Perkins 2206F-E13TA Operation And Maintenance Manual
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Perkins 2206F-E13TA Operation And Maintenance Manual

Perkins 2206F-E13TA Operation And Maintenance Manual

Industrial engine
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SEBU9071-01 (en-us)
October 2017
Operation and
Maintenance
Manual
2206F-E13TA Industrial Engine
PP3 (Engine)
PP4 (Engine)

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Summary of Contents for Perkins 2206F-E13TA

  • Page 1: Operation And Maintenance

    SEBU9071-01 (en-us) October 2017 Operation and Maintenance Manual 2206F-E13TA Industrial Engine PP3 (Engine) PP4 (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

    SEBU9071-01 Table of Contents Table of Contents Engine Stopping ..........61 Maintenance Section Foreword ............4 Refill Capacities..........62 Safety Section Maintenance Recommendations ....78 Safety Messages..........5 Maintenance Interval Schedule....... 81 Additional Messages ......... 7 Warranty Section General Hazard Information......8 Warranty Information........113 Burn Prevention..........11 Reference Information Section...

  • Page 4: Foreword

    Operation Operation and Maintenance Manual except for the 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

    Replace any safety message that is damaged or missing. If a safety message is attached to a part of the engine that is replaced, install a new safety message on the replacement part. Your Perkins distributor can provide new safety messages.
  • Page 6 SEBU9071-01 Safety Section Safety Messages Illustration 1 g02292373 Universal Warning (1) Illustration 2 g01370904 One safety message is located on the left side of the engine. One safety message is located on the right side of the engine.

  • Page 7: Additional Messages

    Replace any message that is damaged, or missing. If exhaust cooler. a message is attached to a part that is replaced, install a message on the replacement part. Any Perkins distributor can provide new messages. Illustration 4 g03422039 Purge notice message...

  • Page 8: General Hazard Information

    SEBU9071-01 Safety Section General Hazard Information This notice should be located next to the battery • When work is performed around an engine that is disconnect switch. operating, wear protective devices for ears in order to help prevent damage to hearing. NOTICE •...

  • Page 9: Pressurized Air And Water

    SEBU9071-01 Safety Section General Hazard Information • Start the engine from the operators station (cab). • Use all cleaning solutions with care. Never short across the starting motor terminals or • Report all necessary repairs. the batteries. This action could bypass the engine neutral start system and/or the electrical system Unless other instructions are provided, perform could be damaged.

  • Page 10: Containing Fluid Spillage

    Perkins equipment and replacement parts that are shipped from Perkins engine company limited are The removal of sulfur and other compounds in ultra- asbestos free. Perkins recommends the use of only low sulfur diesel fuel (ULSD fuel) decreases the genuine Perkins replacement parts. Use the following...

  • Page 11: Burn Prevention

    SEBU9071-01 Safety Section Burn Prevention • Avoid brushing materials that contain asbestos. DEF is not expected to produce significant adverse health effects when the recommended instructions for use are followed. • Avoid grinding materials that contain asbestos. • Do not breathe DEF vapor or mist. •...

  • Page 12: Fire Prevention And Explosion Prevention

    Wash hands after touching batteries. The use of gloves is recommended. If the application involves the presence of combustible gases, consult your Perkins dealer and/ or your Perkins distributor for additional information Engine and Aftertreatment System about suitable protection devices.

  • Page 13: Fire Extinguisher

    SEBU9071-01 Safety Section Fire Prevention and Explosion Prevention Illustration 11 g00704059 Illustration 12 g00704135 Use caution when you are refueling an engine. Do Gases from a battery can explode. Keep any open not smoke while you are refueling an engine. Do not flames or sparks away from the top of a battery.

  • Page 14: Crushing Prevention And Cutting Prevention

    Refer to the OEM for the location of foot and hand holds for your specific application. Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for replacement parts. i04257031 Replace the parts if any of the following conditions...

  • Page 15: Engine Starting

    SEBU9071-01 Safety Section Engine Starting Use the Emergency Stop Button (if equipped) ONLY i02583384 in an emergency situation. Do not use the Engine Starting 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.

