Perkins 1506D Engine

Tools: suitable belt tension gauge

1. Loosen bolts (1) and (2), also loosen nut (3).
2. Loosen bolt (4) and nut (7).
3. Adjust nuts (5) and (7) to increase or decrease tension on union (6); tension belts to 730 N (164 lb).
4. Tighten nuts (5) and (7) securely.
5. Tighten bolts (1) and (2) and nut (3) to 89 N·m (65 lb ft); tighten bolt (4) to 100 N·m (73 lb ft).

Tools: square (A)

1. Loosen bolts (1) and (3); use square (A) to adjust pulley assembly (2) to increase or decrease belt tension.
2. Set the tension on the belt to 560 N (125 lb).
3. With correct tension, tighten bolts (1) and (3) to 28 N·m (247 lb in).

1. Inspect the core for trapped debris and cleanliness; remove debris and repeat cleaning if necessary.
2. Inspect the core for damage and perform a pressure test to detect leaks.
3. Plug both ends of the aftercooler core and pressurize to 205 kPa (30 psi); submerge in water and look for bubbles.
4. If any leaks are found, do not attempt to repair the core.

⚠ Do not use a high concentration of caustic cleaner to clean the core.

Tools: pressure steam cleaner, compressed air

1. Place the aftercooler on the side to remove accessible debris.
2. Back flush the core with cleaner.
3. Use a pressure steam cleaner to remove residue; flush the fins; remove trapped debris.
4. Wash the core with hot, soapy water.
5. Flush the core thoroughly with clean, fresh water until exiting water is clear.
6. Dry the core with compressed air, directed in the reverse direction of normal flow.

⚠ Batteries give off combustible gases which can explode.

⚠ The battery cover should be removed before any servicing is attempted.

1. Switch the engine to OFF and remove all electrical loads; allow 2 minutes for diesel exhaust fluid lines to purge before disconnecting power.
2. Turn off and disconnect any battery chargers.
3. Ensure the battery disconnect switch is in the OFF position.
4. Disconnect the NEGATIVE "-" cable from the NEGATIVE "-" battery terminal.
5. Disconnect the POSITIVE "+" cable from the POSITIVE "+" battery terminal.
6. Remove the used battery and install the new battery.
7. Connect the POSITIVE "+" cable to the POSITIVE "+" terminal.
8. Connect the NEGATIVE "-" cable to the NEGATIVE "-" terminal.
9. Turn the battery disconnect switch to ON.

⚠ Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.

Tools: fine grade sandpaper

1. Turn the start switch to OFF; turn the ignition switch (if equipped) to OFF and remove the key and all electrical loads.
2. Disconnect the negative battery terminal; ensure the cable cannot contact the terminal (with four 12 volt batteries, two negative connections must be disconnected).
3. Remove the positive connection.
4. Clean all disconnected connection and battery terminals.
5. Use fine grade sandpaper to clean the terminals and cable clamps until bright or shiny; coat with silicone lubricant or petroleum jelly.
6. Tape the cable connections to help prevent accidental starting.
7. Proceed with necessary system repairs.
8. To connect the battery, connect the positive connection before the negative connector.

⚠ Incorrect or incomplete flushing of the cooling system can result in damage to copper and other metal components.

1. Drain the coolant into a suitable container.
2. Dispose of the coolant according to local regulations.
3. Fill the cooling system with a 33 percent solution of Perkins ELC, operate until thermostat opens, cool and drain.
4. Again fill with a 33 percent solution of Perkins ELC, operate until thermostat opens, then cool.
5. Drain the cooling system.
6. Fill with Perkins Premixed ELC, operate until all coolant valves open, stop and check coolant level when cool.

⚠ Pressurized System: Hot coolant can cause serious burns.

1. Stop the engine and allow to cool; loosen filler cap slowly to relieve pressure and remove.
2. Remove drain plug (1) and the radiator drain plug; allow coolant to drain.
3. Flush cooling system with clean water to remove debris.
4. Fill with clean water, install filler cap, run engine until normal operating temperature.
5. Stop engine, cool, remove cap and drain plugs; drain water and flush with clean water.
6. Check O ring seal on drain plug, replace if damaged; install drain plugs and tighten drain plug (1) to 80 N·m (59 lb ft).
7. Fill with Extended Life Coolant (ELC); do not install filler cap.
8. Run engine until normal operating temperature; stop engine.
9. Maintain coolant level at maximum mark.
10. Clean and inspect filler cap gasket; replace or pressure test cap as needed.
11. Start engine and inspect cooling system for leaks and proper operating temperature.

⚠ Never run the engine without an air cleaner element installed.

⚠ Never service the air cleaner element with the engine running.

1. Remove the six clips (2) and remove the cover (3).
2. Remove element (5) and discard old element.
3. Ensure cover (3), cap (1) and valve (4) are clean and free from dirt.
4. Install new element (5), install cover (3) and install clips (2); ensure valve (4) is vertically down.
5. If necessary, reset the air cleaner service indicator.

⚠ Perform this maintenance with the engine stopped.

Tools: solvent

1. Thoroughly clean the breather assembly before removing any parts.
2. Loosen hose clamp (3) and remove hose (4) from breather assembly (6).
3. Remove bolt (2) and washer (1); remove breather assembly (6) from housing (5).
4. Wash the breather element in clean nonflammable solvent and allow to dry.
5. Ensure hose (4) is clean and free from damage.
6. Install a clean dry breather element; install breather assembly (6) to housing (5).
7. Install new sealing washer (1) to bolt (2); tighten bolt (2) to 28 N (6.3 lb).
8. Install hose (4) and clip (3); tighten clip (3) to 7 N·m (62 lb in).

⚠ Hot oil and hot components can cause personal injury.

⚠ Do not fill the oil filters with oil before installing them.

Tools: suitable tool

1. Run engine to normal operating temperature, then stop.
2. Drain the crankcase: turn drain valve counterclockwise, or remove oil drain plug (discard O ring seal).
3. Clean the oil drain plug and install a new O ring seal; reinstall and tighten drain plug to 40 N·m (29 lb ft) for aluminum oil pan.
4. Using a suitable tool remove oil filter (3) from housing (1) and discard.
5. Apply clean engine oil to O ring seal (2) and install the new spin on oil filter; tighten by hand only, then rotate 1 full turn after seal contacts.
6. Remove the oil filler cap and refill the crankcase with engine oil.
7. Start engine and run 2 minutes; inspect oil filter for leaks.
8. Stop the engine; allow oil to drain back to sump for a minimum of 10 minutes.
9. Check the oil level and maintain between the Low and High marks.

⚠ Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.

⚠ Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking again.

1. Ensure key switch is OFF, fuel tank is full, and fuel supply valve is ON.
2. Unlock the fuel priming pump handle (1); turn counter clockwise and operate until strong pressure is felt.
3. Press in the fuel pump handle and lock into the fuel pump body (2), turning clockwise.
4. Start the engine.
5. If the engine will not start, repeat Steps 2 to 3.
6. Once the engine starts, allow it to operate with no load for 5 minutes.