Perkins 1706J-E93TA Operation And Maintenance Manual
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Perkins 1706J-E93TA Operation And Maintenance Manual

Industrial engine
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M0087475-03 (en-us)
December 2020
Operation and
Maintenance
Manual
1706J-E93TA Industrial Engine
NGK (Engine)

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  • Page 1 M0087475-03 (en-us) December 2020 Operation and Maintenance Manual 1706J-E93TA Industrial Engine NGK (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

    M0087475-03 Table of Contents Table of Contents Cold Weather Operation ......... 59 Maintenance Section Foreword ............4 Refill Capacities..........61 Safety Section Maintenance Recommendations ....78 Safety Messages..........6 Maintenance Interval Schedule....... 81 Additional Messages ......... 7 Warranty Section General Hazard Information......8 Warranty Information........

  • 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 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. Illustration 1...

  • Page 7: Additional Messages

    Loose adhesive will allow the messages to fall. Replace any message that is damaged, or missing. If a message is attached to a part that is replaced, install a message on the replacement part. Replacement labels may be obtained from Perkins distributors.

  • Page 8: General Hazard Information

    M0087475-03 Safety Section General Hazard Information • Tampering with the engine installation or tampering with the OEM supplied wiring can be dangerous. Personal injury, death and/or engine damage could result. • Vent the engine exhaust to the outside when the engine is operated in an enclosed area.
  • Page 9 M0087475-03 Safety Section General Hazard Information • Do not attempt any repairs that are not understood. Use the correct tools. Replace any equipment that is damaged or repair the equipment. • For initial start-up of a new engine or for starting an engine that has been serviced, make provisions to stop the engine if an overspeed occurs.
  • Page 10 M0087475-03 Safety Section General Hazard Information When pressurized air and/or pressurized water is Dispose of all fluids according to local regulations used for cleaning, wear protective clothing, protective and mandates. shoes, and eye protection. Eye protection includes goggles or a protective face shield. Static Electricity Hazard when Fueling with Ultra-low Sulfur Diesel The maximum air pressure for cleaning purposes...
  • Page 11 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 Illustration 8 g00702022 guidelines when you handle any replacement parts...

  • Page 12: Burn Prevention

    M0087475-03 Safety Section Burn Prevention • Comply with applicable rules and regulations for • Wash thoroughly after handling DEF. the work place. In the United States, use Occupational Safety and Health Administration i06086863 (OSHA) requirements. These OSHA requirements Burn Prevention can be found in “29 CFR 1910.1001”.

  • Page 13: Fire Prevention And Explosion Prevention

    Engine and Aftertreatment System If the application involves the presence of Do not touch any part of an operating engine or combustible gases, consult your Perkins dealer and/ engine aftertreatment system. Allow the engine or the or your Perkins distributor for additional information engine aftertreatment system to cool before any about suitable protection devices.
  • Page 14 M0087475-03 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 15: Crushing Prevention And Cutting Prevention

    Mounting and Dismounting pressure lines. Do not install any lines that are damaged. Leaks can cause fires. Consult your Perkins dealer or Do not climb on the engine or the engine your Perkins distributor for replacement parts. aftertreatment system. The engine and aftertreatment system have not been designed with Check lines, tubes, and hoses carefully.
  • Page 16 M0087475-03 Safety Section High Pressure Fuel Lines Illustration 13 g06263148 (1) High-pressure fuel manifold (rail) (3) High-pressure lines to injectors (2) Fuel transfer lines that are high pressure (4) High-pressure fuel pump The high-pressure fuel lines are the fuel lines that are Do not check the high-pressure fuel lines with the between the high-pressure fuel pump and the high- engine or the starting motor in operation.

  • Page 17: Before Starting Engine

    M0087475-03 Safety Section Before Starting Engine • Do not operate the engine with a fuel leak. If there All protective guards and all protective covers must be installed if the engine must be started in order to is a leak, do not tighten the connection, to stop the perform service procedures.

  • Page 18: Engine Stopping

    M0087475-03 Safety Section Engine Stopping Grounding Practices Note: The engine may be equipped with a device for cold starting. If the engine will be operated in very cold conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with the correct type of starting aid for your region of operation.

