Perkins 1106D-70TA Operation And Maintenance Manual
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Perkins 1106D-70TA Operation And Maintenance Manual

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SEBU8731
April 2013
Operation and
Maintenance
Manual
1106C-70TA and 1106D-70TA Industrial
Engines
PV (Engine)
PW (Engine)

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Summary of Contents for Perkins 1106D-70TA

  • Page 1: Operation And Maintenance

    SEBU8731 April 2013 Operation and Maintenance Manual 1106C-70TA and 1106D-70TA Industrial Engines PV (Engine) PW (Engine)

  • Page 2: Important Safety Information

    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.

  • Page 3: Table Of Contents

    SEBU8731 Table of Contents Table of Contents Maintenance Section Refill Capacities..........52 Foreword............4 Maintenance Recommendations....65 Safety Section Maintenance Interval Schedule ...... 67 Safety Messages..........5 Warranty Section General Hazard Information ......7 Warranty Information ....

  • Page 4: Foreword

    Operation and Maintenance Manual except for the Operation interval and the maintenance items in that interval. Major repairs should only be carried out by Perkins Operating techniques outlined in this manual are authorized personnel. Your Perkins dealer or your basic. They assist with developing the skills and...

  • Page 5: Safety Section

    If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Your Perkins dealer or your Perkins distributor can provide new warning signs. (1) Universal Warning...
  • Page 6 SEBU8731 Safety Section Safety Messages Illustration 2 g03341746 (1) Universal warning 2 Hand (High Pressure) Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service in- structions may cause personal injury or death.

  • Page 7: General Hazard Information

    SEBU8731 Safety Section General Hazard Information Ether Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury. Illustration 7 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.

  • Page 8: Burn Prevention

    SEBU8731 Safety Section Burn Prevention The maximum air pressure for cleaning purposes i05302522 must be below 205 kPa (30 psi). The maximum water Burn Prevention pressure for cleaning purposes must be below 275 kPa (40 psi). Fluid Penetration Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is Pressure can be trapped in the hydraulic circuit long performed on the engine.

  • Page 9: Fire Prevention And Explosion Prevention

    If the application involves the presence of Properly install oil filters and fuel filters. The filter combustible gases, consult your Perkins dealer and/ housings must be tightened to the correct torque. or your Perkins distributor for additional information Refer to the Disassembly and Assembly manual for about suitable protection devices.

  • Page 10: Crushing Prevention And Cutting Prevention

    Lines, Tubes, and Hoses Do not bend high-pressure lines. Do not strike high- pressure lines. Do not install any lines that are damaged. Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for replacement parts. Illustration 10 g00704059 Replace the parts if any of the following conditions Use caution when you are refueling an engine.

  • Page 11: Mounting And Dismounting

    SEBU8731 Safety Section Mounting and Dismounting 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.
  • Page 12 SEBU8731 Safety Section High Pressure Fuel Lines Illustration 12 g03342586 (1) High-pressure line (4) High-pressure line (7) High-pressure fuel manifold (rail) (2) High-pressure line (5) High-pressure line (8) High-pressure supply line (3) High-pressure line (6) High-pressure line (9) High-pressure supply line The high-pressure fuel lines are the fuel lines that are If you inspect the engine in operation, always use the between the high-pressure fuel pump and the high-...

  • Page 13: Before Starting Engine

    SEBU8731 Safety Section Before Starting Engine If a warning tag is attached to the engine start switch NOTICE or to the controls DO NOT start the engine or move The low-pressure fuel system can be pressurized for the controls. Consult with the person that attached a time period after the engine has stopped operating.

  • Page 14: Electrical System

    SEBU8731 Safety Section Electrical System Stop the engine if an overspeed condition occurs during the initial start-up of a new engine or an engine that has been overhauled. To stop an electronically controlled engine, cut the power to the engine and/or shutting off the air supply to the engine.

  • Page 15: Engine Electronics

    Safety Section Engine Electronics Note: Many of the engine control systems and i05272352 display modules that are available for Perkins Engine Electronics Engines will work in unison with the Engine Monitoring System. Together, the two controls will provide the engine monitoring function for the specific engine application.