  • Page 16: Engine Electronics

    However, the monitoring system and the engine monitoring control will be similar for all engines. Note: Many of the engine control systems and display modules that are available for Perkins 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 17: Product Information Section

    SEBU9071-01 Product Information Section General Information Product Information Section General Information i06838242 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. Engine views Illustration 13 g03809306 (1) Engine front lifting eye (6) NOx Reduction System (NRS) valve...
  • Page 18 SEBU9071-01 Product Information Section Model View Illustrations Illustration 14 g03809820 (16) Exhaust gas cooler (NRS) (22) Coolant pump (29) Flywheel housing (17) Turbocharger (23) Oil pump (30) Flywheel (18) Oil filler cap (24) Alternator (31) Oil sampling valve (19) Water temperature regulator valve (25) Coolant intake (32) Oil cooler (Thermostat)
  • Page 19 SEBU9071-01 Product Information Section Model View Illustrations Clean Emission Module Without Aftertreatment Regeneration Device (ARD) Illustration 15 g03809311 (1) Clean emission module (4) Mixer (7) Exhaust intake (2) Selective Catalytic Reduction (SCR) (5) Diesel Oxidation Catalyst (DOC) (8) Exhaust outlet (3) Diesel Exhaust Fluid (DEF) injector (6) Diesel Particulate Filter (DPF).
  • Page 20 SEBU9071-01 Product Information Section Model View Illustrations Clean Emission Module With ARD Illustration 16 g06044166 Typical example (1) Clean Emission Module (CEM) (4) DEF Injector (7) Aftertreatment Regeneration Device (2) Exhaust outlet (5) Diesel Particulate Filter (DPF) (ARD) (3) Selective Catalytic Reduction (SCR) (6) CEM sensors and fuel system (8) Exhaust Inlet...
  • Page 21 SEBU9071-01 Product Information Section Model View Illustrations Off Engine Components Illustration 17 g06136963 (1) Pump electronic unit (4) Flexible exhaust pipe (7) DEF tank header (2) Electric lift pump and primary fuel filter (5) DEF Heated lines (3) NOx sensors (6) ECM for aftertreatment Pump Electronic Tank Unit (PETU) Some DEF tanks are combined with the pump...

  • Page 22: Engine Specifications

    12.5 L (763 cubic inch) There are two different designs for the aftertreatment Firing Order 1-5-3-6-2-4 system that can be installed on the 2206F-E13TA. Rotation (flywheel end) Both systems have the Clean Emissions Module Counterclockwise (CEM), but the configuration of the CEM is different.

  • Page 23: Electronic Engine Features

    ECM. The Engines electronic engine control system provides the following features: Perkins does not warrant the quality or performance • Engine speed governor of non-Perkins fluids and filters. • Automatic air/fuel ratio control...

  • Page 24: Product Identification Information

    SEBU9071-01 Product Information Section Product Identification Information Product Identification Information i06091255 Plate Locations and Film Locations Illustration 21 g01403841 Serial number plate The following information is stamped on the serial number plate: engine serial number, engine model and arrangement number. The engine information plate is located on top of the valve cover near the middle of the engine.
  • Page 25 CEM identification plate The CEM identification plate contains the following information: part number, serial number, change level and configuration ID code. This information may be needed by the Perkins distributor when inquiries are being made on the CEM. Illustration 25 g03049116...

  • Page 26: Emissions Certification Film

    Product Information Section Emissions Certification Film Record the information on the CEM and PETU serial plates. The information will be required by your Perkins dealer or your Perkins distributor in order to identify replacement part numbers. i05951816 Emissions Certification Film Note: This information is pertinent in the United States, in Canada and in Europe.

  • Page 27: Operation Section

    SEBU9071-01 Operation Section Lifting and Storage Operation Section Engine, Clean Emission Module (CEM), and Radiator Lifting Lifting and Storage i06838574 Product Lifting NOTICE Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Re- member that the capacity of an eyebolt is less as the angle between the supporting members and the ob- ject becomes less than 90 degrees.
  • Page 28 SEBU9071-01 Operation Section Product Lifting Illustration 27 g03391555 Typical example Illustration 28 g03389702 load ring When lifting the engine, with a factory-mounted CEM (with or without a factory-mounted radiator) the following procedure must be used. 1. Remove bolts shown in illustration 26 and illustration 27 .
  • Page 29 SEBU9071-01 Operation Section Product Lifting The engine package center of gravity will change depending on the engine attachments. Adjust the spreader bar and chains as necessary to maintain a lift within 5 degrees of horizontal in all directions. The load ring part number is T401848. Engine Only Illustration 29 g03810206...

