Perkins 2000 Series

USER’S HANDBOOK

6 cylinder diesel engines for industrial applications

Publication TSD 3215E (issue 12)

©Proprietary information of Perkins Group Limited, all rights reserved
The information is correct at the time of print.
Published in May 1999 by Technical Publications,
Perkins Engines Company Limited, Lancaster Road,
Shrewsbury, Shropshire SY1 3NX, England

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Contents
1 General information
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
How to care for your engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Engine identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Perkins companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Engine views
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Location of engine parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3 Operation instructions
How to prepare a new or an overhauled engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Normal start procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
How to start the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
How to run the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How to stop the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Running-in after a repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 Preventive maintenance
Preventive maintenance periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Schedule for engines in normal use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Schedule for engines in intermittent use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
How to check the coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to check the lubricating oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
How to check the drive belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
How to adjust the tension of the fan belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
How to adjust the tension of the alternator belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
How to renew the engine lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
How to renew the canisters of the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
How to renew the rotor of the by-pass filter for the lubricating oil . . . . . . . . . . . . . . . . . . 25
How to renew the canister of the main fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
How to drain the primary fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
How to clean the primary fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Continued

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How to check the specific gravity of the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
How to check the pH value of the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fuel injector fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
How to remove a fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Fuel injector sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
How to correct a fuel injector sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
How to fit a fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
How to eliminate air from the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
How to check the tappet clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
How to drain the coolant system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
How to clean the coolant system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
How to fill the coolant system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
How to check the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
How to tighten the bolts of the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Tensioner pulley for fan belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Air compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5 Engine fluids
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Recommended oils for Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Recommended oils for remainder of the world . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6 Fault diagnosis
Problems and possible causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Code list of possible causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7 Engine preservation
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Short period storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Long period storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal from storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Approved products for engine preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

8 Parts and Service

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Service literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

9 Engine data
2000 Series diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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General information 1

Introduction
The new range of industrial engines is the latest Danger is indicated in the text by two methods:
development from Perkins Engines Company
Warning! This indicates that there is a possible
Limited, a world leader in the design and manufacture
danger to the person.
of high performance diesel engines.
Caution: This indicates that there is a possible
More than fifty years of diesel production experience,
danger to the engine.
together with the use of the latest technology, have
been used in the manufacture of your engine to give Note: Is used where the information is important, but
you reliable and economic power. there is not a danger.
To ensure that you use the correct information for
your specific engine type, refer to ‘Engine
identification’ on page 7.

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How to care for your engine
This handbook has been written to assist you to
maintain and operate your engine correctly.
To obtain the best performance and the longest life
from your engine, you must ensure that the
maintenance operations are done at the intervals
shown in ‘Preventive maintenance’. If the engine is
operated in a very dusty environment or other
adverse conditions, certain maintenance intervals will
have to be reduced. Renew the filter elements and the
lubricating oil regularly to ensure that the inside of
your engine remains clean.
Ensure that all adjustments and repairs are done by
personnel who have had the correct training. Perkins
distributors have this type of personnel available. You
can also obtain parts and service from your Perkins
distributor. If you do not know the address of your
nearest distributor, enquire at one of the Perkins
companies listed on page 8.
The left and right sides of the engine are as seen from
the rear (flywheel) end.
Read the ‘Safety precautions’ and remember
them. They are given for your protection and must
be applied at all times.

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Engine identification
The engine number is stamped on the data plate
which is fastened to the right side of the crankcase 1
(A1).
For early engines a typical engine number is
8D26113U 71813P, which consists of these codes:
8D = Engine family
26113 = Engine number
U = Country of origin
71813 = Build line number
P = Year of manufacture
A 05
Engines made after August 1994, have a new engine
number system. For these engines, a typical number
is: SGH 06 0002 U 0059 C, which consists of these
codes:
SG = Engine application
H = Engine type
06 = Number of engine cylinders
0002 = Engine specification number
U = Country of manufacture
0059 = Build line number
C = Year of manufacture
Units such as the fuel injection pump and
turbochargers have their own data plates.
If you need parts, service or information for your
engine, you must give the complete engine number to
your Perkins distributor.

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Perkins companies Korea
Perkins Engines (Korea)
Australia
Textile Center 12F
Perkins Engines Australia Pty. Limited, Daechi 3 dong 944-31
Suite 4, 13A Main Street, Kangnam-Ku
Mornington, Victoria 3931, Australia. Seoul, 135-283
Telephone: 0061 (0)597 51877 Korea
Telex: Perkoil AA 30816 Telephone: (822) 528 3377
Fax: 0061 (0)597 1305 Fax: (822) 528 3378
China Singapore
Perkins Engines (Tianjin) Limited, Perkins Engines (Asia Pacific) Pte. Limited,
Jinwei Road, 20 Harbour Drive,
Beichen District, Tianjin, #07-06A, PSA Vista,
300402 Singapore 117612.
China Telephone: (65) 874 7712
Telephone: (86) (22) 2699 2288 Fax: (65) 874 7722
Fax: (86) (22) 2699 3784
United Kingdom
France
Perkins Engines Company Limited,
Perkins France SAS, Lancaster Road, Shrewsbury, SY1 3NX,
"Parc des reflets", England.
165 Avenue du Bois de la Pie, Telephone: 0044 (0)1743 212000
95700 Roissy Charles de Gaulle, France. Telex: 35171 PESL G
Telephone: 0033 (01) 49-90-7171 Fax: 0044 (0)1743 212700
Fax: 0033 (01) 49-90-7190
United States of America
Germany
Perkins Engines - North America
Perkins Motoren G.m.b.H., 12025, Tech Center Drive
Saalaeckerstrasse 4, Livonia
63801 Kleinostheim, Michigan 48150
Germany. USA
Telephone: 0049 6027 5010 Telephone: 001 313 266 5427
Fax: 0049 6027 501124 Fax: 001 313 266 2700
Italy
Perkins Engines Latin America Inc,
Motori Perkins S.p.A., Suite 620,
Via Socrate 8 999, Ponce de Leon Boulevard,
22070 Casnate con Bernate (Como), Italy. Coral Gables,
Telephone: 0039 (0)31 564625/564633 Florida 33134,
Fax: 0039 (0)31 565480/564145/396001 USA.
Telephone: 001 305 442 7413
Japan
Telex: 32501 Perken G
Perkins Engines, Inc. Japan Branch, Fax: 001 305 442 7419
8 Fl, 2-2-19 Akasaka, Minato-ku,
Tokyo 107-0052, Japan.
In addition to the above companies, there are
Telephone: 0081 (0)3 3560 3877
Perkins distributors in most countries. Perkins
Fax: 0081 (0)3 3560 3878
Engines Company Limited, Shrewsbury or one of
the above companies can provide details.

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Safety precautions ! Do not use salt water or any other coolant which
can cause corrosion in the closed coolant circuit.
These safety precautions are important. ! Do not allow sparks or fire near the batteries
Reference must also be made to the local regulations (especially when the batteries are on charge)
in the country of operation. because the gases from the electrolyte are highly
flammable. The battery fluid is dangerous to the
! Only use these engines in the type of application skin and especially to the eyes.
for which they have been designed.
! Disconnect the battery terminals before a repair is
! Do not change the specification of the engine. made to the electrical system.
! Do not smoke when you put fuel in the tank. ! Only one person must control the engine.
! Clean away fuel which has been spilt. Material ! If your skin comes into contact with high-pressure
which has been contaminated by fuel must be fuel, obtain medical assistance immediately.
moved to a safe place.
! Diesel fuel and lubricating oil (especially used
! Do not put fuel in the tank while the engine runs lubricating oil) can damage the skin of certain
(unless it is absolutely necessary). persons. Protect your hands with gloves or a
! Do not clean, add lubricating oil, or adjust the special solution to protect the skin.
engine while it runs (unless you have had the ! Do not wear clothing which is contaminated by
correct training; even then extreme caution must lubricating oil. Do not put material which is
be used to prevent injury). contaminated with oil into the pockets.
! Do not make adjustments that you do not ! Discard used lubricating oil in a safe place to
understand. prevent contamination.
! Ensure that the engine does not run in a location ! Ensure that the control lever of the transmission
where it can cause a concentration of toxic drive is in the ‘out-of-drive’ position before the
emissions. engine is started.
! Other persons must be kept at a safe distance ! The combustible material of some components of
while the engine or equipment is in operation. the engine (for example certain seals) can
! Do not permit loose clothing or long hair near become extremely dangerous if it is burned. Never
moving parts. allow this burnt material to come into contact with
! Keep away from moving parts during engine the skin or with the eyes.
operation. Warning! Some moving parts cannot ! Fuel and oil pipes MUST be inspected for cracks
be seen clearly while the engine runs. or damage before they are fitted to the engine.
! Do not operate the engine if a safety guard has ! Fit only genuine Perkins parts.
been removed.
! Do not remove the filler cap of the cooling system
while the engine is hot and while the coolant is
under pressure, because dangerous hot coolant
can be discharged.

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Engine views 2

Introduction
Perkins engines are built for specific applications and
the views which follow do not necessarily match your
engine specification.

