is recommended prior to vacuum cleaning the Air Cleaner Service Indicator-Inspect”.
dirty side (outside) of a primary air cleaner element.
NOTICE
Note: Refer to “Inspecting the Primary Air Cleaner Never run the engine without an air cleaner element
Elements”. installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
Inspecting the Primary Air Cleaner damaged pleats, gaskets or seals. Dirt entering the
Elements engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne 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.
A wide variety of air cleaners may be installed for use

with this engine. Consult the OEM information for the
correct procedure to replace the air cleaner.
i02676011
Illustration 27
g00281693 Engine Air Cleaner Service
Indicator - Inspect
Inspect the clean, dry primary air cleaner element.
Use a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element. Some engines may be equipped with a different
Inspect the primary air cleaner element for tears service indicator.
and/or holes. Inspect the primary air cleaner element
for light that may show through the ¿lter material. If it Some engines are equipped with a differential gauge
is necessary in order to con¿rm the result, compare for inlet air pressure. The differential gauge for inlet
the primary air cleaner element to a new primary air air pressure displays the difference in the pressure
cleaner element that has the same part number. that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
Do not use a primary air cleaner element that has element. As the air cleaner element becomes dirty,
any tears and/or holes in the ¿lter material. Do not the pressure differential rises. If your engine is
use a primary air cleaner element with damaged equipped with a different type of service indicator,
pleats, gaskets or seals. Discard damaged primary follow the OEM recommendations in order to service
air cleaner elements. the air cleaner service indicator.
The service indicator may be mounted on the air

cleaner element or in a remote location.
SEBU8325-01 63
Maintenance Section
Engine Air Precleaner - Check/Clean
i02690451
Engine Air Precleaner -

Check/Clean
g00103777
Illustration 28
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: Illustration 29
g00287039
Typical example
• The yellow diaphragm enters the red zone. (1) Wing nut
(2) Cover
• The red piston locks in the visible position. (3) Body
Test the Service Indicator Remove wing nut (1) and cover (2). Check for an
accumulation of dirt and debris in body (3). Clean the
Service indicators are important instruments. body, if necessary.
• Check for ease of resetting. The service indicator After cleaning the precleaner, install cover (2) and
should reset in less than three pushes. wing nut (1).
• Check the movement of the yellow core when the Note: When the engine is operated in dusty
engine is accelerated to the engine rated speed. applications, more frequent cleaning is required.
The yellow core should latch approximately at the
greatest vacuum that is attained.
i02676012
If the service indicator does not reset easily, or if the Engine Mounts - Inspect
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. Note: The engine mounts may not have been
supplied by Perkins. Refer to the OEM information
The service indicator may need to be replaced for further information on the engine mounts and the
frequently in environments that are severely dusty. correct bolt torque.
Inspect the engine mounts for deterioration and for

correct bolt torque. Engine vibration can be caused
by the following conditions:
• Incorrect mounting of the engine

• Deterioration of the engine mounts
• Loose engine mounts
Any engine mount that shows deterioration should
be replaced. Refer to the OEM information for the
recommended torques.
64 SEBU8325-01
Maintenance Section
Engine Oil Level - Check
i02676018 i04478611
Engine Oil Level - Check Engine Oil and Filter - Change
Hot oil and hot components can cause personal Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to injury. Do not allow hot oil or hot components to
contact the skin. contact the skin.
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.
Illustration 30
g01165836 Drain the Engine Oil
(Y) “MIN” mark. (X) “MAX” mark.
NOTICE
Perform this maintenance with the engine stopped.
Note: Ensure that the engine is either level or that

the engine is in the normal operating position in order
to obtain a true level indication.
Note: After the engine has been switched OFF, allow

the engine oil to drain to the oil pan before checking
the oil level.
1. Maintain the oil level between the “MIN” mark (Y)

and the “MAX” mark (X) on the engine oil dipstick.
Do not ¿ll the crankcase above the “MAX” mark
(X).
NOTICE
Operating your engine when the oil level is above the
g01356033
“FULL” mark could cause your crankshaft to dip into Illustration 31
the oil. The air bubbles created from the crankshaft Oil drain plug
dipping into the oil reduces the oil's lubricating char-
acteristics and could result in the loss of power. 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:
2. Remove the oil ¿ller cap and add oil, if necessary.
Clean the oil ¿ller cap. Install the oil ¿ller cap.
• 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.
SEBU8325-01 65
Maintenance Section
Engine Oil and Filter - Change
• If the engine is not equipped with a drain valve,

remove the oil drain plug (1) in order to allow the
oil to drain. If the engine is equipped with a shallow
sump, remove the bottom oil drain plugs from both
ends of the oil pan.
After the oil has drained, the oil drain plugs should
be cleaned and installed. If necessary, renew the O
ring seal on the drain plug.
Some types of oil pans have oil drain plugs that are
on both sides of the oil pan, because of the shape of
the pan. This type of oil pan requires the engine oil to
be drained from both plugs.
Replace the Spin-on Oil Filter

NOTICE
Perkins oil ¿lters are manufactured to Perkins speci-
¿cations. Use of an oil ¿lter that is not recommended
by Perkins could result in severe damage to the en- Illustration 32
g01356034
gine bearings, crankshaft, etc., as a result of the larger
(2) Filter head
waste particles from un¿ltered oil entering the engine (3) O ring seal
lubricating system. Only use oil ¿lters recommended
by Perkins. 3. Clean the sealing surface of the oil ¿lter head (2).
Ensure that the union (4) in the oil ¿lter head is
1. Remove the oil ¿lter with a suitable tool. secure.
Note: The following actions can be carried out as 4. Apply clean engine oil to the O ring seal (3) on
part of the preventive maintenance program. the oil ¿lter.
2. Cut the oil ¿lter open with a suitable tool. Break NOTICE
apart the pleats and inspect the oil ¿lter for metal Do not ¿ll the oil ¿lters with oil before installing them.
debris. An excessive amount of metal debris in This oil would not be ¿ltered and could be contaminat-
the oil ¿lter may indicate early wear or a pending ed. Contaminated oil can cause accelerated wear to
failure. engine components.
Use a magnet to differentiate between the ferrous

metals and the nonferrous metals that are found in 5. Install the oil ¿lter. Tighten the oil ¿lter by hand
the oil ¿lter element. Ferrous metals may indicate according to the instructions that are shown on
wear on the steel and cast iron parts of the engine. the oil ¿lter. Do not overtighten the oil ¿lter.
Nonferrous metals may indicate wear on the Note: Some oil ¿lters may be installed vertically.
aluminum parts, brass parts, or bronze parts of Refer to illustration 33. Start at step (1) in order to
the engine. Parts that may be affected include remove the oil ¿lter and install the oil ¿lter.
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
Due to normal wear and friction, it is not

uncommon to ¿nd small amounts of debris in the
oil ¿lter.
66 SEBU8325-01
Maintenance Section
Engine Valve Lash - Inspect/Adjust
g01165836
Illustration 34
(Y) “MIN” mark. (X) “MAX” mark.
4. Remove the oil level gauge in order to check the

oil level. Maintain the oil level between the “MIN”
and “MAX” marks on the engine oil dipstick.
g02659217
Illustration 33
Typical example i02171102
Fill the Engine Crankcase

Engine Valve Lash -
Inspect/Adjust
1. Remove the oil ¿ller cap. Refer to the Operation
and Maintenance Manual for more information on
lubricant speci¿cations. Fill the crankcase with the
proper amount of oil. Refer to the Operation and This maintenance is recommended by Perkins as
Maintenance Manual for more information on re¿ll part of a lubrication and preventive maintenance
capacities. schedule in order to help provide maximum engine
life.
NOTICE
If equipped with an auxiliary oil ¿lter system or a re- NOTICE
mote oil ¿lter system, follow the OEM or ¿lter manu- Only quali¿ed service personel should perform this
facturer's recommendations. Under ¿lling or over¿lling maintenance. Refer to the Service Manual or your au-
the crankcase with oil can cause engine damage. thorized Perkins dealer or your Perkins distributor for
the complete valve lash adjustment procedure.
NOTICE Operation of Perkins engines with incorrect valve lash

To prevent crankshaft bearing damage, crank the en- can reduce engine ef¿ciency, and also reduce engine
gine with the fuel OFF. This will ¿ll the oil ¿lters before component life.
starting the engine. Do not crank the engine for more
than 30 seconds.
2. Start the engine and run the engine at “LOW

Ensure that the engine can not be started while
IDLE” for 2 minutes. Perform this procedure in
this maintenance is being performed. To help pre-
order to ensure that the lubrication system has
vent possible injury, do not use the starting motor
oil and that the oil ¿lters are ¿lled. Inspect the oil
to turn the Àywheel.
¿lter for oil leaks.
Hot engine components can cause burns. Allow
3. Stop the engine and allow the oil to drain back to
additional time for the engine to cool before mea-
the sump for a minimum of 10 minutes.
suring/adjusting valve lash clearance.
Ensure that the engine is stopped before measuring

the valve lash. The engine valve lash can be
inspected and adjusted when the temperature of the
engine is hot or cold.
SEBU8325-01 67
Maintenance Section
Fuel Injector - Test/Change
Refer to Systems Operation/Testing and Adjusting, The fuel injectors should not be cleaned as cleaning
“Engine Valve Lash - Inspect/Adjust” for more with incorrect tools can damage the nozzle. The fuel
information. injectors should be renewed only if a fault with the
fuel injectors occurs. Some of the problems that may
indicate that new fuel injectors are needed are listed
i02682385
below:
Fuel Injector - Test/Change
• The engine will not start or the engine is dif¿cult
to start.
• Not enough power

• The engine mis¿res or the engine runs erratically.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a ¿re. • High fuel consumption
• Black exhaust smoke
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly • The engine knocks or there is vibration in the
clean the area around a fuel system component that engine.
will be disconnected. Fit a suitable cover over discon-
nected fuel system component. • Excessive engine temperature
NOTICE Removal and Installation of the

If a fuel injector is suspected of operating outside of Fuel Injectors
normal parameters it should be removed by a quali¿ed
technician. The suspect fuel injector should be taken
to an authorised agent for inspection.
Work carefully around an engine that is running.

