Perkins 1206A-E70TTA Operation And Maintenance Manual
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Perkins 1206A-E70TTA Operation And Maintenance Manual

Perkins 1206A-E70TTA Operation And Maintenance Manual

Industrial engines
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M0090743 (en-us)
September 2018
Operation and
Maintenance
Manual
1206A-E70TTA and 1206D-E70TTA
Industrial Engines
BP1 Engine
BQ1 Engine

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Summary of Contents for Perkins 1206A-E70TTA

  • Page 1 M0090743 (en-us) September 2018 Operation and Maintenance Manual 1206A-E70TTA and 1206D-E70TTA Industrial Engines BP1 Engine BQ1 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

    M0090743 Table of Contents Table of Contents Maintenance Section Refill Capacities..........50 Foreword ............4 Maintenance Recommendations ....66 Safety Section Maintenance Interval Schedule....... 69 Safety Messages..........6 Warranty Section General Hazard Information......9 Warranty Information........99 Burn Prevention..........13 Reference Information Section Fire Prevention and Explosion Prevention..

  • 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

    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. Universal Warning 1...
  • Page 7 M0090743 Safety Section Safety Messages Illustration 2 g06276055 Typical example The universal warning label is installed in two positions on the engine. On the valve mechanism cover and on the intake manifold, refer to illustration Ether Warning 2 Do not use aerosol types of starting aids such as ether.
  • Page 8 M0090743 Safety Section Safety Messages Illustration 4 g06276057 The ether warning label is installed on the intake manifold, refer to illustration 4 . Hand (High Pressure) 3 Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard.

  • Page 9: General Hazard Information

    M0090743 Safety Section General Hazard Information Illustration 6 g06276059 Typical example The hand high-pressure warning label is a rap • Tampering with the engine installation or around label installed on the main injection line, refer tampering with the OEM supplied wiring can be to illustration 6 .
  • Page 10 M0090743 Safety Section General Hazard Information • The protective locks or the controls are in the Use caution when cover plates are removed. Gradually loosen, but do not remove the last two applied position. bolts or nuts that are located at opposite ends of the •...
  • Page 11 M0090743 Safety Section General Hazard Information Pressurized Air and Water Dispose of all fluids according to local regulations and mandates. Pressurized air and/or water can cause debris and/or hot water to be blown out. This action could result in Static Electricity Hazard when personal injury.
  • Page 12 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 Illustration 11...

  • Page 13: Burn Prevention

    M0090743 Safety Section Burn Prevention Induction System Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water. i07291419 Sulfuric Acid Burn Hazard may cause serious personal injury or death. Burn Prevention The exhaust gas cooler may contain a small amount of sulfuric acid.

  • Page 14: Fire Prevention And Explosion Prevention

    The lines and hoses If the application involves the presence of must have adequate support and secure clamps. combustible gases, consult your Perkins dealer and/ or your Perkins distributor for additional information Oil filters and fuel filters must be correctly installed.
  • Page 15 M0090743 Safety Section Fire Prevention and Explosion Prevention Illustration 13 g00704059 Illustration 14 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 16: Crushing Prevention And Cutting Prevention

    Do not climb on the engine. The engine has not been damaged. designed with mounting or dismounting locations. Leaks can cause fires. Consult your Perkins dealer or Refer to the OEM for the location of foot and hand your Perkins distributor for replacement parts.
  • Page 17 M0090743 Safety Section High Pressure Fuel Lines Illustration 15 g01877473 (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 line (3) High-pressure line (6) High-pressure line (9) Fuel transfer line that is high pressure The high-pressure fuel lines are the fuel lines that are Visually inspect the high-pressure fuel lines before the engine is started.

  • Page 18: Before Starting Engine

    Some Perkins engines Do not bypass the automatic shutoff circuits. Do not may have a cold starting system that is controlled by disable the automatic shutoff circuits.

  • Page 19: Electrical System

    M0090743 Safety Section Electrical System Grounding Practices Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected.

