Perkins 2506 Operation And Maintenance Manual
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Perkins 2506 Operation And Maintenance Manual

Perkins 2506 Operation And Maintenance Manual

Industrial engine mga/mgb/mgd
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SEBU8313-02 (en-us)
May 2019
Operation and
Maintenance
Manual
2506-15 Industrial Engine
MGA (Engine)
MGB (Engine)
MGD (Engine)

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  • Page 1 SEBU8313-02 (en-us) May 2019 Operation and Maintenance Manual 2506-15 Industrial Engine MGA (Engine) MGB (Engine) MGD (Engine)
  • Page 2 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.

  • Page 3: Table Of Contents

    SEBU8313-02 Table of Contents Table of Contents Cold Weather Operation ......... 39 Maintenance Section Foreword ............4 Refill Capacities..........42 Safety Section Maintenance Interval Schedule....... 54 Safety Messages..........6 Warranty Section General Hazard Information......7 Warranty Information........78 Burn Prevention..........10 Index Section Fire Prevention and Explosion Prevention..11 Index..............

  • Page 4: Foreword

    State of arises regarding your engine, or this manual, please California to cause cancer, birth defects, consult with your Perkins dealer or your Perkins distributor for the latest available information. and other reproductive harm. WARNING – This product can...
  • Page 5 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.

  • Page 6: Safety Section

    Replace any warning sign that is damaged or missing. 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 distributor can provide new warning signs. (1) Universal Warning...

  • Page 7: General Hazard Information

    SEBU8313-02 Safety Section General Hazard Information Illustration 2 g01294688 Typical example i06943715 General Hazard Information Illustration 4 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 SEBU8313-02 Safety Section General Hazard Information Never put maintenance fluids into glass containers. When pressurized air and/or water is used for Drain all liquids into a suitable container. cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles Obey all local regulations for the disposal of liquids.
  • Page 9 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.

  • Page 10: Burn Prevention

    SEBU8313-02 Safety Section Burn Prevention • Avoid brushing materials that contain asbestos. Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a • Avoid grinding materials that contain asbestos. drain, or into any source of water. •...

  • Page 11: Fire Prevention And Explosion Prevention

    These gases could cause the engine to overspeed. Personal injury, property damage, or engine damage could result. 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.
  • Page 12 SEBU8313-02 Safety Section Fire Prevention and Explosion Prevention 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.

  • Page 13: Crushing Prevention And Cutting Prevention

    Keep these items clean damaged. and keep these items in good repair. Leaks can cause fires. Consult your Perkins dealer or Mount the engine and dismount the engine only at your Perkins distributor for replacement parts.

  • Page 14: Engine Starting

    SEBU8313-02 Safety Section Engine Starting Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Engine exhaust contains products of combustion Section. Knowing the correct procedure will help to which may be harmful to your health.

  • Page 15: Electrical System

    SEBU8313-02 Safety Section Electrical System i02469632 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 “−”...

  • Page 16: Engine Electronics

    SEBU8313-02 Safety Section Engine Electronics 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. i02583382 Engine Electronics Tampering with the electronic system installation...

  • Page 17: Product Information Section

    SEBU8313-02 Product Information Section General Information Product Information Section General Information i01889424 Welding on Engines with Electronic Controls NOTICE Proper welding procedures are necessary in order to avoid damage to the engine's ECM, sensors, and as- sociated components. When possible, remove the component from the unit and then weld the compo- nent.

  • Page 18: Model Views

    SEBU8313-02 Product Information Section Model Views Model Views i02572859 Model View Illustrations The following model views show the 2506 Engine features. Due to individual applications, your engine may appear different from the illustrations. Illustration 14 g01289036 Typical example Left side view...
  • Page 19 (ATAAC). Table 1 The electronic engine control system provides the following functions: electronic governing, automatic 2506 Engine Specifications air to fuel ratio control, injection timing control and Cylinders and Arrangement In-line six cylinder system diagnostics.
  • Page 20 DIAGNOSTIC lamp that is mounted on the control panel. An electronic service tool that is provided by Perkins may be used to read the numerical code of the diagnostic flash code. There are three types of diagnostic codes: ACTIVE, LOGGED and EVENT.

