Operation And Maintenance Manual - REED Concrete Pumps & Shotcrete .

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SEBU8325-01July 2012Operation andMaintenanceManual1104D (Mech) Industrial EngineNK (Engine)NL (Engine)NM (Engine)

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure toobserve basic safety rules or precautions. An accident can often be avoided by recognizing potentiallyhazardous situations before an accident occurs. A person must be alert to potential hazards. Thisperson should also have the necessary training, skills and tools to perform these functions properly.Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazardwarnings are not heeded, bodily injury or death could occur to you or to other persons.The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.The meaning of this safety alert symbol is as follows:Attention! Become Alert! Your Safety is Involved.The message that appears under the warning explains the hazard and can be either written orpictorially presented.Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis publication.Perkins cannot anticipate every possible circumstance that might involve a potential hazard. Thewarnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,work method or operating technique that is not specifically recommended by Perkins is used,you must satisfy yourself that it is safe for you and for others. You should also ensure that theproduct will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information beforeyou start any job. Perkins dealers or Perkins distributors have the most current information available.When replacement parts are required for thisproduct Perkins recommends using Perkinsreplacement parts.Failure to heed this warning can lead to premature failures, product damage, personal injury ordeath.

SEBU8325-01Table of ContentsForeword . 4Safety SectionSafety Messages . 5General Hazard Information . 6Burn Prevention . 8Fire Prevention and Explosion Prevention . 8Crushing Prevention and Cutting Prevention . 10Before Starting Engine . 10Engine Starting . 10Engine Stopping . 11Electrical System . 11Product Information SectionModel Views . 13Product Identification Information . 18Operation SectionLifting and Storage . 20Gauges and Indicators . 22Features and Controls . 23Engine Starting . 24Engine Operation . 27Engine Stopping . 28Cold Weather Operation . 29Maintenance SectionRefill Capacities . 33Maintenance Interval Schedule . 50Warranty SectionWarranty Information . 79Index SectionIndex . 803Table of Contents

4ForewordForewordLiterature InformationThis manual contains safety, operation instructions,lubrication and maintenance information. Thismanual should be stored in or near the engine areain a literature holder or literature storage area. Read,study and keep it with the literature and engineinformation.English is the primary language for all Perkinspublications. The English used facilitates translationand consistency.Some photographs or illustrations in this manualshow details or attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuingimprovement and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises regarding your engine, or this manual, pleaseconsult with your Perkins dealer or your Perkinsdistributor for the latest available information.SafetyThis safety section lists basic safety precautions.In addition, this section identifies hazardous,warning situations. Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, maintenance andrepair on this product.OperationOperating techniques outlined in this manual arebasic. They assist with developing the skills andtechniques required to operate the engine moreefficiently and economically. Skill and techniquesdevelop as the operator gains knowledge of theengine and its capabilities.The operation section is a reference for operators.Photographs and illustrations guide the operatorthrough procedures of inspecting, starting, operatingand stopping the engine. This section also includes adiscussion of electronic diagnostic information.MaintenanceThe maintenance section is a guide to engine care.The illustrated, step-by-step instructions are groupedby service hours and/or calendar time maintenanceintervals. Items in the maintenance schedule arereferenced to detailed instructions that follow.SEBU8325-01Recommended service should be performed at theappropriate intervals as indicated in the MaintenanceInterval Schedule. The actual operating environmentof the engine also governs the Maintenance IntervalSchedule. Therefore, under extremely severe,dusty, wet or freezing cold operating conditions,more frequent lubrication and maintenance than isspecified in the Maintenance Interval Schedule maybe necessary.The maintenance schedule items are organized fora preventive maintenance management program. Ifthe preventive maintenance program is followed, aperiodic tune-up is not required. The implementationof a preventive maintenance management programshould minimize operating costs through costavoidances resulting from reductions in unscheduleddowntime and failures.Maintenance IntervalsPerform maintenance on items at multiples ofthe original requirement. We recommend that themaintenance schedules be reproduced and displayednear the engine as a convenient reminder. We alsorecommend that a maintenance record be maintainedas part of the engine's permanent record.Your authorized Perkins dealer or your Perkinsdistributor can assist you in adjusting yourmaintenance schedule to meet the needs of youroperating environment.OverhaulMajor engine overhaul details are not covered inthe Operation and Maintenance Manual exceptfor the interval and the maintenance items in thatinterval. Major repairs should only be carried out byPerkins authorized personnel. Your Perkins dealeror your Perkins distributor offers a variety of optionsregarding overhaul programs. If you experiencea major engine failure, there are also numerousafter failure overhaul options available. Consult withyour Perkins dealer or your Perkins distributor forinformation regarding these options.California Proposition 65 WarningDiesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive harm. Batteryposts, terminals and related accessories contain leadand lead compounds. Wash hands after handling.