  • Page 20: Engine Electronics

    M0090743 Safety Section Engine Electronics The power supply connections and the ground connections for the engine electronics should always be from the isolator to the battery. i07291428 Engine Electronics Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/ or engine damage.
  • Page 21 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 22: Product Information Section

    The following model views show typical features of the engine. Due to individual applications, your engine may appear different from the illustrations. Note: There will be no visual difference between the 1206A-E70TTA and the 1206D-E70TTA engines. Full Engine Views Illustration 18 g06276391...
  • Page 23 M0090743 Product Information Section Model View Illustrations (3) Off engine primary fuel filter (6) Air cleaner (9) Coolant pressure cap (Coolant top up (4) Radiator coolant drain plug (7) Air cleaner service indicator cap) (5) Fuel cooler (8) Coolant header tank Engine Only Illustration 19 g06276515...
  • Page 24 M0090743 Product Information Section Model View Illustrations Illustration 20 g06276523 Typical example (10) Oil filler cap (13) Idler roller for belt (16) Alternator (11) Air intake and throttle valve (14) Crankshaft damper (17) Drive belt (12) Coolant pump (15) Auto-belt tensioner (18) NOx reduction valve...
  • Page 25 The number 1 cylinder is the front cylinder. • The 1206A-E70TTA with a prefix of BP. • The 1206A-E70TTA with a prefix of BQ. The engines have the same characteristics: •...
  • Page 26 M0090743 Product Information Section Product Description • Torque rise shaping • Injection timing control • System diagnostics The ECM provides an electronic governor that controls the injector output to maintain the desired engine speed. For more information on electronic engine features, refer to the Operation and Maintenance Manual, “Features and Controls”...
  • Page 27 “Overhaul Considerations” topic (Maintenance Section). Aftermarket Products and Perkins Engines Perkins does not warrant the quality or performance of non-Perkins fluids and filters. When auxiliary devices, accessories, or consumables (filters, additives, catalysts) which are made by other manufacturers are used on Perkins products, the Perkins warranty is not affected simply because of such use.

  • Page 28: Product Identification Information

    Typical example equipment manufacturer. (1) Location of serial number plate i07297204 Perkins engines are identified by an engine serial Reference Information number. An example of an engine number is BQ*****U000001D. *****...
  • Page 29 M0090743 Product Information Section Reference Information Secondary Fuel Filter Element Lubrication Oil Filter Element Auxiliary Oil Filter Element Total Lubrication System Capacity Total Cooling System Capacity Air Cleaner Element Drive Belt...

  • Page 30: Operation Section

    M0090743 Operation Section Lifting and Storage Engine With Factory Installed Operation Section Radiator Lifting and Storage i07297205 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 31 Sealed Coolant System occur when an engine is in storage after a period in service. Ensure that the cooling system is filled with Perkins ELC, or an antifreeze that meets “ASTM D6210” Your Perkins dealer or your Perkins distributor can specification.

  • Page 32: Features And Controls

    M0090743 Operation Section Features and Controls Features and Controls Intake manifold pressure – The intake manifold pressure sensor checks the rated pressure in the engine manifold. i07297209 Fuel rail pressure – The fuel rail pressure sensor Alarms and Shutoffs measures the high pressure or low pressure in the fuel rail.
  • Page 33 1. Reduce the load on the engine. Determine and correct the cause of any significant change in the readings. Consult your Perkins dealer 2. Determine if the engine must be shut down or your Perkins distributor for assistance.
  • Page 34 M0090743 Operation Section Monitoring System Indicator Lamps • Shutdown lamp • Warning lamp • Low oil pressure lamp • Wait to start lamp (Glow plug warning lamp) For information, refer to this manual, “Monitoring System (Table for the Indicator Lamps)” for the sequence of operation of the shutdown lamp and the warning lamp.
  • Page 35 1. One or more of the shutdown values for diagnostic code. the engine protection strategy has been exceeded. Contact your Perkins dealer or your Perkins distributor. 2. A serious active diagnostic code has been detected. If install, the audible warning will sound.
  • Page 36 M0090743 Operation Section Sensors and Electrical Components Flash Codes Some applications may support flash codes. A flash code can be viewed by an indicator lamp that when asked will flash in a particular sequence. The indicator lamp used to view the codes is the warning lamp, the lamp can then be referred to as a diagnostic lamp.
  • Page 37 M0090743 Operation Section Sensors and Electrical Components (3) Manifold air temperature sensor (7) Primary speed/timing sensor (10) Fuel suction control valve (4) Manifold air pressure sensor (crankshaft) (11) Fuel temperature sensor (5) Electronic control module (8) Oil pressure sensor (6) Electric fuel priming pump (9) Water in fuel switch Illustration 28 g06277422...
  • Page 38 M0090743 Operation Section Sensors and Electrical Components Illustration 29 g06277437 Typical example (18) Secondary speed/timing sensor (19) Starting motor (20) Barometric pressure sensor A turbocharge outlet temperature sensor (not shown) will be installed within the exhaust outlet system.