Location of engine parts

Front and left side view of a 2000 Series engine
1 Fuel injector 9 Coolant pipe
2 Exhaust manifold 10 Fuel filter canister
3 Dipstick and tube 11 Turbocharger
4 Relief valve for the fuel 12 Lubricating oil pipe to the turbocharger
5 Fuel lift pump 13 Drain pipe for the lubricating oil from the
6 Filler cap for the engine lubricating oil turbocharger
7 Filler tube for the engine lubricating oil 14 Governor
8 Connection for the spill fuel

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Front and right side view of a 2000 Series engine

15 Rocker cover 21 Thermostat housing

16 Air charge cooler/inlet manifold 22 Alternator
17 Starter motor 23 Belt tensioner
18 Lubricating oil pipe to the main gallery 24 Oil cooler
19 Breather pipe 25 Canisters of the lubricating oil filter
20 Drain plug for the coolant

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Operation instructions 3

How to prepare a new or an overhauled

engine
Normal start procedures
Every new engine supplied by Perkins Engines
Company Limited, Shrewsbury, is run-in before it Service checks before a new or an overhauled
leaves the factory. engine, or an engine which has been in storage, is
started:
1 Check that all protection covers and blanking plugs
have been removed. If an engine has been in storage for a period of more
2 Fit all components which were removed for storage than one month or if the fuel injection pump or
or for transport. turbocharger has been removed, lubricating oil must
be added to the fuel injection pump, to the governor of
3 Ensure that the drain plugs for the coolant and for
the fuel injection pump and to the turbocharger. The
the lubricating oil are securely fitted.
procedure is given on this page, paragraphs 10 and
4 Where necessary, connect the remote control 11. Use clean engine oil of the same grade and
linkages, the pressure gauge pipes, the air inlet pipes specification as that already in the system.
and the wiring loom.
Service checks each day before the first engine
5 Connect the fuel pipes.
start:
6 Connect the exhaust pipes.
1 Check that the level of the coolant is just at the
7 Fill the fuel tank/s with the correct grade of fuel (see
bottom of the filler extension in the radiator. Fill, if
page 40).
necessary, to the correct level with the approved
8 Fill the cooling system with the approved coolant coolant mixture. Find the reason for large losses of
mixture (see page 39). coolant.
9 Fill the sump to the ‘H’ mark on the dipstick with the 2 Check the engine oil level. With the engine stopped
correct grade of lubricating oil (see page 40). the oil level must be at the ‘H’ mark on the dipstick. If
10 Remove the plug from the right side of the fuel necessary, add oil of the same grade and
injection pump and fill the fuel injection pump and specification as that already in the system. Do NOT
governor with clean engine lubricating oil, of the add more oil than is necessary.
correct grade, until the level of the oil reaches the hole 3 Check the level in the fuel tank. Open the fuel valve,
for the plug. Fit the plug and tighten securely. if one is fitted.
11 Add oil to the turbocharger, or to the two
turbochargers if relevant, as follows: Clean the area
around the blanking plug at the top of the
turbocharger bearing housing. Remove the plug and
insert 0,2 litre (1/3 pint) of engine lubricating oil of the
correct grade. Fit the plug.
12 Eliminate air from the fuel system (see page 31).
13 Lubricate all of the control linkages and check the
linkages for free movement.
14 Ensure that the stop control is in the STOP
position and that the lever of the speed control is in
the IDLE position. Press the start button for 10
seconds and wait for 10 seconds, then press it for 20
seconds and wait for 20 seconds. Oil pressure MUST
be indicated on the gauge.

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How to start the engine
2
Perform the daily service checks then proceed as
follows:
Move the stop control lever to the RUN position.
1 Move the speed control lever to the maximum
speed position.
2 Press the start switch and release it when the
engine starts. 1
3 Move the speed control lever to the idle position.
How to start the engine in low ambient 3
temperatures A 45

In addition to the use of cold starting aids as given

below, efficient starts in low temperatures require the 5 When the engine starts and runs, release the start
use of a suitable engine lubricating oil of the correct switch and continue to operate the pump until the
viscosity and also a good battery. engine speed increases. Then return the lever of the
speed control to the IDLE position.
If a cold engine is started in a temperature of 10°C, it
will increase speed immediately to the maximum
engine speed. At -30°C (-22°F), 20 minutes may
elapse before the engine speed increases from the
minimum of 450 rev/min at which the engine will
continue to run, to the maximum engine speed.
Variable speed engines have an automatic excess
fuel device which is fitted within the fuel injection
pump and operates when the lever for the speed
control is moved to the maximum speed position. The
excess fuel device works as a starting aid when
ambient temperatures are below 0°C.
Engines which drive generators are fitted with manual
excess fuel levers.
‘Start Pilot’ systems
1 ‘ER’ system. Remove the cap (A1) of the capsule
chamber and pull the plunger (A2) fully out. Insert a
fluid capsule into the chamber, fit the cap and push
the plunger fully in to make a hole in the capsule.
2 After a short delay, when the capsule is empty,
repeat the operation with two or three more capsules
according to the adverse ambient temperature. Then
operate the pump (A3) for three double strokes while
the start switch is operated.
3 ‘Viso-F’ system. Use the canister to fill the
reservoir to the MAX mark. Then operate the pump for
three double strokes.
4 Move the lever for the speed control away from the
IDLE position and operate the start switch. Continue
to operate the pump. Do not turn the engine
continuously at cranking speed for more than 20
seconds. If the engine does not start, there must be a
short delay before the start switch and the pump are
operated again.

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‘Fleetguard’ system How to stop the engine
This system consists of an expendable screw-on type
1 Operate the engine for 3 minutes at idle speed with
canister which contains 710 cc of ether under
no load to allow the turbocharger to reduce speed and
pressure. The ether is supplied to the engine by a
temperature.
remotely operated priming valve. Each operation of
the priming valve causes the atomisation and 2 Move the switches for the engine protection
injection of 6 cc of ether into the inlet manifold. devices to their OFF positions.
3 Move the stop control or switch to the STOP
1 Move the lever for the speed control away from the
position and release it after the engine has stopped.
IDLE position and operate the start switch.
2 When the engine turns, pull the control knob to
operate the priming valve for two seconds and then Running-in after a repair
release it. This action causes ether to be discharged
for three seconds into the inlet manifold. Every new or reconditioned engine which is supplied
by Perkins Engines has been given a period of
3 According to the adverse ambient temperature,
running-in before it leaves the Factory and it needs no
repeat the operation of the priming valve until the
special process when it is put into service.
engine starts and runs. Release the start switch but
continue to repeat the operation of the priming valve When a ‘Short engine’ or a ‘Long engine’ has been
until the engine speed increases. Then return the installed, or when a partial overhaul has needed new
lever of the speed control to the IDLE position. cylinder liners and new piston rings, the Operator is
4 Do not turn the engine continuously at cranking advised that the procedure, given below, should be
speed for more than 20 seconds. If the engine does applied before the engine is run at full load.
not start, there must be an interval of 20 seconds 1 Run the engine without a load until the normal
before operations 1 to 3 are repeated. temperature is reached.
2 During a period of three to four hours, increase
How to run the engine gradually the load on the engine until the final
conditions of the full load are reached.
The precautions which follow will help to ensure a Make frequent checks of:
long and fault-free life for the engine:
! Oil pressure.
1 Do not operate the engine at high speeds and loads
! Coolant temperature.
until the coolant has reached a minimum temperature
of 78°C (172°F). ! Pipes and connections for leaks.
2 Do not allow the engine to run at idle speed, or
without load, for prolonged periods.
3 Do not exceed the maximum rated speed of the
engine.
4 Never allow an engine to continue to run if the oil
pressure is below 207 kN/m2 (30 lbf/in2) at the rated
speed.
5 Fill the fuel tank/s at the end of each day to prevent
condensation and to allow sediment to fall to the
bottom of the tank.

15
4
Preventive maintenance 4

Preventive maintenance periods

These preventive maintenance periods apply to
average conditions of operation. Check the periods
given by the manufacturer of the equipment in which
the engine is installed. If necessary, use the shorter
periods. When the operation of the engine must
conform to the local regulations, these periods and
procedures may need to be adapted to ensure correct
operation of the engine.
The service intervals can be reduced for operation in
adverse conditions. The intervals must not be
extended unless Perkins Engines Company Limited
have approved the changes as indicated in the
Perkins Warranty.
It is good preventive maintenance to check for
leakage and loose fasteners at each service. These
maintenance periods apply only to engines that are
operated with fuel and lubricating oil which conform to
the specifications given in this handbook.

17
4
Schedule for engines in normal use
The preventive maintenance operations must be applied at the interval (hours or months) which occurs first.
A - Every 10 hours or daily
B - At pre-delivery inspection
C - Every 400 hours
D - Every 2000 hours
E - Every 10000 hours

A B C D E Operation
! ! Check the restriction indicator for the air filter and, when necessary, renew the
filter element
! ! Check the pressure of the lubricating oil at the gauge, if fitted
! ! Check the level of the lubricating oil
! ! Check the amount of coolant
! Drain all water/sediment from the primary fuel filter
! ! Check the condition and the tension of all drive belts
! Renew thelubricating oil
! Renew the canisters of the lubricating oil filter
Renew the rotor of the by-pass filter for the lubricating oil, if fitted
! Renew the canister of the main fuel filter
! Check the specific gravity and the pH value of the coolant
! Ensure that the nuts which retain the turbocharger(s) are tightened securely
! Ensure that the fuel injectors are checked and corrected, or renewed if
necessary*
! Ensure that the tappet clearances are checked, and adjusted if necessary*
! Loosen and tighten the bolts and the nuts of the cylinder heads to the correct
torque only in accordance with the instructions given in this Section. See ‘Note’
at the beginning of the operation
! Ensure that the turbocharger(s), the coolant pump, the alternator, and the starter
motor are checked*
! Ensure that the belt tensioner pulley, the engine damper, and the air compressor
(if fitted) are checked*
! Engine overhaul
- Intermediate 8 000 to 10 000 hours
- Full 16 000 to 20 000 hours
Use the instructions given in the Workshop Manual

* By a person who has had the correct training.