  • Page 30: Condition For Storage

    (1) PETU lifting eyes i06092636 Product Storage (Engine and Aftertreatment) Your Perkins distributor can assist in preparing the engine for extended storage periods. Some applications, the engine can be equipped with delayed engine shutdown. Allow at least 2 minutes after the engine has stopped before you turn the battery disconnect switch to OFF.
  • Page 31 SEBU9071-01 Operation Section Engine and Aftertreatment 3. Apply lubricant to all points in this Operation and Use a bar or a turning tool in order to turn over the engine slowly. This procedure puts the oil on the Maintenance Manual, “Maintenance Interval cylinder walls.
  • Page 32 (1) Plugs 3. Check the condition of the fan and alternator belts. 8. If an engine is stored for more than 1 year, Perkins Replace the belts, if necessary. Refer to this recommends Pre lubrication of the engine in order Operation and Maintenance Manual, “Belts -...
  • Page 33 SEBU9071-01 Operation Section Engine and Aftertreatment Test the coolant mixture for proper nitrite level. If necessary, adjust the coolant mixture. Prime the engine with clean diesel fuel before starting. 11. Ensure that the cooling system is clean. Ensure that the system is full. Ensure that the system has the correct amount of supplemental cooling system conditioner.

  • Page 34: Features And Controls

    SEBU9071-01 Operation Section Features and Controls Features and Controls The battery disconnect switch and the engine start switch perform different functions. The entire electrical system is disabled when you turn the i05422613 battery disconnect switch to the OFF position. The battery remains connected to the electrical system Battery Disconnect Switch when you turn the engine start switch to the OFF...

  • Page 35: Sensors And Electrical Components

    SEBU9071-01 Operation Section Sensors and Electrical Components Emission Malfunction Indicator – This indicator will illuminate when an emissions system related to DEF or SCR has failed. Refer to Operation and Maintenance Manual, “Selective Catalytic Reduction Warning System” for more information. i06840153 Sensors and Electrical Components...
  • Page 36 SEBU9071-01 Operation Section Sensors and Electrical Components Illustration 35 g03821530 (11) Coolant temperature sensor (13) Crankshaft timing sensor (15) Electric priming/transfer pump (12) Alternator (14) Fuel pressure sensor (16) Fuel temperature sensor...
  • Page 37 SEBU9071-01 Operation Section Sensors and Electrical Components Clean Emissions Module without (ARD) Illustration 36 g03821962 (1) Diesel Exhaust Filter (DPF) outlet (3) Diesel oxidation catalyst temperature (5) Temperature sensor probes pressure sensor sensor (6) Diesel exhaust fluid injector (2) DPF inlet pressure sensor (4) Aftertreatment identification module...
  • Page 38 SEBU9071-01 Operation Section Sensors and Electrical Components Clean Emissions Module with (ARD) Illustration 37 g06048751 Typical example (1) Diesel Exhaust Fluid (DEF) injector (5) DPF pressure sensor (9) Fuel pilot pressure sensor (2) Temperature sensor (6) Temperature sender (10) Fuel main pressure sensor (3) Coil for spark plug (7) 40-Pin connector (11) Identification Module...
  • Page 39 SEBU9071-01 Operation Section Sensors and Electrical Components Loose Aftertreatment Components Illustration 38 g03821970 (1) NOx sensors (4) Voltage load protection module (7) Coolant diverter valve (2) Diesel Exhaust Fluid (DEF) heated lines (5) DEF Tank heater and DEF level gauge (3) Dosing control unit (6) Relays...
  • Page 40 SEBU9071-01 Operation Section Sensors and Electrical Components Pump Electronic Tank Unit (PETU) Illustration 39 g06137439 Typical example (1) DEF Level Sensor and DEF Temperature (3) Customer Connections (6) Voltage Limiting Protection Module Sensor (4) Dosing Control Module (2) Coolant Diverter Valve (5) Relays...

  • Page 41: Engine Diagnostics

    The system provides the capability of Fault Logging. When the Electronic Control Module (ECM) generates an active diagnostic code, the code will be Perkins Electronic Engines have the capability to logged in the memory of the ECM. The codes that perform a self-diagnostics test. When the system...