  • Page 21: Product Identification Information

    Plate Locations and Film Locations Illustration 16 g01291895 (1) Serial number plate Perkins engines are identified by serial numbers. Engine serial number These numbers are shown on the engine serial Designation number plate. Perkins distributors need these numbers in order to determine the components that were included with the engine.
  • Page 22 SEBU8313-02 Product Information Section Reference Numbers Engine Rating i02563635 Reference Numbers Information for the following items may be needed to order parts. Locate the information for your engine. Record the information in the appropriate space. Make a copy of this list for a record. Keep the information for future reference.
  • Page 23 SEBU8313-02 Product Information Section Emissions Certification Film Alternator Belt i02576079 Emissions Certification Film Label for compliant engines Illustration 17 g01290846 Typical example of a label that is installed on engines that comply with emissions...
  • Page 24 SEBU8313-02 Product Information Section Customer Specified Parameters Illustration 18 g01290859 Typical example of a label that is installed on engines that comply with emissions • Coolant Temperature Sensor i02566844 Customer Specified • Engine Oil Pressure Sensor Parameters • Engine Crankshaft/Camshaft Sensors •...
  • Page 25 SEBU8313-02 Product Information Section Customer Specified Parameters Table 2 Event Code Parameter State Trip Point Delay Time E162 High Boost Pressure Warn Operator (1) 300 kPa (43.5 psi) 30 seconds Action Alert (2) Always On None 5 seconds E360 Low Engine Oil Pressure Warn Operator (1) 300 kPa (43.5 psi) 60 seconds...

  • Page 26: Operation Section

    Lifting and Storage Operation Section i04823376 Product Storage Lifting and Storage Refer to Perkins Engine Company limited, Stafford for information on engine storage. i07444135 Product Lifting There are three different levels of engine storage. Level “A, B and C” .

  • Page 27: Gauges And Indicators

    Determine and correct the cause of any significant change in the readings. Consult your Perkins dealer or your Perkins distributor for assistance. NOTICE If no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded, STOP the engine.

  • Page 28: Features And Controls

    • Engine Speed will be logged in the memory of the ECM. A fault code will be transmitted over the Perkins Data link and the If the parameters exceed a trip point for a period of hard wired Action Alert will be energized. If the...
  • Page 29 Standard Warning Outputs engine will not be derated. The engine derate information can be obtained from the Applications Department at Perkins Engines Company Limited The ECM provides individual outputs in order to drive Stafford. These limits for the derate must be warning lamps or relays to indicate each of the observed or severe engine damage may occur.
  • Page 30 SEBU8313-02 Operation Section Sensors and Electrical Components • Desired Speed Input The Diagnostic output differs from the Warning and Shutdown outputs. The outputs refer to the operation of the engine. The Diagnostic output refers to the condition of the electronic system and software system.
  • Page 31 SEBU8313-02 Operation Section Sensors and Electrical Components Failure of Sensors Failure of the Coolant Temperature Sensor All Sensors The ECM will detect a failure of the coolant temperature sensor. The diagnostic lamp will warn A failure of any of the sensors may be caused by one the operator about the status of the coolant of the following malfunctions: temperature sensor.
  • Page 32 SEBU8313-02 Operation Section Sensors and Electrical Components Failure of the Engine Oil Pressure Sensor The ECM will detect failure of the engine oil pressure sensor. The diagnostic lamp warns the user about the status of the engine oil pressure sensor. The engine oil pressure related strategies will be disabled in the event of a failure of the engine oil pressure sensor.

  • Page 33: 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 logged in the memory of the ECM. The Perkins The electronic control module has some self- diagnostic ability. When an electronic problem with electronic service tool can retrieve codes that have been logged.
  • Page 34 SEBU8313-02 Operation Section Engine Operation with Intermittent Diagnostic Codes In most cases, it is not necessary to stop the engine because of an intermittent code. However, the operator should retrieve the logged fault codes and the operator should reference the appropriate information in order to identify the nature of the event.

