Perkins 800D Series User manual

Operation and
Maintenance
Manual
800D Series Industrial Engines
UK (Engine)
UL (Engine)
SEBU8324-02 (en-us)
January 2021

Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessarytraining, skills and tools to performthese functions correctly.
Incorrect operation,lubrication,maintenanceorrepairofthisproductcanbedangerousand
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings 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 or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
The information, specifications, and illustrations in this publication are on the basis of information that
was 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 can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. You must not use
this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of
the product in the location of use, including site-specific rules and precautions applicable to the
worksite. 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 you are authorized to perform this work, and that the product will not
be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.

Table of Contents
Foreword ........................................................... 4
Safety Section
Safety Messages............................................... 6
General Hazard Information.............................. 8
Burn Prevention............................................... 12
Fire Prevention and Explosion Prevention...... 12
Crushing Prevention and Cutting Prevention.. 14
Mounting and Dismounting ............................. 14
Before Starting Engine .................................... 15
Engine Starting................................................ 15
Engine Stopping .............................................. 15
Electrical System............................................. 16
Product Information Section
Model Views .................................................... 17
Product Identification Information ................... 22
Operation Section
Lifting and Storage .......................................... 25
Gauges and Indicators .................................... 27
Features and Controls..................................... 28
Engine Starting................................................ 29
Engine Operation ............................................ 32
Engine Stopping .............................................. 34
Cold Weather Operation ................................. 35
Maintenance Section
Refill Capacities............................................... 39
Maintenance Interval Schedule....................... 51
Warranty Section
Warranty Information....................................... 73
Index Section
Index................................................................ 74
SEBU8324-02 3
Table of Contents

Foreword
California Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth defects,
and other reproductive harm.
WARNING – This product can
expose you to chemicals
including ethylene glycol, which
is known to the State of California to
cause birth defects or other reproductive
harm. For more information go to:
www.P65Warnings.ca.gov
Do not ingest this chemical. Wash hands
after handling to avoid incidental
ingestion.
WARNING – This product can
expose you to chemicals
including lead and lead
compounds, which are known to the
State of California to cause cancer, birth
defects, or other reproductive harm. For
more information go to:
www.P65Warnings.ca.gov
Wash hands after handling components
that may contain lead.
Literature Information
This manual contains safety, operation instructions,
lubrication, and maintenance information. This
manual should be stored in or near the engine area in
a literature holder or literature storage area. Read,
study, and keep the manual with the literature and
engine information.
English is the primary language for all Perkins
publications. The English used facilitates translation
and consistency.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Perkins dealer or your Perkins
distributor for the latest available information.
Safety
This safety section lists basic safety precautions. In
addition, this section identifies hazardous, warning
situations. Read and understand the basic
precautions listed in the safety section before
operating or performing lubrication, maintenance,
and repair on this product.
Operation
Operating techniques outlined in this manual are
basic. The operating techniques assist with
developing the skills and techniques required to
operate the engine more efficiently and economically.
Skill and techniques develop as the operator gains
knowledge of the engine and the capabilities of the
engine.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating,
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
Recommended service should be performed at the
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under severe, dusty, wet, or
freezing cold operating conditions, more frequent
lubrication, and maintenance than is specified in the
Maintenance Interval Schedule may be necessary.
4SEBU8324-02
Foreword

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 through cost
avoidances resulting from reductions in unscheduled
downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation, and application. Perkins recommends that
the maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
Perkins also recommends that a maintenance record
be maintained as part of the permanent record of the
engine.
Your authorized Perkins dealer or your Perkins
distributor can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.
Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or an
authorized Perkins distributor or dealer. Your Perkins
dealer or your Perkins distributor offers various
options regarding overhaul programs. If you
experience a major engine failure, there are also
numerous after failure overhaul options available.
Consult with your Perkins dealer or your Perkins
distributor for information regarding these options.
SEBU8324-02 5
Foreword

Safety Section
i02697668
Safety Messages
There may be several specific warning signs on an
engine. The exact location of the hazards and the
description of the hazards are reviewed in this
section. Please become familiar with all warning
signs.
Ensure that all of the warning signs are legible. Clean
the warning signs or replace the warning signs if the
words cannot be read or if the pictures are not visible.
When the warning signs are cleaned, use a cloth,
water, and soap. Do not use solvent, gasoline, or
other harsh chemicals to clean the warning signs.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the warning signs. The
warning signs that are loosened could drop off of the
engine.
Replace any damaged warning signs or missing
warning signs. If a warning sign is attached to a part
of the engine that is replaced, install a new warning
sign on the replacement part. Any Perkins dealer or
any Perkins distributor can provide new warning
signs.
Do not work on the engine and do not operate the
engine unless the instructions and warnings in the
Operation and Maintenance Manual are understood.
Proper care is your responsibility. Failure to follow the
instructions or failure to heed the warnings could
result in injury or in death.
The warning labels that may be found on the engine
are illustrated and described.
6SEBU8324-02
Safety Section
Safety Messages