  • Page 39: Engine Diagnostics

    The sequence of flashes represents the system diagnostic message. Count the first sequence of flashes in Perkins Electronic Engines have the capability to order to determine the first digit of the flash code. perform a self-diagnostics test. When the system...
  • Page 40 M0090743 Operation Section Engine Operation with Intermittent Diagnostic Codes Note: If the customer has selected “DERATE” and if there is a low oil pressure condition, the Electronic Control Module (ECM) will limit the engine power until the problem is corrected. If the oil pressure is within the normal range, the engine may be operated at the rated speed and load.

  • Page 41: Engine Starting

    M0090743 Operation Section Engine Starting Engine Starting i06092747 Starting with Jump Start i02837427 Cables Before Starting Engine (Do Not Use This Procedure in Hazardous Locations that have Perform the required daily maintenance and other Explosive Atmospheres) periodic maintenance before the engine is started. Inspect the engine compartment.
  • Page 42 M0090743 Operation Section After Starting Engine 1. Turn the start switch on the stalled engine to the • Check for any fluid or for any air leaks at idle rpm and at one-half full rpm (no load on the engine) OFF position.

  • Page 43: 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 44: Cold Weather Operation

    Cold Weather Operation • Check all rubber parts (hoses, fan drive belts) weekly. Perkins Diesel Engines can operate effectively in • Check all electrical wiring and connections for any cold weather. During cold weather, the starting and fraying or damaged insulation.
  • Page 45 A block heater can be 110 V dc or 240 V dc. The output can be 750/1000W. Consult • Other damage to valve train components can your Perkins dealer or your Perkins distributor for result. more information.
  • Page 46 This return ensures that coolant flows around the engine Perkins recommends a warning device for the inlet under cold operating conditions. The water manifold temperature and/or the installation of an temperature regulator begins to open when the inlet air temperature gauge.
  • Page 47 M0090743 Operation Section Fuel Related Components in Cold Weather Be aware of these properties when diesel fuel is Drain the water and sediment from any fuel storage purchased. Consider the average ambient air tank at the following intervals: weekly, service temperature for the engines application.

  • Page 48: Engine Stopping

    M0090743 Operation Section Engine Stopping Engine Stopping i05298684 After Stopping Engine i07306275 Stopping the Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan. NOTICE Stopping the engine immediately after it has been working under load, can result in overheating and ac-...
  • Page 49 M0090743 Operation Section After Stopping Engine Pressurized System: Hot coolant can cause seri- ous burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.