  • Page 42: Configuration Parameters

    SEBU9071-01 Operation Section Engine Operation with Intermittent Diagnostic Codes i01797063 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 43: Customer Specified Parameters

    SEBU9071-01 Operation Section Configuration Parameters Table 3 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 44 SEBU9071-01 Operation Section Configuration Parameters (Table 4, contd) Transmission Default Torque Limit Reset Not Reset Air Filter Restriction Switch Installation Status Not Installed Air Filter Restriction Switch Configuration Normally Open Intermediate Engine Speed 1400. rpm Air Shutoff Disabled Air Intake Shutoff Detection Installation Status Not Installed Coolant Level Sensor Not Installed...
  • Page 45 SEBU9071-01 Operation Section Configuration Parameters (Table 4, contd) Engine Fan Manual Purge Disabled Engine Fan Suspend Purge Disabled Engine Fan Purge Cycle Interval 1200 sec Engine Fan Purge Cycle Duration 180.0sec Enabled Engine Fan Control Charge Air Cooler Outlet Temperature Input Enable Engine Cooling Fan Maximum Air Flow Charge Air Cooler Outlet 46.6°...

  • Page 46: Engine Starting

    SEBU9071-01 Operation Section Engine Starting Engine Starting • Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or i02109067 to the controls. Before Starting Engine •...
  • Page 47 SEBU9071-01 Operation Section Starting the Engine Note: If the engine has not been run for several During the key on, all warning lamps will illuminate for a few seconds, in order to test the circuits. If weeks, fuel may have drained. Air may have moved any lamps do not illuminate, check the bulbs and into the filter housing.

  • Page 48: Starting With Jump Start Cables

    1000 to 1200 rpm in order to raise 3. Start the engine. If the engine does not start, check engine temperature. Do not exceed the for a diagnostic code and consult your Perkins recommended rpm in order to increase the speed of distributor.

  • Page 49: After Starting Engine

    SEBU9071-01 Operation Section After Starting Engine When the engine is idling during warm-up, observe NOTICE the following conditions: Using a battery source with the same voltage as the electric starting motor. Use ONLY equal voltage for • Check for fluid or air leaks at idle rpm and at one- jump starting.

  • Page 50: Engine Operation

    SEBU9071-01 Operation Section Engine Operation Engine Operation This design of DPF will require a service maintenance interval. Refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information. The DPF can be i06101183 expected to function properly for the useful life of the engine (emissions durability period), as defined by Engine Operation regulation, subject to prescribed maintenance...

  • Page 51: Fuel Conservation Practices

    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 52: Aftertreatment Operation

    SEBU9071-01 Operation Section Aftertreatment Operation Aftertreatment Operation HC Evap To evaporate Hydrocarbons that can accumulate in the DPF, when operating at cold exhaust temperatures regeneration is necessary. Running HC Evap regenerations protects the DPF i06860403 against possible thermal events. Diesel Particulate Filter Desulfation Regeneration To keep the SCR catalyst Regeneration free of sulfur, and the DEF injector and mixing tube...
  • Page 53 The escalating time inducement fault Regenerations may be locked out and require an code is just an indicator of what level of inducement authorized Perkins distributor to perform the engine is in and how much time remains until the regeneration with service tool.
  • Page 54 SEBU9071-01 Operation Section Selective Catalytic Reduction Warning System Illustration 43 g03676102 Illustration 45 g03676111 DEF Level Normal If the DEF level falls below 13.5%, a level 1 inducement event will occur. The check engine lamp Inducement Strategy for DEF Level and the emissions malfunction indicator lamp will illuminate.
  • Page 55 SEBU9071-01 Operation Section Selective Catalytic Reduction Warning System The check engine and emissions malfunction indicator lamp will illuminate for a level 1 inducement- related fault. There are two inducement categories. If the inducement is a result of a category 1 fault, then a level 1 inducement will occur for a duration of 36 hours.
  • Page 56 If set to “Shutdown” , the engine may be restarted, but will only run for 5 minutes at derated condition before shutting down again. This action will continue until the issue is resolved. Note: Contact your Perkins dealer for repairs if a fault occurs. Illustration 53 g03676174 Inducement Strategy for DEF Level If the DEF level is below 7.5%, a level 2 inducement...
  • Page 57 SEBU9071-01 Operation Section Selective Catalytic Reduction Warning System If the inducement is a result of a category 2 fault, then a level 1 inducement will occur for a duration of 10 hours. There is no repeat occurrence for category 2, level 1 inducement faults.
  • Page 58 "Shutdown", the engine may be restarted, but will only run for 5 minutes at derated condition before shutting down again. This action will continue until the issue is resolved. Note: Contact your Perkins dealer for repairs if a fault occurs.