  • Page 19: Engine Electronics

    Note: Many of the engine control systems and discharge. display modules that are available for Perkins Engines will work in unison with the Engine To ensure that the engine and the engine electrical Monitoring System.

  • Page 20: Product Information Section

    M0087475-03 Product Information Section Model Views Product Information Section Model Views i07287396 Model View Illustrations Illustration 16 g06275201 View of the top of a typical 1706J Engine (1) Oil pan (3) Turbocharger (2) Lifting eyes (4) Oil cap...
  • Page 21 M0087475-03 Product Information Section Model View Illustrations Illustration 17 g06275205 View of the left side of a typical 1706J Engine (5) Oil filler tube (7) Electronic Control module (ECM) (6) Fuel Injection pump (8) Starting motor...
  • Page 22 M0087475-03 Product Information Section Model View Illustrations Illustration 18 g06275226 View of the left side of a typical 1706J Engine (9) Secondary fuel filters (12) Crankcase ventilation filter (15) Oil dipstick (10) Primary fuel filter/ water separator (13) Crankcase breather (11) Fuel pump switch assembly (14) Flywheel housing...
  • Page 23 View of the front right side of a typical 1706J Engine (16) Oil filter (17) Alternator i07200486 Product Description The Perkins 1706J-E93TA Industrial Engine has the following characteristics: • Four-stroke cycle • Turbocharged Engine Specifications Note: The front end of the engine is opposite the...
  • Page 24 Aftermarket Products and Perkins injectors. The fuel injection is controlled by the Engines engine electronic control module. Perkins does not warrant the quality or performance Electronic Engine Features of non-Perkins fluids and filters. The Perkins 1706J-E93TA industrial engine is When auxiliary devices, accessories, or designed for electronic controls.

  • Page 25: Product Identification Information

    M0087475-03 Product Information Section Product Identification Information Product Identification Information i07200488 Plate Locations and Film Locations Illustration 21 g06251121 Typical example (1) Engine serial number plate location Viewed from the rear of the engine, the serial number plate is on the right side of the cylinder block below the turbocharger.
  • Page 26 The Clean Emission Module (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. Pump Tank Unit (PTU)
  • Page 27 Product Information Section Emissions Certification Film Record the information on the CEM and PTU serial plates. The information will be required by your Perkins distributor to identify replacement part numbers. i05951816 Emissions Certification Film Note: This information is pertinent in the United States, in Canada and in Europe.

  • Page 28: Operation Section

    If alterations are made, Lifting and Storage ensure that proper lifting devices are provided. Consult your Perkins dealer for information regarding fixtures for proper engine lifting. i07433043 Product Lifting...
  • Page 29 M0087475-03 Operation Section Product Lifting Engine and Factory Mounted CEM Illustration 29 g06263203 Typical example (1) Rear lifting eye (2) Front lifting eye Engines with a factory-mounted CEM with or without a factory-mounted radiator, can be lifted by the CEM front and rear brackets load ring (provided) and using a certified spreader bar.
  • Page 30 (4) Diesel Exhaust Fluid (DEF) and electronic unit lifting locations i07249571 Product Storage (Engine and Aftertreatment) Your Perkins distributor can help in preparing the engine for extended storage periods. Illustration 30 g06251427 Some applications, the engine can be equipped with delayed engine shutdown.
  • Page 31 M0087475-03 Operation Section Engine and Aftertreatment Engine Open the fuel tank drain valve to drain any water and dirt from the fuel tank. Apply a spray of 1. Clean the engine of any dirt, rust, grease, and oil. calibration fluid or kerosene at the rate of Inspect the exterior.
  • Page 32 1. Ensure normal engine shutdown, allow the DEF to (1) Plug be purged. Do not disconnect the battery 8. If an engine is stored for more than 1 year, Perkins disconnect switch, allow 2 minutes after key off recommends Pre lubrication of the engine to avoid before disconnection.
  • Page 33 M0087475-03 Operation Section Engine and Aftertreatment 10. Before start-up, test the cooling system for a 3 percent to a 6 percent concentration of coolant conditioner. Add liquid coolant conditioner or a coolant conditioner element, if equipped. Test the coolant mixture for proper nitrite level. If necessary, adjust the coolant mixture.