SEBU8325-015Safety SectionSafety MessagesSafety SectionThe Universal Warning label (2) is located on therear end of the valve mechanism cover. Refer toillustration 2.i02690461Safety MessagesThere may be several specific warning signs on yourengine. The exact location and a description of thewarning signs are reviewed in this section. Pleasebecome familiar with all warning signs.Ensure that all of the warning signs are legible. Cleanthe warning signs or replace the warning signs ifthe words cannot be read or if the illustrations arenot visible. Use a cloth, water, and soap to cleanthe warning signs. Do not use solvents, gasoline, orother harsh chemicals. Solvents, gasoline, or harshchemicals could loosen the adhesive that secures thewarning signs. The warning signs that are loosenedcould drop off of the engine.Replace any warning sign that is damaged ormissing. If a warning sign is attached to a part of theengine that is replaced, install a new warning sign onthe replacement part. Your Perkins dealer or yourdistributor can provide new warning signs.(1) Universal WarningDo not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions orheed the warnings could result in serious injuryor death.Illustration 1Typical exampleg01154807

6Safety SectionGeneral Hazard InformationSEBU8325-01g01353108Illustration 2(1) Ether Warning Label(2) Universal warning(2) Etheri02677370General Hazard InformationDo not use aerosol types of starting aids such asether. Such use could result in an explosion andpersonal injury.Illustration 4Illustration 3g01154809Typical exampleThe ether warning label (1) is located on the inletmanifold cover. Refer to illustration 2.g00104545Attach a “Do Not Operate” warning tag or a similarwarning tag to the start switch or to the controlsbefore you service the equipment or before yourepair the equipment.

SEBU8325-017Safety SectionGeneral Hazard InformationWhen pressurized air and/or water is used forcleaning, wear protective clothing, protective shoes,and eye protection. Eye protection includes gogglesor a protective face shield.The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi). The maximumwater pressure for cleaning purposes must be below275 kPa (40 psi).Fluid PenetrationIllustration 5g00702020Wear a hard hat, protective glasses, and otherprotective equipment, as required.Do not wear loose clothing or jewelry that can snagon controls or on other parts of the engine.Make sure that all protective guards and all coversare secured in place on the engine.Pressure can be trapped in the hydraulic circuit longafter the engine has been stopped. The pressure cancause hydraulic fluid or items such as pipe plugs toescape rapidly if the pressure is not relieved correctly.Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has been relievedor personal injury may occur. Refer to the OEMinformation for any procedures that are required torelieve the hydraulic pressure.Keep the engine free from foreign material. Removedebris, oil, tools, and other items from the deck, fromwalkways, and from steps.Never put maintenance fluids into glass containers.Drain all liquids into a suitable container.Obey all local regulations for the disposal of liquids.Use all cleaning solutions with care.Report all necessary repairs.Do not allow unauthorized personnel on theequipment.Illustration 6g00687600Perform maintenance on the engine with theequipment in the servicing position. Refer to theOEM information for the procedure for placing theequipment in the servicing position.Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.Pressure Air and WaterContaining Fluid SpillagePressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.Care must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting and repair of theengine. Make provision to collect the fluid with asuitable container before any compartment is openedor before any component is disassembled.Ensure that the power supply is disconnected beforeyou work on the bus bar or the glow plugs.The direct application of pressurized air orpressurized water to the body could result in personalinjury. Only use the tools that are suitable for collectingfluids and equipment that is suitable for collectingfluids.