  • Page 16: Product Information Section

    SEBU8731 Product Information Section Model View Illustrations Product Information Section General Information i05241813 Model View Illustrations The following model views show typical features of the engine. Due to individual applications, your engine may appear different from the illustrations. Illustration 15 g03343017 (1) Secondary fuel filters (4) Electronic control module...
  • Page 17 SEBU8731 General Information Model View Illustrations Illustration 16 g03343019 (9) Coolant outlet (12) Vibration damper (15) Belt idler pulley (10) Water pump (13) Belt tensioner (11) Coolant intake (14) Belt...
  • Page 18 SEBU8731 General Information Model View Illustrations Illustration 17 g03343041 (16) Exhaust manifold (20) Turbocharger (24) Flywheel housing (17) Font lifting eye (21) Starting motor (25) Rear lifting eye (18) Alternator (22) Solenoid for starting motor (19) Refrigerant compressor (23) Flywheel...

  • Page 19: Product Description

    (30) Spin on crankcase breather (27) Primary fuel filter (29) Primary fuel filter i05272410 Product Description The Perkins 1106C-E70TA and the 1106D-E70TA Industrial Engines has the following characteristics. • In-line 6 cylinder • Four stroke cycle • Turbocharged aftercooled Engine Specifications...

  • Page 20: Engine Cooling And Lubrication

    SEBU8731 General Information Product Description Engine Cooling and Lubrication (Table 1, contd) Compression Ratio 16.5:1 The cooling system consists of the following components: Displacement 7.01 L (427.77 cubic inch) Firing Order • Gear-driven centrifugal water pump 1-5-3-6-2-4 Rotation (flywheel end) Counterclockwise •...

  • Page 21: Product Identification Information

    Plate Locations and Film Locations Illustration 21 g02433756 Typical example Illustration 20 g03343476 Perkins engines are identified by an engine serial number. An example of an engine number is P- *****R000001X. ***** The list number for the engine Type of engine...

  • Page 22: Emissions Certification Film

    SEBU8731 Product Identification Information Emissions Certification Film i05275515 Emissions Certification Film Illustration 22 g03355218 Typical example Lubrication Oil Filter Element i05242876 Total Lubrication System Capacity Reference Information Total Cooling System Capacity Air Cleaner Element Information for the following items may be needed to order parts.

  • Page 23: Operation Section

    The engine must be stored in a water proof building. The building must be kept at a constant temperature. Engines that are filled with Perkins ELC will have coolant protection to an ambient temperature of −36° C (−32.8° F). The engine must not be subjected to extreme variations in temperature and humidity.

  • Page 24: Open Cooling System

    SEBU8731 Lifting and Storage Product Storage Sealed Coolant System Ensure that the cooling system is filled with Perkins ELC, or an antifreeze that meets ASTM D6210 specification. Open Cooling System Ensure that all cooling drain plugs have been opened. Allow the coolant to drain. Install the drain plugs.

  • Page 25: Features And Controls

    SEBU8731 Features and Controls Alarms and Shutoffs Features and Controls Intake manifold air temperature – The intake manifold air temperature sensor indicates high intake air temperature. i05251301 Intake manifold pressure – The intake manifold Alarms and Shutoffs pressure sensor checks the rated pressure in the engine manifold.

  • Page 26: Gauges And Indicators

    Determine and correct the cause of any significant procedure: change in the readings. Consult your Perkins dealer or your distributor Perkins for assistance. 1. Reduce the load and the engine rpm. Some engine applications are equipped with Indicator 2.

  • Page 27: Monitoring System

    SEBU8731 Features and Controls Monitoring System • Shutdown Lamp i05245144 Monitoring System • Warning Lamp • Wait to Start Lamp • Low Oil Pressure Lamp For information, refer to this manual, “Monitoring System (Table for the Indicator Lamps)” for the If the Shutdown mode has been selected and the sequence of operation of the shutdown lamp and the warning indicator activates, engine shutdown...
  • Page 28 SEBU8731 Features and Controls Monitoring System “ “ Warning” ” The “Warning” lamp and the warning signal (orange lamp) turn “ON” and the warning signal is activated continuously in order to alert the operator that one or more of the engine parameters is not within normal operating range.