Engine parts that are hot, or parts that are moving,
can cause personal injury.
Make sure that you wear eye protection at all

times during testing. When fuel injection nozzles
are tested, test Àuids travel through the ori¿ces
of the nozzle tip with high pressure. Under this
amount of pressure, the test Àuid can pierce the
skin and cause serious injury to the operator.
Always keep the tip of the fuel injection nozzle
pointed away from the operator and into the fuel
collector and extension.
NOTICE
If your skin comes into contact with high pressure fuel,
obtain medical assistence immediately.
Operate the engine at a fast idle speed in order to

identify the faulty fuel injector. Individually loosen and
tighten the union nut for the high pressure pipe to
each fuel injector. Do not loosen the union nut more
than half a turn. There will be little effect on the engine
g01347499 speed when the union nut to the faulty fuel injection
Illustration 35
Typical fuel Injector nozzle is loosened. Refer to the Disassembly and
Assembly Manual for more information. Consult your
authorized Perkins dealer or your Perkins distributor
for assistance.
68 SEBU8325-01
Maintenance Section
Fuel System - Prime
i04429191
NOTICE
Fuel System - Prime Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
If air enters the fuel system, the air must be purged
from the fuel system before the engine can be 4. Cycle the throttle lever from the low idle position to
started. Air can enter the fuel system when the the high idle position three times. The cycle time
following events occur: for the throttle lever is one second to six seconds
for one complete cycle.
• The fuel tank is empty or the fuel tank has been
partially drained. Note: In order to purge air from the fuel injection
pump on engines with a ¿xed throttle, the engine
• The low-pressure fuel lines are disconnected. should be run at full load for 30 seconds. The load
should then be decreased until the engine is at high
• A leak exists in the low-pressure fuel system. idle. The process should be repeated three times.
Repeating the process three times will assist in
• The fuel ¿lter is replaced. removing trapped air from the fuel injection pump.
• A new injection pump is installed. 5. Check for leaks in the fuel system.
Use the following procedure in order to remove air

from the fuel system: i02699996
1. Turn the keyswitch to the RUN position. Leave the

Fuel System Primary Filter
keyswitch in the RUN position for 3 minutes. If (Water Separator) Element -
a manual purging screw is installed, the purging
screw should be slackened during priming the fuel
Replace
system.
Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a ¿re. To help pre-
vent possible injury, turn the start switch off when
changing fuel ¿lters 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
g01003929 nected fuel system component.
Illustration 36
Injector nuts
2. Crank the engine with the throttle lever in the

CLOSED position until the engine starts.
Note: If necessary, loosen the union nuts (1) on the

fuel injection lines at the connection with the fuel
injector until fuel is evident. Stop cranking the engine.
Tighten the union nuts (1) to a torque of 30 N·m
(22 lb ft).
3. Start the engine and run the engine at idle for 1

minute.
SEBU8325-01 69
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
9. Remove the container and dispose of the fuel

safely.
10. Open the fuel supply valve.
11. Prime the fuel system. Refer to the Operation and

Maintenance Manual, “Fuel System - Prime” for
more information.
i02699081
Fuel System Primary

Filter/Water Separator - Drain

NOTICE
g01353878 The water separator is not a ¿lter. The water separa-
Illustration 37
tor separates water from the fuel. The engine should
(1) Screw never be allowed to run with the water separator more
(2) Element
(3) Bowl
than half full. Engine damage may result.
(4) Bottom cover
(5) Drain
(6) Sensor connection NOTICE
The water separator is under suction during normal
1. Turn the fuel supply valve (if equipped) to the OFF engine operation. Ensure that the drain valve is tight-
position. ened securely to help prevent air from entering the fuel
system.
2. Place a suitable container under the water
separator. Clean the outside of the water
separator.
3. Open the drain (5). Allow the Àuid to drain into

the container.
4. Tighten the drain (5) by hand pressure only.
5. Hold the element (2) and remove the screw (1).

Remove the element and the bowl (3) from the
base. Discard the old element.
6. Clean the bowl (4). Clean the bottom cover (6).
7. Install the new O ring seal. Install the bottom cover

onto the new element. Install the assembly onto
the base.
8. Install the screw (1) and tighten the screw to a

torque of 8 N·m (6 lb ft).
70 SEBU8325-01
Maintenance Section
Fuel System Secondary Filter - Replace
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
nected fuel system component.
Element ¿lter
Turn the valves for the fuel lines (if equipped) to the
OFF position before performing this maintenance.
Place a tray under the fuel ¿lter in order to catch
any fuel that might spill. Clean up any spilled fuel
immediately.
g01353878
Illustration 38
(1) Screw
(2) Element
(3) Bowl
(4) Bottom cover
(5) Drain
(6) Sensor connection
1. Place a suitable container below the water

separator. g01353856
Illustration 39
2. Open the drain (5). Allow the Àuid to drain into (1) Filter bowl
(2) Drain
the container.
3. When clean fuel drains from the water separator 1. Close the valves for the fuel lines (if equipped).
close the drain (5). Tighten the drain by hand
pressure only. Dispose of the drained Àuid 2. Clean the outside of the fuel ¿lter assembly. Open
correctly. the fuel drain (2) and drain the fuel into a suitable
container.
i04478612
Fuel System Secondary Filter -

Replace

SEBU8325-01 71
Maintenance Section
Fuel System Secondary Filter - Replace
Spin-on ¿lter
Turn the valves for the fuel lines (if equipped) to the
OFF position before performing this maintenance.
Place a tray under the fuel ¿lter in order to catch
any fuel that might spill. Clean up any spilled fuel
immediately.
g02659218
Illustration 40
Typical example
(3) Filter head
(4) Element
(5) O ring seal
3. Remove the ¿lter bowl (1) from the ¿lter head

(3). Press on the element (4). Rotate the element
counterclockwise in order to release the element
for the ¿lter bowl and remove the element from the
bowl. Discard the used element.
4. Remove the O ring (5) from the ¿lter bowl and

clean the ¿lter bowl. Check that the threads of the
g01353858
¿lter bowl are not damaged. Illustration 41
(1) Filter Head
5. Install a new O ring seal (5) to the ¿lter bowl (1). (2) Spin-on ¿lter
(3) Drain
6. Locate a new ¿lter element (4) into the ¿lter bowl
(1). Press on the element and rotate the element 1. Clean the outside of the fuel ¿lter assembly. Open
clockwise in order to lock the element into the the fuel drain (3) and drain the fuel into a suitable
¿lter bowl. container.
7. Install the ¿lter bowl (1) into the top of the ¿lter 2. Use a suitable tool in order to remove the spin-on
head (3). ¿lter (2) from the ¿lter head (1).
8. Tighten the ¿lter bowl by hand until the ¿lter bowl 3. Ensure that the fuel drain (3) on the new spin-on
contacts the ¿lter head. Rotate the ¿lter bowl ¿lter is closed.
through 90 degrees.
Note: Do not use a tool to tighten the ¿lter bowl.
9. Open the valves for the fuel lines (if equipped).

72 SEBU8325-01
Maintenance Section
Fuel Tank Water and Sediment - Drain
Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system.
Water can be introduced into the fuel tank when the

fuel tank is being ¿lled.
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
g02659219
water and draining sediment from the bottom of the
Illustration 42 fuel tanks.
Typical example
(4) O ring seal Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
4. Lubricate the sealing ring (4) with clean fuel oil. the drain valve.
5. Install the spin-on ¿lter (2) into the top of the ¿lter Check the fuel daily. Allow ¿ve minutes after the
head (1). fuel tank has been ¿lled before draining water and
sediment from the fuel tank.
6. Tighten the spin-on ¿lter by hand until the sealing
ring contacts the ¿lter head. Rotate the spin-on Fill the fuel tank after operating the engine in
¿lter through 90 degrees. order to drive out moist air. This will help prevent
condensation. Do not ¿ll the tank to the top. The
7. Prime the fuel system. Refer to Operation and fuel expands as the fuel gets warm. The tank may
Maintenance Manual, “Fuel System - Prime”. overÀow.
Some fuel tanks use supply pipes that allow water

i02677376 and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
Fuel Tank Water and Sediment take fuel directly from the bottom of the tank. If
- Drain the engine is equipped with this system, regular
maintenance of the fuel system ¿lter is important.
Fuel Storage Tanks

NOTICE
Care must be taken to ensure that Àuids are contained Drain the water and the sediment from the fuel
during performance of inspection, maintenance, test- storage tank at the following intervals:
ing, adjusting, and repair of the product. Be prepared
to collect the Àuid with suitable containers before • Weekly
opening any compartment or disassembling any com-
ponent containing Àuids. • Service intervals
Dispose of all Àuids according to local regulations and • Re¿ll of the tank
mandates.
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank.
SEBU8325-01 73
Maintenance Section
Hoses and Clamps - Inspect/Replace
If a bulk storage tank has been re¿lled or moved Each installation application can be different. The
recently, allow adequate time for the sediment to differences depend on the following factors:
settle before ¿lling the engine fuel tank. Internal
bafÀes in the bulk storage tank will also help trap • Type of hose
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel. • Type of ¿tting material
When possible, water separators should be used.
• Anticipated expansion and contraction of the hose
i02677365
• Anticipated expansion and contraction of the
Hoses and Clamps - ¿ttings
Inspect/Replace Replace the Hoses and the Clamps

Refer to the OEM information for further information
on removing and replacing fuel hoses (if equipped).
Inspect all hoses for leaks that are caused by the
following conditions:
The coolant system and the hoses for the coolant
system are not usually supplied by Perkins. The
• Cracking following text describes a typical method of replacing
coolant hoses. Refer to the OEM information for
• Softness further information on the coolant system and the
hoses for the coolant system.
• Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
NOTICE ous burns. To open the cooling system ¿ller cap,
Do not bend or strike high pressure lines. Do not in- stop the engine and wait until the cooling system
stall bent or damaged lines, tubes or hoses. Repair components are cool. Loosen the cooling system
any loose or damaged fuel and oil lines, tubes and pressure cap slowly in order to relieve the pres-
hoses. Leaks can cause ¿res. Inspect all lines, tubes sure.
and hoses carefully. Tighten all connections to the rec-
ommended torque. 1. Stop the engine. Allow the engine to cool.
Check for the following conditions: 2. Loosen the cooling system ¿ller cap slowly in
• End ¿ttings that are damaged or leaking system ¿ller cap.
• Outer covering that is chafed or cut Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
• Exposed wire that is used for reinforcement
3. Drain the coolant from the cooling system to a
• Outer covering that is ballooning locally level that is below the hose that is being replaced.
• Flexible part of the hose that is kinked or crushed 4. Remove the hose clamps.
• Armoring that is embedded in the outer covering 5. Disconnect the old hose.
A constant torque hose clamp can be used in place 6. Replace the old hose with a new hose.
of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard 7. Install the hose clamps with a torque wrench.
clamp.
Note: For the correct coolant, see this Operation and
Due to extreme temperature changes, the hose will Maintenance Manual, “Fluid Recommendations”.
harden. Hardening of the hoses will cause hose
clamps to loosen. This can result in leaks. A constant 8. Re¿ll the cooling system. Refer to the OEM
torque hose clamp will help to prevent loose hose information for further information on re¿lling the
clamps. cooling system.
74 SEBU8325-01
Maintenance Section
Radiator - Clean
9. Clean the cooling system ¿ller cap. Inspect the After cleaning the radiator, start the engine. Allow
cooling system ¿ller cap's seals. Replace the the engine to operate at low idle speed for three to
cooling system ¿ller cap if the seals are damaged. ¿ve minutes. Accelerate the engine to high idle. This
Install the cooling system ¿ller cap. will help in the removal of debris and the drying of
the core. Slowly reduce the engine speed to low idle
10. Start the engine. Inspect the cooling system for and then stop the engine. Use a light bulb behind
leaks. the core in order to inspect the core for cleanliness.
Repeat the cleaning, if necessary.
i02335774
Inspect the ¿ns for damage. Bent ¿ns may be opened
Radiator - Clean with a “comb”. Inspect these items for good condition:
Welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.
The radiator is not usually supplied by Perkins. The i02678846

following text describes a typical cleaning procedure
for the radiator. Refer to the OEM information for Severe Service Application -
further information on cleaning the radiator.
Check
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Inspect the radiator for these items: Damaged ¿ns, Severe service is the application of an engine that
corrosion, dirt, grease, insects, leaves, oil, and other exceeds the current published standards for that
debris. Clean the radiator, if necessary. engine. Perkins maintains standards for the following
engine parameters:
• Performance such as power range, speed range,

and fuel consumption
• Fuel quality
er procedure. When using pressure air, wear a pro- • Operational Altitude
tective face shield and protective clothing.
• Maintenance intervals
than 205 kPa (30 psi) for cleaning purposes. • Oil selection and maintenance
Pressurized air is the preferred method for removing