In addition to the operations listed above, the operations listed below must be applied at 12 month
intervals:
! Drain and flush the coolant system and renew the coolant mixture.
! Check that the intercooler and the radiator are clean and free from debris.

18
 4
Schedule for engines in intermittent use
For engines which are in use for a total of less than 400 hours in every twelve months, the schedule below
must be used:
The preventive maintenance operations must be applied at the interval (hours or months) which occurs first.
A - Every month
B - Every 200 hours or 12 months
C - Every 1000 hours or 24 months

A B C Operation
! Check the amount of coolant
! Check the level of the lubricating oil
! Check the restriction indicator for the air filter and, when necessary, renew the
filter element
! Drain all water/sediment from the primary fuel filter
! Start and run the engine until normal temperature of operation is reached. If the
engine has not been run for more than a month, add oil to the turbocharger(s) as
given in Section 3 before the engine is started
! Check the condition and the tension of all drive belts
! Renew the lubricating oil
! Renew the canisters of the lubricating oil filter
Renew the rotor of the by-pass filter for the lubricating oil, if fitted
! Renew the canister of the main fuel filter
! Ensure that the fuel injectors are checked and corrected, or renewed if
necessary*
! Ensure that the tappet clearances are checked, and adjusted if necessary*

* By a person who has had the correct training.

In addition to the operations listed above, the operations listed below must be applied at 12 month
intervals:
! Check the coolant pump, drain and flush the coolant system and renew the coolant mixture.
! Check the turbocharger(s) and give it/them a service if necessary*. Ensure that the nuts which retain the
turbocharger(s) are tightened securely.
! Ensure that the alternator and the starter motor are checked, and corrected if necessary*.
! Ensure that the belt tensioner pulley, the engine damper and the air compressor (if fitted) are checked*.
! Check that the intercooler and the radiator are clean and free from debris.

19
4
How to check the coolant level
Remove the filler cap from the radiator and check that
the level of the coolant mixture just touches the
bottom of the filler tube inside the radiator, or as given
in the equipment manufacturer's manual. If
necessary, add coolant until the level of the coolant
reaches the filler tube. Fit the filler cap.
For radiators which have a short filler tube: check that
the level of the coolant mixture is 76mm (3 in) below
the top of the filler tube. If necessary, add coolant until
the level is correct. Fit the filler cap.
Caution: If coolant is added to the system during the
service, it must consist of the same original mixture as
used to fill the system.
Warning! On a hot engine release the filler cap
carefully as the system will be under pressure.

How to check the lubricating oil level

At the periods given in the service schedule, use the
dipstick to check the amount of lubricating oil in the
sump.
Stop the engine and check that the oil level is at the H
mark on the dipstick. If necessary, put more oil into
the sump. The oil must be of the same grade and
specification as that which is already in the system.
Do NOT overfill.

20
 4
Air filter
The air filter (A) is a 14 inch dry type unit which is fitted
with a restriction indicator which gives a visual
warning when the filter needs a service.
When the red warning indicator is seen through the
clear panel to have reached the ‘service level’ mark
after the engine has stopped, the element of the air
filter must be cleaned or renewed.
After a clean element has been fitted, press the reset
button (B1) on the restriction indicator. 1
How to maintain the air filter
1 Loosen the clamp ring and remove the assembly of
the dust bowl and the baffle plate.
2 Remove the wing nut and separate the dust bowl
and the baffle plate.
3 Remove the debris from the dust bowl; clean and
assemble the two components.
4 Remove the wing nut which retains the filter
element and withdraw carefully the filter element.
5 Use compressed air at a maximum pressure of
700 kN/m² (100 lbf/in²) to clean the inner side of the
element. DO NOT hold the outlet for the compressed
air near to the element.
Another method to clean the element is to soak it in a A 44
solution of ‘D1400’ detergent. The detergent, with
instructions for its use, may be obtained from
Donaldson Filter Components Limited, or their
1
distributors.
6 Put a light inside the element and inspect the
material of the element for damage. Thin areas or
holes indicate that the element must be renewed
immediately.
7 Clean the body of the air filter, fit the element and
the assembly of the dust bowl and the baffle plate,
and tighten the clamp ring.
8 Press the reset button (B1) on the restriction
indicator.
B 37

21
4
How to check the drive belts
Check all drive belts and renew a belt if it is worn or 2 2
damaged. Where more than one belt is used between
two pulleys, all of the belts must be renewed together.
Check the belt tension at the centre of the longest free
length (A1).
Use a ‘Gates "Krikit" V-belt tension gauge’ or similar
tool to check the tension of the belts.
The correct tension for all belts is 400 to 489 N (90 to
100 lbf).
Note: When new belts are fitted they must be
checked again after the engine has been run for 15
minutes and, if necessary, adjusted to the correct
tension.

How to adjust the tension of the fan belts

Loosen the bolt (B1) which is covered by the triple fan
belts. The plate (B2), which holds the tensioner
pulley, pivots about this bolt. Loosen the bolt (B3)
which locks the cam plate (B4) and also clamps the 1
plate (B2). Use a spanner on the hexagon (B5) and
rotate the cam plate until the correct tension is
obtained (as given above). Then tighten the bolts (B3
and B1).

How to adjust the tension of the

alternator belt
Loosen the two bolts (A2) and rotate the alternator on
the pivot bolt to tighten the belt to the correct tension.
Tighten the two bolts.
Check again the belts to ensure that the tensions are
still correct. Maximum belt life will be obtained only if
the belts are kept at the correct tensions.
Where more than one belt is used between two
pulleys, check/adjust the tension on the tightest belt.
A 157

3 5

4
6

B 158

22
 4
How to renew the engine lubricating oil
Ensure that the engine is on level ground.
1 Operate the engine until it is warm.
2 Stop the engine, remove the sump drain plug (A1,
B1, C1, C2 or D1) and drain the lubricating oil into a
suitable container.
Caution: A thread insert is fitted to certain sumps.
Inspect the thread to find which type is fitted to your
engine.
3 Fit the drain plug and a new sealing washer and,
1
according to the type of thread, proceed as follows:
A 16
Sump with a thread insert (A): This plug has a
7
/8 UNS thread. Use a spanner - size 1 1/8 AF - to
tighten the drain plug (A1) to a torque of 115 Nm
(85 lbf ft). Retain the drain plug with locking wire
if it is possible.
Sump without a thread insert (B): This plug has
a 5/8 BSP thread. Use a spanner - size 13/16 AF -
to tighten the drain plug (B1) to a torque of 47,5 Nm
(35 lbf ft). Retain the drain plug with locking wire if
it is possible.
Sump without a thread insert (C): These plugs
have a 3/4 BSP thread. Use a spanner - size 15/16 1
AF - to tighten the drain plug (C1 or C2) to a torque
of 61 Nm (45 lbf ft). B 17

Plastic composite sump (D): These engines are

fitted with a plug which has a 19 mm socket. For
some applications the plug may have a 1/2 inch
square recess. Tighten the sump plug by use of a
19 mm socket spanner or a 1/2 inch extension bar
from a set of socket spanners as necessary.
Tighten the plug (D1) to a torque of 61 Nm (45 lbf ft).
1
Continued

2
C 363

1
D 159

23
4
4 Renew both of the oil filter canisters as instructed
on page 25.
5 Clean the area around the oil filler cap and remove 1
the cap. Fill the sump to the H mark on the dipstick
(A1) with clean new lubricating oil of an approved
grade as given on page 40. Do NOT overfill.
6 perate the engine and check for leakage from the
filter canisters. When the engine has cooled, check
the oil level on the dipstick and put more oil into the
sump, if necessary.

A 15

24
 4
How to renew the canisters of the oil filter
Two screw-on type canisters are fitted to the filter
head, which is integral with the casing of the heat
exchanger and is fitted to the right side of the engine
at the front.
1 Put a tray under the canisters and use a strap
wrench, 21825 825, to remove each canister.
2 Check that the sealing rings (A1) are correctly fitted 1
to the new canisters and clean the contact faces of
the filter head.
3 Fill the two new canisters with new engine
lubricating oil of the correct grade and lubricate the
top of each canister seal with the same oil.
4 To install the new canisters use this procedure:
Tighten the canisters, on their adaptors, until the
sealing rings are in contact with the face of the filter
head, then turn the canisters a further 11/4 turns, by
hand. Do NOT overtighten.

How to renew the rotor of the by-pass

filter for the lubricating oil
Some engines are also fitted with a by-pass filter for
the lubricating oil. The rotor of the by-pass filter must
be renewed at the periods given in the relevant
schedule. A 171

1 Clean the area around the by-pass filter. Remove

the filter bowl (B2), remove and discard the rotor (B3).
2 Remove the seal (B4) from the filter bowl and clean 1
all the components, especially the recess for the seal
in the filter bowl and the contact face for the seal on
2
the housing.
3 Fit a new seal to the recess in the filter bowl and
lubricate the face of the seal with clean engine
lubricating oil.
4 Fit a new rotor to the spindle and ensure that it can
rotate freely. Fit the filter bowl and tighten the nut (B1)
3
to a torque of 20 Nm (15 lbf ft).
5 When the engine is operated, check for leakage
from the by-pass filter.