  • Page 59: Cold Weather Operation

    The following components can provide a means of fan blades could cause a fan failure. minimizing fuel waxing problems in cold weather: Perkins recommends a warning device for the inlet • Fuel heaters, which may be an OEM option manifold temperature and/or the installation of an inlet air temperature gauge.

  • Page 60: Fuel Related Components In Cold Weather

    Fuel Related Components in the fuel in warm-weather operation. Cold Weather For further information on fuel heaters, consult your Perkins distributor . Fuel Tanks Condensation can form in partially filled fuel tanks. Top off the fuel tanks after operating the engine.

  • Page 61: Engine Stopping

    SEBU9071-01 Operation Section Engine Stopping Engine Stopping Note: Individual applications have different control systems. Ensure that the shutoff procedures are understood. Use the following general guidelines in order to stop the engine. i06832774 Stopping the Engine 1. Remove the load from the engine so that the engine has no more than 30% power.

  • Page 62: Maintenance Section

    SEBU9071-01 Maintenance Section Refill Capacities Maintenance Section Table 5 2206 Industrial Engine Approximate Refill Capacities Refill Capacities Oil Sump Quarts Liters Standard Oil Pan 33.8 qt 32 L i06093491 Deep Oil Pan 39.1 qt 37 L Refill Capacities Center Oil Pan 31.7 qt 30 L These values are approximate capacities for the crankcase oil...
  • Page 63 Machine or engine surfaces should be wiped clean and rinsed with DEF that is used in Perkins engines must meet the water. Caution should be used when dispensing DEF ISO specification 22241-1 for quality. The ISO near an engine that has recently been running.

  • Page 64: General Coolant Information

    SEBU9071-01 Maintenance Section Fluid Recommendations Water Materials NOT compatible with DEF solutions include Aluminum, Magnesium, Zinc, Nickel coatings, Silver Water is used in the cooling system in order to and Carbon steel and Solders containing any of the transfer heat. above.

  • Page 65: Coolant Recommendations

    SEBU9071-01 Maintenance Section Fluid Recommendations • Leakage of the water pump seal The following two coolants are used in Perkins diesel engines: • Plugging of radiators, coolers, and small passages Preferred – Perkins ELC Glycol Acceptable – A commercial heavy-duty antifreeze Glycol in the coolant helps to provide protection that meets “ASTM D6210 ”...

  • Page 66: Elc Cooling System Maintenance

    Before the cooling system is filled, the heater control agents with low amounts of nitrite. Perkins ELC has (if equipped) must be set to the HOT position. Refer been formulated with the correct amount of these additives in order to provide superior corrosion to the OEM in order to set the heater control.
  • Page 67 SCA that is required when the cooling ness of the ELC and shortens the ELC service life. system is initially filled. Use only Perkins Products for premixed or concen- trate coolants. Failure to follow these recommenda- Table 12...

  • Page 68: Diesel Fuel Requirements

    • Clean the cooling system whenever the coolant is contaminated or whenever the coolant is foaming. Diesel Fuel Requirements i06863492 Perkins is not in a position to continuously evaluate Fluid Recommendations and monitor all worldwide distillate diesel fuel specifications that are published by governments and (General Fuel Information) technological societies.
  • Page 69 SEBU9071-01 Maintenance Section General Fuel Information Table 16 "Perkins Specification for Distillate Diesel Fuel" Property UNITS Requirements “ASTM”Test “ISO/Other”Test Aromatics %Volume 35% maximum “D1319” “ISO 3837” %Weight 0.01% maximum “D482” “ISO 6245” Carbon Residue on 10% %Weight 0.35% maximum “D524”...
  • Page 70 “BS 2869: 2010 CLASS A2 or EU equivalent” “EU Off-Road Diesel fuel. Acceptable from 2011 MUST have less than 10 PPM sulfur level” All the fuels must comply with the specification in the table for the Perkins Specification Distillate Diesel Fuel.

  • Page 71: Diesel Fuel Characteristics

    CFR engine. (59 °F). Refer to “ISO 5165” for the test method. Perkins recommends a density of 841 kg/m Cetane numbers more than 45 are normally expected obtain the correct power output. Lighter fuels are from current diesel fuel. However, a cetane number acceptable but these fuels will not produce the rated of 40 may be experienced in some territories.
  • Page 72 0.52 mm (0.0205 inch) will Protection Agency (EPA) and European Certification lead to reduced service life and premature failure of fuels. Perkins does not certify engines on any other the fuel system. fuel. The user of the engine has the responsibility of using the correct fuel that is recommended by the Fuel additives can enhance the lubricity of a fuel.
  • Page 73 • Perkins recommend the use of oil analysis to Perkins strongly recommended that seasonally check the quality of the engine oil if biodiesel fuel operated engines have the fuel systems, including is used.
  • Page 74 “Operation and Maintenance If biodiesel or biodiesel blends of fuel are to be used, Manual” Fluid Recommendations Perkins require the use of Perkins fuel cleaner. The use of the fuel is to remove deposits within the fuel Fuel for Cold-Weather Operation system that is created with the use of biodiesel.