  • Page 50: Maintenance Section

    M0090743 Maintenance Section Refill Capacities Maintenance Section Table 4 Engine Refill Capacities Refill Capacities Compartment or System Liters 51.2 L Engine Only i07318308 (13.5 US gal) Refill Capacities Engine and radiator 22 L (5.8 US gal) i07306220 Lubrication System Fluid Recommendations The refill capacities for the engine crankcase reflect General Coolant Information the approximate capacity of the crankcase or sump...
  • Page 51 If distilled water or deionized water is not available, use water with the properties that are listed in Table 5 • Cavitation of the water pump Table 5 For optimum performance, Perkins recommends a 1:1 mixture of a water/glycol solution. Acceptable Water Property...
  • Page 52 ELC is Materials an ethylene glycol base coolant. However, ELC The following two coolants are used in Perkins diesel contains organic corrosion inhibitors and antifoam engines: agents with low amounts of nitrite. Perkins ELC has been formulated with the correct amount of these Preferred –...
  • Page 53 Check the antifreeze (glycol concentration) to ensure adequate protection against boiling or freezing. 6. Fill the cooling system with the Perkins Premixed Perkins recommends the use of a refractometer for checking the glycol concentration. A hydrometer ELC. Operate the engine. Ensure that all coolant should not be used.
  • Page 54 Use the equation that is in Table 11 to determine the the American Petroleum Institute (API) is recognized amount of SCA that is required, if necessary: by Perkins. For detailed information about this system, see the latest edition of the “API publication Table 11 No.
  • Page 55 “SAE 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 56 Lubricant Viscosity Recommendations Aftermarket Oil Additives for Direct Injection (DI) Diesel Engines Perkins does not recommend the use of aftermarket additives in oil. It is not necessary to use aftermarket The correct SAE viscosity grade of oil is determined additives to achieve the engines maximum service by the minimum ambient temperature during cold life or rated performance.
  • Page 57 14 . i07329421 NOTICE Fluid Recommendations The footnotes are a key part of the Perkins Specifica- tion for Distillate Diesel Fuel Table. Read ALL of the (General Fuel Information) footnotes. • Glossary •...
  • Page 58 M0090743 Maintenance Section General Fuel Information Table 14 Perkins Specification for Distillate Diesel Fuel Property UNITS Requirements “ASTM Test” “ISO 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 59 Fuel with a low cetane number can be the root cause NOTICE of problems during cold start. Operating with fuels that do not meet the Perkins rec- ommendations can cause the following effects: Start- Viscosity ing difficulty, poor combustion, deposits in the fuel...
  • Page 60 M0090743 Maintenance Section General Fuel Information Perkins recommends a value of density of 841 kg/m3 NOTICE to obtain the correct power output. Lighter fuels are The fuels system has been qualified with fuel having acceptable but these fuels will not produce the rated lubricity up to 0.52 mm (0.02047 inch) wear scar di-...
  • Page 61 Note: Minimum cetane number of 40 is Protection Agency (EPA) and European Certification recommended otherwise cold starting problems or fuels. Perkins does not certify engines on any other light load misfire might occur. Since jet fuel fuel. The user of the engine has the responsibility of...
  • Page 62 Standby generator sets and certain emergency vehicles. • Perkins recommends the use of oil analysis to check the quality of the engine oil if biodiesel fuel For standby generator sets and emergency vehicles is used. Ensure that the level of biodiesel in the that cannot avoid use of biodiesel blends fuel quality fuel is noted when the oil sample is taken.
  • Page 63 Consult your supplier of fuel for assistance in selecting appropriate antimicrobial NOTICE additive. Perkins does not warrant the quality or performance of non-Perkins fluids and filters. Water accelerates microbial contamination and growth. When biodiesel is compared to distillate...
  • Page 64 The diesel fuel conditioner is a proprietary metal and and of injector nozzles. ash free formulation that has been extensively tested for use with distillate diesel fuels for use in Perkins Water in the fuel causes cavitation, corrosion of fuel diesel engines. The diesel fuel conditioner helps...
  • Page 65 M0090743 Maintenance Section General Fuel Information • Ensure that you use Perkins Advanced Efficiency BTL and HVO fuels are considered to be low carbon fuels as they reduce carbon foot print compared to Fuel Filters. Change your fuel filters per fossil fuels and are commonly referred to as recommended service requirements or as needed.

  • Page 66: Maintenance Recommendations

    The engine can have the ability to auto start. Ensure a chassis frame or rail. Consult the OEM of the equip- that the power supply is isolated before any service ment or your Perkins dealer regarding welding on a or repair is performed. chassis frame or rail.
  • Page 67 M0090743 Maintenance Section Welding on Engines with Electronic Controls 4. Disconnect all electronic components from the wiring harnesses. Include the following components: • Electronic components for the driven equipment • ECM • Sensors • Electric operated fuel pump • Electronically controlled valves •...
  • Page 68 • 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 69: Maintenance Interval Schedule

    M0090743 Maintenance Section Maintenance Interval Schedule “ Radiator - Clean” ......94 i07307463 Maintenance Interval Schedule Every 1000 Service Hours When Required “...

  • Page 70: Battery - Replace

    Alternator - Inspect Refer to the Systems Operation Testing and Adjusting for more information. Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and correct battery charging. Check the ammeter (if equipped) during engine operation in...

  • Page 71: Battery Or Battery Cable - Disconnect

    M0090743 Maintenance Section Battery Electrolyte Level - Check The battery cables or the batteries should not be All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a removed with the battery cover in place. The bat- face shield and protective clothing when working tery cover should be removed before any servic- on or near batteries.

  • Page 72: Belt - Inspect

    M0090743 Maintenance Section Belt - Inspect 4. Clean all disconnected connection and battery • More than one section of the belt is displaced in one rib of a maximum length of 50.8 mm (2 inch). terminals. 5. Use a fine grade of sandpaper to clean the To replace the belt, refer to Disassembly and Assembly, “Alternator Belt - Remove and Install”.