B 07

25
4
How to renew the canister of the main fuel
filter
The main fuel filter is at the rear of the engine on the
‘A’ bank side and has a single canister.
1 Clean the area around the filter and remove the fuel
filter canister. If necessary, use a strap wrench 21825
825. Discard the canister. 1
2 Check that the sealing ring (A1) is fitted correctly to
the new canister and clean the contact face of the
filter head.
3 Fill the new canister with clean fuel oil of the correct
specification, lubricate the top of the canister seal with
clean fuel oil and renew the sealing ring on the
adaptor.
4 To install the new canister use this procedure:
Tighten the canister on its adaptor, until the sealing
ring is in contact with the face of the filter head, then
turn the canister a further 11/4 turns, by hand, or to a
torque of 20 Nm (15 lbf ft). Do NOT overtighten.
After the fuel filter canister has been renewed, turn on
the fuel supply. Eliminate air from the low pressure
fuel system as given on page 31.

How to drain the primary fuel filter

The primary fuel filter (B) is fitted between the fuel A 46
tank and the lift pump and works on the principle of
centrifugal separation. The fuel is obtained from the
tank by the suction of the lift pump and enters the filter 1
through the port (B2).
The fuel rotates around the tapered tube (B4) to
cause all sediment and water to move toward the
2
outer wall of the filter, and then to fall to the bottom of
the sediment bowl. The fuel flows out through the port
(B1) to the fuel lift pump.
1 Remove the drain plug (B5) from the base of the
filter bowl and allow all water and sediment to drain 3
from the unit.
2 Fit the drain plug and tighten it securely.

4
How to clean the primary fuel filter
1 Remove the three bolts and remove the sediment
bowl.
2 Clean all of the components with paraffin and dry
them with compressed air.
3 Fit the sediment bowl to the filter head, together
with a new sealing ring (B3). Align the clamp ring and
fasten it with the three bolts.

5
B 47

26
 4
How to check the specific gravity of the
coolant
Drain some coolant from the cooling system after the
engine has been stopped and before the formation of
A
40 45 50 55 60
sediment. Proceed as follows: 60 140

1 For mixtures which contain inhibited ethylene 50 122

glycol:
(a) Put a hydrometer, and a reliable thermometer, 40 104

into the antifreeze mixture and check the readings C D

30 86
on both instruments.
(b) Compare the readings obtained with the chart 20 68
and adjust the strength of the mixture as
10 50
necessary.
2 For mixtures which contain inhibited propylene 0
1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11
glycol:
(a) Open the cover of the refractometer, check that B
the clear panel is clean and use a small syringe to
apply three or four drops of the coolant mixture to
the clear panel.
Specific gravity chart
(b) Spread the coolant over the full area of the
clear panel and close the cover. Hold the A = Percentage anti-freeze by volume
refractometer horizontally with the clear panel at B = Specific gravity
the top and inspect the sample through the viewer. C = Mixture temperature in Centigrade
(c) Compare the reading with the chart in the D = Mixture temperature in Fahrenheit
instructions; adjust the strength of the mixture as
necessary.
Caution: The clear panel must be cleaned
thoroughly before use. If some of the fluid which was
tested earlier remains on the clear panel, the reading
of the sample will be affected.
Protection against frost is as follows:

Antifreeze/water Protection down to

(% by volume) (°C)
50/50 -35
60/40 -40

How to check the pH value of the coolant

The pH value of the coolant must not be less than pH7
or more than pH9.5. The pH value can be found by
the use of a pH meter or test papers, which are
available from pharmaceutical manufacturers.
If these limits are exceeded the pH value may be
adjusted by the addition of a corrosion inhibitor to the
same specification as that already in use. If this is not
possible, the system must be drained, flushed and
filled with new coolant.

27
4
Fuel injector fault
A fuel injector fault can cause an engine misfire.
1
To find which injector is defective, operate the engine
at a fast idle speed. Loosen and tighten the union nut
of the high-pressure fuel pipe at each injector. When
the union nut of the defective injector is loosened, it
has little or no effect on the engine speed.

Warnings!
! Ensure that the fuel does not spray onto your skin.
! Ensure that the fan guards are fitted.

How to remove a fuel injector

1 Clean the area around the fuel injector.
2 Disconnect and remove the leak-off pipe from the
fuel injector.
3 Disconnect and remove the high pressure pipe. If
necessary, release the pipe clip. Do NOT bend the
pipe.
Caution: Ensure that dirt does not enter the fuel
injector.
4 Remove the bolts and the clamp which retains the
fuel injector and withdraw the fuel injector. Remove
and discard the copper sealing washer and the rubber A 49
seal, and temporarily seal the top of the fuel injector
sleeve to prevent the entry of contamination.
5 To remove a tight fuel injector, use the slide
hammer, 21825 849 (A1) and the relevant adaptor
21825 860.

28
 4
Fuel injector sleeves
1
Steel fuel injector sleeves are fitted through the
coolant galleries of each cylinder head and are
retained by a thread at the bottom of the cylinder
head. The thread is sealed with ‘Hylomar Universal’
sealing compound. The top of the fuel injector sleeve
is sealed by an ‘O’ ring (A1) which is fitted to a groove
in the cylinder head.

How to correct a fuel injector sleeve

Before the fuel injectors are renewed, the faces of the 2
seats in the fuel injector sleeves should be cleaned by A 50

the method given below.

1 To retain carbon and metal particles, grease must
be applied to both of the cutters of the tool in the
cleaning kit 21825 909 before it is used. Insert the tool
into the fuel injector sleeve and remove the carbon
deposits from the faces of the seats. DO NOT
REMOVE METAL FROM THE FACES OF THE
SEATS.
2 When a fuel injector is removed, if the copper
sealing washer remains in the fuel injector sleeve, it
can be removed with the tool which is used to clean
the fuel injector sleeve.

29
4
How to fit a fuel injector
The seal between the nozzle of the fuel injector and
the fuel injector sleeve is made by a copper sealing
washer which must be renewed at the recommended
intervals given in the schedules for the preventive
maintenance of the fuel injectors.
To prevent the entry of dirt between the fuel injector
and the fuel injector sleeve, a rubber seal is fitted onto
the body of the fuel injector over a counterbore in the
cylinder head. An aluminium distance piece is then
fitted above the rubber seal. When the clamp for the 1
fuel injector is tightened, the rubber seal is pressed
into the counterbore. The rubber seal should be
renewed at the recommended intervals given in the
schedules for the preventive maintenance of the fuel
injectors.
1 Ensure that the fuel injector sleeve is clean and is
free from carbon deposits.
2 Fit a new rubber seal (A1) onto the body of the fuel
injector and a new copper sealing washer (A2) to the
nozzle. Fit the aluminium distance piece above the 2
rubber seal.
3 Apply evenly anti-seize compound (‘Morris K72’ or
equivalent) to the body of the fuel injector between the
arrows (B1). Do NOT allow the anti-seize compound
to contaminate the copper washer or the nozzle of the A 125
fuel injector (B2).
Caution: Ensure that dirt does not enter the fuel
injector.
4 Fit the fuel injector into the fuel injector sleeve.
Apply an even layer of anti-seize compound of 1 mm
thickness to the threads of the retaining bolts. Retain
the fuel injector with the clamp and the bolts. Tighten
evenly the bolts to a torque of 11 Nm (8 lbf ft).
5 Fit the high-pressure fuel pipe. Ensure that there is
no tension on the connections and that the
connections do not turn when the nut is tightened.
6 Fit and tighten all clamps which may have been 1
removed.
7 Fit the leak-off pipe, complete with new washers,
and eliminate air from the fuel system as given on
page 31.
8 Run the engine and check for leakage.

A 126

30
 4
How to eliminate air from the fuel system
If air enters the fuel system, the injection pump
pressure may become insufficient to operate the
valves of the fuel injectors and the engine may stop,
misfire, run badly or not start.
If air has entered the fuel system, the source of the
problem must be found and corrected.
Air can enter the system if:
! The fuel tank is drained during normal operation.
! The low-pressure fuel pipes are disconnected.
! There is a leakage in the fuel system during the 1
operation of the engine.
! The fuel filter canister has been removed.
! There is a leakage at the bowl of the preliminary
fuel filter.
To eliminate air from the system, use the procedure
which follows:
1 Ensure that there is fuel in the fuel tank and that the
source of any leakage has been eliminated.
2 Loosen the union at the outlet pipe of the lift pump.
Operate the hand priming pump to allow fuel to flow
from the union, then tighten the union.
3 Continue to operate the hand priming pump and
loosen the union on the outlet side of the fuel filter. A 54
When fuel which is free from air flows from the union,
tighten the union.
4 Continue to operate the hand priming pump and
loosen, one at a time, each union where the high
pressure fuel pipe is connected to its fuel injector.
Tighten each union once any air has been eliminated.
Do NOT loosen more than one connection at the
same time.
5 When all the unions are tightened fully, continue to
operate the hand priming pump until the relief valve
on the fuel injection pump is heard to open.

Warnings!
! Ensure that he pipes have not become bent and
that they are free from distortion.
! Ensure that unions and clamps have been
tightened correctly.
! Ensure fuel does not spray onto your skin.
! Ensure that spilt fuel has been cleaned away.