  • Page 34: Features And Controls

    M0087475-03 Operation Section Features and Controls Features and Controls i07201709 Monitoring System The monitoring system is designed to alert the operator to an immediate problem with any of the engine systems that are monitored. The monitoring system is also designed to alert the operator to an impending problem with any of the engine systems that are monitored.
  • Page 35 M0087475-03 Operation Section Sensors and Electrical Components Engine Views Illustration 33 g06263600 Typical example (1) Alternator (5) Intake throttle valve (9) Remote fuel priming switch (2) Intake manifold pressure sensor (6) Fuel pressure before filter (10) Fuel priming pump (3) Fuel rail pressure sensor (7) Fuel temperature sensor (4) Atmospheric pressure sensor (8) Fuel pressure after filter...
  • Page 36 M0087475-03 Operation Section Sensors and Electrical Components Illustration 34 g06263606 Typical example (11) Intake manifold temperature sensor (13) Starting motor (15) Camshaft spped/timing sensor (12) Engine electronic control module (14) Oil pressure sensor (16) fuel suction control valve...
  • Page 37 M0087475-03 Operation Section Sensors and Electrical Components Illustration 35 g06263610 Typical example (17) Coolant temperature (18) Crankshaft speed/timing sensor...
  • Page 38 M0087475-03 Operation Section Sensors and Electrical Components Aftertreatment System Views Illustration 36 g06263677 Typical example (1) Diesel Exhaust Fluid (DEF) injector (3) Differential pressure sensor (5) Temperature sensor (2) Post NOx sensor (4) NOx sensor...
  • Page 39 M0087475-03 Operation Section Battery Disconnect Switch i05422613 Battery Disconnect Switch (If Equipped) Illustration 38 g03422039 NOTICE Do not turn off the battery disconnect switch until the indicator lamp has turned off. If the switch is turned off when the indicator lamp is illuminated the Diesel Illustration 37 g06263708 Exhaust Fluid (DEF) system will not purge the DEF.
  • Page 40 M0087475-03 Operation Section Selective Catalytic Reduction Warning System The battery disconnect switch and the engine start NOTICE switch perform different functions. The entire Allow at least 2 minutes after shutting down the en- electrical system is disabled when you turn the gine before you turn the battery disconnect switch to battery disconnect switch to the OFF position.
  • Page 41 M0087475-03 Operation Section Selective Catalytic Reduction Warning System Safe Harbor Mode (European Union) – Safe Harbor Mode is a 30 minute engine run time period. During the Safe Harbor Mode the engine can be operated with full power after reaching a level 3 inducement.
  • Page 42 M0087475-03 Operation Section Selective Catalytic Reduction Warning System The check engine and emissions malfunction indicator lamp will illuminate for any 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 43 Operation Section Selective Catalytic Reduction Warning System If a fault condition exists for the entire duration of Note: Contact your Perkins dealer for repairs if a fault inducement level 1, the strategy advances to occurs. inducement level 2. The check engine lamp and the...
  • Page 44 M0087475-03 Operation Section Selective Catalytic Reduction Warning System Note: Turn the key to the OFF and add DEF to the DEF tank to reset the DEF level inducement. Inducement Strategy for Escalating Time Inducement Faults (Worldwide) Illustration 49 g03676174 If the DEF level is below 7.5%, a level 2 inducement Illustration 51 g03676215 event will occur.
  • Page 45 2 inducement will occur for a duration of 64 hours. For repeat occurrence, a category 3 level 2 Note: Contact your Perkins dealer for repairs if a fault inducement fault will occur for a duration of 5 hours.

  • Page 46: Engine Diagnostics

    Engine Diagnostics Engine Diagnostics i05194988 Self-Diagnostics Perkins Electronic Engines have the capability to perform a self-diagnostics test. When the system detects an active problem, a diagnostic lamp is activated. Diagnostic codes will be stored in permanent memory in the Electronic Control Module (ECM).