  • Page 73: Coolant (Deac) - Change

    M0090743 Maintenance Section Coolant (DEAC) - Change Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist: • The engine overheats frequently. • Foaming is observed. • The oil has entered the cooling system and the coolant is contaminated.
  • Page 74 M0090743 Maintenance Section Coolant (DEAC) - Change Drain Illustration 36 g06279668 Typical example (1) Coolant pressure filler cap (2) Radiator plug drain (3) Alternative Drain Plug 1. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap (1) slowly to relieve any pressure.

  • Page 75: Coolant (Elc) - Change

    Coolant (ELC) - Change NOTICE Perkins ELC must be using with an extender to achieve 12000 hours operation. For more information on a suitable extender contact your Perkins dealer or Perkins distributor.
  • Page 76 M0090743 Maintenance Section Coolant (ELC) - Change Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist: • The engine overheats frequently. • Foaming is observed. • The oil has entered the cooling system and the coolant is contaminated.
  • Page 77 M0090743 Maintenance Section Coolant (ELC) - Change Illustration 38 g06279668 1. Stop the engine and allow the engine to cool. 4. Properly dispose of the drained material. Obey Loosen the cooling system filler cap (1) slowly to local regulations for the disposal of the material. relieve any pressure.

  • Page 78: Coolant Level - Check

    Install , the cylinder block drain plug (4) and tighten securely. 6. Install the radiator drain plug (2) and tighten to In order for Perkins ELC to achieve 12000 hours an 6 N·m (53 lb in). extender must be added at 6000 hours. For a suitable extender, contact your Perkins dealer or Perkins distributor.

  • Page 79: Driven Equipment - Check

    M0090743 Maintenance Section Crankshaft Vibration Damper - Inspect Illustration 41 g06279060 Typical example Inspect the damper and replace the damper for any of the following reasons: • The damper is dented, cracked, or leaking. Illustration 40 g06281806 For information on removal of the crankshaft damper, refer to Disassembly and Assembly, “Vibration 2.

  • Page 80: Engine - Clean

    M0090743 Maintenance Section Engine - Clean i07307312 i07307324 Engine - Clean Engine Air Cleaner Element - Replace NOTICE Personal injury or death can result from high Never run the engine without an air cleaner element voltage. installed. Never run the engine with a damaged air cleaner element.

  • Page 81: Engine Air Cleaner Service Indicator - Inspect

    M0090743 Maintenance Section Engine Air Cleaner Service Indicator - Inspect Some engines are equipped with a differential gauge for inlet air pressure. The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element.

  • Page 82: Engine Air Precleaner - Check/Clean

    Note: The engine mounts may not have been 1. Maintain the oil level between the mark (L) and the supplied by Perkins. Refer to the OEM information for mark (H) on the engine oil dipstick. Do not fill the further information on the engine mounts and the correct bolt torque.

  • Page 83: Engine Oil Sample - Obtain

    Do not allow hot oil or hot components to valve is positioned on the cylinder block. 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 NOTICE used.
  • Page 84 Engine Oil sample - Obtain for more information. cations. Use of an oil filter that is not recommended by Perkins could result in severe damage to the en- If the engine is operated infrequently less than 500 gine bearings, crankshaft, and so forth. As a result of...

  • Page 85: Fan Clearance - Check

    M0090743 Maintenance Section Fan Clearance - Check 4. Install the new oil filter (4). Spin on the oil filter until 4. Remove the engine oil level gauge to check the oil the O ring contacts the sealing surface (2). Then level.

  • Page 86: Fuel System - Prime

    M0090743 Maintenance Section Fuel System - Prime Illustration 49 g06279045 Typical example The gap (A) must be checked in the vertical position i05774864 and in the horizontal position. Fuel System - Prime In the vertical position the gap can be checked at the vertically top position or at the vertically bottom position.

  • Page 87: Fuel System Primary Filter (Water Separator) Element - Replace

    M0090743 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace • A leak exists in the low-pressure fuel system. i07311245 Fuel System Primary Filter • The fuel filter has been replaced. (Water Separator Element - Use the following procedures in order to remove air from the fuel system: Replace 1.
  • Page 88 M0090743 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace Illustration 50 g06282821 Illustration 51 g06279151 Typical example 3. Disconnect electrical connector (6). Drain fluid (A) Off engine primary fuel filter (B) On engine primary fuel filter from off engine primary fuel filter. Refer to this “Operation and Maintenance Manual”Fuel System Off Engine Primary Fuel Filter Primary Filter/ Water Separator - Drain for more...
  • Page 89 M0090743 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 9. The on engine primary fuel filter must be serviced. On Engine Primary Fuel Filter Element Remove 1. Place a suitable container under the water separator to catch any fuel that might spill. Clean up any spilled fuel.