• Coolant type and maintenance
loose debris. Direct the air in the opposite direction
to the fan's air Àow. Hold the nozzle approximately
• Environmental qualities
6 mm (0.25 inch) away from the radiator ¿ns. Slowly
move the air nozzle in a direction that is parallel with
• Installation
the radiator tube assembly. This will remove debris
that is between the tubes.
• The temperature of the Àuid in the engine
Refer to the standards for the engine or consult your
Pressurized water may also be used for cleaning. Perkins dealer or your Perkins distributor in order to
The maximum water pressure for cleaning purposes determine if the engine is operating within the de¿ned
must be less than 275 kPa (40 psi). Use pressurized parameters.
water in order to soften mud. Clean the core from
both sides. Severe service operation can accelerate component
wear. Engines that operate under severe conditions
Use a degreaser and steam for removal of oil and may need more frequent maintenance intervals in
grease. Clean both sides of the core. Wash the core order to ensure maximum reliability and retention of
with detergent and hot water. Thoroughly rinse the full service life.
core with clean water.
Due to individual applications, it is not possible
If the radiator is blocked internally, refer to the OEM to identify all of the factors which can contribute
Manual for information regarding Àushing the cooling to severe service operation. Consult your Perkins
system. dealer or your Perkins distributor for the unique
maintenance that is necessary for the engine.
SEBU8325-01 75
Maintenance Section
Starting Motor - Inspect
The operating environment, incorrect operating Check the starting motor for correct operation. Check
procedures and incorrect maintenance procedures the electrical connections and clean the electrical
can be factors which contribute to a severe service connections. Refer to the Systems Operation, Testing
application. and Adjusting Manual, “Electric Starting System -
Test” for more information on the checking procedure
and for speci¿cations or consult your Perkins dealer
Environmental Factors or your Perkins distributor for assistance.
Ambient temperatures – The engine may be
exposed to extended operation in extremely i02677378
cold environments or hot environments. Valve
components can be damaged by carbon buildup if Turbocharger - Inspect
the engine is frequently started and stopped in very
cold temperatures. Extremely hot intake air reduces
(If Equipped)
engine performance.
Quality of the air – The engine may be exposed

A regular visual inspection of the turbocharger is
to extended operation in an environment that is
recommended. Any fumes from the crankcase are
dirty or dusty, unless the equipment is cleaned
¿ltered through the air inlet system. Therefore,
regularly. Mud, dirt and dust can encase components.
by-products from oil and from combustion can collect
Maintenance can be very dif¿cult. The buildup can
in the turbocharger compressor housing. Over time,
contain corrosive chemicals.
this buildup can contribute to loss of engine power,
increased black smoke and overall loss of engine
Buildup – Compounds, elements, corrosive
ef¿ciency.
chemicals and salt can damage some components.
If the turbocharger fails during engine operation,
Altitude – Problems can arise when the engine is
damage to the turbocharger compressor wheel
operated at altitudes that are higher than the intended
and/or to the engine may occur. Damage to the
settings for that application. Necessary adjustments
turbocharger compressor wheel can cause additional
should be made.
damage to the pistons, the valves, and the cylinder
head.
Incorrect Operating Procedures
NOTICE
• Extended operation at low idle Turbocharger bearing failures can cause large quanti-
ties of oil to enter the air intake and exhaust systems.
• Frequent hot shutdowns Loss of engine lubricant can result in serious engine
damage.
• Operating at excessive loads
Minor leakage of oil into a turbocharger under extend-
• Operating at excessive speeds ed low idle operation should not cause problems as
long as a turbocharger bearing failure has not oc-
• Operating outside the intended application cured.
Incorrect Maintenance Procedures When a turbocharger bearing failure is accompanied

by a signi¿cant engine performance loss (exhaust
• Extending the maintenance intervals smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is renewed.
• Failure to use recommended fuel, lubricants and
coolant/antifreeze A visual inspection of the turbocharger can minimize
unscheduled downtime. A visual inspection of the
i02678843 turbocharger can also reduce the chance for potential
damage to other engine parts.
Starting Motor - Inspect
Removal and Installation
Note: The turbochargers that are supplied are
Perkins recommends a scheduled inspection of the
nonserviceable.
starting motor. If the starting motor fails, the engine
may not start in an emergency situation.
76 SEBU8325-01
Maintenance Section
V-Belts - Inspect/Adjust/Replace
For options regarding the removal, installation, and i02690446

replacement, consult your Perkins dealer or your
Perkins distributor. Refer to the Disassembly and V-Belts - Inspect/Adjust/
Assembly Manual, “Turbocharger - Remove and
Turbocharger - Install” for further information.
Replace
Inspecting
Inspection
NOTICE
The compressor housing for the turbocharger must
not be removed from the turbocharger for cleaning.
The actuator linkage is connected to the compressor

housing. If the actuator linkage is moved or disturbed
the engine may not comply with emmissions legisla-
tion.
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. Check for the presence of oil. If oil is leaking from

the back side of the compressor wheel, there is a
possibility of a failed turbocharger oil seal.
The presence of oil may be the result of extended

g01249073
engine operation at low idle. The presence of oil Illustration 43
may also be the result of a restriction of the line Arrangement for the V-belts
for the intake air (clogged air ¿lters), which causes
the turbocharger to slobber. To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are
3. Inspect the bore of the housing of the turbine worn or damaged.
outlet for corrosion.
For applications that require multiple drive belts,
4. Fasten the air intake pipe and the exhaust outlet replace the belts in matched sets. Replacing only
pipe to the turbocharger housing. 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 accurately check the belt tension, a suitable gauge

should be used.
SEBU8325-01 77
Maintenance Section
Walk-Around Inspection
i02678854
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

g01003936
Illustration 44 inspection of the engine compartment before starting
Typical example the engine. Look for items such as oil leaks or coolant
(1) Belt tension gauge
leaks, loose bolts, worn belts, loose connections and
trash buildup. Make repairs, as needed:
Fit the gauge (1) at the center of the longest free
length and check the tension. The correct tension for • The guards must be in the correct place. Repair
a new belt is 535 N (120 lb). If the tension of the belt is damaged guards or replace missing guards.
below 250 N (56 lb) adjust the belt to 535 N (120 lb).
• Wipe all caps and plugs before the engine is
If twin belts are installed, check the tension on both serviced in order to reduce the chance of system
belts and adjust the tension on the tightest belt. contamination.
NOTICE
Adjustment For any type of leak (coolant, lube, or fuel) clean up the
Àuid. If leaking is observed, ¿nd the source and correct
the leak. If leaking is suspected, check the Àuid levels
more often than recommended until the leak is found
or ¿xed, or until the suspicion of a leak is proved to be
unwarranted.
NOTICE
Accumulated grease and/or oil on an engine is a ¿re
hazard. Remove the accumulated grease and oil. Re-
fer to this Operation and Maintenance Manual, “En-
gine - Clean” for more information.
• Ensure that the cooling system hoses are correctly

Illustration 45
g01003939 clamped and that the cooling system hoses are
tight. Check for leaks. Check the condition of all
1. Loosen The alternator pivot bolt (2) and the bolt pipes.
(3).
• Inspect the water pump for coolant leaks.
2. Move the alternator in order to increase or
decrease the belt tension. Tighten the alternator Note: The water pump seal is lubricated by the
pivot bolt and the link bolt to 22 N·m (16 lb ft).(1). 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.
Replace
Excessive coolant leakage may indicate the need
Refer to Disassembly and Assembly manual for more to replace the water pump seal. For the removal of
information. 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.
78 SEBU8325-01
Maintenance Section
Water Pump - Inspect
• Inspect the lubrication system for leaks at the front Note: The water pump seal is lubricated by the
crankshaft seal, the rear crankshaft seal, the oil coolant in the cooling system. It is normal for a small
pan, the oil ¿lters and the rocker cover. amount of leakage to occur as the engine cools down
and parts contract.
• Inspect the fuel system for leaks. Look for loose
fuel line clamps and/or tie-wraps. Visually inspect the water pump for leaks. Renew
the water pump seal or the water pump if there
• Inspect the piping for the air intake system and the is an excessive leakage of coolant. Refer to the
elbows for cracks and for loose clamps. Ensure Disassembly and Assembly Manual, “Water Pump
that hoses and tubes are not contacting other - Remove and Install” for the disassembly and
hoses, tubes, wiring harnesses, etc. assembly procedure.
• 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.
• 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.
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
SEBU8325-01 79
Warranty Section
Warranty Information
Warranty Section
Warranty Information
i02676009
Emissions Warranty
Information
This engine may be certi¿ed 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 certi¿ed and
if your engine is subject to an Emissions Warranty.
80 SEBU8325-01
Index Section
Index
A E
After Starting Engine ............................................. 26 Electrical System .................................................... 11

After Stopping Engine............................................ 28 Grounding Practices ........................................... 11
Aftercooler Core - Clean/Test ................................ 51 Emergency Stopping ............................................. 28
Aftercooler Core - Inspect...................................... 51 Emissions Certi¿cation Film .................................. 19
Alternator - Inspect ................................................ 52 Emissions Warranty Information............................ 79
Alternator Belt - Inspect/Adjust/Replace (Poly Engine - Clean....................................................... 59
V-Belt).................................................................. 52 Engine Air Cleaner Element (Dual Element) -
Adjustment ......................................................... 52 Clean/Replace ..................................................... 60
Inspection........................................................... 52 Cleaning the Primary Air Cleaner Elements ...... 61
Replace.............................................................. 52 Servicing the Air Cleaner Elements ................... 60
Engine Air Cleaner Element (Single Element) -
Inspect/Replace ................................................... 62
B Engine Air Cleaner Service Indicator - Inspect...... 62
Test the Service Indicator................................... 63
Battery - Replace................................................... 52 Engine Air Precleaner - Check/Clean.................... 63
Battery Electrolyte Level - Check .......................... 53 Engine Description ................................................ 15
Battery or Battery Cable - Disconnect ................... 53 Engine Cooling and Lubrication ......................... 16
Before Starting Engine .................................... 10, 24 Engine Service Life ............................................ 17
Burn Prevention....................................................... 8 Engine Speci¿cations......................................... 16
Batteries............................................................... 8 Engine Identi¿cation .............................................. 18
Coolant................................................................. 8 Engine Mounts - Inspect........................................ 63
Oils....................................................................... 8 Engine Oil and Filter - Change .............................. 64
Drain the Engine Oil........................................... 64
Fill the Engine Crankcase .................................. 66
C Replace the Spin-on Oil Filter ............................ 65
Engine Oil Level - Check ....................................... 64
Cold Weather Operation........................................ 29 Engine Operation................................................... 27
Hints for Cold Weather Operation...................... 29 Engine Starting ................................................ 10, 24
Idling the Engine ................................................ 30 Engine Stopping ............................................... 11, 28
Recommendations for Coolant Warm Up .......... 30 Engine Valve Lash - Inspect/Adjust ....................... 66
Recommendations for the Coolant .................... 29
Viscosity of the Engine Lubrication Oil............... 29
Cooling System Coolant (Commercial Heavy-Duty) - F
Change ................................................................ 54
Drain .................................................................. 54 Features and Controls ........................................... 23
Fill ...................................................................... 55 Fire Prevention and Explosion Prevention .............. 8
Flush .................................................................. 55 Fire Extinguisher .................................................. 9
Cooling System Coolant (ELC) - Change.............. 55 Lines, Tubes and Hoses .................................... 10
Drain .................................................................. 56 Fluid Recommendations........................................ 33
Fill ...................................................................... 57 Engine Oil .......................................................... 34
Flush .................................................................. 56 General Lubricant Information ........................... 33
Cooling System Coolant Level - Check ................. 57 Fluid Recommendations (Coolant Information) ..... 37
Engines With a Coolant Recovery Tank............. 57 Cooling System Speci¿cations........................... 37
Engines Without a Coolant Recovery Tank........ 58 ELC Cooling System Maintenance .................... 39
Cooling System Supplemental Coolant Additive Fluid Recommendations (Fuel
(SCA) - Test/Add.................................................. 58 Recommendations).............................................. 42
Add the SCA, If Necessary ................................ 58 Diesel Fuel Characteristics ................................ 44
Test for SCA Concentration ............................... 58 Diesel Fuel Requirements.................................. 42
Crankcase Breather (Canister) - Replace ............. 59 General Information ........................................... 42
Crushing Prevention and Cutting Prevention ........ 10
Driven Equipment - Check..................................... 59