  • Page 35: Engine Starting

    1. Move the ignition switch to the ON position. If a Schedule” for more information. system fault is indicated, investigate the cause. If necessary, use the Perkins electronic service tool. • Open the fuel supply valve (if equipped). 2. Push the start button or turn the keyswitch to the START position in order to crank the engine.
  • Page 36 Check for leaks in the air and in the fluid systems. start. 3. If the engine fails to start, investigate the problem. Use the Perkins electronic service tool. A system fault may be indicated after the engine is started. If a fault is indicated, the ECM has detected a problem with the system.

  • Page 37: 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 38: Engine Stopping

    SEBU8313-02 Operation Section Engine Stopping Engine Stopping Ensure that any components for the external system that support the engine operation are secured after the engine is stopped. i02572824 i02583411 Manual Stop Procedure After Stopping Engine Stopping the Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to NOTICE allow the engine oil to return to the oil pan.

  • Page 39: Cold Weather Operation

    An electric block heater can be activated once the engine is stopped. An effective block heater is • Install the correct specification of engine lubricant typically a 1250/1500 W unit. Consult your Perkins before the beginning of cold weather. distributor for more information.
  • Page 40 Note: Group 3 fuels reduce the life of the engine. The fuel storage tank and into the engine fuel tank. use of Group 3 fuels is not covered by the Perkins warranty. Fuel Filters...
  • Page 41 SEBU8313-02 Operation Section Fuel Related Components in Cold Weather The micron rating and the location of a primary fuel filter is important in cold weather operation. The primary fuel filter and the fuel supply line are the most common components that are affected by cold fuel.

  • Page 42: Maintenance Section

    American Petroleum Institute (API) is recognized These values are the approximate capacities for the crankcase by Perkins. For detailed information about this oil sump (aluminum) which includes the standard factory in- system, see the latest edition of the “API publication stalled oil filters.
  • Page 43 DHD-1 oils are designed to control the The oil CD-2 is for a two-cycle diesel engine. Perkins does not harmful effects of soot with improved wear resistance sell engines that utilize CD-2 oil.
  • Page 44 API CH-4 oils are recommended for wear metal analysis. conditions that demand a premium oil. Your Perkins dealer or your Perkins distributor has specific Excessive piston deposits can be produced by an oil guidelines for optimizing oil change intervals.
  • Page 45 Perkins does not recommend the automatic Perkins does not recommend the use of aftermarket extending of the oil change intervals for any type of additives in oil. It is not necessary to use aftermarket oil.
  • Page 46 To get the correct power and performance from the engine, use a fuel of the correct quality. The Note: Only use Arctic fuels when the temperature is recommended fuel specification for Perkins engines below 0 °C (32 °F). Do not use Arctic fuels when the is shown below: ambient temperature is above 0 °C (32 °F).
  • Page 47 These fuels need additives to achieve lubricity of 650 Table 8 micrometers wear scar and the reliability of the fuel Perkins Specifications for Distillate Diesel Fuel pump and fuel injectors will be reduced. The fuel injection pump is not covered by a warranty, even...
  • Page 48 The fuels that are listed in this Table may not meet the require- Gum and Resins 10 mg per 100 mL “D381” ments that are specified in the “Perkins Specifications for Distil- maximum late Diesel Fuel” Table. Consult the supplier for the recommended additives in order to maintain the correct fuel 0.38 mm...
  • Page 49 • Freezing use water with the properties that are listed in Table 10 . • Cavitation of the water pump Table 10 For optimum performance, Perkins recommends a Acceptable Water 1:1 mixture of a water/glycol solution. Property Maximum Limit Note: Use a mixture that will provide protection...
  • Page 50 3000 Service Hours or Two Years D4985” Coolant Recommendations Perkins POWERPART SCA 3000 Service Hours or Two Years The following two coolants are used in Perkins diesel Commercial SCA and Water 3000 Service Hours or Two Years engines: Preferred – Perkins Extended Life Coolant (ELC)
  • Page 51 Maintenance Section Fluid Recommendations Changing to Perkins ELC Containers of several sizes are available. Consult your Perkins dealer or your Perkins distributor for the part numbers. To change from heavy-duty antifreeze to the Perkins ELC, perform the following steps: ELC Cooling System Maintenance...
  • Page 52 Use the equation that is in Table 15 to determine the the system with the Perkins ELC. amount of Perkins SCA that is required when the cooling system is initially filled. • Drain a portion of the cooling system into a suitable container according to local regulations.
  • Page 53 × 0.014 0.2 L (7 oz) Cleaning the System of Heavy-Duty Antifreeze Perkins cooling system cleaners are designed to clean the cooling system of harmful scale and corrosion. Perkins cooling system cleaners dissolve mineral scale, corrosion products, light oil contamination and sludge.