  • Page 75: General Lubricant Information

    500 ppm certification of exhaust emissions from the engine, water or less. the lubricant recommendations must be followed. • Perkins recommends the use of bulk fuel filter / • API American Petroleum Institute coalescer units which clean the fuel of both particulate contamination and water in a single •...
  • Page 76 “EMA Recommended Guideline on Diesel Engine monitor the condition of the engine oil. Use oil Oil”. In addition to Perkins definitions, there are other analysis also to determine the oil change interval that definitions that will be of assistance in purchasing is optimum.

  • Page 77: Aftermarket Oil Additives

    Maintenance Section Fluid Recommendations Refer to illustration 62 (maximum temperature) to To achieve the best performance from a Perkins select the oil viscosity for engine operation at the engine, conform to the following guidelines: highest ambient temperature that is anticipated.

  • Page 78: Maintenance Recommendations

    Consult the OEM of the equip- To relieve the pressure from the coolant system, turn ment or your Perkins dealer regarding welding on a off the engine. Allow the cooling system pressure cap chassis frame or rail.
  • Page 79 SEBU9071-01 Maintenance Section Welding on Engines with Electronic Controls • Electronic components for the driven equipment • ECM • Sensors • Electric operated fuel pump • Electronically controlled valves • Relays • Aftertreatment ID module NOTICE Do not use electrical components (ECM or ECM sen- sors) or electronic component grounding points for grounding the welder.

  • Page 80: Severe Service Application

    • The temperature of the fluid in the engine coolant/antifreeze Refer to the standards for the engine or consult your Perkins distributor to determine if the engine is operating within the defined parameters. Severe service operation can accelerate component wear. Engines that operate under severe conditions...

  • Page 81: Maintenance Interval Schedule

    SEBU9071-01 Maintenance Section Maintenance Interval Schedule “ Hoses and Clamps - Inspect/Replace”..109 i06837237 Maintenance Interval Schedule Every 500 Service Hours or 1 Year When Required “ Cooling System Supplemental Coolant Additive (SCA) - Test/Add” ......90 “...
  • Page 82 SEBU9071-01 Maintenance Section Maintenance Interval Schedule “ Injector (Diesel Exhaust Fluid) - Replace” ..110 Every 6000 Service Hours or 3 Years “ Coolant Extender (ELC) - Add” ....90 Every 10 000 Service Hours “...
  • Page 83 SEBU9071-01 Maintenance Section ARD Spark Plug - Clean 2. Debris may have collected in the spark plug well. i06615956 Thoroughly remove any debris. Use compressed ARD Spark Plug - Clean air. The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). Ensure that the area around the spark plug is clean and free of dirt and debris.
  • Page 84 All personnel should also stay clear of the air compressor when the engine is operating and the air compressor is exposed. Consult your Perkins distributor for assistance. Do not disconnect the air line from the air com- pressor governor without purging the air brake i06111591 and the auxiliary air systems.
  • Page 85 SEBU9071-01 Maintenance Section Air Tank Moisture and Sediment - Drain i00847451 i01878164 Battery - Replace Air Tank Moisture and Sediment - Drain (If Equipped) Batteries give off combustible gases which can Moisture and sediment in the air starting system can explode.
  • Page 86 SEBU9071-01 Maintenance Section Battery Electrolyte Level - Check 8. Connect the cable from the NEGATIVE “-” terminal i05424317 on the starter motor to the NEGATIVE “-” battery Battery or Battery Cable - terminal. Disconnect i02747977 Battery Electrolyte Level - Check The battery cables or the batteries should not be removed with the battery cover in place.
  • Page 87 SEBU9071-01 Maintenance Section Belts - Inspect/Replace i06093624 Belts - Inspect/Replace (Multi Vee Belt) To maximize the engine performance, inspect the belt for wear and for cracking. Replace the belt if the belt is worn or damaged. • Inspect the belt for cracks, splits, glazing, grease, displacement of the cord and evidence of fluid contamination.
  • Page 88 NOTICE 4. Drain the cooling system. Perkins ELC must be using with an extender in order to achieve 12000 hours operation. For more informa- 5. Fill the cooling system with clean water and tion on a suitable extender contact your Perkins operate the engine until the engine is warmed to distributor.
  • Page 89 SEBU9071-01 Maintenance Section Coolant (ELC) - Change NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. 3. Fill the cooling system with clean water. Install the cooling system filler cap. 4.

