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Perkins 6.3544 Series User Manual

Perkins 6.3544 Series
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Perkins 6.3544 Series
Models TU, TW and TX
USER’S HANDBOOK
6 cylinder diesel engines for vehicle, industrial and
agricultural use
Publication TPD 1289E, Issue 2.
© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in 1994 by Technical Publications,
Perkins Engines Company Limited, Peterborough PE1 5NA England
This document has been printed from SPI². Not for Resale

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Perkins 6.3544 Series Specifications

General IconGeneral
Engine Model6.3544
Cylinder Count6
Fuel SystemDirect Injection
Engine TypeDiesel
Displacement5.8 L (354 cu in)
Bore98.4 mm (3.875 inches)
Stroke127 mm (5.0 in)
AspirationTurbocharged
Torque372-475 Nm (275-350 lb-ft) (depending on variant)
Cooling SystemLiquid Cooled

Summary

General Information

Introduction to Perkins 6.3544 Series Engines

Overview of the Perkins 6.3544 Series engines for vehicle, industrial, and agricultural use.

Safety Precautions for Perkins Engines

Important safety precautions for operating and maintaining Perkins engines.

Engine Care and Maintenance

Guidance on maintaining and operating the engine for optimal performance and longevity.

Engine Preservation Procedures

Procedures to prevent engine damage during prolonged periods of non-use.

Parts and Service Information

Information on obtaining genuine Perkins parts and service support.

Perkins POWERPART Consumable Products

List and description of Perkins consumable products for engine operation and maintenance.

Perkins 6.3544 Series Engine Identification

Details on identifying different engine types within the 6.3544 Series.

Perkins 6.3544 Series Engine Data

Technical specifications and data for the 6.3544 Series engines.

Engine Views and Component Identification

Introduction to Engine Views

Introduction to engine component views, noting variations between engine specifications.

Location of Parts: Naturally Aspirated Engines (Front/Left)

Diagram and labels for engine parts on the front and left side of naturally aspirated engines.

Location of Parts: Naturally Aspirated Engines (Rear/Right)

Diagram and labels for engine parts on the rear and right side of naturally aspirated engines.

Location of Parts: Turbocharged Engines (Front/Left)

Diagram and labels for engine parts on the front and left side of turbocharged engines.

Location of Parts: Turbocharged Engines (Rear/Right)

Diagram and labels for engine parts on the rear and right side of turbocharged engines.

Location of Parts: Turbocharged Engines with Intercooler (Front/Left)

Diagram and labels for engine parts on the front and left side of turbocharged engines with intercooler.

Location of Parts: Turbocharged Engines with Intercooler (Rear/Right)

Diagram and labels for engine parts on the rear and right side of turbocharged engines with intercooler.

Operation Instructions

How to Start the Engine

Factors affecting engine start and descriptions of various cold start systems.

How to Start a Warm Engine

Step-by-step procedure for starting a warm Perkins engine.

How to Start a Cold Engine Without Starting Aids

Procedure for starting a cold engine when no specific starting aids are fitted.

How to Start a Cold Engine with Fuelled Starting Aid

Procedure for starting a cold engine using the fuelled starting aid system.

How to Start a Cold Engine with Manually Operated Start Pilot

Procedure for starting a cold engine using the manually operated Start Pilot system.

How to Start a Cold Engine with KBi or Electrically Operated Start Pilot

Procedure for starting a cold engine using KBi or electrically operated Start Pilot.

How to Stop the Engine

Instructions for stopping the engine using the start key or manual stop control.

Engine Speed Range Adjustment Warning

Warning against unauthorized adjustment of engine speed settings.

Engine Running-In Procedures

Guidance on running-in new or rebuilt Perkins engines.

Turbocharged Engine Operation

Operating recommendations for turbocharged engines during gradients.

Operating at Altitude

Considerations for operating naturally aspirated and turbocharged engines at high altitudes.

Preventive Maintenance

Preventive Maintenance Periods

Guidelines for preventive maintenance intervals under average operating conditions.

Maintenance Schedules

Maintenance schedules based on kilometres, miles, hours, or months.

How to Drain the Cooling System

Step-by-step instructions for draining the engine's cooling system.

How to Check Drive Belts

Procedure for checking and adjusting the tension of drive belts.

How to Clean Fuel Lift Pump Gauze Strainer

Instructions for cleaning the gauze strainer in the fuel lift pump.

Fuel Pre-filter Checks

Notes on the fuel pre-filter and checking for water.

How to Renew Fuel Filter Elements

Detailed steps for replacing fuel filter elements, emphasizing genuine parts.

Atomiser Fault Diagnosis

Identifying a defective atomiser through engine speed checks.

How to Renew an Atomiser

Step-by-step procedure for replacing an engine atomiser.

How to Eliminate Air from the Fuel System

Procedure for purging air from the fuel system for various pump types.

How to Renew Lubricating Oil

Instructions for changing the engine lubricating oil.

How to Renew Lubricating Oil Filter Canister

Procedure for replacing the lubricating oil filter canister.

How to Clean Engine Breather Valve

Steps for cleaning the engine breather valve on specific engine types.

Air Cleaner Maintenance

Maintenance instructions for the wet type air cleaner.

Air Filter Service

Service recommendations for air filters based on environmental conditions and indicators.

Restriction Indicator Usage

Explanation of the restriction indicator for air filter service.

How to Check Valve Tip Clearances

Procedure for checking and adjusting valve tip clearances with a cold engine.

Engine Fluids

Fuel Specification Requirements

Recommended specifications for fuel quality to ensure optimal engine performance.

Lubricating Oil Specification

Recommended specifications and viscosity grades for lubricating oil based on engine type and temperature.

Coolant Specification and Maintenance

Recommendations for coolant quality, antifreeze, and corrosion inhibitors.

Fault Diagnosis

Engine Problems and Possible Causes

Table listing engine problems and their potential causes with user/workshop checks.

Code List of Possible Causes

A numbered list of possible causes for engine problems.

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