SEBU8325-01 81
Index Section
Foreword ................................................................. 4 Model View Illustrations......................................... 14

California Proposition 65 Warning ....................... 4 1104 Engine Model Views.................................. 14
Literature Information........................................... 4 Model Views .......................................................... 13
Maintenance ........................................................ 4
Maintenance Intervals.......................................... 4
Operation ............................................................. 4 O
Overhaul .............................................................. 4
Safety................................................................... 4 Operation Section.................................................. 20
Fuel and the Effect from Cold Weather ................. 31
Fuel Conservation Practices.................................. 27
Fuel Injector - Test/Change ................................... 67 P
Removal and Installation of the Fuel Injectors ... 67
Fuel Related Components in Cold Weather .......... 32 Product Identi¿cation Information .......................... 18
Fuel Filters ......................................................... 32 Product Information Section .................................. 13
Fuel Heaters ...................................................... 32 Product Lifting........................................................ 20
Fuel Tanks.......................................................... 32 Product Storage..................................................... 20
Fuel Shutoff ........................................................... 23 Condition for Storage ......................................... 20
Fuel System - Prime .............................................. 68
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................... 68 R
Fuel System Primary Filter/Water Separator -
Drain .................................................................... 69 Radiator - Clean .................................................... 74
Fuel System Secondary Filter - Replace ............... 70 Reference Numbers .............................................. 18
Element ¿lter ...................................................... 70 Record for Reference......................................... 18
Spin-on ¿lter....................................................... 71 Re¿ll Capacities..................................................... 33
Fuel Tank Water and Sediment - Drain ................. 72 Cooling System.................................................. 33
Drain the Water and the Sediment..................... 72 Lubrication System ............................................ 33
Fuel Storage Tanks ............................................ 72
Fuel Tank ........................................................... 72
S
G Safety Messages ..................................................... 5

(1) Universal Warning .......................................... 5
Gauges and Indicators .......................................... 22 (2) Ether ............................................................... 6
General Hazard Information .................................... 6 Safety Section ......................................................... 5
Containing Fluid Spillage ..................................... 7 Serial Number Plate .............................................. 18
Fluid Penetration.................................................. 7 Severe Service Application - Check ...................... 74
Pressure Air and Water........................................ 7 Environmental Factors ....................................... 75
Incorrect Maintenance Procedures .................... 75
Incorrect Operating Procedures......................... 75
H Starting Motor - Inspect ......................................... 75
Starting the Engine ................................................ 25
Hoses and Clamps - Inspect/Replace ................... 73 Starting with Jump Start Cables ............................ 25
Replace the Hoses and the Clamps .................. 73 Stopping the Engine .............................................. 28
I T
Important Safety Information ................................... 2 Table of Contents..................................................... 3

Turbocharger - Inspect (If Equipped)..................... 75
Inspecting........................................................... 76
L Removal and Installation.................................... 75
Lifting and Storage ................................................ 20

V
M V-Belts - Inspect/Adjust/Replace ........................... 76

Adjustment ......................................................... 77
Maintenance Interval Schedule ............................. 50 Inspection........................................................... 76
Maintenance Section ............................................. 33 Replace.............................................................. 77
82 SEBU8325-01
Index Section
Walk-Around Inspection ........................................ 77

Inspect the Engine for Leaks and for Loose
Connections ..................................................... 77
Warranty Information ............................................. 79
Warranty Section ................................................... 79
Water Pump - Inspect............................................ 78
Product and Dealer Information
Note: For product identi¿cation plate locations, see the section “Product Identi¿cation Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identi¿cation Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name: Branch:
Address:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
©2012 Perkins Engines Company Limited
All Rights Reserved
M-1001
Model: e28
MANUFACTURING
Section 2 - Marathon Generator Manual

M-1001
Model: e28
MANUFACTURING

Servicore GS Corp
Chapter 7 | Page 4
GENERATOR
280–430 Frame
Installation, Operation,
and Maintenance Manual
Marathon Electric Mfg. Corp.

A REGAL-BELOIT COMPANY
P.O. Box 8003
Wausau, WI 54402-8003
Phone: (715) 675 3359
Fax: (715) 675 8026
www.marathonelectric.com
CONTENTS When in doubt, ask. Questions are much easier to handle
Safety 2 than mistakes caused by a misunderstanding of the
Receiving and Storage 2 information presented in this manual.
Principles of Operation 3-4
Installation 4-6
Wiring Connections 6-9 RECEIVING AND STORAGE
Operation 9 - 10
Maintenance 11 - 12 RECEIVING AND STORAGE
Testing 12 - 13
Service 13 - 15 Upon receipt of the generator, it is recommended that it be
Troubleshooting 15 - 18 carefully examined for possible shipping damage. The
Specifications 19 generator was given to the freight carrier in good condition;
Parts List & Recommended Spare Parts 20 - 22 thus, the carrier is responsible for the product from the
factory dock to the destination. Any damage should be noted
on the freight bill before accepting the shipment. Any claims
for damage must be promptly filed with the delivering carrier.
SAFETY
PLEASE REMEMBER SAFETY FIRST. If you are not sure of UNPACKING AND HANDLING
the instructions or procedures contained herein, seek
qualified help before continuing. Carefully read all instruction tags shipped with the unit. When
lifting, attach an overhead crane to the lifting lug(s) on the
This service manual emphasizes the safety precautions generator frame. Apply lifting forces in a vertical direction.
necessary during the installation, operation, and When transporting single bearing generators, the generator’s
maintenance of your MagnaPLUS® generator. Each section of rotor must be adequately supported to prevent damage.
this manual has caution and warning messages. These
messages are for your safety, and the safety of the equipment
involved. If any of these cautions or warnings are not
readily understood, seek clarification from qualified
personnel before proceeding.
THE LIFTING LUG(S) ON THE GENERATOR ARE
Before any service work is done, disconnect all power DESIGNED TO SUPPORT THE GENERATOR ONLY.
sources and lock out all controls to prevent an unexpected DO NOT LIFT A COMPLETE GENERATOR AND
start up of the generator set driver. Proper grounding DRIVER ASSEMBLY BY MEANS OF LIFTING LUG(S)
(earthing) of the generator frame and distribution system in ON THE GENERATOR. PERSONAL INJURY OR
compliance with local and national electrical codes and EQUIPMENT DAMAGE MAY RESULT.
specific site requirements must be provided. These safety
precautions are necessary to prevent potential serious
personal injury, or even death.
STORAGE
The hazards associated with lifting or moving your
MagnaPLUS® generator are pointed out in the installation and In the event that the generator is not immediately installed on
maintenance sections. Incorrect lifting or moving can result in its prime mover, it is recommended that the unit be stored
personal injury or damage to the unit. indoors in a clean, dry area which is not subject to rapid
changes in temperature and humidity. If the generator is
Prior to start up of the unit ensure that all generator leads are stored for a long period of time, the generator should be
properly connected to the generator link board located inside tested, cleaned and dried as required before being put into
the connection box. Always assume that there will be voltage service. See the maintenance section of this manual for
present at the generator terminals whenever the generator's further information. If the unit has been stored in an area
shaft is rotating, and proceed accordingly. Residual voltage is where it has been subject to vibration, it is recommended that
present at the generator terminals and at the automatic the bearing(s) be inspected and replaced as necessary.
voltage regulator panel connections even with the regulator
fuse removed. Caution must be exercised, or serious injury or
death can result.
This manual is not intended to be a substitute for properly

trained personnel. Installation and repairs should only be
attempted by qualified, trained people. The cautions and
warnings point out known conditions and situations that are
potentially hazardous. Each installation may well create its
own set of hazards.
2
PRINCIPLES OF OPERATION
FIGURE 1 -- MagnaPLUS® Circuit Diagram
FIGURE 2 -- Typical MagnaPLUS® Layout Diagram
3
PRINCIPLE OF OPERATION generator KW in motor starting capability. For specific data
contact Marathon Electric.
MagnaPLUS® generators are brushless, self excited,
externally voltage regulated, synchronous AC generator. The
PARALLEL OPERATION
generator is made up of six major components: main stator
(armature), main rotor (field), exciter stator (field), exciter
All MagnaPlus® generators are built with 2/3 pitch main
rotor (armature), rectifier assembly, and voltage regulator. In
stator windings and full amortisseur (damper) windings.
understanding the above terminology, note the following:
These features make the MagnaPlus® generators suitable for
stators are stationary, rotors rotate, a field is a DC electrical
parallel operation when equipped with the proper voltage
input, and an armature is an AC electrical output. These
regulators and voltage regulator accessories. Consult with the
system components are electrically interconnected as shown
factory for further information relative to parallel operations.
in Figure 1 and physically located as shown in Figure 2.
The generator’s exciter consists of a stationary field and a