  • Page 29: Sensors And Electrical Components

    SEBU8731 Features and Controls Monitoring System i02330192 Monitoring System Table 2 Shutdown Warning Lamp Lamp Status Description of lamp status Engine Status Lamp Lamp check When the engine start switch is turned to the “ON” po- The engine has not been sition both lamps will illuminate for 2 seconds only.
  • Page 30 SEBU8731 Features and Controls Sensors and Electrical Components Illustration 24 g03344459 (1) Connector for the injectors (5) Wastegate regulator (9) Oil pressure sensor (2) Intake manifold pressure sensor (6) Fuel rail pressure sensor (10) Solenoid for the high-pressure fuel (3) Intake manifold temperature sensor (7) Electronic control module pump (4) Connector for glow plugs...
  • Page 31 SEBU8731 Features and Controls Sensors and Electrical Components Illustration 25 g03344462 (12) Secondary speed/timing sensor (14) Refrigerant compressor (16) Priming pump relay (13) Alternator (15) Starting motor and solenoid...
  • Page 32 SEBU8731 Features and Controls Sensors and Electrical Components Illustration 26 g03344866 (1) Connections for injectors (2) Intake manifold pressure sensor (3) Intake manifold temperature sensor...
  • Page 33 SEBU8731 Features and Controls Sensors and Electrical Components Illustration 27 g03344871 (4) Connector for glow plugs (7) Electronic control module (10) Solenoid for the high-pressure fuel (5) Wastegate regulator (8) Oil pressure sensor pump (6) Fuel rail pressure sensor (9) Primary speed/timing sensor...
  • Page 34 SEBU8731 Features and Controls Sensors and Electrical Components Illustration 28 g03344872 (11) Coolant temperature sensor (12) Secondary speed/timing sensor • Item (13) the alternator can be 12 V or 24 V • Item (14) refrigerant compressor is an option only •...

  • Page 35: Engine Diagnostics

    Retrieval Self-Diagnostics “ “ Diagnostic” ” Lamp Perkins electronic engines have the capability to perform a self-diagnostics test. When the system Use the “DIAGNOSTIC” lamp or an electronic detects an active problem, a diagnostic lamp is service tool to determine the diagnostic flash code.
  • Page 36 SEBU8731 Engine Diagnostics Diagnostic Flash Code Retrieval Table 3 Flash Codes for the Industrial Engine Diagnostic Effect On Engine Performance Suggested Operator Action Flash Code Description Engine Low Power Reduced Engine Service Schedule a Misfire Engine Shutdown Service. Speed No. 1 Injector Fault No.

  • Page 37: Fault Logging

    SEBU8731 Engine Diagnostics Fault Logging (Table 3, contd) Idle Validation Switch 2 Engine Fuel Supply Pump Relay Software Mismatch Machine Security Module Ignition Key Switch Fault ECM Power Supply Voltage Fault SAE J1939 Data Link Fault 5 Volt Sensor DC Power Supply Fault 8 Volt Sensor DC Power Supply Fault...

  • Page 38: Configuration Parameters

    SEBU8731 Engine Diagnostics Engine Operation with Intermittent Diagnostic Codes i01902995 Engine Operation with Intermittent Diagnostic Codes If a diagnostic lamp illuminates during normal engine operation and the diagnostic lamp shuts off, an intermittent fault may have occurred. If a fault has occurred, the fault will be logged into the memory of the Electronic Control Module (ECM).

  • Page 39: Customer Specified Parameters

    SEBU8731 Engine Diagnostics Configuration Parameters Table 4 System Configuration Parameters Configuration Parameters Record Engine Serial Number Rating Full Load Setting Full Torque Setting ECM Software Release Date Customer Specified Parameters Customer specified parameters allow the engine to be configured to the exact needs of the application. The electronic service tool is required in order to alter the customer configuration parameters.
  • Page 40 SEBU8731 Engine Diagnostics Configuration Parameters (Table 5, contd) Throttle Lock Engine Set Speed 1 Throttle Lock Engine Set Speed 2 Throttle Lock Increment Speed Ramp Rate Throttle Lock Decrement Speed Ramp Rate Throttle Lock Engine Set Speed Increment Throttle Lock Engine Set Speed Decrement Miscellaneous Monitoring Mode Shutdowns Monitoring Mode Derates...
  • Page 41 SEBU8731 Engine Diagnostics Configuration Parameters (Table 5, contd) Transmission Oil Temperature Input Enable Status Hydraulic Oil Temperature Input Enable Status Auxiliary #1 Temperature Input Enable Status Auxiliary #2 Temperature Input Enable Status Configurable Inputs Coolant Level Sensor Air Filter Restriction Switch Installation Status Air Filter Restriction Switch Configuration Water in Fuel Switch Installation Status User Defined Switch Installation Status...