Illustration 1 g01353473
Typical example
(1) Universal Warning (2) Warning label for the Starting Aid
Universal Warning (1)
The universal warning label (1) is located on the top
of the valve mechanism cover.
SEBU8324-02 7
Safety Section
Safety Messages

Illustration 2 g01273386
Do not operate or work on this engine unless you
have read and understand the instructions and
warnings in the Operation and Maintenance Man-
ual. Failure to follow the instructions or heed the
warnings could result in injury or death.
Starting Aid (2)
The warning label for the starting aid (2) is located on
the side of the air inlet manifold.
Illustration 3 g01273387
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
i08312758
General Hazard Information
Illustration 4 g00104545
Attach a “Do Not Operate”warning tag or a similar
warning tag to the start switch or to the controls
before you service the equipment or before you
repair the equipment.
8SEBU8324-02
Safety Section
General Hazard Information

Illustration 5 g00702020
Wear a hard hat, protective glasses, and other
protective equipment, as required.
Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the engine.
Make sure that all protective guards and all covers
are secured in place on the engine.
Keep the engine free from foreign material. Remove
debris, oil, tools, and other items from the deck, from
walkways, 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 the
equipment.
Disconnect the batteries when maintenance is
performed or when the electrical system is serviced.
Disconnect the battery ground leads. Tape the leads
to help prevent sparks. If equipped, allow the diesel
exhaust fluid to be purged before disconnecting the
battery.
Perform maintenance on the engine with the
equipment in the servicing position. Refer to the OEM
information for the procedure for placing the
equipment in the servicing position.
Do not attempt any repairs that are not understood.
Use the proper tools. Replace any equipment that is
damaged or repair the equipment.
For initial start-up of a new engine or for starting an
engine that has been serviced, make provisions to
stop the engine if an overspeed occurs. The stopping
of the engine may be accomplished by shutting off
the fuel supply and/or the air supply to the engine.
Ensure that only the fuel supply line is shut off.
Ensure that the fuel return line is open.
Start the engine from the operators station (cab).
Never short across the starting motor terminals or the
batteries. This action could bypass the engine neutral
start system and/or the electrical system could be
damaged.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a ventilated area. If
the engine is in an enclosed area, vent the engine
exhaust to the outside.
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of the
cover plate or the device. Before removing the last
two bolts or nuts, pry the cover loose to relieve any
spring pressure or other pressure.
Pressure Air and Water
Pressurized air and/or water can cause debris and/or
hot water to be blown out. This action could result in
personal injury.
The direct application of pressurized air or
pressurized water to the body could result in personal
injury.
When pressurized air and/or water is used for
cleaning, wear protective clothing, protective shoes,
and eye protection. Eye protection includes goggles
or a protective face shield.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved
correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
information for any procedures that are required to
relieve the hydraulic pressure.
SEBU8324-02 9
Safety Section
General Hazard Information

Illustration 6 g00687600
Always use a board or cardboard when you check for
a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting, and repair of the
engine. Make provision to collect the fluid with a
suitable container before any compartment is opened
or before any component is disassembled.
• Only use the tools that are suitable for collecting
fluids and equipment that is suitable for collecting
fluids.
• Only use the tools that are suitable for containing
fluids and equipment that is suitable for containing
fluids.
Obey all local regulations for the disposal of liquids.
Static Electricity Hazard when
Fueling with Ultra-low Sulfur Diesel
Fuel
The removal of sulfur and other compounds in ultra-
low sulfur diesel fuel (ULSD fuel) decreases the
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.
Avoid static electricity risk when fueling. Ultra-
low sulfur diesel fuel (ULSD fuel) poses a greater
static ignition hazard than earlier diesel formula-
tions with a higher sulfur contents. Avoid death
or serious injury from fire or explosion. Consult
with your fuel or fuel system supplier to ensure
the delivery system is in compliance with fueling
standards for proper grounding and bonding
practices.
Inhalation
Illustration 7 g00702022
Exhaust
Use caution. Exhaust fumes can be hazardous to
health. If you operate the equipment in an enclosed
area, adequate ventilation is necessary.
10 SEBU8324-02
Safety Section
General Hazard Information