NONLINEAR LOADING
rotating armature. The stationary field (exciter stator) is
designed to be the primary source of the generator’s residual
Solid state electronic control devices (variable frequency
magnetism. This residual magnetism allows the exciter rotor
drives, precision motor controls, battery chargers, etc.) utilize
(armature) to produce AC voltage even when the exciter
electronic switching circuits (thyristors, SCRs, Diodes, etc.).
stator (field) is not powered. This AC voltage is rectified to DC
These switching circuits introduce high frequency harmonics
by the rotating rectifier assembly and fed directly to the main
which distort the normal wave form of the generator. This
rotor (field). As the generator shaft continues to rotate, the
creates additional heat in the generator windings and may
main rotor (field) induces a voltage into the generator's main
cause the generator to over-heat. Problems which can occur
stator (armature). At rated speed, the main stator’s voltage
are not limited to the generator. Poor wave shape may
produced by the residual magnetism of the exciter allows the
adversely effect various loads connected to the generator.
automatic voltage regulator to function. The regulator
Consult Marathon Electric for further information relative to
provides voltage to the exciter field resulting in a build-up of
nonlinear loads.
generator terminal voltage. This system of using residual
magnetism eliminates the need for a special field flashing
circuit in the regulator. After the generator has established the
initial residual voltage, the regulator provides a controlled DC
field voltage to the exciter stator resulting in a controlled
INSTALLATION
generator terminal voltage.
PREPARATION FOR USE
Although the generator has been carefully inspected and
Voltage Regulation tested in operation prior to shipment from the factory, it is
recommended that the generator be thoroughly inspected.
In the standard configuration (shunt excited), the automatic
Check all bolts for tightness and examine the insulation on
voltage regulator receives both its input power and voltage
lead wires for chafing prior to proceeding with installation.
sensing from the generator's output terminals (See Figure 1).
Remove all shipping tapes, bags, skids and rotor support
With the optional PMG configuration, the regulator receives
blocking. For two bearing units, rotate the shaft by hand to
input power from the PMG. The regulator automatically
ensure that it rotates smoothly without binding.
monitors the generator's output voltage against an internal
reference set point and provides the necessary DC output
voltage to the exciter field required to maintain constant
generator terminal voltage. The generator's terminal voltage
is changed by adjusting the regulator's reference set point.
Consult the regulator manual for specific adjustment and
operating instructions.
MOTOR STARTING
When a motor is started, a large surge of current is drawn by
the motor. This starting current is equivalent to the motors
locked rotor or stall current and is 5 to 10 times normal full
load current. When the generator supplies this in-rush of
starting current, the generator voltage dips temporarily. If the
motor is too large for the generator, the generator’s voltage
dips greater than 30 percent. This may result in the motor
starter de-energizing or the motor stalling. MagnaPlus®
generators generally supply .3 to .4 horsepower per
4
GENERATOR MOUNTING
Two Bearing Generators -- Direct Drive
DISABLE AND LOCKOUT ANY ENGINE CRANKING Two bearing generators are provided with a keyed shaft
DEVICES BEFORE ATTEMPTING TO INSTALL OR extension. For direct drive generators, the assembler
SERVICE THE GENERATOR. FOR ELECTRIC START furnishes a flexible coupling which is installed between the
SETS, DISCONNECT THE CRANKING BATTERY. FOR driver and the generator's shaft. Aligning the generator and its
AIR START, DISCONNECT THE AIR SUPPLY. FOR driver as accurately as possible will reduce vibration, increase
MOTOR GENERATOR SETS, OPEN THE POWER bearing life, and ensure minimum coupling wear. It may be
SUPPLY TO THE DRIVE MOTOR. FAILURE TO necessary to shim the generator feet for proper
COMPLY WITH THESE SAFETY PROCEDURES support and alignment. Secure the feet of the generator with
COULD RESULT IN SEVERE PERSONAL INJURY OR grade 5 or greater bolts through the holes provided in the
EQUIPMENT DAMAGE. mounting feet. Consult the coupling manufacturer's
instructions for alignment specifications and procedures.
NEVER "BAR OVER" THE ENGINE GENERATOR SET
USING THE GENERATOR'S FAN. THE FAN IS NOT
DESIGNED FOR THIS PURPOSE. BARRING OVER GENERATOR MOUNTING
THE SET WITH THE FAN COULD DAMAGE THE FAN Two Bearing Units -- Belt Driven
AND RESULT IN PERSONAL INJURY OR
EQUIPMENT DAMAGE. Two bearing MagnaPLUS® generators can be belt driven
provided belts are sized and applied correctly. Please refer to
your supplier of belts and sheaves for correct sizing and
tensioning specifications. A bearing life calculation should be
GENERATOR MOUNTING performed. Marathon Electric recommends a minimum B-10
Single Bearing Units. life of 40,000 hours. If cog type belts are used, a vibration may
be introduced which could lead to premature failure of the
Single bearing units are provided with an SAE flywheel bearings.
housing adapter flange and flexible drive discs. Coupling the
generator's shaft to the engine flywheel is accomplished with
special steel drive discs bolted to the shaft. In addition to the HYDRAULIC DRIVE WITH SHAFT SPLINE
drive discs, there may be a hub spacer, spacer discs, or a Two Bearing Units
combination of hub spacer and spacer discs inserted
between the drive discs and the shaft to achieve the proper All 280 PDL MagnaPLUS® two bearing hydraulic drive
shaft extension ("G" dimension per SAE J620c). Holes are generators are equipped with a Zerk grease fitting mounted in
provided in the periphery of the coupling discs which the drive end of the shaft. Prior to assembly to the hydraulic
correspond to tapped holes in the prime mover's flywheel. drive motor, lightly coat the hydraulic drive motor shaft, and/or
The outside diameter of the drive discs fit in a rabbet in the grease the generator spline per the greasing instructions in
flywheel so that concentricity is assured. the MAINTENANCE section, page 12. DO NOT assemble
the generator to the hydraulic drive motor with the spline
Grade 8 place bolts and hardened washers are recommended dry.
to mount the drive discs to the flywheel. DO NOT USE SPLIT
TYPE LOCK WASHERS. Split lock washers when biting into
the drive disc cause stress risers which may result in the disc END PLAY TESTING
fracturing.
Refer to the engine manual for recommended end play
The SAE flywheel housing adapter ring and the engine specifications and measurement procedures. If end play is
flywheel housing are designed to match each other with no not to specification, it is an indication that the generator shaft
further alignment necessary. Use grade 5 or greater is not moving freely in the assembly, and normal life of the
mounting bolts. MagnaPLUS® generator frames are thrust bearing could be impaired. Probable causes of this
constructed with two or three bolt holes per foot. The feet problem are:
should be shimmed where necessary to obtain solid contract
with the sub-base. With the frame securely bolted to the 1. Improper seating of drive discs in the flywheel resulting in
engine flywheel housing, there is no side thrust or pull on the misalignment.
generator frame, thus no real need to secure the feet with
more than one bolt per foot. 2. Improper mating of generator frame to engine flywheel
housing resulting in misalignment.
3. Improper "G" dimension per SAE J620c on either the

engine or generator.
5
TORSIONAL VIBRATION The generator conduit box construction allows cable entry
from multiple sides. A hole saw or other appropriate tool may
Torsional vibrations are generated in all rotating shaft be used to provide for conduit entrance. Protect the interior of
systems. In some cases, the amplitude of these vibrations at the generator from shavings when drilling or sawing. An
critical speeds may cause damage to either the generator, its approved connector must be used in conjunction with the
driver, or both. It is therefore necessary to examine the conduit. To minimize the transmission of vibration, it is
torsional vibration effect on the entire rotating system. IT IS essential that flexible conduit be used for all electrical
THE RESPONSIBILITY OF THE GENERATOR SET ASSEM- entrance to the generator conduit box.
BLER TO ASSURE THE TORSIONAL COMPATIBILITY OF
THE GENERATOR AND ITS DRIVER. Drawings showing All MagnaPLUS® generators are equipped with link boards
pertinent dimensions and weights of the rotating assembly (terminal strips) for both internal and external connections. All
will be supplied by Marathon Electric upon request. connections made to the studs of the link board should be
made with high quality ring terminals. Ring terminal sizes are:
6 mm (280 Series Frames) and 10 mm (360 and 430 Series
ENVIRONMENTAL CONSIDERATIONS Frames). Torque link board connections to the
following specifications: 280 frame -- 5.4 NM (4 Ft Lb); 360 &
The MagnaPLUS® generator is designed for heavy duty 430 frame -- 27 NM (20 Ft Lb).
industrial applications; however, dirt, moisture, heat and
vibration are enemies of rotating electrical machinery. Refer to the connection diagram supplied with the generator
Excessive exposure to the elements may shorten generator and / or the proper diagrams shown in this manual. Install all
life. The temperature of the cooling air entering the intake inter component and external wiring in accordance with
openings of the generator should not exceed the ambient national and local electrical codes. The neutral in the
temperature shown on the generator’s nameplate. Generators following connection diagrams shown below may be either
intended for outdoor application should be protected with grounded (earthed) or left above ground potential (floating).
housings having adequate ventilation. Although the standard See national and local codes and / or the system distribution
insulation systems are moisture and humidity resistant, space wiring schematic diagram for the proper connection of the
heaters are recommended for extreme conditions. If the neutral.
generator is to be installed in an area where blowing sand
and dust are present, the enclosure should be fitted with The following connection diagrams are shown for twelve
filters. Filters reduce erosion on the generator's insulation by lead generators. Ten lead generators have the same
blocking high velocity abrasive particles generated by the flow terminal designations except for leads T10, T11, and T12.
of cooling air through the generator. Consult the factory for These three leads are internally connected inside the
appropriate filters and generator deratings required. generator and brought out as a single lead (T0). Ten lead
generators can only be connected in a wye configuration.
WIRING CONNECTIONS
Wiring of the generator and accessories should be
done in accordance with good electrical practices.
Follow government, industry and association
standards.
HIGH (SERIES) WYE CONNECTION

L1
T1
VOLTAGE (HIGH WYE)

T4
Hz L-L L-Lo
12 Lead 60 380 219
T7 416 240
L-L
440 254
T12 T10 460 266
480 277
T9
T6 T11 50 380 219
T8 400 231
T3 T5 415 240
T2
L3 L - L0 L2 440 254
6
LOW (PARALLEL) WYE CONNECTION
L1
T7 T1
VOLTAGE (LOW WYE)
Hz L-L L-L0
12 Lead 60 190 110
208 120
L-L
T10 T4
220 127
T12 T5 230 133
240 139
T6 T11 50 190 110
T9 T2
200 115
L3 L2
208 120
T3 T8 220 127
L - L0
HIGH (SERIES) DELTA CONNECTION
L1
T12 T1
VOLTAGE (HIGH DELTA)
L-L0 Hz L-L L-L0
60 240 120
T9 T4 277 139
L-L L0
T6 T7 50 200 100
220 110
L-L0 240 120
T3 T10
L3 T11 T8 T5 T2 L2
LOW (PARALLEL) DELTA CONNECTION
L1
12 Lead
T12
T1 VOLTAGE (LOW DELTA)
T6 T
7 Hz L-L
L-L 60 110
T9 120
T4
T3 50 100
T10
110
T5 T2
L3 T11 T8 L2
L-L
7
DOUBLE DELTA -- SINGLE PHASE CONNECTION
VOLTAGE (DOUBLE DELTA)

T3 T5 T9 T11 Hz L-L L-LO
60 200 100
220 110
240 120
T6 T12 T8 50 220 110
T2 L0 Note: Single phase KW/KVA ratings are
approximately equal to 50% of the
L2 T1 T4 T7 T10 L1 generator’s three phase ratings.
L - L0 L - L0
L-L
LOW ZIG ZAG -- SINGLE PHASE (PARALLEL) CONNECTION
VOLTAGE (LOW ZIGZAG)

T6 T2
Hz L-L L-LO
T12 T8 12 Lead 60 200 100
220 110
T3 T5 240 120
T11 50 220 110
T9
T4 T1 L1
L2 L0 Note: Single phase KW/KVA ratings are
T10 T7
approximately equal to 50% of the
L - L0 L - L0 generator’s three phase ratings.
L-L
HIGH ZIG ZAG -- SINGLE PHASE (SERIES) CONNECTION
T12 T1
VOLTAGE (HIGH ZIGZAG)
Hz L-L L-L0
12 Lead
60 480 240
T9 T4
T6 T7
T10
T3 T11 T8 T5 T2 Note: Single phase KW/KVA ratings are
L0 L1 approximately equal to 50% of the
L2 L - L0 L - L0 generator’s three phase ratings.
L-L
8
DEDICATED SINGLE PHASE CONNECTION
HIGH VOLTAGE - SERIES CONNECTED
VOLTAGE (DEDICATED)
Hz L-L L-N
60 240 120
220 110
50 220 110
200 100
SINGLE PHASE CONNECTION - SINGLE VOLTAGE PARALLEL
VOLTAGE
L-L
60 HZ 120
50 HZ 110
Note: For 120 volt only service. Use an