  • Page 42: Engine Starting

    SEBU8731 Engine Starting Before Starting Engine Engine Starting i05298520 Cold Weather Starting i02837427 Before Starting Engine Perform the required daily maintenance and other Do not use aerosol types of starting aids such as periodic maintenance before the engine is started. ether.

  • Page 43: Starting The Engine

    SEBU8731 Engine Starting Starting the Engine 5. Repeat step 2 through step 4 if the engine fails to 4. Allow the keyswitch to return to the RUN position start. after the engine starts. 5. Repeat step 2 through step 4 if the engine fails to Note: The engine should not be “raced”...

  • Page 44: After Starting Engine

    SEBU8731 Engine Starting After Starting Engine 3. Connect one negative end of the jump start cable Note: Gauge readings should be observed and the data should be recorded frequently while the engine to the negative cable terminal of the electrical is operating.

  • Page 45: Engine Operation

    Fuel Conservation Practices The efficiency of the engine can affect the fuel economy. Perkins design and technology in manufacturing provides maximum fuel efficiency in all applications. Follow the recommended procedures in order to attain optimum performance for the life of the engine.

  • Page 46: Cold Weather Operation

    • The cooling system and the lubrication system for Perkins Diesel Engines can operate effectively in the engine do not lose heat immediately upon cold weather. During cold weather, the starting and shutdown.

  • Page 47: Viscosity Of The Engine Lubrication Oil

    Lubrication will be improved. There will be less acid 240 V dc. The output can be 750/1000W. Consult and less sludge in the oil. This condition will provide your Perkins dealer or your Perkins distributor for longer service life for the engine bearings, the piston more information.

  • Page 48: Fuel Related Components In Cold Weather

    Note: Only use grades of fuel that are recommended the fuel system filter is important. by Perkins . Refer to this Operation and Maintenance Drain the water and sediment from any fuel storage Manual, “Fluid Recommendations”.

  • Page 49: Fuel Heaters

    SEBU8731 Cold Weather Operation Fuel Related Components in Cold Weather Fuel Heaters Note: The OEM may equip the application with fuel heaters. If this is the case, the temperature of the fuel must not exceed 73 °C (163 °F) at the fuel transfer pump.

  • Page 50: Engine Stopping

    SEBU8731 Engine Stopping Stopping the Engine Engine Stopping Emergency Stop Button i05298681 Stopping the Engine NOTICE Stopping the engine immediately after it has been working under load, can result in overheating and ac- celerated wear of the engine components. Avoid accelerating the engine prior to shutting it down.
  • Page 51 SEBU8731 Engine Stopping After Stopping Engine • After the engine has stopped, wait for 60 seconds in order to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed on the engine fuel lines.

  • Page 52: Maintenance Section

    SEBU8731 Maintenance Section Refill Capacities Maintenance Section NOTICE If the engine is to be stored in, or shipped to an area with below freezing temperatures, the cooling system Refill Capacities must be either protected to the lowest outside temper- ature or drained completely to prevent damage. i05259518 NOTICE Refill Capacities...

  • Page 53: Coolant Recommendations

    • Plugging of radiators, coolers, and small passages • ASTM American Society for Testing and Materials Glycol The following two coolants are used in Perkins Glycol in the coolant helps to provide protection diesel engines: against the following conditions: Preferred – Perkins ELC Acceptable –...

  • Page 54: Elc Cooling System Maintenance

    3000 Service Hours or One Year (SCA). Water Use the interval that occurs first. The cooling system must also When using Perkins ELC, do not use standard SCA's be flushed out at this time. or SCA filters. ELC Cooling System Cleaning...
  • Page 55 As needed, add the is completely clean. coolant mixture in order to fill the system to the specified level. 9. Fill the cooling system with the Perkins Premixed ELC. Changing to Perkins ELC ELC Cooling System Contamination...

  • Page 56: Engine Oil Specification

    X is the amount of SCA that is required. hydrometer should not be used. Perkins engine cooling systems should be tested at Table 15 is an example for using the equation that is 500 hour intervals for the concentration of SCA.

  • Page 57: Engine Oil

    J754. Some classifications follow SAE J183 abbreviations, and some classifications follow the EMA Recommended Guideline on Diesel Engine Oil. In addition to Perkins definitions, there are other definitions that will be of assistance in purchasing lubricants. Recommended oil viscosities can be found in this publication, “Fluid Recommendations/...
  • Page 58 Fluid Recommendations Engines Operating on High Sulfur Fuel Aftermarket Oil Additives Perkins does not recommend the use of aftermarket Refer to this Manual Fluid Recommendations, “Fuel additives in oil. It is not necessary to use aftermarket Specification” for the required service interval for additives in order to achieve the engines maximum operating with high sulfur fuel.