  • Page 54: Maintenance Interval Schedule

    SEBU8313-02 Maintenance Section Maintenance Interval Schedule “ Fuel System Primary Filter (Water Separator) i02583998 Element - Replace” ......70 Maintenance Interval Schedule “...

  • Page 55: Battery - Replace

    Aftercooler Core - Clean/Test Alternator - Inspect (Air-To-Air Aftercooler) Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose Note: Adjust the frequency of cleaning according to connections and correct battery charging. Check the the effects of the operating environment.

  • Page 56: Battery Or Battery Cable - Disconnect

    SEBU8313-02 Maintenance Section Battery Electrolyte Level - Check 3. The NEGATIVE “-” cable connects the NEGATIVE 4. Keep the batteries clean. “-” battery terminal to the NEGATIVE “-” terminal Clean the battery case with one of the following on the starter motor. Disconnect the cable from the cleaning solutions: NEGATIVE “-”...

  • Page 57: Belts - Inspect/Adjust/Replace

    SEBU8313-02 Maintenance Section Belts - Inspect/Adjust/Replace If the belts are too tight, unnecessary stress is placed i02576025 on the components. This reduces the service life of Belts - Inspect/Adjust/Replace the components. Replacement Inspection For applications that require multiple drive belts, replace the drive belts in matched sets.

  • Page 58: Cooling System Coolant (Elc) - Change

    Be prepared to collect the fluid with suitable contain- lation procedure is the only method acceptable by ers before opening any compartment or disassem- Perkins to reclaim the coolant. bling any component containing fluids. Dispose of all fluids according to Local regulations...

  • Page 59: Cooling System Coolant Level - Check

    Cooling System Coolant Level - Check For information regarding the disposal and the 4. Check the coolant level. Maintain the coolant level recycling of used coolant, consult your Perkins dealer within 13 mm (0.5 inch) below the bottom of the or your Perkins distributor.

  • Page 60: Replace

    If the engine is Install” for the replacement procedure of the water equipped with a sight glass, maintain the coolant temperature regulator, or consult your Perkins level to the proper level in the sight glass. distributor.

  • Page 61: Driven Equipment - Check

    • The temperature of the damper fluid is too high. Only qualified service personnel should perform this maintenance. Refer to the following topics for your Refer to the Service Manual or consult your Perkins engine for the correct procedure: Refer to the distributor for information about damper replacement.

  • Page 62: Engine - Clean

    Servicing the Air Cleaner Element Note: The air filter system may not have been Personal injury or death can result from high provided by Perkins. The procedure that follows is for voltage. a typical air filter system. Refer to the OEM...
  • Page 63 SEBU8313-02 Maintenance Section Engine Air Cleaner Service Indicator - Inspect Refer to the OEM information in order to determine Note: Refer to “Inspecting the Air Cleaner Element”. the number of times that the air cleaner element can be cleaned. Do not clean the air filter element more Vacuum Cleaning than three times.

  • Page 64: Engine Crankcase Breather - Replace

    SEBU8313-02 Maintenance Section Engine Crankcase Breather - Replace Some engines are equipped with a differential gauge i02583379 for inlet air pressure. The differential gauge for inlet Engine Crankcase Breather - air pressure displays the difference in the pressure that is measured before the air cleaner element and Replace the pressure that is measured after the air cleaner element.

  • Page 65: Engine Oil Sample - Obtain

    Note: The engine mounts may not have been “Low” mark. “High” mark. supplied by Perkins. Refer to the OEM information for further details on the engine mounts and the correct bolt torque. NOTICE Perform this maintenance with the engine stopped.

  • Page 66: Engine Oil And Filter - Change

    SEBU8313-02 Maintenance Section Engine Oil and Filter - Change Perkins recommends using a sampling valve in order The sample can be checked for the following: the to obtain oil samples. The quality and the consistency quality of the oil, the existence of any coolant in the...
  • Page 67 Due to normal wear and friction, it is not uncommon to find small amounts of debris in the oil filter. Consult your Perkins distributor in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter.