AVC63-4A or a VR63-4C voltage regulator to
replace the standard SE350 regulator.
9
OPERATION START-UP
The following procedure should be followed when starting the
PRE-START INSPECTION generator set for the first time.
Before starting the generator for the first time, the following 1. The generator output must be disconnected from the
inspection checks are recommended: load. Be sure that the main circuit breaker or fused
disconnect is in the open position.
1. A visual inspection should be made for any loose parts,
bad connections, or foreign materials. 2. Open the input power to the automatic voltage
regulator. Remove the fuse or disconnect and insulate
2. Bar the set over by hand for at least 2 revolutions to be one of the regulator input power leads. (See separate
sure that there is no interference and that the set turns regulator manual)
freely. If the set does not turn freely, check for clearance
in the generator and exciter air gap. 3. Verify that all prime mover start-up procedures have
been followed.
3. Check all wiring against the proper connection diagrams,
and ensure that all connections and terminations are 4. If the unit is provided with space heaters, ensure that
tight and properly insulated. they are de energized. In some installations, a set of
auxiliary contacts on the main circuit breaker or transfer
4. Verify that all equipment is properly grounded (earthed). switch will automatically open the space heater circuit
when the generator is connected to the load.
5. Start the prime mover, and adjust it for proper speed. See
generator nameplate.
MAGNAPLUS® GENERATORS MAY HAVE VOLTAGE
PRESENT AT THE LEAD TERMINALS WHEN THE 6. The purpose of this initial test with the regulator out of the
SHAFT IS ROTATING. DO NOT PERMIT OPERATION circuit is to detect any wiring mistakes without exposing
OF THE GENERATOR UNTIL ALL LEADS HAVE the unit to undue risk. Check all line to line and line to
BEEN CONNECTED AND INSULATED. FAILURE TO neutral voltages for balanced voltage. If voltages are
DO THIS MAY RESULT IN PERSONAL INJURY OR balanced, shut down the set and reconnect the
EQUIPMENT DAMAGE. regulator. If voltages are unbalanced, shut down the
equipment and check for improper wiring. If the
problem persists, consult the factory.
5. Clear the surrounding area of any materials that could be
drawn into the generator. With the regulator de energized, the residual voltage
should be 10 - 25% of rated value. It is recommended
6. Check all fasteners for tightness. that this residual voltage and driver RPM be recorded for
use as a future troubleshooting benchmark.
7. Check all access plates, covers, screens and guards. If
they have been removed for assembly or inspection,
reinstall and check for security.
8. Review all prime mover prestart up instructions, and THE FOLLOWING TEST MUST BE CONDUCTED BY
ensure that all recommended steps and procedures have QUALIFIED ELECTRICAL PERSONNEL. LETHAL
been followed. VOLTAGE MAY BE PRESENT AT BOTH THE
GENERATOR AND VOLTAGE REGULATOR
9. Remove any masking materials affixed during painting. TERMINALS DURING THIS PROCEDURE. CAUTION
Inspect the generator, prime mover, and any accessory MUST BE EXERCISED NOT TO COME INTO
equipment to ensure that nameplates, and all safety PERSONAL CONTACT WITH LIVE TERMINALS,
warning / caution signs and decals provided with the LINKS, OR STUDS. SERIOUS INJURY OR DEATH
equipment are in place and clearly visible. COULD RESULT.
Note: It is strongly recommended that the authority

having jurisdiction over the installation site be 7. Start the set and adjust the terminal voltage to the
consulted to determine if any additional warning or desired value by means of the regulator voltage
caution notices, or additional safety devices are adjustment. If the regulator is equipped with a stability
required by local codes / standards. Any such adjustment, follow the instructions in the regulator
required notices or devices should be installed prior manual to adjust the stability. Again, check all line to line
to initial startup. and line to neutral voltages for balance. It is
10
recommended practice to record the no load excitation rather one that should be conducted by an authorized
(DC voltage to the exciter stator), generator terminal service center equipped with the appropriate apparatus
voltage, and driver speed as a benchmark for future and solvents necessary to properly clean and dry the
troubleshooting. generator.
8. Close the main circuit breaker to the load.
9. Monitor the generator output current to verify that it is at

or below nameplate value.
THE FOLLOWING TEST MUST BE CONDUCTED BY
10. Check generator speed (frequency) under load. Adjust as QUALIFIED ELECTRICAL PERSONNEL. LETHAL
necessary. (Refer to prime mover or governor manuals) VOLTAGE MAY BE PRESENT AT BOTH THE
TERMINALS DURING THIS PROCEDURE. CAUTION
SHUTDOWN PROCEDURE MUST BE EXERCISED NOT TO COME INTO
PERSONAL CONTACT WITH LIVE TERMINALS,
There are no specific instructions for shutting down the LINKS, OR STUDS. SERIOUS INJURY OR DEATH
generator; however, several good practices should be COULD RESULT.
observed to prolong equipment life.
1. It is advisable to disconnect all loads (open main circuit 4. Every 2,000 operating hours or in conjunction with
breaker or disconnect) prior to shutdown. This is scheduled engine maintenance, check the DC no load
especially important if loads can be damaged by low excitation voltage per item #7 in the startup procedure.
voltage or low frequency conditions during generator Compare this voltage with the value recorded during
"coast down". initial startup. If this value of no load excitation voltage is
markedly higher than the bench mark reading, it is an
2. Isolate all conditions that could apply voltage to the indication of problems in either the exciter, main field, or
generator terminals while the generator is at rest. Failure the rotating rectifier assembly. Ensure that RPM is the
to comply could result in personnel injury or equipment same as initial test.
damage.
5. Monitor and record insulation resistance with a 500 volt
3. If the unit is equipped with space heaters, verify that the mega-ohm meter. The minimum acceptable reading is 2
heater circuit is energized. mega-ohms. If the reading drops below the minimum, the
generator should be cleaned and dried at an authorized
service shop. Consult Marathon Electric for more
information.
MAINTENANCE
The following maintenance procedures should be followed to DRYING WINDINGS
ensure long equipment life and satisfactory performance.
Maintenance intervals will depend upon operating conditions. Generators in service may inadvertently have their windings
exposed to splashing or sprayed water. Units that have been
1. Routinely check intake and exhaust air screens to ensure in transit or storage for long periods of time may be
that they are clean and free of debris. Clogged intake air subjected to extreme temperature and moisture changes
screens will reduce cooling air flow and result in higher causing excessive condensation. Regardless of the source of
operating temperatures. This will reduce generator life moisture, wet windings should be thoroughly dried out before
and may result in generator damage. operating the unit. If this precaution is not taken,
serious damage to the generator can result. The following
2. All MagnaPLUS® generators are equipped with double procedures may be utilized in drying the generator’s
shielded ball bearings lubricated for the life of the windings. The method selected will be influenced by winding
bearing. Every 1,000 hours check the bearing(s) for wetness and situation limitations.
smooth, quiet operation. For continuous duty generators,
recommended practice is to replace the bearing during Space Heaters
major overhauls of the engine. An electric heater may have been supplied with the
generator. When energized from a power source other than
3. Periodically inspect the unit for any buildup of the generator, the heater will gradually dry the generator. This
contamination (dirt, oil, etc.) on the windings. If the process can be accelerated by enclosing the unit with a
wound components have become coated with heavy covering and inserting additional heating units. A hole should
concentrations of oil and grime, the unit should be be left at the top of the covering to permit the escape of
disassembled and thoroughly cleaned. This operation is moisture. Care should be taken not to overheat various
not one that can be accomplished effectively on site, but accessory equipment mounted with the generator.
11
Forced Air that the generator’s air gaps (main rotor and exciter) are free
Another method to dry the generator is to run the set with no from obstructions. If possible, rotate the generator manually
excitation (see startup procedure item #2). The natural flow of to ensure free rotation. Never “bar over” the engine generator
ambient air through the generator will tend to dry the set using the generator fan.
windings. This method can be accelerated by adding a source
of heat at the air intake to the generator. Heat at point of entry
should not exceed 80 C (180° F).
THE FOLLOWING TEST MUST BE CONDUCTED BY

HYDRAULIC DRIVE GENERATORS, QUALIFIED ELECTRICAL PERSONNEL. LETHAL
SHAFT SPLINE LUBRICATION VOLTAGE MAY BE PRESENT AT BOTH THE
The shaft spline should be greased prior to initial assembly to TERMINALS DURING THIS PROCEDURE. CAUTION
the driver, and every three (3) months to reduce maintenance, MUST BE EXERCISED NOT TO COME INTO
and prolong the life of the spline coupling per the following PERSONAL CONTACT WITH LIVE TERMINALS,
procedure: LINKS, OR STUDS. SERIOUS INJURY OR DEATH
COULD RESULT.
1. Material: Molybdenum Disulfide - sometimes referred to
as “Molly Grease.”
2. Turn the rotor assembly so that the Zerk fitting is in line CONSTANT EXCITATION TEST
with the access hole in the top of the drive end bearing (12V BATTERY TEST)
bracket as illustrated in Figure 3.
The generator “no load” voltage is dependent on exciter input
3. Using a hand held grease gun with a solid coupling, voltage and generator speed. With the generator operating at
apply a small amount of grease into the fitting. DO NOT rated speed and 12 volts dc applied to the exciter field, the
OVER GREASE. Limit the amount of grease to one (1) generators terminal voltage will be near rated value.
trigger pull of the grease gun.
1. Shutdown the generator set and connect a voltmeter on
the generator terminals.
Shaft Mounted 2. Disconnect the regulator’s F+ (F1) and F- (F2) leads and
Zerk Fitting connect them to a 12V battery. Caution should be taken
to ensure that the battery is not exposed to any
potential arcing.
Grease Gun
Access Hole
3. With no load on the generator (main breaker open) run
the generator at rated speed. Measure the generator’s
terminal voltage and compare this value with values
recorded during installation.
If voltage readings are normal, the main generator and

excitation are operating properly. Troubleshooting should
continue with the regulator. If readings are not normal the
problem is in the generator. Continue testing diodes, surge
suppressor, and windings.
Figure 3--Drive End Bearing Bracket Continuity / Resistance Test

The generator has four components which can be checked
using an ohm meter: exciter stator, exciter rotor, main stator
and main rotor. Each of these components are comprised of
TESTING various windings which form a complete electrical path of
relatively low resistance. Using an ohm meter measure the
Visual Inspection loop resistance of each component. Compare these
measured values with the values listed in the specification
Remove covers and look for any obvious problems: burnt section of this manual. Note that very small resistance values
windings, loose connections, broken wires, frayed insulation, require precision equipment to make accurate
cracked brackets, missing hardware, etc. Check for foreign measurements; however, a standard ohm meter will provide a
objects which may have been drawn into the generator. Verify good indication of winding continuity.
12
Insulation Test When the positive test probe is connected to the diode's
anode and the negative test probe is connected to the diode's
Insulation resistance is a measure of the integrity of the cathode (forward biased), the diode will switch on and
insulating materials that separate the electrical windings from conduct electricity (Figure 4). This is observed by a low
the generator’s steel core. This resistance can degrade over resistance reading when using an ohm meter or the lighting
time or be degraded by contaminants: dust, dirt, oil, grease, of the bulb when using a battery light continuity tester.
and especially moisture. Most winding failures are due to a Reversing the test leads (reverse biased) will result in the
breakdown in the insulation system. In many cases, low diode switching off and no electricity will be conducted. The
insulation resistance is caused by moisture collected when results of these tests should indicate one of three conditions:
the generator is shutdown
1. Good diode: Will have a much greater resistance in one
Insulation resistance is measured with a megger (mega-ohm direction than the other. Typical reverse biased resistance
meter). A megger measures insulation resistance by placing will be 30,000 ohms or greater, while forward biased
500 volts between the winding and the frame of the resistance will be less than 10 ohms. The battery light
generator. Caution must be taken to remove all electronic tester will have the light "on" in one direction and "off" in
devices (regulators, diodes, surge protectors, capacitors, the other.
protective relays, etc.) from the winding circuit before
checking the insulation. Winding insulation can be checked on 2. Shorted condition: Ohmmeter reading will be zero, or
the main stator, main rotor, exciter stator, and exciter rotor. very low in both directions. The continuity tester will have
Minimum resistance is 2 mega-ohms. If the winding the light "on" in both directions.
resistance is low it must be dried (see maintenance section)
or repaired. 3. Open condition: Ohmmeter will have a maximum
(infinity) reading in both directions. Continuity tester light
will be off in both directions.
DIODE TESTING
Diode failure after a 25 hour "run in" period is generally
If the generator is close coupled to an engine, it may be traceable to external causes such as a lightning strike,
necessary to "bar over" the engine in order to gain access to reverse current, line voltage spikes, etc. All 6 diodes are
a given area of the rectifier assembly. NEVER use the essentially in the same circuit. When a diode is stressed to
generator's fan as a fulcrum to accomplish this. Use the failure, there is no easy method to determine remaining life in
engine manufacturer's recommended practice to manually the other diodes. To avoid possible continued failures, it is
turn over the engine. To prevent possible injury to personnel, recommended that the entire rectifier assembly be replaced
and damage to the equipment, ensure that the engine rather than replacing individual diodes.
cannot start during this procedure.
Remove the two main rotor leads and the three exciter rotor
leads from the rectifier assembly (Figure 5). The rectifier SERVICE
assembly is now electrically isolated from the generator. The
diodes remain mounted and the diode leads remain
connected to the terminal posts. Using an ohmmeter or a GENERAL
battery light continuity tester, place one test probe on the
diode lead terminal post. In succession, touch the other test The service procedures given in this section are those which
probe to the lead screw hole in each heat sink. Reverse the can reasonably be conducted on-site with a minimum
probes and repeat the procedure. You have now tested the number of special tools and equipment. All service
three diodes connected to this terminal post in both the procedures should be conducted by qualified maintenance
forward and reverse direction. Repeat the procedure using personnel. Replacement parts may be ordered through an
the other diode terminal post. authorized service center or directly from the factory.
Forward Reverse FIELD FLASHING