  • Page 59: Diesel Fuel Requirements

    • Tests are conducted in order to detect contamination of the oil by water, glycol, or fuel. Perkins is not in a position to continuously evaluate and monitor all worldwide distillate diesel fuel • The Oil Condition Analysis determines the loss of specifications that are published by governments and the oils lubricating properties.
  • Page 60 Regional regulations, national regulations, or international regulations can require a fuel with a specific sulfur limit. Consult all applicable regu- lations before selecting a fuel for a given engine application. Perkins fuel systems and engine components can operate on high sulphur fuels.

  • Page 61: Diesel Fuel Characteristics

    European Certification. temperatures and extremely hot temperatures . If the Perkins does not certify diesel engines on any other kinematic viscosity of the fuel is lower than “1.4 cSt” fuel.
  • Page 62 Protection Agency (EPA) and European Certification • ASTM D975 Grade No. 1-D and 2-D fuels. Perkins does not certify engines on any other fuel. The user of the engine has the responsibility of • JIS K2204 Grades 1, 2 & 3 & Special Grade 3...
  • Page 63 Consult your supplier of fuel for • Perkins recommend the use of oil analysis in assistance in selecting appropriate anti-microbial order to check the quality of the engine oil if additive.
  • Page 64 Perkins . If biodiesel or biodiesel blends of fuel are to be used, Perkins require the use of Perkins fuel cleaner. The use of the fuel is in order to remove deposits within the fuel system that is created with the use of biodiesel.

  • Page 65: Maintenance Recommendations

    Consult the OEM of the equip- ment or your Perkins dealer regarding welding on a chassis frame or rail. Proper welding procedures are necessary in order to avoid damage to the engines ECM, sensors, and associated components.

  • Page 66: Environmental Factors

    • Failure to use recommended fuel, lubricants, and Refer to the standards for the engine or consult your coolant/antifreeze Perkins dealer or your Perkins distributor in order to determine if the engine is operating within the defined parameters. Severe service operation can accelerate component wear.

  • Page 67: Maintenance Interval Schedule

    SEBU8731 Maintenance Recommendations Maintenance Interval Schedule “Engine Oil and Filter - Change”......83 i05277354 Maintenance Interval Schedule “Fan Clearance - Check” .........85 Every 500 Service Hours or 1 Year Oil specification will depend on the engine power. “Battery Electrolyte Level - Check” ......69 Refer to this Manual, “Fluid Recommendation”...

  • Page 68: Aftercooler Core - Clean/Test

    Alternator - Inspect Note: Adjust the frequency of cleaning according to the effects of the operating environment. Perkins recommends a scheduled inspection of the Inspect the aftercooler for these items: damaged fins, alternator. Inspect the alternator for loose corrosion, dirt, grease, insects, leaves, oil and other connections and correct battery charging.

  • Page 69: Battery - Replace

    SEBU8731 Maintenance Recommendations Battery - Replace i03559623 10. Turn the battery disconnect switch to the ON Battery - Replace position. i02724529 Battery Electrolyte Level - Check Batteries give off combustible gases which can explode. A spark can cause the combustible gases to ignite.

  • Page 70: Belt Tensioner - Check

    SEBU8731 Maintenance Recommendations Battery or Battery Cable - Disconnect i02323088 i04907925 Battery or Battery Cable - Belt Tensioner - Check Disconnect The battery cables or the batteries should not be removed with the battery cover in place. The bat- tery cover should be removed before any servic- ing is attempted.

  • Page 71: Belt - Inspect

    SEBU8731 Maintenance Recommendations Belt - Inspect i04907868 i05277504 Belt - Inspect Coolant (Commercial Heavy- Duty) - Change NOTICE Care must be taken to ensure that fluids are con- tained during performance of inspection, mainte- nance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
  • Page 72 Run the engine at high idle for 1 minute in order to purge the air from the For information regarding the disposal and the recycling of used coolant, consult your Perkins cavities of the engine block. Decrease the engine dealer or your Perkins distributor.