Hexavalent Chromium
Perkins equipment and replacement parts comply
with applicable regulations and requirements where
originally sold. Perkins recommends the use of only
genuine Perkins replacement parts.
Hexavalent chromium has occasionally been
detected on exhaust and heat shield systems on
Perkins engines. Although laboratory testing is the
only accurate way to know if hexavalent chromium is,
in fact, present, the presence of a yellow deposit in
areas of high heat (for example, exhaust system
components or exhaust insulation) may be an
indication of the presence of hexavalent chromium.
Use caution if you suspect the presence of
hexavalent chromium. Avoid skin contact when
handling items that you suspect may contain
hexavalent chromium, and avoid inhalation of any
dust in the suspect area. Inhalation of, or skin contact
with, hexavalent chromium dust may be hazardous to
your health.
If such yellow deposits are found on the engine,
engine component parts, or associated equipment or
packages, Perkins recommends following local
health and safety regulations and guidelines, utilizing
good hygiene, and adhering to safe work practices
when handling the equipment or parts. Perkins also
recommends the following:
• Wear appropriate Personal Protective Equipment
(PPE)
• Wash your hands and face with soap and water
prior to eating, drinking, or smoking, and also
during rest room breaks, to prevent ingestion of
any yellow powder
• Never use compressed air for cleaning areas
suspected of containing hexavalent chromium
• Avoid brushing, grinding, or cutting materials
suspected of containing hexavalent chromium
• Obey environmental regulations for the disposal of
all materials that may contain or have come into
contact with hexavalent chromium
• Stay away from areas that might have hexavalent
chromium particles in the air.
Asbestos Information
Perkins equipment and replacement parts that are
shipped from Perkins engine company limited are
asbestos free. Perkins recommends the use of only
genuine Perkins replacement parts. Use the following
guidelines when you handle any replacement parts
that contain asbestos or when you handle asbestos
debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning.
• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.
• Use a wet method to clean up asbestos materials.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
• Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos
particles in the air.
SEBU8324-02 11
Safety Section
General Hazard Information

Dispose of Waste Properly
Illustration 8 g00706404
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of in accordance with local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i08162288
Burn Prevention
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
air system, hydraulic system, lubrication system, fuel
system, and cooling system before any lines, fittings,
or related items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check that the coolant level after the engine has
stopped and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly to
relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.
Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for
servicing batteries. Wash hands after touching the
batteries and connectors. Use of gloves is
recommended.
i07188311
Fire Prevention and Explosion
Prevention
Illustration 9 g00704000
All fuels, most lubricants, and some coolant mixtures
are flammable.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a
fire. Fire may cause personal injury and property
damage.
A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an
emergency shutdown.
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
12 SEBU8324-02
Safety Section
Burn Prevention

If the application involves the presence of
combustible gases, consult your Perkins dealer and/
or your Perkins distributor for additional information
about suitable protection devices.
Remove all flammable combustible materials or
conductive materials such as fuel, oil, and debris
from the engine. Do not allow any flammable
combustible materials or conductive materials to
accumulate on the engine.
Store fuels and lubricants in correctly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line, a
tube, or a seal failure. Exhaust shields must be
installed correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame-cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Ensure that all
electrical wires are correctly installed and securely
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and correctly
maintained battery cables will help to prevent arcing
or sparking.
Inspect all lines and hoses for wear or for
deterioration. The hoses must be correctly routed.
The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
Oil filters and fuel filters must be correctly installed.
The filter housings must be tightened to the correct
torque.
Illustration 10 g00704059
Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not
refuel an engine near open flames or sparks. Always
stop the engine before refueling.
Illustration 11 g00704135
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a
hydrometer.
SEBU8324-02 13
Safety Section
Fire Prevention and Explosion Prevention

Incorrect jumper cable connections can cause an
explosion that can result in injury. Refer to the
Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. This action may
cause an explosion.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Ether
Ether is flammable and poisonous.
Do not smoke while you are replacing an ether
cylinder or while you are using an ether spray.
Do not store ether cylinders in living areas or in the
engine compartment. Do not store ether cylinders in
direct sunlight or in temperatures above 49° C
(120° F). Keep ether cylinders away from open
flames or sparks.
Lines, Tubes, and Hoses
Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent
or damaged. Do not clip any other items to the high-
pressure lines.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Perkins dealer or your
Perkins distributor for repair or for replacement parts.
Check lines, tubes, and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions
are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are ballooning.
• Flexible parts of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation,
correct installation will help to prevent vibration,
rubbing against other parts, and excessive heat.
i08162291
Crushing Prevention and
Cutting Prevention
Support the component properly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving parts.
Leave the guards in place until maintenance is
performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective glasses to
avoid injury to the eyes.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
i02235492
Mounting and Dismounting
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these items in good repair.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine.
Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
controls as handholds.
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
14 SEBU8324-02
Safety Section
Crushing Prevention and Cutting Prevention