31
4
How to check the tappet clearances
Check and adjust the tappet clearances in the
sequence which follows, while the injectors are
removed for service.
The tappet clearances are measured between the
rocker levers and the tips of the valves (A), see page
53 for the sizes of the clearances.

Valves set on Check tappets on

cylinder No cylinder No
6 1
3 4
5 2
1 6
4 3
2 5

1 Remove the rocker covers.

2 Turn the crankshaft in the normal direction of
rotation until the inlet valve of number 6 cylinder has
just opened and the exhaust valve of the same
cylinder has not closed completely. The valves of
number 6 cylinder are then ‘set’.
3 Check the clearances of the valves of number 1
cylinder and adjust them if it is necessary (A). When A 151
the clearance has been set, tighten the lock nut.
4 Continue to turn the engine and adjust the
remainder of the tappets in the sequence given
above.
5 Fit the rocker covers.

32
 4
Alternator
The alternator which is fitted on the 2000 Series 1 2
3
engine is belt driven and has an integral regulator.
The three phase alternator is of the rotating field and
stationary armature type. The rectifier consists of six
silicon diodes. These are retained by the two heat
sinks in the assembly of the rectifier, which is in the
housing at the slip ring end.
Excitation of the field is done by three auxiliary diodes
which are assembled in the centre of the rectifier.
The output is controlled by an integral regulator and
the maximum rated output (hot) is 32 amps at 28 A 75

volts.
A centrifugal fan causes a flow of cool air through the
1 2
alternator and the fins of the heat sinks.
How to maintain the alternator
4
Clean the outside of the alternator and ensure that the
ventilation holes are clean, at the periods given in the
service schedule. Contamination near to the diodes
can cause sparks and must be removed with an
approved cleaning fluid. A recommended fluid is
Electronic Cleaning Fluid, Grade 8-23, available in
aerosol containers or in larger quantities from Applied
Chemicals Limited, Uxbridge, Middlesex. 3
The alternator must be checked and corrected, if
B 76

necessary, by a person who has had the correct

Key (A)
training, at the recommended intervals given in the
schedules for the preventive maintenance of the 1 Carbon brush housing
alternator. Proceed as follows:
2 Slip ring assembly
1 Check the condition and the tension of the drive 3 Rectifier assembly
belt, and adjust or renew as necessary.
2 Disconnect the two wires of the regulator (B1) from Key (B)
the terminals on the holder (B2) of the carbon
brushes. Make a note of the correct position of each
1 Regulator
wire for their subsequent assembly. Remove the two 2 Carbon brush holder
screws which retain the regulator and lift away the 3 Capacitor
regulator.
4 Plastic cover
3 Remove the screws which retain the holder of the
carbon brushes, disconnect the wires and lift out the
assembly of the holder.
4 Check the carbon brushes for damage and ensure
that they are suitable for use. The minimum possible
protrusion of the carbon brushes from the holder must
be 10,0 mm (0.394 in). Renew the carbon brushes if
the protrusion is less than 10 mm.
5 Remove the four screws which retain the housing
of the carbon brushes, withdraw the housing and
inspect the assembly of the slip rings.
6 Clean the components and remove all of the dirt.
Use a soft clean rag which is damp with gasoline or
white spirit. Slip rings which are worn or rough must
be renewed.

33
4
Starter motor
The starter motor is an electrically operated 24 volt
unit with a solenoid switch.
fitted on the outside of the yoke. The drive gear
engages with a starter ring which is a component of
the flywheel assembly.
How to maintain the starter motor
Caution: Before the starter motor is removed from
the engine or other work is done to it, disconnect the
cables from the battery terminals.
At intervals, inspect the starter cables for damage and A 55
ensure that the nuts of the terminals and the bolts
which hold the starter motor are tight. A new unit, or an exchange unit, should also be
The starter motor must be checked and corrected, if lubricated by the same procedure before it is fitted.
necessary, by a person who has had the correct 7 Clean the splines of the pinion assembly and
training, at the recommended intervals given in the lubricate them with a thin application of graphite
schedules for the preventive maintenance of the grease. Check that the pinion moves freely.
starter motor. Remove the starter motor and proceed
8 Ensure that the starter motor is assembled correctly
as follows:
to the engine and retain it securely with the three
1 Clean the outside of the starter motor and remove bolts. Check that the terminals are clean.
the commutator cover. Use dry compressed air to 9 Fit the lugs of the relevant cables to the two
remove dust from the area of the carbon brushes. terminals. Ensure that the polarity of the cables is
2 Inspect the commutator for wear and damage. A correct and fit the locking washers and the lock nuts,
polished dark copper finish indicates that the or the stiffnuts if relevant.
condition is acceptable. Signs of wear or damage 10 Hold a 19 mm (0.75 in) A/F spanner on the inner
indicate that a new or reconditioned commutator is lock nuts to ensure that they do not move while the
necessary. outer nuts are tightened to 25 to 30 lbf ft (34 Nm to
3 Ensure that the carbon brushes slide freely in their 41 Nm) with a suitable torque wrench.
holder and check that the load of the springs is 1,42
to 1,68 kgf (50 to 59 ozf). An excessively lower load
indicates that the carbon brushes are worn. The
minimum acceptable length is 15,9 mm (0.625 in).
4 If new carbon brushes are necessary, the shape of
the contact faces must conform to the radius of the
commutator. Keep away the wires of the carbon
brushes from other components.
5 Spread a thin application of glycerine on the gasket
of the cover for the carbon brushes, and fit the ends
of the cover across one of the ribbed sections of the
yoke. Tighten the two screws which retain the cover
to 1,13 to 1,70 Nm (10 to 15 lbf in).
6 Remove the screws from the three points shown by
arrows (A) and put three or four drops of SAE 5W/20
engine lubricating oil on the lubricator wicks. Fit the
screws to the three points.

34
 4
How to drain the coolant system
Drain and flush the coolant system every 12 months
or less. It is recommended that the coolant system is
drained as soon as possible after the engine has been
stopped and before the formation of sediment.
Proceed as follows:
1 Ensure that the engine is level.
2 Remove carefully the filler cap of the radiator,
especially if the engine is hot. 1
Warning! Use care during the removal of the filler
cap as the coolant system will be under pressure.
3 Remove the coolant drain plug (A1) from the rear of A 25

the left side of the engine. Ensure that the drain holes
are not restricted. 6 Repeat operations 3, 4 and 5.
4 To drain the radiator, refer to the Manufacturer’s 7 Drain the system completely and close the drain
Instruction Publication. outlets. Fill the system with the correct coolant
mixture.
5 Flush the system with clean water.
Note: In very cold ambient conditions, the thermostat
6 Fit the engine drain plug and all items which were
may not open to allow full circulation of the cleaning
removed in accordance with the Manufacturer’s
fluid. If this occurs the engine must be operated on
Instruction Publication.
load. The thermostat is open when the pipe between
7 Fit a ‘coolant drained’ label if the coolant system is the thermostat housing and the radiator is hot. If the
not to be filled immediately. pipe is cool, the thermostat valve is closed.

How to clean the coolant system How to fill the coolant system
The coolant system must be drained and flushed Fill the system slowly, with the approved coolant
through with clean water until it flows clear from all of mixture, until the coolant is just in contact with the
the drain outlets. bottom of the filler tube inside the radiator. For
If the system has become contaminated, it must be radiators which have a short filler tube: check that the
cleaned. Use clean water with 1% of Symperonic ‘N’. level of the coolant mixture is 76 mm (3 in) below the
This is equivalent to 10 ml/litre or 45 ml/UK gallon. top of the filler tube of the radiator. Operate the engine
until the coolant reaches the normal temperature of
1 Fill the system with clean water, at the same time operation. Stop the engine, check the coolant level
add the necessary amount of Symperonic ‘N’ at the and, if necessary, add extra coolant. Fit the filler cap.
filler cap.
Warning! Use care during the removal of the filler
2 Operate the engine until the coolant reaches the
cap as the coolant system will be under pressure.
normal temperature of operation, then operate the
engine at maximum rated speed for 10 minutes. See
‘Note’ at the end of this section.
3 Stop the engine and drain immediately the coolant
from all of the drain outlets.
4 Allow the engine to cool, then fill the system with
clean water. Allow a minimum of 5 litres (1 UK gallon)
to drain from the system before the drain outlets are
closed.
5 Operate the engine as in operation 2, but maintain
maximum speed for 5 minutes only.