  • Page 73: Coolant (Elc) - Change

    SEBU8731 Maintenance Recommendations Coolant (ELC) - Change • The engine overheats frequently. • Foaming of the coolant is observed. • The oil has entered the cooling system and the coolant is contaminated. • The fuel has entered the cooling system and the coolant is contaminated.
  • Page 74 For information regarding the disposal and the 3. Start and run the engine at low idle. Increase the recycling of used coolant, consult your Perkins engine rpm to high idle. Run the engine at high idle dealer or your Perkins distributor.

  • Page 75: Test For Sca Concentration

    Maintenance Recommendations Coolant Extender (ELC) - Add i05330512 Coolant Extender (ELC) - Add In order for Perkins ELC to achieve 12000 hours an extender must be added at 6000 hours. For a suitable extender, contact your Perkins dealer or Perkins distributor.

  • Page 76: Add The Sca, If Necessary

    SEBU8731 Maintenance Recommendations Driven Equipment - Check Add the SCA, If Necessary 4. Clean the cooling system filler cap and inspect the gasket. If the gasket is damaged, discard the old NOTICE filler cap and install a new filler cap. If the gasket is Do not exceed the recommended amount of supple- not damaged, use a suitable pressurizing pump in mental coolant additive concentration.

  • Page 77: Servicing The Air Cleaner Elements

    If the air cleaner element becomes plugged, the air can split the material of the air cleaner element. Unfiltered air will drastically accelerate internal engine wear. Your Perkins dealer or your Perkins distributor has the proper air cleaner elements for your application.

  • Page 78: Cleaning The Primary Air Cleaner Elements

    SEBU8731 Maintenance Recommendations Engine Air Cleaner Element (Dual Element/Canister Type) - Clean/Replace NOTICE 1. Remove the cover. Remove the primary air cleaner Do not clean the air cleaner elements by bumping or element. tapping. This could damage the seals. Do not use ele- ments with damaged pleats, gaskets or seals.
  • Page 79 SEBU8731 Maintenance Recommendations Engine Air Cleaner Element (Single Element) - Inspect/Replace Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry, dusty environment. Cleaning with pressurized air is recommended prior to vacuum cleaning.

  • Page 80: Test The Service Indicator

    SEBU8731 Maintenance Recommendations Engine Air Cleaner Service Indicator - Inspect i02335405 NOTICE Never run the engine without an air cleaner element Engine Air Cleaner Service installed. Never run the engine with a damaged air Indicator - Inspect cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals.

  • Page 81: Engine Mounts - Inspect

    Note: When the engine is operated in dusty applications, more frequent cleaning is required. Note: The engine mounts may not have been supplied by Perkins . Refer to the OEM information i05277600 for further information on the engine mounts and the Engine Crankcase Breather correct bolt torque.

  • Page 82: Obtain The Sample And The Analysis

    Perkins recommends using a sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when a sampling valve is used.

  • Page 83: Drain The Engine Lubricating Oil

    SEBU8731 Maintenance Recommendations Engine Oil and Filter - Change To avoid contamination of the oil samples, the tools and the supplies that are used for obtaining oil samples must be clean. The sample can be checked for the following: the quality of the oil, the existence of any coolant in the oil, the existence of any ferrous metal particles in the oil and the existence of any nonferrous metal...

  • Page 84: Replace The Oil Filter

    Use of an oil filter that is not recommended Do not fill the oil filters with oil before installing them. by Perkins could result in severe damage to the en- This oil would not be filtered and could be contami- gine bearings, crankshaft, etc., as a result of the larg-...

  • Page 85: Engine Valve Lash - Check

    Do not fill the crankcase above the “H” mark. i05277638 Engine Valve Lash - Check This maintenance is recommended by Perkins as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life. NOTICE Only qualified service personel should perform this maintenance.

  • Page 86: Fuel System - Prime

    SEBU8731 Maintenance Recommendations Fuel System - Prime Illustration 53 g01348394 Adjustment of the cover will change the clearance Refer to the Operation and Maintenance Manual, (gap) between the edge of the cover and the tip of the “General Hazard Information and High Pressure Fuel Lines”...