i08258438
Before Starting Engine
NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.
Engine exhaust contains products of combustion
which may be harmful to your health. Always
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust
to the outside.
Inspect the engine for potential hazards.
Do not start the engine if there is a “DO NOT
OPERATE”warning tag or similar warning tag
attached to the start switch. Do not move any of the
controls if there is a “DO NOT OPERATE”warning
tag or similar warning tag attached to the controls.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights work properly, if equipped.
All protective guards and all protective covers must
be installed if the engine must be started to perform
service procedures. To help prevent an accident that
is caused by parts in rotation, work around the parts
carefully.
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
provided to help prevent personal injury. The circuits
are also provided to help prevent engine damage.
See the Service Manual for repairs and for
adjustments.
i01933350
Engine Starting
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started in order to
perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Start the engine from the operator's compartment or
from the engine start switch.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
properly, check the water temperature gauge and the
oil temperature gauge during the heater operation.
Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
Note: The engine is equipped with an automatic
device for cold starting for normal conditions of
operation. If the engine will be operated in very cold
conditions, then an extra cold starting aid may be
required. Normally, the engine will be equipped with
the correct type of starting aid for your region of
operation.
The 800 Series engine is equipped with a glow plug
starting aid in each individual cylinder that heats the
intake air in order to improve starting.
i08194343
Engine Stopping
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
according to this Operation and Maintenance
Manual, “Engine Stopping” topic (Operation Section).
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. DO NOT use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.
SEBU8324-02 15
Safety Section
Before Starting Engine

On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop the
engine if an overspeed condition occurs. Engine
stopping may be accomplished by shutting off the
fuel supply and/or the air supply to the engine.
i02176668
Electrical System
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” jump start cable should be connected
last from the external power source to the negative
“−” terminal of the starting motor. If the starting motor
is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. See the
Operation and Maintenance Manual for specific
starting instructions.
Grounding Practices
Correct grounding for the engine electrical system is
necessary for optimum engine performance and
reliability. Incorrect grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.
Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
discharge.
To ensure that the engine and the engine electrical
systems function correctly, an engine-to-frame
ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct
engine ground to the frame.
All grounds should be tight and free of corrosion. The
engine alternator must be grounded to the negative
“-” battery terminal with a wire that is adequate to
handle the full charging current of the alternator.
16 SEBU8324-02
Safety Section
Electrical System

i02697676
Product Information
Section
Model Views
Model View Illustrations
Illustration 12 g01264543
Left side view of a naturally aspirated engine
This view is shown without one of the fuel injectors for clarity.
(1) Fan
(2) Fuel injector
(3) Glow plug
(4) Oil filler cap
(5) Lifting eye
(6) Water drain plug or drain valve
(7) Oil level gauge
(8) Flywheel housing
(9) Oil filter
SEBU8324-02 17
Product Information Section
Model Views

(10) Relief valve
(11) Oil drain plug
(12) Oil pressure switch
(13) Fuel injection pump
(14) Oil Filler
(15) Water pump
Illustration 13 g01264517
(16) Oil filler cap
(17) Lifting eye
(18) Thermostat
(19) Alternator
(20) V-Belt
(21) Crankshaft vibration damper
(22) Starting motor
(23) Exhaust manifold
18 SEBU8324-02
Product Information Section
Model View Illustrations

Illustration 14 g01353575
Left side view of turbocharged engine
(1) Glow plug
(2) Inlet manifold
(3) Fuel injector
(4) Crankcase breather
(5) Water drain plug or drain valve
(6) Oil level gauge
(7) Fuel injection pump
(8) Oil filter
(9) Relief valve
(10) Oil drain plug
(11) Oil filler
(12) V-belt
(13) Oil cooler
(14) Fan
SEBU8324-02 19
Product Information Section
Model View Illustrations

Illustration 15 g01353864
Right side view of turbocharged engine
(15) Turbocharger
(16) Front lifting eye
(17) Coolant switch
(18) Alternator
(19) Starting motor
(20) Oil pan
(21) Flywheel housing
(22) Flywheel
(23) Exhaust manifold
(24) Rear lifting eye
(25) Top oil filler
i02700110
Engine Description
Table 1
Naturally Aspirated Specifications
Type Four Stroke Cycle
(continued)
(Table 1, contd)
Number of Cylinders 4 In-Line
Bore 94 mm (3.70 inch)
Stroke 120 mm (4.72 inch)
Aspiration Naturally Aspirated
Compression ratio 22:1
(continued)
20 SEBU8324-02
Product Information Section
Engine Description