35
4
How to check the turbocharger
Disconnect and remove the pipes from between the
air filters and the turbocharger, at the periods given in
the service schedule. Turn, rapidly, the rotor
assembly, check for freedom of movement and for
sounds of interference. If necessary, recondition or
renew the turbocharger.
Deposits must not be removed from the turbine wheel
nor the compressor wheel, or the balance of the
assembly will be affected.
Waste-gates are fitted to the turbochargers of certain
engines. These check the boost delivery pressure in A 56
the turbocharger compressor and, when it reaches a
set amount, a valve opens and releases the excess 4 Work on one nut or one bolt at a time, use the
pressure. The operation of the waste-gate should be sequence shown (A) and proceed as follows:
checked as follows:
(a) Remove the bolt, or nut, lubricate lightly the
1 Apply air pressure up to a maximum of 207 kN/m2 threads and the face under the head of the bolt.
(30 lbf/in2) and feel for movement of the end of the (b) Fit the bolt or nut and tighten it to 204 Nm
control rod. This should be about 1,15 mm (0.045 in). (150 lbf ft) or until the marks align (the tighter of
2 If the rod fails to move, disconnect the rod from its the two). If the bolt is one of those shown in a
lever and try to move the lever by hand. If the lever is black circle, tighten it by a further 40° or until the
tight, that part of the turbocharger must be dismantled marks align (the tighter of the two). A suitable
and cleaned. torque angle gauge (part number 21825 924) is
3 With the rod still disconnected, test the assembly available.
again with air pressure upto 207 kN/m2 (30 lbf/in2). If (c) Continue in the correct sequence (A).
the rod fails to move, the diaphragm and rod 5 Fit the rocker gear, tighten the bolts evenly and
assembly must be renewed. gradually to a torque of 40 Nm (30 lbf ft).
6 Check the tappet clearances and, if necessary,
How to tighten the bolts of the cylinder adjust them to the correct dimensions as given on
head page 53.
7 Pour approximately 0,6 litre (1 pint) of clean engine
Note: For engines from build line number 91880, this lubricating oil over the rocker assembly and fit the
procedure is not necessary because of new rocker covers.
procedures used when the engine is assembled.
Caution: Certain engines have a bolt marked "OIL"
fitted at position 22 on the illustration (A). For these
engines, the special bolt MUST be used at the correct
position.
1 Remove the rocker covers and the rocker
assembly.
2 Clean the nuts and the heads of the bolts which
retain the cylinder heads.
3 Make a temporary mark on each nut and the head
of each bolt, and also on the cylinder heads. Ensure
that the marks are aligned.
Caution: Do NOT loosen more than one nut or bolt
at a time.

36
 4
Coolant pump
Inspect the exterior of the coolant pump. Check for
signs of leakage. Overhaul or renew as necessary.

Tensioner pulley for fan belts

At the periods given in the service schedule the
tensioner pulley must be inspected. Proceed as
follows:
1 Remove the fan belts as given on page 22.
2 Check that the pulley assembly is retained
securely.
3 Check the condition of the bearings and renew if
necessary.
4 Fit the fan belts and alternator belt as given on
page 22.

Engine damper
At the periods given in the service schedule, examine
the engine damper. Check for damage and signs of
leakage. Renew if necessary.

Air compressor
At the periods given in the service schedule, check
the performance of the air compressor. Examine the
exterior for damage or signs of oil or air leaks.
Overhaul or renew as necessary.

37
5
Engine fluids 5

Diesel fuel
Diesel fuel must conform to the specifications given Corrosion inhibitor
below:
If anti-freeze is not available and is not required
On highway then clean soft water, with 1% of PE(S)L corrosion
BS EN 590 1997 - maximum sulphur content 0.05%; inhibitor, may be used. This ratio is equivalent to
minimum cetane number 49 and minimum cetane 0,5 litres of corrosion inhibitor to 50 litres (11 UK
index 46. gallons) of water. The corrosion inhibitor is
available from the Perkins worldwide distributor
Low sulphur fuels must conform to a lubricity network, part number 21825 735 (1 litre). The use
performance such that when tested using HFRR of this product should be controlled in accordance
(CEC F-06-A96) the wear scar meets a maximum of with the manufacturer’s instructions. For CHP
460 microns. (combined heat and power) sets an alternative
Off highway inhibitor, part number OE45765, is recommended
at a strength of 3%.
BS 2869: Part 2 1998 Class A2 - maximum sulphur
content 0.20%; minimum cetane number 45 and Water quality
minimum cetane index 45.
Soft water means de-ionised water, distilled water,
The use of fuels which do not conform to the above rain water, or water from a mains supply which has
standards can cause damage and/or reduced engine a maximum combined chloride and sulphate level
life and could affect the warranty. Further details can of 150 mg/litre and a maximum total hardness of
be obtained from the Service Department at Perkins 250 mg/litre.
Engines Company Limited, Shrewsbury.
1 If soft water is not used, the cooling system may be
affected by the formation of hard deposits which can
Coolant cause the engine to overheat. This is especially
important for engines which have coolant added
Coolant mixture frequently.
The coolant approved for use in all diesel engines 2 The use of products which are not approved for the
manufactured by PE(S)L is a mixture of 50% inhibited cooling system may cause serious problems. Coolant
ethylene glycol, or inhibited propylene glycol, and mixtures with insufficient corrosion inhibitor can
50% clean soft water. cause erosion and/or corrosion of the cooling system
Mixtures which contain methanol are NOT approved. components.

The corrosion inhibitor in the anti-freeze or coolant

concentrate, must be based on sodium nitrite, sodium
benzoate, sodium borate, sodium metasillicate and
benzotriazole.
Amines or phosphates must not be used. If operators
are in doubt, they should consult their source of supply.
In addition, all products which are used should
conform to BS 6580-1992.
For marine engines and engines which have
aluminium water-cooled exhaust manifolds, only
‘BASF 007/400F’ or Perkins anti-freeze are approved.
The Perkins anti-freeze, part numbers 21825 166
(1 litre) and 21825 167 (5 litre), can be obtained
from the Perkins worldwide distributor network.
Caution: Do NOT use salt water or any other coolant
which can cause corrosion in the closed coolant circuit.

39
5
Lubricating oil
1 Viscosity - Perkins Engines Company Limited
recommend the use of SAE15W/40 for all engines
that work in ambient temperatures above -15°C
(5°F). Below -15°C (5°F) and down to -20°C (-4°F)
the use of a 10W/30 oil is recommended. Down to -
30°C (-22°F) a 5W/40 fully synthetic oil is
recommended. For engines which operate in arctic
conditions, below -30°C (-22°F), contact the Service
Department at Perkins Engines Company Limited,
Shrewsbury.
2 Performance Specification - For heavy duty
operation, base load, or extended drain (Eagle Tx
only), super high performance oils (SHPD) must be
used. These oils exceed the requirements of ACEA
E3 and are listed in the ‘preferred’ columns of the
table shown.
For light duty operation, oils which exceed the
requirements ACEA E2 may be used. These oils are
listed in the ‘acceptable’ columns of the table shown.
It is recommended that the operator uses oils shown
in the ‘preferred’ columns as these give the greatest
protection.

40
 5
Below is a list of oils recommended by Perkins Engines Company Limited, Shrewsbury. The operator must
ensure that the oil used conforms to the above requirements.

Recommended oils for Europe

Manufacturer of Preferred multi-grade oils which conform Acceptable multi-grade oils which
lubricating oil to ACEA E3 conform to ACEA E2
AGIP Sigma Turbo 15W/40 Universal Multifleet 15W/40
Blitum T 15W/40 Master Super Turbo SHPD 15W/40
BP Vanellus C3 Extra 15W/40 Vanellus C3 Multi-grade 15W/40
Vanellus FE Extra10W/40
Vanellus HT 10W/40
Vanellus HT Extra 10W/40
CALTEX ONLY AVAILABLE IN FAR EAST, MIDDLE
EAST, SOUTHERN AND EASTERN
AFRICA AND AUSTRALASIA
CASTROL Syntruck 5W/40 RX Super Plus 15W/40
Dynamax 10W/40
Turbomax 15W/40
CHEVRON Delo XLD 15W/40 Delo 500 15W/40
Delo SHP 15W/40
ELF Performance EXPERTY 10W/40 Performance Super D 15W/40
Performance TROPHY DX 15W/40 Performance 3D 15W/40
ESSO Essolube XTS 501 Essolube XTS 301
Essolube XT 401 Essolube XT 301
FINA Kappa First 5W/30 Kappa Supra 15W/40
Kappa Extra 15W/40
Kappa Ultra 10W/40
FUCHS Turbolene HPE 15W/40 Titan Formel Plus 15W/40
Titan Unic Plus 10W/40 Turbolene D 15W/40
Titan Cargo MC 10W/40 Turbolene D Plus 15W/40
KUWAIT Q8T 700 15W/40 Q8T 500 15W/40
Q8T 710 15W/40
Q8T 800 10W/40
MILLERS Multifleet XPD 15W/40 Maxifleet MP 15W/40
Truckmaster Global XD 15W/40 Suprex 15W/40
Truckmaster XHFE 10W/40
MOBIL Delvac 1 SHC 5W/40 Delvac MX 15W/40
Delvac XHP 15W/40
Delvac HP 15W/40
MORRIS XHD Plus 15W/40 Duplex CDX 15W/40
XHD FE 10W/40 XHD 15W/40
Ring Free Ultra 10W/40
SHELL Rimula Ultra 5W/30 Rimula X 15W/40
Rimula Super 15W/40 Rimula TX 15W/40
SUN Super HPD 15W/40 Forza 15W/40
TEXACO URSA Super TDX 10W/40 URSA Super LA 15W/40
URSA Super TD 15W/40
TOTAL Rubia TIR 8600 10W/40 Rubia 4400 15W/40
Rubia TIR 6400 15W/40 Rubia XT 15W/40