Terminal End Restoring Residual Magnetism
(not applicable on PMG equipped generators)
Anode Cathode
(+) (-)
To restore residual magnetism to the generator, connect a 12
volt battery to the exciter field while the generator using the
following procedure:
Stud End
Cathode Anode
1. Shutdown the generator set. Remove the exciter field
(-) (+) leads F+ and F from the regulator.
FIGURE 4: DIODE POLARITY
13
Reassembly note: Before the bearing bracket is seated
against the frame, a threaded rod may be used to help align
Failure to remove the exciter field leads from the the inner bearing cap with the bearing bracket.
automatic voltage regulator during flashing
procedures may destroy the regulator.
BEARING REPLACEMENT
2. Connect the F+ and F- leads to the battery’s
corresponding positive and negative terminals. This Using a bearing puller, remove the existing bearing. It is
should be done using an appropriate length of lead wire strongly recommended that the bearing be replaced any time
to separate the battery from the point of connection the it is removed from the shaft. ALWAYS install the same
(batteries may explode when exposed to an electric arc). type and size bearing that was supplied as original
After 3 to 5 seconds, remove the F- lead. An inductive arc equipment. Order by part number from the parts list, and
should result. If no arc is drawn, repeat the procedure. include the unit serial number and part number when
ordering. Heat the bearing to a maximum of 100°C (212°F) in
3. Reconnect the F+ and F- leads to the regulator. Restart an oven. Apply a thin coat of clean lubricating oil to the press
the generator and verify that terminal voltage is fit area of the rotor shaft. Using suitable heat resistant gloves,
developed. If terminal voltage does not develop, repeat install the bearing over the end of the shaft until it seats
the field flashing procedure and / or consult the trouble against the shaft shoulder. The bearing should slide on the
shooting section. shaft and be seated without excessive force. Should the
bearing bind on the shaft prior to being seated against the
shoulder, a piece of tubing slightly larger than the press fit
BEARING REMOVAL area can be used to drive the bearing to its final position.
Using light taps with a soft mallet, apply pressure to the inner
Prior to performing this operation, it is suggested that the race only.
alternator's shaft be rotated until two of the main rotor poles
are in a vertical position. Once the bearing bracket is backed
out, the rotor will drop on the main stator core. Having the RECTIFIER ASSEMBLY REMOVAL
rotor in this position will limit the amount of rotor drop to that
of the air gap. Visually inspect the bearing bore for damage or The rectifier assembly cannot be removed until the opposite
wear. If worn or damaged, replace prior to reassemble. drive end bearing bracket and bearing have been removed
(see bearing removal procedure). Remove the three exciter
Opposite Drive End Bearing Bracket Removal. rotor leads from the heat sinks and the two main rotor leads
Prior to proceeding with bracket removal, disconnect exciter from the main rotor posts (see Figures 5). Remove the screws
field leads F+ and F- from the automatic voltage regulator and securing the rectifier assembly and pull the assembly free
ensure that they are free to move when the bearing bracket is from the shaft.
removed. Remove the bearing bracket retaining bolts. Using a
pair of screw drivers, wedge the bracket off the frame. After
approximately 1/8 inch, the bracket will clear the locating DIODE REPLACEMENT
register on the frame and will drop until the rotor is resting on
the main stator core. Continue to pull the bracket free from the Prior to installing a replacement diode on the heat sink, apply
bearing. Visually inspect the bearing bore and o-ring (if a thin film of conductive heat sink compound around the base
equipped) for damage or wear. If worn or damaged, repair or of the diode (do not coat the threads). When installing a diode
replace prior to reassembly. on the heat sink, care should be taken not to over torque the
retaining nut which could cause damage to the device. Torque
Drive End Bearing Bracket Removal, to 28 pound inches. If not damaged, the existing diode lead
Two Bearing Units. wire may be unsoldered from the failed diode, and resoldered
Remove any drive arrangement from the generator shaft on the replacement.
extension. Remove the bearing lock ring retaining screws.
There is no o-ring in the drive end bearing bracket. The shaft
extension must be supported before proceeding further. A
hoist and sling, jack, or some other means of support with a
capacity of 2 tons should be used.
Remove the bearing bracket retaining cap screws. Using a flat

bladed screw driver or chisel, pry the bracket back from the
frame. After approximately 1/8 inch, the bracket will clear the
locating register on the frame. Lower the shaft extension until
the rotor is resting on the main stator core. Continue to pull
the bracket free from the bearing. Visually inspect the
bearing bore for damage or wear. If worn or damaged, sleeve
or replace prior to reassembly.
14
430 FRAME 280 / 360 FRAME
A - Exciter Rotor Lead, B - Main Rotor Lead, C - Red (+) Suppressor Lead, D - Black (-) Suppressor Lead
FIGURE 5: ROTATING RECTIFIER ASSEMBLY
RETURNED GOODS
TROUBLESHOOTING
Contact Marathon Electric Manufacturing Corporation for
This section is intended to suggest a systematic approach to
authorization before returning any product. We can not be
locating and correcting generator malfunctions. The section is
responsible for any items returned without authorization.
arranged according to the symptoms of the problem. The
steps have been arranged in an attempt to do the easy
checks first and prevent further damage when
troubleshooting a disabled machine.
Single bearing generators must have their rotor
The first step of troubleshooting is to gather as much
assembly properly secured to prevent damage during
information as is possible from operating personnel and
transit to the factory, or to an authorized service cen-
individuals present during the failure. Typical information
ter.
includes: how long the unit had been operating; what loads
were on line; weather conditions; protective equipment that
did or did not function. In addition, information as to the
operating condition of the generator's prime mover is vital.
Has the prime mover been maintaining constant speed? If
not, have there been extended periods of under speed
operation? Has the prime mover experienced an over-speed
condition? If yes, what was the maximum speed, and how
long did the unit operate at that elevated speed?
The generator speed should be maintained at rated

nameplate value during all operating tests. The frequency of
the generator depends upon rotational speed. Most
regulators used with MagnaPLUS® generators have built in
under frequency protection such that if the speed is reduced
more than 5%, the voltage will drop off rather rapidly with
further reductions in speed.
15
WARNING
HIGH VOLTAGES MAY BE PRESENT AT THE GENERATOR’S TERMINALS WHEN THE UNIT IS RUNNING. SOME
ACCESSORY EQUIPMENT SUCH AS SPACE HEATERS MAY BE ENERGIZED FROM AN OUTSIDE POWER SOURCE
WHEN THE UNIT IS AT REST. TOOLS, EQUIPMENT, CLOTHING AND YOUR BODY MUST BE KEPT CLEAR OF
ROTATING PARTS AND ELECTRICAL CONNECTIONS. SPECIAL PRECAUTIONS MUST BE TAKEN DURING
TROUBLESHOOTING SINCE PROTECTIVE COVERS AND SAFETY DEVICES MAY BE REMOVED OR DISABLED TO
GAIN ACCESS AND PERFORM TESTS. BE CAREFUL. SERIOUS PERSONAL INJURY OR DEATH CAN RESULT FROM
THESE HAZARDS. CONSULT QUALIFIED PERSONNEL WITH ANY QUESTIONS.
GENERATOR PRODUCES NO VOLTAGE

CAUSE CHECK AND REMEDY
Voltmeter off or defective Check voltage with a separate meter at the generator terminals.
Incorrect or defective connections Verify generator connections. See drawings supplied with the generator or lead
connection diagrams in this manual. Inspect all wiring for loose connections, open
circuits, grounds, and short circuits.
Loss of residual Flash the field. Refer to field flashing in the service section. If the generator is equipped
with a PMG, field flashing is not necessary -- check regulator fuse and input power
from the PMG.
Defective diodes, suppressor, or windings Test the generator using the 12 volt battery test as specified in the testing section. If
the results indicate generator problems, perform insulation, continuity, and diode tests
as specified in the testing section.
Regulator protection operating Adjust regulator. Consult regulator manual.
Regulator inoperative Adjust or replace regulator. Consult regulator manual.
GENERATOR PRODUCES LOW VOLTAGE, NO LOAD

Underspeed operation Check speed using a tachometer or frequency meter.
Voltmeter off or defective Check voltage with a separate meter at the generator terminals.
Incorrect or defective connections Verify generator connections. See drawings supplied with the generator or lead
connection diagrams in this manual. Inspect all wiring for grounds, open circuits and
short circuits.
Loss of regulator power Check regulator fuse and input power. Input power is produced by the generator’s
residual voltage or from an optional PMG.
Regulator adjustment Adjust regulator settings. Consult regulator manual.
Regulator incorrectly connected Review the generator connection diagram or reference the regulator manual.
Regulator inoperative Adjust or replace regulator. Consult regulator manual.
16
GENERATOR PRODUCES LOW VOLTAGE WHEN LOAD APPLIED
Excessive load Reduce load. The load on each leg should be evenly balanced, and rated current
should not be exceeded on any leg.
Large motor starting or low Motor starting currents are too large for the generator. When starting multiple motors,
load power factor sequence the motors and start the largest motors first. Reduce lagging power factor
load.
Driver speed droop or belt slip Check driver. If belt driven, check belt tension. Check under frequency setting on
regulator. Under frequency voltage roll-off may be activated.
Reactive droop If the generator is equipped for parallel operation, some droop is normal as reactive
load increases. When operating as a single unit, the parallel CT can be shorted to
eliminate this effect. Refer to Regulator manual.
Line drop If voltage is proper at generator terminals but low at load terminals, increase external
wire size.
GENERATOR PRODUCES FLUCTUATING VOLTAGE

Fluctuating engine speed Check engine and governor systems for malfunctions. Check load for fluctuation.
Regulator stability Adjust Regulator stability. Refer to Regulator manual.
Regulator external rheostat Replace defective or worn rheostat. Use shielded cable to minimize electrical noise.
Defective rectifier assembly Check assembly for loose connections. Test the diodes as specified in the test section.
Loose terminal or load connections Improve connections both mechanically and electrically.
Defective regulator Replace regulator.
GENERATOR PRODUCES HIGH VOLTAGE