8Safety SectionBurn PreventionSEBU8325-01 Only use the tools that are suitable for containingfluids and equipment that is suitable for containingfluids.Obey all local regulations for the disposal of liquids.i02813488Fire Prevention and ExplosionPreventioni02143195Burn PreventionDo not touch any part of an operating engine.Allow the engine to cool before any maintenanceis performed on the engine. Relieve all pressurein the air system, in the hydraulic system, in thelubrication system, in the fuel system, or in thecooling system before any lines, fittings or relateditems are disconnected.CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.Check the coolant level after the engine has stoppedand the engine has been allowed to cool.Ensure that the filler cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.OilsHot oil and hot lubricating components can causepersonal injury. Do not allow hot oil to contact theskin. Also, do not allow hot components to contactthe skin.BatteriesElectrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.Illustration 7g00704000All fuels, most lubricants, and some coolant mixturesare flammable.Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.A flash fire may result if the covers for the enginecrankcase are removed within fifteen minutes afteran emergency shutdown.Determine whether the engine will be operated in anenvironment that allows combustible gases to bedrawn into the air inlet system. These gases couldcause the engine to overspeed. Personal injury,property damage, or engine damage could result.If the application involves the presence of combustiblegases, consult your Perkins dealer and/or yourPerkins distributor for additional information aboutsuitable protection devices.Remove all flammable combustible materials orconductive materials such as fuel, oil, and debris fromthe engine. Do not allow any flammable combustiblematerials or conductive materials to accumulate onthe engine.Store fuels and lubricants in correctly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.Do not expose the engine to any flame.

SEBU8325-019Safety SectionFire Prevention and Explosion PreventionExhaust shields (if equipped) protect hot exhaustcomponents from oil or fuel spray in case of a line,a tube, or a seal failure. Exhaust shields must beinstalled correctly.Use caution when you are refueling an engine. Donot smoke while you are refueling an engine. Do notrefuel an engine near open flames or sparks. Alwaysstop the engine before refueling.Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines or tanks that containflammable fluid. Clean any such lines or tanksthoroughly with a nonflammable solvent prior towelding or flame cutting.Wiring must be kept in good condition. All electricalwires must be correctly routed and securely attached.Check all electrical wires daily. Repair any wiresthat are loose or frayed before you operate theengine. Clean all electrical connections and tightenall electrical connections.Eliminate all wiring that is unattached or unnecessary.Do not use any wires or cables that are smaller thanthe recommended gauge. Do not bypass any fusesand/or circuit breakers.Arcing or sparking could cause a fire. Secureconnections, recommended wiring, and correctlymaintained battery cables will help to prevent arcingor sparking.Inspect all lines and hoses for wear or fordeterioration. The hoses must be correctly routed.The lines and hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.Oil filters and fuel filters must be correctly installed.The filter housings must be tightened to the correcttorque.Illustration 9g00704135Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.Incorrect jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.Do not charge a frozen battery. This may cause anexplosion.The batteries must be kept clean. The covers(if equipped) must be kept on the cells. Use therecommended cables, connections, and battery boxcovers when the engine is operated.Fire ExtinguisherMake sure that a fire extinguisher is available. Befamiliar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.Illustration 8g00704059