41
5
Recommended oils for remainder of the world

Manufacturer of Mono-grade oils which Preferred multi-grade oils Acceptable multi-grade

lubricating oil conform to ACEA E2 which conform to oils which conform to
ACEA E3 ACEA E2
AGIP Sigma Turbo 15W/40 Universal Multifleet
Blitum T 15W/40 15W/40
Master Super Turbo
SHPD 15W/40
BP Vanellus C3 30 Vanellus C3 Extra 15W/40 Vanellus C3 multi-
Vanellus C3 40 Vanellus FE Extra 10W/30 grade15W/40
CALTEX Delo SHP SAE 30 and Delo XLD multi-grade Delo SHP multi-grade
SAE 40 SAE 10W/40 SAE 15W/40
Delo 600 SAE 30 and Delo 600 multi-grade
SAE 40 SAE 15W/40
Delo 350 SAE 30 and Delo 350 multi-grade
SAE 40 SAE 15W/40
CASTROL Syntruck 5W/40 RX Super Plus 15W/40
Dynamax 10W/40
Turbomax 15W/40
CHEVRON Delo 1000 Marine Delo 400 multi-grade RPM Heavy Duty Motor
SAE 30 or 40 SAE 15W/40 oil 15W/40
ELF Performance Super D Performance TROPHY DX Performance Super D
SAE 30 and 40 15W/40 15W/40
Performance 3D SAE 30 Performance 3D 15W/40
and 40
ESSO Essolube X 301 SAE 30 Essolube XT 431 Essolube XT 331
Essolube X 301 SAE 40 Essolube XD 3 Extra+ Essolube XD 3+
Essolube XD 3+ SAE 30
Essolube XD 3+ SAE 40
FINA Kappa Super 30 Kappa First 5W/30 Kappa Supra 15W/40
Kappa Super 40 Kappa Extra 15W/40
Kappa Ultra 10W/40
KUWAIT Q8T 500 SAE 30 Q8T 700 15W/40 Q8T 500 15W/40
Q8T 500 SAE 40 Q8T 710 15W/40
Q8T 800 10W/40
MOBIL Delvac 1430 Delvac 1 SHC 5W/40 Delvac MX 15W/40
Delvac 1330 Delvac XHP 15W/40
Delvac HP 15W/40
MORRIS XHD SAE 30 or 40 XHD Plus 15W/40 Duplex CDX 15W/40
XHD FE 10W/40 XHD 15W/40
SHELL Rimula X 30 Rimula Ultra 5W/30 Rimula X 15W/40
Rimula X 40 Rimula Super 15W/40 Rotella TX 15W/40
SUN Super HPD 40 Super HPD 15W/40 Forza 15W/40
TEXACO URSA Super LA 30 URSA Super TDX 10W/40 URSA Super LA 15W/40
URSA Super LA 40 URSA Super TD 15W/40
TOTAL Rubia FP 40 Rubia TIR 8600 15W/40 Rubia 4400 15W/40
Rubia TIR 6400 15W/40 Rubia XT 15W/40

Warranty
The engine must be operated with the approved fuel, lubricant and coolant, and maintained in accordance with
the service schedule or the warranty can become invalid.

42
6
Fault diagnosis 6

Continued

43
6
Problems and possible causes

Possible causes

Problem
Checks by service
Checks by the user
personnel

The starter motor turns the engine too slowly 1, 2, 3, 4

The engine will not start 5, 6, 7, 8, 9, 10, 12, 13, 14, 34, 35, 36, 37, 38, 42, 43,
15, 17 44
The engine is difficult to start 5, 7, 8, 9, 10, 11, 12, 13, 14, 34, 36, 37, 38, 40, 42, 43,
15, 16, 17, 19 44, 64
Not enough power 8, 9, 10, 11, 12, 13, 16, 17, 34, 36, 37, 38, 39, 42, 43,
18, 19, 20, 21 44, 61, 63, 64
Misfire 8, 9, 10, 12, 13, 15, 20, 22 34, 36, 37, 38, 39, 40, 41,
43
High fuel consumption 11, 13, 15, 17, 18, 19, 21, 34, 36, 37, 38, 39, 40, 42,
22 43, 44, 63, 64
Black exhaust smoke 11, 13, 15, 17, 19, 21, 22 34, 36, 37, 38, 39, 40, 42,
43, 44, 61, 63, 64
Blue or white exhaust smoke 4, 15, 21, 23 36, 37, 38, 39, 42, 44, 45,
52, 58, 62
The pressure of the lubricating oil is too low 4, 24, 25, 26 46, 47, 48, 50, 51, 59
The engine knocks 9, 13, 15, 17, 20, 22, 23 36, 37, 40, 42, 44, 46, 52,
53, 60
The engine runs erratically 7, 8, 9, 10, 11, 12, 13, 15, 34, 38, 40, 41, 44, 52, 60
16, 18, 20, 22, 23
Vibration 13, 18, 20, 27, 28 34, 38, 39, 40, 41, 44, 52,
54
The pressure of the lubricating oil is too high 4, 25 49
The engine temperature is too high 11, 13, 15, 19, 27, 29, 30, 34, 36, 37, 39, 52, 55, 56,
32 57
Crankcase pressure 31, 33 39, 42, 44, 45, 52
Bad compression 11, 22 37, 39, 40, 42, 43, 44, 45,
53, 60
The engine starts and stops 10, 11, 12 6, 7, 8, 9, 10, 12, 16, 34, 35

44
 6
Code list of possible causes 34 A fault in the fuel injection pump.
35 A broken drive on the fuel injection pump.
1 The battery capacity is low.
36 The timing of the fuel injection pump is incorrect.
2 A bad electrical connection.
37 The valve timing is incorrect.
3 A fault in the starter motor.
38 There is bad compression.
4 The wrong grade of lubricating oil.
39 The cylinder head gasket leaks.
5 The starter motor turns the engine too slowly.
40 The valves are not free.
6 The fuel tank is empty.
41 Wrong high-pressure pipes.
7 A fault in the stop control.
42 The cylinder bores are worn.
8 A restriction in a fuel pipe.
43 A leakage between the valves and the seats.
9 A fault in the fuel lift pump.
44 The piston rings are not free, or they are worn or
10 A dirty element of the fuel filter. damaged.
11 A restriction in the air filter or the induction system. 45 The valve stems and/or the guides are worn.
12 There is air in the fuel system. 46 The crankshaft bearings are worn or damaged.
13 A fault in the fuel injectors, or the fuel injectors are 47 The lubricating oil pump is worn.
of the wrong type.
48 The relief valve does not close.
14 The cold start system is not used correctly.
49 The relief valve does not open.
15 A fault in the cold start system.
50 The spring of the relief valve is broken.
16 A restriction in the vent of the fuel tank.
51 A fault in the suction pipe of the lubricating oil
17 The wrong type or grade of fuel has been used. pump.
18 A restriction in the movement of the engine speed 52 A piston is damaged.
control.
53 The piston height is incorrect.
19 A restriction in the exhaust pipe.
54 The flywheel housing, or the flywheel, is not
20 The engine temperature is too high. aligned correctly.
21 The engine temperature is too low. 55 A fault in the thermostat or the thermostat is of a
22 The tappet clearances are incorrect. wrong type.
23 Too much oil, or oil of a wrong specification is 56 A restriction in the coolant passages.
used in a wet type air cleaner. 57 A fault in the water pump.
24 Not enough lubricating oil in the sump. 58 There is damage to the oil seals (if they are fitted)
25 A defective gauge. of the valve stems.
26 A dirty element of the lubricating oil filter. 59 A restriction in the sump strainer.
27 The fan is damaged. 60 A valve spring is broken.
28 A fault in the mountings of the engine or the 61 The impeller of the turbocharger is damaged or is
flywheel housing. dirty.
29 Too much lubricating oil in the sump. 62 Leakage of lubricating oil from the oil seal of the
30 A restriction in the air passages or in the water turbocharger.
passages of the radiator. 63 The induction system leaks (turbocharged
31 A restriction in the breather. engines).
32 There is insufficient coolant in the system. 64 Damaged or defective waste-gate (if fitted).
33 A fault in the exhauster, or there is a leakage in the
vacuum pipe.

45
7
Engine preservation 7

Storage
When the engine is not in use, temporarily or for a 2 Operate the engine until the normal temperature of
longer period, it must be protected from corrosion. operation is reached. Stop the engine and drain
The amount and the type of treatment to prevent immediately the lubricating oil from the sump and
corrosion during storage is according to the length of from the canisters of the oil filter (see the 'Note' about
the period of storage. When necessary, there must canisters on this page).
also be protection from frost. 3 Fill the canisters of the oil filter with PX4 corrosion
If the engine is fitted with a composite sump, and to inhibitor and fit the canisters to the filter head (see
avoid possible damage, it must not be allowed to rest page 25).
on its sump. 4 Fill the sump, to the normal oil level, with PX4
corrosion inhibitor and, once again, run the engine
All new and reconditioned engines which leave the
until the normal temperature of operation is reached.
Factory have been inhibited to Perkins Engines
standards. An engine may be in storage, under a 5 Stop the engine, disconnect the fuel supply pipe
cover and in dry conditions, for a maximum period of and connect the pipe to a supply of PX4 corrosion
12 months from the date it left the Factory, without the inhibitor. Start the engine, while it is still hot, and
need for it to be inhibited again. operate the engine, with no load, for ten minutes. Stop
the engine.
After a period of 12 months of storage, the engine
6 Disconnect the supply of PX4 corrosion inhibitor
must be inspected thoroughly and must be again
from the fuel system and seal the end of the pipe.
inhibited.
Drain the fuel filters.
Note: The canisters of the oil filters and the fuel filters
Short period storage are designed so that when fitted upside down, the
lubricating oil or fuel does not drain from the canister,
Up to seven days: when the engine is stopped.
No treatment is necessary. To drain a canister, hold it over a suitable container,
Up to three months: insert a small tool into one of the inlet openings and
carefully press open the rubber, non-return seal.
Each week, operate the engine until the normal During this operation, do not damage the rubber seal
temperature of operation is reached. If the engine or the element of the filter.
cannot be operated, turn the crankshaft by hand,
in the normal direction of rotation (anti-clockwise Fasten a label, at a position where it will be seen, to
as seen on the flywheel), a minimum of three indicate that the fuel system has been disconnected.
revolutions. 7 Remove the fuel injectors and put them in a
container of PX4 corrosion inhibitor.
Long period storage 8 Set the fuel control lever to the NO FUEL position,
remove the rocker covers and disconnect the air
If it is necessary to put an engine into storage for a filter(s).
period of between three and twelve months, use this 9 Turn the engine by the use of the starter and, at the
procedure: same time, spray PX4 corrosion inhibitor into the
1 Remove the thermostat from its housing and manifolds until an emission of vapour is seen from
carefully clean it. Apply a silicone grease, such as each opening for the fuel injectors. Connect the air
MS4, to the valve stems of the thermostat and inlet pipes. Connect the air filter(s).
operate the valves by hand to ensure that the grease 10 Spray 40 cc of PX4 corrosion inhibitor into each
enters the glands. Fit the thermostat to its housing. cylinder, through the openings for the fuel injectors.
Fit the fuel injectors.