  • Page 87: Hand Fuel Priming Pump

    SEBU8731 Maintenance Recommendations Fuel System - Prime • The fuel tank is empty or the fuel tank has been 4. Operate the hand priming pump for 2 minutes. partially drained. After 2 minutes, the system should be primed and the engine ready to be started. Lock and priming •...
  • Page 88 2. Remove the protection cap (1). Depress valve (2) penetration hazard . Refer to Operation and in order to purge air. Perkins recommend that a Maintenance Manual, “General hazard Information”. tire inflator with a suitable length of clear hose attached to be used.
  • Page 89 SEBU8731 Maintenance Recommendations Fuel System Primary Filter (Water Separator) Element - Replace Note: Refer to Testing and Adjusting Manual, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. NOTICE Ensure that the engine is stopped before any servic- ing or repair is performed.
  • Page 90 SEBU8731 Maintenance Recommendations Fuel System Primary Filter/Water Separator - Drain i05268151 Fuel System Primary Filter/ Water Separator - Drain Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.

  • Page 91: Remove The Element

    SEBU8731 Maintenance Recommendations Fuel System Secondary Filter - Replace Note: Refer to Systems Operation, Testing and 2. Install a suitable tube onto connection (4). Rotate Adjusting, “Cleanliness of Fuel System the drain valve (3) counterclockwise. Two full turns Components” for detailed information on the are required.

  • Page 92: Fuel Tank

    SEBU8731 Maintenance Recommendations Fuel Tank Water and Sediment - Drain i02348492 Fuel Tank Water and Sediment - Drain NOTICE Care must be taken to ensure that fluids are con- tained during performance of inspection, mainte- nance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

  • Page 93: Fuel Storage Tanks

    SEBU8731 Maintenance Recommendations Hoses and Clamps - Inspect/Replace Fuel Storage Tanks • End fittings that are damaged or leaking Drain the water and the sediment from the fuel • Outer covering that is chafed or cut storage tank at the following intervals: •...

  • Page 94: Starting Motor - Inspect

    Adjusting Manual, “Electric Starting System - Test” for more information on the checking procedure Inspect the radiator for these items: damaged fins, and for specifications or consult your Perkins dealer corrosion, dirt, grease, insects, leaves, oil and other or your Perkins distributor for assistance.

  • Page 95: Removal And Installation

    SEBU8731 Maintenance Recommendations Walk-Around Inspection 4. Inspect the bore of the housing of the turbine outlet NOTICE for corrosion. Turbocharger bearing failures can cause large quanti- ties of oil to enter the air intake and exhaust systems. 5. Fasten the air intake pipe and the exhaust outlet Loss of engine lubricant can result in serious engine pipe to the turbocharger housing.

  • Page 96: Water Pump - Inspect

    Disassembly and Assembly Manual, • Other potential damage to the engine “Water Pump - Remove and Install” for more information or consult your Perkins dealer or your Perkins distributor. • Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters and the rocker cover.

  • Page 97: Warranty Section

    Emissions Warranty. Consult your authorized Perkins dealer or your authorized Perkins distributor in order to determine if your engine is emissions certified and if your engine is subject to an Emissions Warranty.

  • Page 98: Reference Information Section

    Why buy an Extended Service Contract? 1. No surprises - total protection from unexpected repair cost (parts, labor, and travel). 2. Enjoy longer lasting product support from Perkins global network. 3. Genuine Perkins parts ensure continued engine performance. 4. Highly trained technicians carry out all repairs.

  • Page 99: Index

    SEBU8731 Index Section Index Cooling System Supplemental Coolant Additive (SCA) - Test/Add..........75 After Starting Engine........44 Add the SCA, If Necessary ......76 After Stopping Engine........50 Test for SCA Concentration ......75 Aftercooler Core - Clean/Test (Air-To-Air Crushing Prevention and Cutting Prevention .. 10 Aftercooler) ............
  • Page 100 SEBU8731 Index Section Engine Operation with Active Diagnostic Fuel System Primary Filter/Water Separator Codes ............37 - Drain ............90 Engine Operation with Intermittent Fuel System Secondary Filter - Replace ..90 Diagnostic Codes........... 38 Install the Element ........91 Engine Protection Plans (Extended Service Remove the Element ........
  • Page 101 SEBU8731 Index Section Every Year............ 67 Safety Section ........... 5 Initial 500 Service Hours ......67 Self-Diagnostics..........35 When Required..........67 Sensors and Electrical Components ....29 Maintenance Recommendations..... 65 Severe Service Application......66 Maintenance Section........52 Environmental Factors......... 66 Model View Illustrations........
  • Page 102 SEBU8731 Index Section...
  • Page 103 Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment...
  • Page 104 ©2013 Perkins Engines Company Limited All Rights Reserved...

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1106c-70ta

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