  • Page 90: Fuel System Primary Filter/Water Separator

    M0090743 Maintenance Section Fuel System Primary Filter/Water Separator - Drain 8. Rotate the filter element (5) counterclockwise and 5. Both primary fuel filters must be replaced. Also, the remove the filter element . Clean the filter bowl. secondary filter element must be replaced at the same time as the primary fuel filters .

  • Page 91: Fuel System Secondary Filter - Replace

    M0090743 Maintenance Section Fuel System Secondary Filter - Replace Off Engine Primary Filter Water Separator Drain Illustration 56 g03858194 Typical example 3. Install a suitable tube onto drain (3). Open the Illustration 55 g06278735 drain valve (2). Rotate the drain valve counterclockwise.
  • Page 92 M0090743 Maintenance Section Fuel System Secondary Filter - Replace Refer to Systems Operation, Testing, and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. Remove the Element 1.

  • Page 93: Drain

    M0090743 Maintenance Section Fuel Tank Water and Sediment - Drain 3. Do not use a tool to install the filter assembly. Check the fuel daily. Allow five minutes after the fuel tank has been filled before draining water and Tighten the assembly by hand. Install the filter sediment from the fuel tank.

  • Page 94: Radiator - Clean

    M0090743 Maintenance Section Radiator - Clean • Softness Refer to the Disassembly and Assembly for the correct instructions when replacing hoses and • Loose clamps clamps. Replace hoses that are cracked or soft. Tighten any i07313498 loose clamps. Radiator - Clean Check for the following conditions: •...

  • Page 95: Starting Motor - Inspect

    Refer to the Systems Operation, Testing and Adjusting Manual, “Electric Starting System - Test” for more information on the checking procedure and for specifications or consult your Perkins dealer or your Perkins distributor for assistance.

  • Page 96: Walk-Around Inspection

    M0090743 Maintenance Section Walk-Around Inspection Engine Installed with High- 5. Check for the presence of oil. If oil is leaking from the back side of the compressor wheel, there is a Pressure Turbocharger and Low- possibility of a failed turbocharger oil seal. Pressure Turbocharger The presence of oil may be the result of extended engine operation at low idle.
  • Page 97 Remove and Install”. For more information, consult wires. Check for any loose tie-wraps or missing your Perkins dealer or your Perkins distributor. tie-wraps. • Inspect the lubrication system for leaks at the front •...

  • Page 98: Water Pump - Inspect

    M0090743 Maintenance Section Water Pump - Inspect • Disconnect any battery chargers that are not Visually inspect the water pump for leaks. protected against the current drain of the starting Note: If engine coolant enters the engine lubricating motor. Check the condition and the electrolyte system the lubricating oil and the engine oil filter must level of the batteries, unless the engine is be replaced.

  • Page 99: 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 100: 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 101 M0090743 Reference Information Section Maintenance Log i05204675 Maintenance Log Table 15 Engine Model Customer Identifier Arrangement Number Serial Number Service Quantity Of Service Item Date Authorization Hours Fuel...
  • Page 102 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 103: Index

    M0090743 Index Section Index After Starting Engine ........42 Diagnostic Flash Code Retrieval..... 39 After Stopping Engine ........48 Diagnostic Lamp..........39 Aftercooler Core - Clean/Test......70 Driven Equipment - Check ......79 Aftercooler Core - Inspect ....... 70 Alarms and Shutoffs ........32 Alarms............
  • Page 104 M0090743 Index Section General Coolant Information ....... 50 General Hazard Information......9 Fluid Recommendations (Engine Oil Containing Fluid Spillage......11 Specification) ..........54 Dispose of Waste Properly ......12 Engine Oil ............ 55 Fluid Penetration ..........11 General Lubricant Information..... 54 Inhalation ............. 12 Fluid Recommendations (General Fuel Pressurized Air and Water......11 Information) ...........
  • Page 105 Serial Number Plate (1) ....... 28 Engine Oil ............ 66 Product Description ......... 25 Fuel System..........66 Aftermarket Products and Perkins Engines ............27 Electronic Engine Features ......26 Engine Cooling and Lubrication ....26 Table of Contents ..........3 Engine Diagnostics........
  • Page 107 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 108 M0090743 ©2018 Perkins Engine Company Limited All Rights Reserved September 2018...

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