Faulty metering Check voltage with separate meter at generator terminals.
Incorrect connections Verify generator connections. Refer to drawings supplied with the generator or
connection diagrams in this manual.
Regulator adjustments Adjust regulator. Consult regulator manual.
Leading power factor Check the power factor of the load. If power factor is leading, change load
configuration. Excessive leading power factor (capacitors) can cause voltage to climb
out of control.
Incorrect regulator connection Verify regulator voltage sensing is connected correctly. Consult regulator manual.
Defective regulator Replace regulator.
17
GENERATOR BUILDS VOLTAGE FROM STARTUP,
THEN GOES TO LOW (RESIDUAL) VOLTAGE
Regulator protective circuit operating Check indicators on regulator. Correct problems and adjust regulator as is required.
Refer to regulator manual.
GENERATOR IS OVERHEATING
Generator is overloaded Reduce load. Check with ammeter and compare with nameplate rating.
Clogged ventilating screens Clean air passages.
High room temperature or altitude Improve ventilation or reduce load.
Insufficient circulation of cooling air Generator location and enclosure design must provide adequate air flow and
minimize recirculation of hot air.
Unbalanced load The load on each leg should be as evenly balanced as possible and should not exceed
rated current on any one leg.
GENERATOR PRODUCES MECHANICAL NOISE

Defective bearing Replace bearing.
Loose or misaligned coupling Tighten, realign, or replace coupling.
Belt slap or loose guards Check belt tensioning. Check belt guard fasteners.
EQUIPMENT RUNS NORMALLY ON UTILITY POWER,

BUT WILL NOT RUN ON GENERATOR SET
Distorted voltage waveform Analyze load. Excessive SCR (thyristor) loading will cause distortion. Some equipment
may be sensitive to distorted waveforms. Refer to Marathon Electric..
Improper generator voltage or frequency Check name plates of devices comprising the load. Compare required voltage and
frequency with that of the generator. Adjust driver speed and/or generator voltage as
necessary to match generator output to load requirements.
Compare required voltage, frequency, and KVA with generator nameplate to ensure adequate generator capacity. If in
doubt, consult Marathon Electric for information regarding generator capacity.
18
SPECIFICATIONS
EXCITER RESISTANCE
MODEL / FRAME SIZE
STATOR ROTOR
281, 282, 283, 284, 285, 286, 287 18.0 .120
361, 362, 363 -- three phase 23.5 .120
361, 362, 363 -- dedicated single phase 23.0 .135
431, 432, 433 -- three phase 18.5 .120
431, 432 -- dedicated single phase 18.0 .105
EXCITER FIELD DEDICATED EXCITER FIELD

MODEL GENERATOR RESISTANCE NO LOAD VOLTS SINGLE GENERATOR RESISTANCE NO LOAD VOLTS
STATOR* ROTOR 480 V / 60 HZ PHASE STATOR ROTOR 480 V / 60 HZ
281PSL1500 4.20 .400 11.0 281PSL1500 4.20 .400 11.0
281PSL1501 4.15 .400 11.0 281CSL1513 0.47 0.72 4.3
281CSL1502 0.47 0.72 6.40 281PSL1511 1.420 .381 8.3
281PSL1502 3.20 .439 9.0 281PSL1512 1.106 .395 8.1
282PSL1703 1.07 0.34 14.70 281PSL1513 .632 .430 8.7
282CSL1504 1.24 0.80 6.20 282CSL1515 0.21 0.82 6.2
282PSL1704 1.07 0.34 14.70 282PSL1714 0.19 0.35 13.0
282CSL1505 0.87 0.90 5.80 282PSL1715 0.19 0.35 13.0
282PSL1705 0.74 0.37 14.35 282PSL1716 0.11 0.36 12.4
283CSL1506 0.54 1.00 8.20 283CSL1517 0.08 1.14 12.7
283PSL1706 0.45 0.40 12.95 283PSL1717 0.5 0.41 11.8
283CSL1507 0.44 1.18 9.20 283PSL1718 0.07 0.46 10.1
283PSL1707 0.39 0.46 11.20 284CSL1518 0.06 1.41 12.5
284CSL1508 0.29 1.36 10.00 284CSL1550 0.05 1.48 16
284PSL1708 0.27 0.52 14.18 284PSL1750 0.05 0.55 11.1
284CSL1542 0.27 1.36 8.30 285PSL1711 0.04 0.58 11.0
284PSL1742 0.22 0.54 14.00 286PSL1712 0.03 0.71 9.7
285PSL1700 0.20 0.58 11.90 287PSL1713 0.02 0.78 12.3
286PSL1701 0.14 0.72 10.68 361PSL1611 .070 .750 17.5
287PSL1702 0.12 0.79 10.9 361PSL1612 .043 .857 16.1
361CSL1600 .381 .750 11.8 361CSL1613 .037 .926 13.6
361CSL1601 .264 .810 12.5 362CSL1615 .019 1.20 17.0
361CSL1602 .181 .990 14.1 363CSL1617 .012 1.35 23.0
362CSL1604 .138 1.05 12.2 431PSL6222 .025 .516 9.9
362CSL1606 .098 1.20 10.8 431PSL6224 .013 .615 13.8
363CSL1607 .069 1.37 12.2 431PSL6226 .009 .643 15.1
431CSL6202 .021 .811 15.1 432PSL6228 .007 .852 11.2
431CSL6204 .048 .637 13.6
431CSL6206 .037 .679 13.82
431CSL6208 .013 .715 12.20
432PSL6210 .021 .811 15.1
432PSL6212 .023 .866 14.1
433PSL6216 .012 1.067 16.2
433PSL6220 .012 .974 15.6
* Stator resistance measured line to line in a high wye

connection.
19
PARTS LIST – SINGLE BEARING
Typical Generator Cross Section
8 9 10 11 12 13 14 15
16
7
17
5
18
20 19
Reference Part Name Reference Part Name

Number Number
1 End Bracket (under end cover 360 & 430 frames) 11 Main Stator
2 Bearing 12 Main Rotor
3 O-ring (280 and 360 frame only) 13 Rotor Integral Keyway
4 Rectifier Assembly 14 Fan
5 Air Intake Cover 15 Mounting Adapter (SAE)
6 Exciter Rotor 16 Shaft
7 Exciter Stator 17 Drive Hub
8 Link Board (terminal block) 18 Drive Disk (SAE)
9 Conduit Box 19 Exhaust Screen (drip cover not shown)
10 Generator Frame 20 Mounting Base
Note: Illustration above is a 360 frame MagnaPLUS®. Other Frame sizes are typical. Optional PMG not shown. The generator
model and serial numbers are required when ordering parts.
20
PARTS LIST – DUAL BEARING
Typical Generator Cross Section
8 9 10 11 12 13 14 15
16
7
17
5
18
20 19
Reference Part Name Reference Part Name

Number Number
1 End Bracket (under end cover 360 & 430 frames) 11 Main Stator
2 Bearing (nondrive end) 12 Main Rotor
3 O-ring (280 and 360 frame only) 13 Rotor Integral Keyway
4 Rectifier Assembly 14 Fan
5 Air Intake Cover 15 End Bracket (drive end)
6 Exciter Rotor 16 Bearing (drive end)
7 Exciter Stator 17 Shaft
8 Link Board (terminal block) 18 Key
9 Conduit Box 19 Exhaust Screen (drip cover not shown)
10 Generator Frame 20 Mounting Base
Note: Illustration above is a 360 frame MagnaPLUS®. Other Frame sizes are typical. Optional PMG not shown. The generator
model and serial numbers are required when ordering parts.
21
PARTS LIST – PMG GENERATORS
3 10
11
12 Typical 280 and 360 Frame Add-On PMG
5 6 Item Description Qty

1 PMG Stator Assembly 1
1 2 PMG Rotor Assembly 1
3 Stator Adaptor 1
2
LEADS TO 4 Shaft, PMG rotor 1
CONDUIT BOX 5 Screw, Hex Hd Flg Lock 1/4 - 20 4
7 8 6 Washer, Belleville - 1/4 4
7 Hex Hd Cap Screw, 1/2 - 13 x 4" 1
8 Washer, Belleville - 1/2 4
4 9 Roll Pin 0.25 x .88 1
10 Drip Cover - PMG Add-on 1
11 Screw, Hex Hd Flg Lock 1/4-20 4
9
12 Pushpin 4
13 14 15
Typical 430 Frame Add-On PMG

3 11
Item Description Qty
5 6
1 PMG Stator Assembly 1
2 PMG Rotor Assembly 1
1 3 Stator Adaptor 1
4 Shaft, PMG rotor 1
LEADS TO
2 CONDUIT BOX 5 Screw, Hex Hd Flg Lock 1/4 - 20 4
6 Washer, Belleville, 1/4 4
7 Hex Hd Cap Screw, 1/2 - 13 x 4" 1
7 8 8 Washer, Belleville, 1/2 1
9 Roll Pin 0.25 x .88 1
4 10 Air Intake - PMG Add-on 1
11 Screw, Hex Hd Flg Lock 1/4 - 20 4
9 12 PMG Cover 1
13 Hex Hd Cap Screw, 3/8 - 16 6
14 Washer, flat - 3/8 6
12
15 Washer, split lock - 3/8 6
10
22
23
Marathon Electric Mfg. Corp.
P.O. Box 8003
Wausau, WI 54402-8003 USA
Phone: 715.675.3359
Fax: 715.675.8026
www.marathonelectric.com
Printed in USA
SB504 05/06
5481J/10K/5-06/ML/BH

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MANUFACTURING

PREPARED FOR: LASA S.A.

Operation and Maintenance Manual

Page left blank intentionally.

For replacement parts and service contact:

For replacement parts and service contact:

Page left blank intentionally.

For replacement parts and service contact:

Safety Warnings and Cautions

For replacement parts and service contact:

Installation and Grounding of Electrically Powered Equipment

Output Cables and Terminals

For replacement parts and service contact:

Service and Maintenance

• C. Disconnect power to equipment if it is out of service.

• D. If troubleshooting must be done with the unit energized, have another

Fire and Explosion Prevention

Electrical Short Circuits and Overloads

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Toxic Fume Prevention

Bodily Injury Prevention

Medical and First Aid Treatment

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Equipment Precautionary Labels

Red AP Reflective Decal Tire Pressure Decal Electrical Hazard Decal

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• The unit should be installed and operated as stated in the manual.

• Warranty does not cover damage by misuse, carelessness or accident.

• The unit should be maintained as stated in the manual.

• All parts exchanged would be subjected to full inspection.

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Chapter 2 - Maintenance ............................................................................ 1

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Chapter 6 - Electrical Diagrams................................................................... 1

Chapter 7 – Manufacture’s Literature.......................................................... 1

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Chapter 1 - Description & Operation

Chapter 1 | Page 1 For replacement parts and service contact:

With 3 simple steps, the generator can start working inmideatly:

2. Start the e28.

3. Close contactor on the e28.

For replacement parts and service contact: Chapter 1 | Page 2

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For replacement parts and service contact: Chapter 1 | Page 4

Identification & Orientation – Section 3

The e28 units come with a designated serial num-

Every unit comes with a Perkins engine and a Mar-

The Serial Number Plate of the engine is located

Typical engine serial number plate

(1) Temporary Parts List number

Chapter 1 | Page 5 For replacement parts and service contact:

Record for Reference

e28 Serial Number ______________________

For replacement parts and service contact: Chapter 1 | Page 6