Perkins — The air cleaner manufacturer recommends the following:
A Perkins service procedure — check it applies to your exact model before use.
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Before you start
- Do not attempt this while engine is running.
- Exhaust back pressure, air inlet restriction and
- Do not attempt to remove the air cleaner
- Do not over oil.
Procedure
- Continue to operate hand primer but loosen the cap nut on top of secondary fuel filter. Once the filter is full, fuel should be observed coming out around the ring. If not remove cap nut, cap insert and O-ring. Remove the white plastic volume plug in the center of the filter. With an external fuel source fill the filter down thru the center hole until full. Reinstall volume plug, O-ring, cap insert and cap nut. Tighten nut making sure O-ring seated properly.
- Start engine by manual crank Sw-#1 or Sw-#2, manual start instructions on instrument panel.
- If engine fails to start or does start but runs erratic, recheck all fuel lines, connections and filters for some- thing obvious. If a simple solution cannot be located it may be necessary to contact your local Distributor / Dealer for service assistance. Page 15 PDFP SECTION 3.1 Figure 7 - Fuel System Primary Filter Secondary Filter Fuel Injection Pump Speed Adjustment Page 16 PDFP AIR INTAKE AND EXHAUST SYSTEM Air Intake Operation Air Cleaner Crankcase Ventilation Exhaust Operation Maintenance And Service Procedures AIR INTAKE OPERATION During the intake stroke, the piston travels downward, the intake valve is open, and the exhaust valve is closed. The downstroke of the piston permits air to enter the cylinder that has been drawn from the air cleaner through the open intake valve. The intake air is never restricted by any con- trolling valve or mixing devices. The intake charge consists of fresh, clean air which provides for efficient combustion. On some engines a turbocharger is introduced in the air sys- tem. Power to drive the turbocharger is extracted from the waste energy in the engine exhaust gas. The expanding exhaust gases turn a single stage turbo wheel which drives an impeller thus supplying air under pressure to the cylin- ders. AIR CLEANER The air cleaner is designed to remove foreign matter from the air, pass the required volume of air for proper combus- tion, and maintain efficient operation for a reasonable peri- od of time before requiring service. The importance of keeping foreign matter out of the engine cannot be over-emphasized, since clean air is essential to satisfactory engine operation and long engine life. Should dust in the air supply enter the engine it would be carried into the cylinders and due to its abrasive properties, cause premature wear of the moving parts. Dirt, which is allowed to build-up in the air cleaner passages, will eventually restrict the air supply to the engine and result in heavy car- bon deposits on the valves and pistons due to incomplete combustion. The air cleaner used on PDFP engines is a reusable type. Should a situation occur where the air cleaner becomes plugged with dirt (starving the engine of air), low power and heavy black smoke will result; the air cleaner should be ser- viced immediately. CAUTION: Do not attempt to remove the air cleaner while an engine is running nor run the engine while the air cleaner is off. Exposed compo- nents could cause severe injury to personnel and major internal engine damage could occur should any foreign matter be drawn into the engine. The air cleaner manufacturer recommends the following:
- The pre-oiled reusable elements are serviced with a spe- cial oil. The elements can be serviced or replaced.
- Figure 1 shows the air filter Service Instructions.
- When servicing the element is not practical, you can im- prove filter efficiency by re-spraying with oil. NOTE: Do not attempt this while engine is running. NOTE: Do not over oil. SECTION 3.2 Page 17 PDFP SECTION 3.2 AIR FILTER SERVICE INSTRUCTIONS Figure 1 - Air Filter Service Instructions Page 18 PDFP SECTION 3.2 CRANKCASE VENTILATION Vapors which may form within the engine are removed from the crankcase and gear train compartment by a continuous, pressurized ventilation system. A slight pressure is maintained within the engine crankcase Figure 2 - Crankcase Ventilation compartment. This crankcase pressure and resulting ventila- tion is accomplished by the air seepage past the piston rings sweeping up through the cylinder block and into the rocker arm compartment. Here it is expelled through a vent pipe attached to the rocker cover breather element (Fig. 2). exhaust piping elbows and outlet. In addition to providing engine exhaust data and back-pressure limitations, Clarke offers a service to installers, through the local Pump OEM Dealer, for making recommendations on exhaust system siz- ing for specific installations. If the exhaust system should become restricted, the hot ex- haust gases cannot escape from the engine. This condition would cause a loss of power, extreme internal engine heat, and very high exhaust gas temperatures. These conditions can and will cause internal engine damage and a reduction of engine life. Should any exhaust manifold studs or bolts break or come loose, engine exhaust gases can start leaking into the pump room. Under these conditions, the engine should be attend- ed to immediately. Indications of an exhaust leak would be the smell of diesel exhaust, possible eye irritation and soot collecting on the engine around the leak. Contact your local Distributor/Dealer for repair. NFPA-20 requirements are to have exhaust system high tem- perature personnel protection. Don't run PDFP engines without insulation blankets installed. Serious injuries may result by contact with hot exhaust system components. EXHAUST OPERATION Internal combustion engines convert fuel energy into both useful work and wasted heat. The useful work is the fly- wheel rotation that drives the pump. The wasted heat involves the engine water cooling system, radiated heat and the exhaust gases. Approximmately 2/3 of the fuel energy is wasted. Critical review must be made of these systems to assure that the engine delivers the useful power required and maintains the engine within the operating parameters estab- lished by the engine manufacturer. Some engines are turbocharged (T). Turbochargers increase the air flow into the engine cylinder and permit increased horsepower by burning more fuel than is possible in a natu- rally aspirated (N) engine. Turbochargers enhance the effi- ciencies of engines and add power to a similar displacement (N) engine. Turbochargers are maintenance free. The exhaust system is critical to the proper engine perfor- mance. When initially installed, consideration must be given to the exhaust gas flow requirements, the exhaust tempera- tures and the exhaust back-pressure limitations of the spe- cific engine. Refer to Section 5 for specific engine model and operating speed back-pressure limitations. All the com- ponents in an exhaust system contribute to the back-pressure determination including the flexible section, muffler, Page 19 PDFP SECTION 3.2 NOTE: Exhaust back pressure, air inlet restriction and crankcase pressure limits are listed for each PDFP Model in Technical Data Section 5. These limits are not to be exceeded.
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.