Perkins — Repair Procedure

A Perkins service procedure — check it applies to your exact model before use.

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Procedure

1. Blue Smoke — Possible engine oil consumption - too many areas to list for possibilities.
2. White Smoke — Possibility of water in cylinders Source — Possible water in fuel or internal engine prob- lem. Should any of these or any other conditions be found, con- tact your local Distributor/Dealer for assistance. Check con- dition of the air inlet system ducting, clamp tightness hose condition. MAINTENANCE AND SERVICE PROCEDURES Weekly Prior to each engine run make a visual check of the exhaust system to verify condition of piping and muffler. Investigate thoroughly any areas that would appear to have rusty condi- tions such as rain water running down pipe and getting inside the engine. Severe internal engine damage could occur if water enters the engine exhaust system. Inspect the engine air cleaner for dirt buildup or damage. 6 Months Inspect exhaust system for leaks or plugging, if any are found, repair immediately. Inspect and tighten if necessary exhaust manifold, turbo mount (if equipped) and piping bolts/nuts. Inspect the insulations condition for any deterio- ration or looseness; repair as necessary. Check for any petrolium products on the blankets and replace if any are found. Exhaust system back pressure limits are not to be exceeded. Yearly Re-oil and clean the air cleaner element per the manufactur- ers directions. Each engine is shipped with the cleaning in- structions. Refer to Figure 1, Page 18. Page 20 PDFP SECTION 3.3 LUBRICATION SYSTEM OPERATION The lubricating oil system is schematically illustrated in Figure 1. Pressure lubrication is supplied by a rotor type pump. The pump is driven through an idler gear from the crankshaft gear. On all 4 cylinders a balancer unit is used, the pump is fitted to the balancer frame and is driven by the balancer drive shaft. The oil from this pump circulates through the balancer unit then passes through a full flow filter to the pressure rail. On 6 cylinder units the oil passes directly from the pump to the filters. The filter has a by-pass valve which lets oil pass directly to the pressure rail, if the filter becomes restricted. From the pressure rail, lubricating oil passes to the main bearings of the crankshaft and through passages in the crank- shaft to the end bearings. The pistons and the cylinder bores are lubricated by splash and oil mist. Lubricating oil for the camshaft journals is supplied from the main bearings and a reduced supply is sent from the camshaft journal, through passages in the cylinder block and the cylin- der head, to the rocker assembly. Lubricating oil passes through the rocker shaft to the bearings of the rocker levers. The valve stems and valve springs are lubricated by splash and oil mist. The hub of the idler gear is supplied with lubricating oil from the pressure rail and the timing gears are splash lubricated. The maximum pressure in the system is controlled by a relief valve. This valve controls the pressure of the oil and is located between the oil cooler and the oil filter. All PDFP engines include oil coolers. The oil passes through the cooler before the filter. When cold oil increases the restriction in the cooler, a by-pass valve lets the lubricating oil pass directly to the oil filter. The turbocharger is lubricated by oil from the pressure rail. The lubricating oil is sent through a passage across the cylinder block to an adaptor fitted to the right side of the engine and then by pipe to the turbocharger. The lubricating oil returns from the turbocharger to the sump. Operation Oil Cooler Lube Oil Fill Oil Level Dipstick Lube Oil Filter Lubricating Oil Requirements Changing The Lubricating Oil Lubricating Oil Analysis Changing The Lubricating Oil Filter Maintenance Procedure Page 21 PDFP Page 22 Fig. 1 - Typical PDFP 1000 Series Engine Lubricating System Schematic SECTION 3.3 PDFP SECTION 3.3 OIL COOLER PDFP engines use a plate type oil cooler. The only difference is the number of plates used between the 4 and 6 cylinder models. The number of plates is determined by the amount of cooling that is required. All of the oil cooler systems incor- porate oil bypass valves in the event of plate core plugging. LUBE OIL FILL On all models the oil fill is located on the rocker cover at the top of the engine. See Fig. 2, for typical oil fill location. (See Page 24 for lube oil requirements.) Figure 2 - Typical Oil Fill Location LUBE OIL FILTER All engines use full flow oil filters of the "spin on" type element. They have a non-replaceable pleated paper cartridge. Each engine has an integral bypass valve to bypass the filters in the event of plugging or for cold start purposes. The 6 cylinders have dual filters and the 4 cylinders have one. Use only Perkins filters. Refer to Section 6 for proper service part numbers. OIL LEVEL DIPSTICK On all PDFP engines the dipstick is located on the left center of the engines. Oil level can only be checked when the engine is not running and has been off for at least 10 minutes. See Page 24 for lube oil requirements if additional oil is needed. Page 23 PDFP API Symbol: SAE Viscosity Grade: 15W-40 API Classification: CF4 HT/HS Viscosity: 3.7 cP min. Sulfate ASH: MAX 1% MASS SECTION 3.3 Figure 3 - Changing Oil CHANGING THE LUBRICATING OIL 1 Operate the engine until it is warm. Refer to Page 33 "Manual Starting Instructions" for instruc- tions. 2 Stop the engine. Remove the sump drain plug (Fig. 3 - Item 1) and its "O" ring and drain the lubricating oil from the sump. Ensure that the "O" ring is not damaged. Fit the drain plug and its "O" ring and tighten the plug to 34 Nm (25 lbf ft) 3,5 kgf m. 3 Fill the sump to the "MAX" mark on the dipstick (Fig. 3 - Item 2) with new and clean lubricating oil of an approved grade. 4 Return the unit back into service by returning the AEC selector to "automatic" position and the manual operating lever to manual stop position. Close cooling system manual by-pass valve. 5 Dispose used oil properly Page 24 LUBRICATING OIL REQUIREMENTS Hundreds of commercial oils are marketed today, but labeling terminology differs among suppliers and can be confusing. Some marketers may claim that their lubricant is suitable for all makes of diesel engines and may list engine makes and types, including Perkins, on their containers. Such claims, by themselves, are insufficient as a method of lubricant selection for PDFP engines. The proper lubricating oil for all PDFP engines is selected, based on SAE Viscosity Grade and API (American Petroleum Institute) Service Designation. Both of these properties are displayed in the API Symbol, which is illustrated within the specific requirements. For PDFP engines, the proper lub

Source: manual:Manual_PDFP_MP-5_C13196.sflb.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.