  • Page 68: Engine Protective Devices - Check

    Maintenance Section Engine Protective Devices - Check 4. Remove the oil level gauge in order to check the oil Consult your Perkins distributor or refer to the Service Manual for more information. level. Maintain the oil level between the “Low” and “High”...

  • Page 69: Fuel System - Prime

    Refer to the Service Manual or your au- 1. Turn the ignition switch to the “OFF” position. thorized Perkins dealer or your Perkins distributor for 2. Fill the fuel tank(s) with clean diesel fuel. the complete valve lash adjustment procedure.

  • Page 70: Fuel System Primary Filter (Water Separator)

    SEBU8313-02 Maintenance Section Fuel System Primary Filter/Water Separator - Drain 4. Unlock and operate the hand priming pump (2). Use a suitable container to collect excess fuel. 5. Tighten the union of the pipe for the fuel (1). 6. Operate the hand priming pump until a strong pressure is felt on the pump.

  • Page 71: Fuel System Secondary Filter - Replace

    SEBU8313-02 Maintenance Section Fuel System Secondary Filter - Replace i02570757 Fuel System Secondary Filter - 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 72: Fuel Tank Water And Sediment - Drain

    SEBU8313-02 Maintenance Section Fuel Tank Water and Sediment - Drain 5. Remove the O-ring from the secondary fuel filter Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes assembly. through the fuel system and the fuel returns to the 6.
  • Page 73 Due to extreme temperature changes, the hose will procedure for the radiator. For information on heat set. Heat setting causes hose clamps to loosen. equipment that is not supplied by Perkins, refer to the This can result in leaks. A constant torque hose OEM.

  • Page 74: Severe Service Application - Check

    • Installation • The temperature of the fluid in the engine Refer to the standards for the engine or consult your Perkins dealer or your Perkins distributor in order to determine if the engine is operating within the defined parameters.

  • Page 75: Turbocharger - Inspect

    Starting Motor - Inspect inspections of the cartridge. Removal and Installation Perkins recommends a scheduled inspection of the For options regarding the removal, installation, repair starting motor. If the starting motor fails, the engine and replacement, consult your Perkins distributor.

  • Page 76: Walk-Around Inspection

    7. Fasten the air inlet piping and the exhaust outlet or seals, refer to the Service Manual for the engine or consult your Perkins distributor. piping to the turbocharger housing. • Inspect the lubrication system for leaks at the front...
  • Page 77 Refer to the Service Manual for the disassembly and assembly procedure. Note: Refer to the Service Manual or consult your Perkins distributor if any repair is needed or any replacement is needed.

  • Page 78: Warranty Section

    This engine may be covered by an Emissions Warranty. Consult your authorized Perkins dealer or distributor to determine if your engine is emissions certified and if your engine is subject to an Emissions...

  • Page 79: Index

    Adjustment of the Fan Drive Belt....58 Engine Crankcase Breather - Replace ... 64 Alternator Belt Adjustment......57 Engine Description .......... 19 Inspection ............ 57 Aftermarket Products and Perkins Replacement..........57 Engines ............20 Burn Prevention..........10 Engine Diagnostics ......... 33 Batteries............11...
  • Page 80 SEBU8313-02 Index Section Lines, Tubes, and Hoses ......13 Fluid Recommendations ......... 42 Lifting and Storage .......... 26 Cooling System Specifications ....48 ELC Cooling System Maintenance....51 Engine Oil ............ 43 Fuel Specifications ........46 Maintenance Interval Schedule....... 54 General Lubricant Information.....
  • Page 81 SEBU8313-02 Index Section Radiator - Clean ..........73 Reference Numbers ........22 Record for Reference ........22 Refill Capacities..........42 Cooling System..........42 Lubrication System ........42 Safety Messages..........6 (1) Universal Warning ........6 Safety Section ........... 6 Self-Diagnostics ..........33 Sensors and Electrical Components....
  • Page 83 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 84 SEBU8313 ©2019 Perkins Engines Company Limited All Rights Reserved May 2019...

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2506-15

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