10Safety SectionCrushing Prevention and Cutting PreventionSEBU8325-01Lines, Tubes and HosesDo not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged. Do not clip any other items to the highpressure lines.Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Perkins dealer or yourPerkins distributor for repair or for replacement parts.Check lines, tubes and hoses carefully. Do not useyour bare hand to check for leaks. Use a board orcardboard to check for leaks. Tighten all connectionsto the recommended torque.Replace the parts if any of the following conditionsare present: End fittings are damaged or leaking.When objects are struck, wear protective glasses inorder to avoid injury to the eyes.Chips or other debris may fly off objects when objectsare struck. Before objects are struck, ensure that noone will be injured by flying debris.i02675470Before Starting EngineThe initial start-up of a new engine or a engine thathas been serviced or repaired make provision to shutthe engine off, in order to stop an overspeed. Thismay be accomplished by shutting off the air and/orfuel supply to the engine.Overspeed shutdown should occur automatically forengines that are controlled electronically. If automaticshutdown does not occur, press the emergency stopbutton in order to cut the fuel and/or air to the engine. Outer coverings are chafed or cut. Wires are exposed.Inspect the engine for potential hazards. Outer coverings are ballooning.Before starting the engine, ensure that no one is on,underneath, or close to the engine. Ensure that thearea is free of personnel. Flexible part of the hoses are kinked. Outer covers have embedded armoring. End fittings are displaced.Make sure that all clamps, guards, and heat shieldsare installed correctly. During engine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.i02143194Crushing Prevention andCutting PreventionSupport the component correctly when work beneaththe component is performed.Unless other maintenance instructions are provided,never attempt adjustments while the engine isrunning.If equipped, ensure that the lighting system for theengine is suitable for the conditions. Ensure that alllights work correctly, if equipped.All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.Do not bypass the automatic shutoff circuits. Do notdisable the automatic shutoff circuits. The circuits areprovided in order to help prevent personal injury. Thecircuits are also provided in order to help preventengine damage.See the Service Manual for repairs and foradjustments.i02678897Engine StartingStay clear of all rotating parts and of all movingparts. Leave the guards in place until maintenanceis performed. After the maintenance is performed,reinstall the guards.Keep objects away from moving fan blades. The fanblades will throw objects or cut objects.Do not use aerosol types of starting aids such asether. Such use could result in an explosion andpersonal injury.

SEBU8325-0111Safety SectionEngine StoppingIf a warning tag is attached to the engine start switchor to the controls, DO NOT start the engine or movethe controls. Consult with the person that attachedthe warning tag before the engine is started.All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.Start the engine from the operator's compartment orfrom the engine start switch.Always start the engine according to the procedurethat is described in the Operation and MaintenanceManual, “Engine Starting” topic in the OperationSection. Knowing the correct procedure will help toprevent major damage to the engine components.Knowing the procedure will also help to preventpersonal injury.To ensure that the jacket water heater (if equipped)and/or the lube oil heater (if equipped) is workingcorrectly, check the water temperature gauge and theoil temperature gauge during the heater operation.Engine exhaust contains products of combustionwhich can be harmful to your health. Always start theengine and operate the engine in a well ventilatedarea. If the engine is started in an enclosed area,vent the engine exhaust to the outside.Note: The engine is equipped with an automaticdevice for cold starting for normal conditions ofoperation. If the engine will be operated in very coldconditions, then an extra cold starting aid may berequired. Normally, the engine will be equipped withthe correct type of starting aid for your region ofoperation.The engines are equipped with a glow plug startingaid in each individual cylinder that heats the intakeair in order to improve starting.i02678838Engine StoppingStop the engine according to the procedure inthe Operation and Maintenance Manual, “EngineStopping (Operation Section)” in order to avoidoverheating of the engine and accelerated wear ofthe engine components.Use the Emergency Stop Button (if equipped) ONLYin an emergency situation. Do not use the EmergencyStop Button for normal engine stopping. After anemergency stop, DO NOT start the engine until theproblem that caused the emergency stop has beencorrected.Stop the engine if an overspeed condition occursduring the initial start-up of a new engine or an enginethat has been overhauled. This may be accomplishedby shutting off the fuel supply to the engine and/orshutting off the air supply to the engine.i02176668Electrical SystemNever disconnect any charging unit circuit or batterycircuit cable from the battery when the charging unitis operating. A spark can cause the combustiblegases that are produced by some batteries to ignite.To help prevent sparks from igniting combustiblegases that are produced by some batteries, thenegative “ ” jump start cable should be connectedlast from the external power source to the negative“ ” terminal of the starting motor. If the starting motoris not equipped with a negative “ ” terminal, connectthe jump start cable to the engine block.Check the electrical wires daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is started. Repair all frayedelectrical wires before the engine is started. Seethe Operation and Maintenance Manual for specificstarting instructions.Grounding PracticesCorrect grounding for the engine electrical systemis necessary for optimum engine performanceand reliability. Incorrect grounding will result inuncontrolled electrical circuit paths and in unreliableelectrical circuit paths.Uncontrolled electrical circuit paths can result indamage to main bearings, to crankshaft bearingjournal surfaces, and to aluminum components.Engines that are installed without engine-to-frameground straps can be damaged by electricaldischarge.To ensure that the engine and the engine electricalsystems function correctly, an engine-to-frameground strap with a direct path to the battery must beused. This path may be provided by way of a directengine ground to the frame.