  • Page 47: Engine Starting

    M0087475-03 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 48 M0087475-03 Operation Section Starting the Engine Starting the Engine Note: Oil pressures and fuel pressures should be in the normal range on the instrument panel. Engines that are equipped with “WARNING” lamps do not Refer to the Owner's Manual of the OEM for your type of controls.
  • Page 49 (Do Not Use This Procedure in 3. Start the engine. If the engine does not start, Hazardous Locations that have consult the nearest Perkins dealer for assistance. Explosive Atmospheres) i04132731 Cold Weather Starting Startability will be improved at temperatures below The connection of battery cables to a battery and 10°C (50°F) from the use of a cylinder block coolant...
  • Page 50 M0087475-03 Operation Section After Starting Engine 3. Connect one negative end of the jump-start cable to the negative cable terminal of the electrical source. Connect the other negative end of the Improper jump start cable connections can cause an explosion resulting in personal injury. jump-start cable to the engine block or to the chassis ground.
  • Page 51 M0087475-03 Operation Section After Starting Engine Extended Idle at Cold Ambient Temperature The engine may automatically change speeds when the engine is idling in cold ambient temperatures (typically less than 0° C (32° F) for extended periods. The purpose of the automatic speed change is threefold: to maintain the desired operation of the NOx reduction system, to maintain the desired operation of the regeneration system and to keep the...

  • Page 52: Engine Operation

    M0087475-03 Operation Section Engine Operation Engine Operation i07201785 Diesel Particulate Filter i07290374 Regeneration Engine Operation Regeneration Proper operation and maintenance are key factors in obtaining the maximum life and economy of the Regeneration is the process of increasing exhaust engine. If the directions in the Operation and temperatures to remove soot from the DPF.
  • Page 53 The illuminated occurs, regeneration can only be done through DPF indicator indicates that complete regeneration Perkins Electronic Service Tool (EST), by an has not been performed. Complete regeneration is authorized Perkins dealer. The engine may be...
  • Page 54 The efficiency of the engine can affect the fuel This CO measurement results from testing over a economy. Perkins design and technology in fixed test cycle, under laboratory conditions, with a(n) manufacturing provides maximum fuel efficiency in (parent) engine representative of the engine type all applications.
  • Page 55 M0087475-03 Operation Section Fuel Conservation Practices • Ensure that the driven equipment is in good working order. • Cold engines consume excess fuel. Utilize heat from the jacket water system and the exhaust system, when possible. Keep cooling system components clean and keep cooling system components in good repair.

  • Page 56: Engine Stopping

    M0087475-03 Operation Section Engine Stopping Engine Stopping i07201818 Stopping the Engine NOTICE Stopping the engine immediately after working under load, can result in overheating and accelerated wear of the engine components. Refer to the following stopping procedure, to allow the engine to cool, and to prevent excessive temper- Illustration 59 g03740766 atures in the turbocharger center housing and DEF...
  • Page 57 M0087475-03 Operation Section Manual Stop Procedure For more information on the engine key switch, refer to Operation and Maintenance Manual, “Operator Controls”. Leaving the machine unattended when the engine is running may result in personal injury or death. Immediate Engine Shutdown (Type Before leaving the machine operator station, neu- tralize the travel controls, lower the work tools to the ground and deactivate all work tools, and...
  • Page 58 M0087475-03 Operation Section After Stopping Engine i07222343 After Stopping Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes to allow the engine oil to return to the oil pan. • Check the crankcase oil level. Maintain the oil level between the “ADD”...

  • Page 59: Cold Weather Operation

    Perkins recommends a warning device for the inlet When No. 2 diesel fuel is used the following manifold temperature and/or the installation of an components provide a means of minimizing problems inlet air temperature gauge.
  • Page 60 37° C (100° F). Note: Heat exchanger type fuel heaters should have a bypass provision to prevent overheating of the fuel in warm weather operation. For further information on fuel heaters, consult your Perkins dealer.