  • Page 90: Test For Sca Concentration

    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 91 SEBU9071-01 Maintenance Section DEF Filler Screen - Clean Use a Coolant Conditioner Test Kit in order to check 4. Clean the cooling system filler cap and inspect the the concentration of the SCA. gasket. If the gasket is damaged, discard the old filler cap and install a new filler cap.
  • Page 92 SEBU9071-01 Maintenance Section DEF Manifold Filters - Replace 3. The filter screen can be cleaned in clean water and dried using compressed air. Refer to this Operation and Maintenance Manual, “General Hazard Information” for information on using compressed air. 4. If the filter screen cannot be cleaned or the filter screen is damaged, then the filter screen must be replaced.
  • Page 93 SEBU9071-01 Maintenance Section DEF Manifold Filters - Replace Illustration 73 g03806581 Illustration 74 g03806583 Illustration 72 g03806580 4. Remove the suction filter (4) at the bottom of the header coils by pulling tabs (5). Replace with a 2. Remove band clamp (2) from filter base (1). new suction filter.
  • Page 94 SEBU9071-01 Maintenance Section Diesel Exhaust Fluid - Fill 6. Install the retaining plate (6) and install screws (7). Tighten screws (7) to a torque of 1.1 N·m (9.8 lb in). 7. Install new outer filter (3) onto DEF tank header (1).
  • Page 95 SEBU9071-01 Maintenance Section Diesel Exhaust Fluid Filter - Replace Caution should be used when dispensing DEF near an engine that has recently been running. Spilling DEF onto hot components may cause the release of ammonia vapors. Do not breathe ammonia vapors. Do not clean up any spills with bleach.
  • Page 96 A clean engine provides the following benefits: • Easy detection of fluid leaks Consult your Perkins distributor when the diesel • Maximum heat transfer characteristics particulate filter needs to be cleaned for the options that are available.
  • Page 97 Note: The air filter system may not have been Typical example provided by Perkins. The procedure that follows is for a typical air filter system. Refer to the OEM Note: Do not allow dirt to enter the air system during information for the correct procedure.

  • Page 98: Test The Service Indicator

    SEBU9071-01 Maintenance Section Engine Air Cleaner Service Indicator - Inspect Note: Before removal, check the orientation of the Observe the service indicator. The air cleaner element should be cleaned or the air cleaner element end cover (3). Some air cleaners the end cover must should be replaced when one of the following be installed in the correctly aligned position.
  • Page 99 Partial view of the oil level gauge (Y) “ADD” mark Note: The engine mounts may not have been (X) “FULL” mark supplied by Perkins. Refer to the OEM information for further information on the engine mounts and the NOTICE correct bolt torque.
  • Page 100 Do not allow hot oil or hot components to contact the skin. 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 101: Drain The Engine Lubricating Oil

    Use of an oil filter that is not recommended Refer to this Operation and Maintenance Manual, by Perkins could result in severe damage to the en- Engine Oil sample - Obtain for more information. gine bearings, and crankshaft. As a result of the larg-...

  • Page 102: Fill The Oil Pan

    Refer to the Service Manual or your au- Contaminated oil can cause accelerated wear to en- thorized Perkins dealer or your Perkins distributor for gine components. the complete valve lash adjustment procedure.
  • Page 103 SEBU9071-01 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace i06096676 Fuel System Primary Filter (Water Separator) Element - Replace 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 104 SEBU9071-01 Maintenance Section Fuel System Primary Filter/Water Separator - Drain 10. Dispose of the fluid and old filter in accordance with local regulations. i06096654 Fuel System Primary Filter/ Water Separator - Drain Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire.
  • Page 105 SEBU9071-01 Maintenance Section Fuel System Secondary Filter - Replace NOTICE The water separator is under suction during normal engine operation. Ensure that the drain valve is tight- ened securely to help prevent air from entering the fuel system. i06098561 Fuel System Secondary Filter - Replace Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire.