12Safety SectionElectrical SystemAll grounds should be tight and free of corrosion. Theengine alternator must be grounded to the negative“-” battery terminal with a wire that is adequate tohandle the full charging current of the alternator.SEBU8325-01

SEBU8325-0113Product Information SectionModel ViewsProduct InformationSectionModel Viewsi02693072Model View Illustrations

14Product Information SectionModel ViewsSEBU8325-011104 Engine Model Viewsg01351713Illustration 10Typical example(1)(2)(3)(4)PulleyAlternatorFront Lifting EyeWater Outlet(5)(6)(7)(8)Valve Mechanism CoverRear Lifting EyeAir IntakeSecondary Fuel Filter(9) Fuel Injection Pump(10) Oil Filter(11) Crankshaft Pulley(12) Water Pump

SEBU8325-0115Product Information SectionModel Viewsg01352705Illustration 11(13)(14)(15)(16)FlywheelFlywheel HousingOil Filler CapExhaust Manifold(17)(18)(19)(20)TurbochargerOil GaugeOil PanStarting motorNote: The primary fuel filter may be mounted off theengine.(21) Oil Drain Plug(22) Primary Fuel Filteri04430909Engine DescriptionThe engines are available in the following types ofaspiration:

16Product Information SectionModel ViewsSEBU8325-01 Turbocharged aftercooledTable 11104D (Mech) Industrial Engine Specifications TurbochargedNumber of Cylinders Naturally aspirated4 In-LineBoreEngine Specifications105 mm (4.134 inch)StrokeNote: The front end of the engine is opposite theflywheel end of the engine. The left and the rightsides of the engine are determined from the flywheelend. The number 1 cylinder is the front cylinder.Aspiration127 mm (5.0 inch)Naturally aspiratedTurbochargedTurbocharged aftercooledCompression RatioDisplacementNA 19.3:1T, TA 18.2:14.4 L (268 in 3)Firing OrderRotation (flywheel end)1 3 4 2CounterclockwiseValve Lash Setting (Inlet)0.20 mm (0.008 inch)Valve Lash Setting(Exhaust)0.45 mm (0.018 inch)Engine Cooling and LubricationIllustration 12g00984281A typical example of the layout of the valves(A) Inlet valves(B) Exhaust valvesEmissions Control SystemsNK - Direct Diesel InjectionNL - Turbocharger, Direct Diesel InjectionNM - Turbocharger with Air to Air Charge Cooler,Direct Diesel InjectionThe cooling system consists of the followingcomponents: Gear-driven centrifugal water pump Water temperature regulator which regulates theengine coolant temperature Gear-driven oil pump (gear type) Oil coolerThe engine lubricating oil is supplied by a geartype pump. The engine lubricating oil is cooled andthe engine lubricating oil is filtered. Bypass valvesprovide unrestricted flow of lubrication oil to theengine parts when oil viscosity is high. Bypass valvescan also provide unrestricted flow of lubrication oilto the engine parts if the oil cooler should becomeplugged or if the oil filter element should becomeplugged.Engine efficiency, efficiency of emission controls, andengine performance depend on adherence to properoperation and maintenance recommendations.Engine performance and efficiency also depend onthe use of recommended fuels, lubrication oils, andcoolants. Refer to the Operation and MaintenanceManual, “Maintenance Interval Schedule” for moreinformation on maintenance items.

SEBU8325-01Engine Service LifeEngine efficiency and maximum utilization of engineperformance depend on the adherence to properoperation and maintenance recommendations. Inaddition, use recommended fuels, coolants, andlubricants. Use the Operation and MaintenanceManual as a guide for required engine maintenance.Expected engine life is generally predicted by theaverage power that is demanded. The average powerthat is demanded is based on fuel consumption ofthe engine over a time period. Reduced hours ofoperation at fu

specified in the Maintenance Interval Schedule may be necessary. The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs .

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