  • Page 61: Maintenance Section

    System approximately 32.5%. Total Cooling Sys- Specification DEF that is used in Perkins engines must meet the ISO specification 22241-1 for quality. The ISO (continued) specification 22241-1 requirements are met by many brands of DEF, including those that carry the AdBlue...
  • Page 62 Above 35° C (95° F) test quality before use Filling the DEF Tank Perkins recommend that all DEF taken from storage should be checked to ensure the DEF meets ISO The fill cap on the DEF tank must be colored blue.
  • Page 63 Unexpected reactions may occur if DEF solutions come in contact with any non-compatible Diesel Fuel Requirements material or unknown materials. Perkins is not in a position to continuously evaluate i07290461 and monitor all worldwide distillate diesel fuel specifications that are published by governments and Fluid Recommendations technological societies.
  • Page 64 M0087475-03 Maintenance Section General Fuel Information Table 6 "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 65 “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 66 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 67 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 68 Test should include acid number • Perkins recommend the use of oil analysis to (EN14104), oxidation stability (EN 15751 commonly check the quality of the engine oil if biodiesel fuel know as the Rancimant test), and sediment is used.
  • Page 69 “Operation and Maintenance Manual” Fluid Recommendations If biodiesel or biodiesel blends of fuel are to be used, Perkins require the use of Perkins fuel cleaner. The Fuel for Cold-Weather Operation use of the fuel is to remove deposits within the fuel system that is created with the use of biodiesel.
  • Page 70 Never add coolant to an overheated engine. Engine damage could result. Allow the engine to cool first. • Perkins recommends the use of bulk fuel filter / coalescer units which clean the fuel of both particulate contamination and water in a single...
  • Page 71 M0087475-03 Maintenance Section Fluid Recommendations Table 8 NOTICE If the engine is to be stored in, or shipped to an area Acceptable Water with below freezing temperatures, the cooling system Property Maximum Limit must be either protected to the lowest outside tem- perature or drained completely to prevent damage.
  • Page 72 Do not use propylene glycol in concentrations that NOTICE exceed 50 percent glycol because of the reduced The Perkins industrial engines with a NOx reduc- heat transfer capability of propylene glycol. Use ethyl- tion system must be operated with a minimum...
  • Page 73 Perkins ELC has level stabilizes. As needed, add the coolant mixture been formulated with the correct amount of these to fill the system to the specified level.
  • Page 74 Perkins. NOTICE Do not mix types and brands of coolant. 6. Fill the cooling system with the Perkins Premixed ELC. Operate the engine. Ensure that all coolant Do not mix brands and types of SCAs. valves open then stop the engine. When cool Do not mix SCAs and Extenders.
  • Page 75 Association des Constructers European Automobiles deposits. and (ACRA) is recognized by Perkins. For detailed information about this system, see the latest edition • Drain the cooling system. of the “API publication No. 1509”. Engine oils that •...
  • Page 76 “EMA Recommended Guideline on Diesel Engine is left behind as the soot is burnt. This matter will Oil”. In addition to Perkins definitions, there are other eventually block the filter, causing loss of definitions that will be of assistance in purchasing performance and increased fuel consumption.
  • Page 77 Aftermarket Oil Additives allows technicians to determine the amount of deterioration of the oil during use. This analysis Perkins does not recommend the use of aftermarket also allows technicians to verify the performance additives in oil. Aftermarket additives are not...

  • 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 (2) Welding electrode Refer to the standards for the engine or consult your (3) Keyswitch in the OFF position Perkins distributor to determine if the engine is (4) Battery disconnect switch in the open position operating within the defined parameters.
  • Page 80 Severe Service Application Due to individual applications, identification is not possible for all the factors which can contribute to severe service operation. Consult your Perkins distributor for the unique maintenance that is necessary for the engine. The operating environment, incorrect operating...