Continued

47
7
Caution: The engine must NOT be turned after this Removal from storage
operation and a label must be fitted to this effect.
To prepare the engine for use, after it has been in
11 Spray PX4 corrosion inhibitor around the valves
storage, refer to section 3 - Operation instructions.
and around the rocker assemblies. Fit the rocker
The information given applies to new engines and to
covers.
those engines which have been removed from
12 Drain the PX4 corrosion inhibitor from the sump of storage.
the engine and from the oil filter canisters. Fit a NO
OIL label to the oil filler cap.
13 Drain the cooling system and fill with the
recommended coolant mixture (see page 39).
Caution: The mixture must NOT contain less than
50% inhibited ethylene glycol or propylene glycol, and
may contain up to 90% by volume.
14 Wait for 15 minutes, then drain completely the
coolant mixture. Fit a NO COOLANT label to the filler
cap of the radiator.
15 Disconnect the exhaust pipe at the turbocharger
outlet, or at the junction of the manifolds if the engine
has a normal aspiration system. Inject two grammes
of VPI 260 powder and fit a blanking plug. Do NOT
connect the exhaust pipe.
16 Inject two grammes of VPI 260 powder into the
turbocharger, if relevant.
17 Disconnect the air ducts between the air filter(s)
and the turbocharger and inject two grammes of VPI
260 powder into the air ducts.
18 Inject two grammes of VPI 260 powder into each
paper element type air filter. Other types of air
cleaners may be sprayed inside with PX4 corrosion
inhibitor. Fit the air ducts.
19 Spray Crodafluid PM47 onto areas of the engine
and auxiliary equipment which are not protected by
paint. Ensure that the fuel control linkage is sprayed
with Crodafluid PM47.
Caution: Do NOT spray PM47 into the vent holes of
the alternator.
20 Cover, completely, the alternator and the starter
motor in mouldable wax wrapping, and seal with
adhesive tape.
21 Seal the air filter inlets, the crankcase breather
and all other openings with mouldable wax wrapping
and adhesive tape.
22 Remove all drive belts, apply French chalk to the
belts and put them in a sealed plastic bag. Fasten the
bag to the engine.
23 Fasten to the engine a label which indicates:
(a) That the exhaust system has been sealed.
(b) The dates when the corrosion inhibitors were
applied to the engine and when the corrosion
inhibitors must be applied again.
If the engine is to remain in storage for more than one
year, the above procedure must be repeated at the
end of each period of twelve months.

48
 7
Approved products for engine preservation

Component Product Manufacturer

Thermostat MS4 silicone grease Ambersil Limited
Whitney Road
Basingstoke
Hampshire
Lubrication system PX4 corrosion inhibitor Croda Chemicals Limited
Churchill Road
Doncaster
Yorkshire
Fuel system PX4 corrosion inhibitor Croda Chemicals Limited
Valves and rocker assemblies PX4 corrosion inhibitor Croda Chemicals Limited
Cooling system Inhibited ethylene glycol or Various
Inhibited propylene glycol
Induction/exhaust systems PX4 corrosion inhibitor Croda Chemicals Limited

VPI 260 powder Shell Chemicals Limited

Stanlow Terminal
Ellesmere Port
Cheshire
Engine and auxiliaries Crodafluid PM47 Croda Chemicals Limited
- outer casing
Mouldable wax wrapping Carrs Paper Limited
Shirley
Solihull
West Midlands

49
8
Parts and Service 8

Introduction
If problems occur with your engine or with the
components fitted to it, your Perkins distributor can
make the necessary repairs. Your Perkins distributor
will ensure that only the correct parts are fitted and
that the work is done correctly.
Certain components can be supplied by your Perkins
distributor through the Perkins Exchange Component
Programme. These will enable you to reduce the cost
of certain repairs.

Service literature
Workshop manuals and other service publications are
available from your Perkins distributor at a nominal
cost.

Training
A four day course on the service and the overhaul of
the 2000 Series range of engines is available at the
Factory. For details, apply to: The Customer Training
Centre, Perkins Engines Company Limited,
Shrewsbury, SY1 3NX, England.

Service Bulletins
Service procedures and engine design are checked
continuously at Perkins Engines. As a result of this
development work, it may become necessary to alter
the information in manuals and other service
publications. Between revisions of the literature, all
relevant personnel are provided with full details of
changes as they occur. The information is produced
as a Service Bulletin; these are supplied to
distributors for distribution as necessary.
Changes to engine design and service procedures
are published as Service Bulletins for addition to any
relevant Manuals.

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Engine data 9

2000 Series diesel engine

General
Number of cylinders 6
Cylinder arrangement In-line
Cycle Four stroke
Induction system
165 kW (221 bhp) to
257 kW (345 bhp) versions Turbocharged
229 kW (307 bhp) to
368 kW (494 bhp) versions Turbocharged and charge cooled
Combustion system Direct injection
Nominal bore 130,17 mm (5.125 in)
Stroke 152,4 mm (6.000 in)
Compression ratio 15.9:1 nominal (except TTAG - 15:1)
Cubic capacity 12,17 litres (742.64 in3)
Firing order 1, 4, 2, 6, 3, 5
No. 1 cylinder is at front (fan end)
Tappet clearances (cold)
Inlet 0,25 mm (0.010 in)
Exhaust 0,50 mm (0.020 in)
Direction of rotation Anti-clockwise: view on flywheel
Injection timing As stamped on engine data plate
Dry weight of engine (approximate) Engine only: Typical electropak
TG1, TG1A, TG2, TG2A 1118 kg (2465 lb) 1180 kg (2601 lb)
TAG, TAG2 1231 kg (2714 lb) 1365 kg (3009 lb)
TWG, TWG2 1138 kg (2509 lb) 1216 kg (2681 lb)
TTAG 1325 kg (2921 lb) 1459 kg (3217 lb)
Cooling system
Capacity of coolant system
(does not include radiator) 24,4 litres (4.5 UK gallons)
Coolant system pressure Maximum 70 kN/m2 (10 lbf/in2) to suit installation
Temperature (normal)
(At sea level) 78 to 95°C (172 to 203°F)
Thermostat Three-element wax capsule type with radiator by-pass

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Fuel system
Type Low-pressure supply to fuel injection pump with through flow
return to tank
Fuel injection pump
165 kW (221 bhp) to S3000 with 12mm lower helix elements (damper plates fitted to
257 kW (345 bhp) gross variable speed engines over 300 bhp only). Boost control device
fitted to 300 bhp engines only. Automatic selection of excess fuel
and retarded timing for starting. The engine is retarded by 6°.

229 kW (307 bhp) to S7100 with 12mm lower helix elements and snubber valves.
368 kW (494 bhp) gross Boost control device fitted. Automatic selection of excess fuel and
retarded timing for starting. The engine is retarded by 6°.
Governor All speed, integral with fuel injection pump or electric (depending
on requirements)
Lift pump Single acting
Fuel supply pressure 103 to 207 kN/m2 (15 to 30 lbf/ft2)
Fuel injectors Low spring type, opening pressure 240 bar
Main fuel filter Single screw-on type canister
Lubrification system
Type Wet sump
Capacity of lubricating oil sump
Max. mark on dipstick 25 litres (5.5 UK gallons)
Max. mark on dipstick 36 litres (7.9 UK gallons)
(composite sump)
Lubricating oil pressure
Normal load conditions 350 to 480 kN/m2 (50 to 70 lbf/in2)
Minimum at rated speed *207 kN/m2 (30 lbf/in2)
Pressure relief valve Spring loaded plunger in body of oil pump
Oil-to-coolant heat exchanger Single unit, tube stack type with partial by-pass for coolant
Filters Two screw-on type canisters with integral by-pass valves
Induction/exhaust system
Aspiration
TG, TAG and TWG Pressure charged by a single turbocharger
TTAG Pressure charged by two turbochargers connected in series
Air charge cooler
TG Not fitted
TAG and TTAG Air-to-air type, integral with radiator
TWG Air-to-coolant type, integral with induction manifold
Cold start aids Optional - Start Pilot or Fleetguard

* Important for the protection of the turbocharger bearings

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Electrical equipment
Alternator Belt driven unit, 24 volt, 40 amp
Starter motor Single, 24 volt - flange-mounted
Stop control Electrical, 24 volt
Auxiliary equipment
Air compressor (if fitted) Single cylinder, flange mounted

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