  • Page 106: Fuel Storage Tanks

    SEBU9071-01 Maintenance Section Fuel Tank Water and Sediment - Drain Some fuel tanks use supply pipes that allow water i02348492 and sediment to settle below the end of the fuel Fuel Tank Water and Sediment supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank.
  • Page 107 SEBU9071-01 Maintenance Section If Equipped Cap A Illustration 90 g03814471 (A) Cap (B) Cap Element Service The filter element can be serviced by removing cap (A) or by removing cap (B). Ensure that the outlet of hose (4) is clean and free from debris. Illustration 91 g03814811 1.
  • Page 108 SEBU9071-01 Maintenance Section Grounding Stud - Inspect/Clean/Tighten Cap B 7. Install hose (4) and tighten clip (3) securely . Install hose (2) and tighten clip (1) securely. i05970985 Grounding Stud - Inspect/ Clean/Tighten The connection of battery cables to a battery and the disconnection of battery cables from a battery may cause an explosion which may result in in- jury or death.

  • Page 109: Replace The Hoses And The Clamps

    SEBU9071-01 Maintenance Section Hoses and Clamps - Inspect/Replace • Anticipated expansion and contraction of the i06103230 fittings Hoses and Clamps - Inspect/ Replace the Hoses and the Clamps Replace Refer to the OEM information for further information on removing and replacing fuel hoses (if equipped). The following text describes a typical method of replacing coolant hoses.

  • Page 110: Overhaul Considerations

    Disassembly and Assembly manual for i05971077 more information. Overhaul Considerations i05389715 Injector (Diesel Exhaust Fluid) For an overhaul solution, contact your Perkins - Replace distributor. i03901481 Power Take-Off Clutch - Check NOTICE New power take-offs should have the clutch adjust- ment checked before being placed into service.
  • Page 111 Proper safeguards must be followed to help prevent accidents. Perkins recommends a scheduled inspection of the starting motor. If the starting motor fails, the engine i04020194 may not start in an emergency situation.

  • Page 112: Aftertreatment System

    Service Manual for the engine or consult 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 valve cover.

  • Page 113: Warranty Section

    (emissions durability period) subject to prescribed maintenance requirements being followed. Warranty Information For a detailed explanation of the Emission Control Warranty, contact your authorized Perkins dealer or i07198750 your authorized Perkins distributor Emissions Warranty Information...

  • Page 114: Reference Information Section

    Maintenance records are a key element of a maintenance program that is correctly managed. Accurate maintenance records can help your Perkins dealer to fine-tune the recommended maintenance intervals in order to meet the specific operating situation. This should result in a lower engine operating cost.

  • Page 115: Maintenance Log

    SEBU9071-01 Reference Information Section Maintenance Log i05204675 Maintenance Log Table 19 Engine Model Customer Identifier Arrangement Number Serial Number Service Quantity Of Service Item Date Authorization Hours Fuel...
  • Page 116 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 117: Index

    SEBU9071-01 Index Section Index Cooling System Supplemental Coolant Additive (SCA) - Test/Add..........90 Additional Messages ......... 7 Add the SCA, If Necessary ......91 After Starting Engine ........49 Test for SCA Concentration ......90 Extended Idle at Cold Ambient Crushing Prevention and Cutting Prevention..
  • Page 118 SEBU9071-01 Index Section Obtain the Sample and the Analysis ..100 Fuel System Primary Filter/Water Separator - Engine Operation ..........50 Drain ............104 Engine Operation and the Aftertreatment Fuel System Secondary Filter - Replace ..105 System ............50 Fuel Tank Water and Sediment - Drain ..
  • Page 119 Power Take-Off Clutch - Check......110 Clean Emissions Module with (ARD) ..38 Product Description ......... 22 Clean Emissions Module without (ARD) ..37 Aftermarket Products and Perkins Engine Views ..........35 Engines ............23 Loose Aftertreatment Components ..... 39 Electronic Engine Features ......23 Severe Service Application ......
  • Page 120 SEBU9071-01 Index Section Fuel System..........78 Table of Contents ..........3 Walk-Around Inspection ......... 111 Inspect the Engine for Leaks and for Loose Connections ..........111 Warranty Information........113 Warranty Section..........113 Welding on Engines with Electronic Controls ............78...
  • Page 121 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 Number:...
  • Page 122 SEBU9071 ©2017 Perkins Engines Compony Limited All Rights Reserved October 2017...

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