  • Page 81: Maintenance Interval Schedule

    M0087475-03 Maintenance Section Maintenance Interval Schedule “ Fuel System Primary Filter/Water Separator - i07478144 Drain” ........113 Maintenance Interval Schedule “...
  • Page 82 M0087475-03 Maintenance Section Maintenance Interval Schedule “ Engine Mounts - Inspect” ..... . Every 4000 Service Hours or 2 Years “...
  • Page 83 M0087475-03 Maintenance Section Air Compressor - Check Consult your Perkins dealer for further information i07223730 concerning the air compressor. Air Compressor - Check (If equipped) i07297207 Air Shutoff - Test To ensure that the air shutoff valve always shuts down when the engine ingests gaseous fumes,...
  • Page 84 M0087475-03 Maintenance Section Battery - Recycle • Malfunction of the air starting system The battery cables or the batteries should not be removed with the battery cover in place. The bat- tery cover should be removed before any servic- When opening the drain valve, wear protective ing is attempted.
  • Page 85 M0087475-03 Maintenance Section Battery or Battery Cable - Disconnect 2. Disconnect the negative battery terminal. Ensure that the cable cannot contact the terminal. When four 12 V batteries are involved, 2 negative All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a connections must be disconnected.
  • Page 86 M0087475-03 Maintenance Section Belts - Inspect/Adjust/Replace Inspect For applications that require multiple drive belts, replace the belts in matched sets. Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched. The additional load on the new belt could cause the new belt to break.
  • Page 87 If new drive belts are installed, check the drive belt engine damage. tension again after 30 minutes of engine operation at the rated rpm. Perkins engines incorporate a shunt bypass design cooling system and require operating the engine with Belt Tension Chart a water temperature regulator installed.
  • Page 88 M0087475-03 Maintenance Section Cooling System Coolant (DEAC) - 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 and operate the engine, ensure that the thermostat opens.
  • Page 89 Cooling System Coolant (ELC - Change NOTICE Perkins ELC must be using with an extender in order to achieve 12000 hours operation. For more informa- tion on a suitable extender contact your Perkins distributor. Clean the cooling system and flush the cooling...
  • Page 90 49 °C to 66 °C (120 °F to 150 °F). For Perkins ELC to achieve 12000 hours an extender must be added at 6000 hours. For a suitable 5. Stop the engine and allow the engine to cool.
  • Page 91 M0087475-03 Maintenance Section Cooling System Supplemental Coolant Additive (SCA) - Test/Add Use a Coolant Conditioner Test Kit in order to check the concentration of the SCA. Add the SCA, If Necessary NOTICE Do not exceed the recommended amount of supple- mental coolant additive concentration.
  • Page 92 Perkins dealer. order to pressure test the filler cap. The correct pressure is stamped on the face of the filler cap. If...
  • Page 93 M0087475-03 Maintenance Section DEF Manifold Filters (Emission Related Component) - 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.
  • Page 94 M0087475-03 Maintenance Section DEF Manifold Filters (Emission Related Component) - Replace Illustration 74 g03806581 Illustration 75 g03806583 Illustration 73 g03806580 4. Remove the suction filter (4) at the bottom of the header coils by pulling tabs (5). Replace with a 2.
  • Page 95 M0087475-03 Maintenance Section Diesel Exhaust Fluid (Emission Related Component) - 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 96 M0087475-03 Maintenance Section Diesel Exhaust Fluid Filter (Emission Related Component) - Replace 4. The opening on the DEF tank (2) is a special diameter. Ensure that the correct nozzle is used when filling the DEF tank. 5. Check the cleanliness of DEF cap and install the DEF cap.
  • Page 97 M0087475-03 Maintenance Section Diesel Exhaust Fluid Filter (Emission Related Component) - Replace Illustration 81 g06215916 Typical example 3. Use supplied tool (5) to remove filter element (2) from DEF pump assembly (1). Note: Avoid twisting the diesel exhaust fluid filter upon removal.
  • Page 98 (Emission Related (Emission Related Component) - Replace Component) - Clean Consult your Perkins dealer when the DPF needs to be cleaned. The approved Perkins DPF maintenance procedure requires that one of the following actions be taken when the DPF needs to be cleaned: •...
  • Page 99 Servicing the Air Cleaner Element • Ease of maintenance Note: The air filter system may not have been provided by Perkins. The procedure that follows is for Note: Caution must be used to prevent electrical a typical air filter system. Refer to the OEM components from being damaged by excessive water information for the correct procedure.
  • Page 100 M0087475-03 Maintenance Section Engine Air Cleaner Service Indicator - Inspect Replace the dirty air cleaner elements with new air 3. Remove the primary air filter element (2) and cleaner elements. Before installation, the air cleaner remove the secondary air filter element (not elements should be thoroughly checked for tears shown) from air cleaner body (1).
  • Page 101 Refer to the OEM information for the (Y) “ADD” mark recommended torques. (X) “FULL” mark When the engine mounts are supplied by Perkins the maintenance procedure will be supplied in the NOTICE Disassembly and Assembly manual for your engine.
  • Page 102 M0087475-03 Maintenance Section Engine Oil Sample - Obtain Perkins recommends using a sampling valve in order NOTICE to obtain oil samples. The quality and the consistency Engine damage can occur if the crankcase is filled of the samples are better when a sampling valve is above the “FULL”...
  • Page 103 250 hours. If the engine is operated in severe service conditions, i07227939 Perkins recommends the use of engine oil sampling. Refer to this Operation and Maintenance Manual, Engine Oil and Filter - Change Engine Oil sample - Obtain for more information.
  • Page 104 Normal Severe Service Application Perkins DEO 500 hr 250 hr or Perkins DEO-ULS Preferred Oil meeting the requirements of the Perkins 500 hr 250 hr ECF-3 Specification or the API CK-4 classification 8 minimum TBN Preferred Oil meeting the requirements of the ACEA C9/...
  • Page 105 Perkins oil filters are manufactured to Perkins specifi- cations. Use of an oil filter that is not recommended by Perkins could result in severe damage to the en- gine bearings, crankshaft, and so forth. As a result of the larger waste particles from unfiltered oil entering the engine lubricating system.
  • Page 106 Under-filling or over filling • Fuel consumption the crankcase with oil can cause engine damage. Perkins recommends the use of Volatile Corrosion Inhibitors (VCI) oil to prevent internal engine damage due to moisture during storage. These inhibitors act by evaporating inside the engine, then condensing over the inside surfaces.
  • Page 107 M0087475-03 Maintenance Section Engine Storage Procedure - Check This evaporation and condensing process offers full 7. Remove the air filter element or elements. Turn the protection to surfaces that cannot be reached with engine at cranking speed with the throttle control preservatives that require a direct application.
  • Page 108 If the batteries are not removed, wash the tops of the batteries until clean. Apply an electrical charge Note: All Perkins engines equipped with Air-to-Air to the batteries to obtain a specific gravity of Aftercooling (ATAAC) require a minimum of 30 1.225.
  • Page 109 M0087475-03 Maintenance Section Engine Storage Procedure - Check 4. Replace the fuel filter elements. An optional prelube pump is available for some engines. After the crankcase has been filled with the 5. Remove the plastic covers from the air cleaner correct quantity of oil, the prelube pump sends oil to elements.
  • Page 110 Note: Dispose of all fluids according to applicable regulations and mandates. Initial Operation after Storage The quality of oil control components used in Perkins Engines ensures that only an operational check at initial start is necessary before operation. The purpose of this operational check is to ensure that the correct pressures and temperatures are kept in the lubrication, cooling, and fuel systems.
  • Page 111 Refer to the Service Manual or your au- will cycle the fuel priming pump again. thorized Perkins dealer or your Perkins distributor for the complete valve lash adjustment procedure. 4. When the water separator is full of fuel, attempt to start the engine.
  • Page 112 M0087475-03 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 3. Attempt to start the engine. If engine starts and runs rough or misfires, operate at low idle until the engine is running smoothly. If the engine cannot be started, continue to prime the fuel system for 30 more seconds.
  • Page 113 M0087475-03 Maintenance Section Fuel System Primary Filter/Water Separator - Drain 12. Apply clean diesel fuel to the seal of the new filter. 13. Install the new filter onto the base. Tighten the filter by hand until the seal contacts the filter base. Tighten the filter by anadditional1/3 to 1/2 rotation.
  • Page 114 M0087475-03 Maintenance Section Fuel Tank Water and Sediment - Drain NOTICE Do not fill the secondary and tertiary fuel filters with fuel before installing. The fuel would not be filtered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts. 5.
  • Page 115 If the cup was removed, When possible, water separators should be used. replace the cup. Tighten hand tight. Note: Perkins will not be held liable for an engine that i07293948 does not comply with Environmental Protection...
  • Page 116 M0087475-03 Maintenance Section Grounding Stud - Inspect/Clean/Tighten If you inspect the engine in operation, always use the i03965989 proper inspection procedure in order to avoid a fluid Grounding Stud - Inspect/ penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”. Clean/Tighten Inspect all hoses for leaks that are caused by the following conditions:...
  • Page 117 If the clutch is damaged to the point of burst fail- ure, expelled pieces can cause personal injury to more information. anyone in the immediate area. Proper safeguards must be followed to help prevent accidents. i05971077 Overhaul Considerations For an overhaul solution, contact your Perkins distributor.
  • Page 118 Radiator - Clean connections. Refer to the Service Manual for more information on the checking procedure and for specifications or consult your Perkins distributors for assistance. Note: Adjust the frequency of cleaning according to the effects of the operating environment.
  • Page 119 Disassembly and Assembly repair is performed on the engine fuel lines. If Manual for the engine or consult your Perkins dealer. necessary, perform minor adjustments. Repair any leaks from the low-pressure fuel system and from the •...

  • Page 120: Warranty Section

    (“emission-related components”), are: For a detailed explanation of the Emission Control Warranty, contact your authorized Perkins dealer or a. Designed, built, and equipped so as to conform, your authorized Perkins distributor. at the time of sale, with applicable emission...

  • Page 121: Reference Information Section

    Refer to this Operation and Maintenance Manual, “Configuration Parameters” for information about the rating for this engine. Note: The examples of the applications are only for reference. For an exact determination of the appropriate rating, follow the OEM specifications or consult your Perkins dealer.

  • Page 122: Customer Service

    Failure to heed this warning can lead to prema- ture failures, product damage, personal injury, or death. Quality Perkins replacement parts are available from Perkins dealers throughout the world. Perkins dealers parts inventories are up-to-date. The parts stocks include all the parts that are normally needed to protect your Perkins engine investment.

  • Page 123: Reference Materials

    To purchase an Extended Service Contract, is quick and simple! Contact your local Perkins Distributor now and the distributor can provide you with a quote i07306250 in minutes. You can locate your nearest Perkins Distributor by visiting: Reference Material www.perkins.com...
  • Page 124 M0087475-03 Reference Information Section Maintenance Records • Dealer work orders and itemized bills • Owners repair costs • Owners receipts • Maintenance log...

  • Page 125: Index

    M0087475-03 Index Section Index Cooling System Supplemental Coolant Additive (SCA) - Test/Add......91 Additional Messages ......... 7 Add the SCA, If Necessary ......91 After Starting Engine ........50 Test for SCA Concentration ......91 Extended Idle at Cold Ambient Cooling System Water Temperature Temperature..........
  • Page 126 M0087475-03 Index Section Engine Electronics........... 19 Safety............. 4 Engine Mounts - Inspect........ 101 Fuel and the Effect from Cold Weather ... 59 Engine Oil and Filter - Change ...... 103 Fuel Conservation Practices ......54 Drain the Engine Lubricating Oil....104 Fuel Related Components in Cold Weather ...
  • Page 127 Power Take-Off Clutch - Check......117 Sensors and Electrical Components....34 Product Description ......... 23 Aftertreatment System Views ...... 38 Aftermarket Products and Perkins Engine Views ..........35 Engines ............24 Severe Service Application ......79 Electronic Engine Features ......24 Environmental Factors.........
  • Page 128 M0087475-03 Index Section Delayed Engine Shutdown (If Enabled) ..56 Immediate Engine Shutdown (Type 1) ..57 Immediate Engine Shutdown (Type 2) ..57 System Pressure Release....... 78 Coolant System ........... 78 Engine Oil ............ 78 Fuel System..........78 Table of Contents ..........3 Walk-Around Inspection .........118 Inspect the Engine for Leaks and for Loose Connections ..........118...
  • Page 129 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 130 M0087475 ©2020 Perkins Engines Company Limited All Rights Reserved December 2020...

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