Perkins 1204F-E44TA Operation And Maintenance Manual
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Perkins 1204F-E44TA Operation And Maintenance Manual

Industrial engines
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SEBU9063-07 (en-us)
December 2020
Operation and
Maintenance
Manual
1204F-E44TA and 1204F-E44TTA
Industrial Engines
MT (Engine)
MU (Engine)
MW (Engine)

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Summary of Contents for Perkins 1204F-E44TA

  • Page 1 SEBU9063-07 (en-us) December 2020 Operation and Maintenance Manual 1204F-E44TA and 1204F-E44TTA Industrial Engines MT (Engine) MU (Engine) MW (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

    SEBU9063-07 Table of Contents Table of Contents Maintenance Section Refill Capacities..........82 Foreword ............4 Maintenance Recommendations ....100 Safety Section Maintenance Interval Schedule..... 103 Safety Messages..........6 Warranty Section General Hazard Information......9 Warranty Information........137 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

    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 distributor can provide new warning signs. (1) Universal Warning...
  • Page 7 SEBU9063-07 Safety Section Safety Messages Illustration 2 g03404355 (1) Universal Warning (2) Hand (High Pressure) Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service in- structions may cause personal injury or death.
  • Page 8 SEBU9063-07 Safety Section Safety Messages Illustration 4 g03404354 (2) Hand (High Pressure) The warning label for the Hand (High Pressure) (2) is a wrap around label that is installed on the high- pressure fuel line. Ether Warning An ether warning label will be installed on the air cleaner or close to the air cleaner.

  • Page 9: General Hazard Information

    SEBU9063-07 Safety Section General Hazard Information • Wear a hard hat, protective glasses, and other protective equipment, as required. • When working around an engine, the engine must not be in operation. You may only be near a running engine to carry out maintenance procedures that require the engine to be in operation.
  • Page 10 Safety Section General Hazard Information • For initial start-up of a new engine or for starting • Perkins recommend that you do not stand next to an engine that has been serviced, make an exposed running engine unless it is necessary...
  • Page 11 SEBU9063-07 Safety Section General Hazard Information Do not remove any hydraulic components or parts Dispose of all fluids according to local regulations until pressure has been relieved or personal injury and mandates. may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved Static Electricity Hazard when or personal injury may occur.
  • Page 12 (ULSD fuel) poses a greater good hygiene, and adhering to safe work practices static ignition hazard than earlier diesel formula- when handling the equipment or parts. Perkins also tions with a higher sulfur contents. Avoid death recommends the following: or serious injury from fire or explosion.

  • Page 13: Burn Prevention

    SEBU9063-07 Safety Section Burn Prevention • Use exhaust ventilation on permanent machining Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a jobs. drain, or into any source of water. • Wear an approved respirator if there is no other way to control the dust.
  • Page 14 SEBU9063-07 Safety Section Burn Prevention After the engine has stopped, wait for 10 minutes to Cooling system conditioner contains alkali. Alkali can allow the fuel pressure to be purged from the high- cause personal injury. Do not allow alkali to contact pressure fuel lines before any service or repair is the skin, the eyes, or the mouth.

  • Page 15: Fire Prevention And Explosion Prevention

    Ensure that If the application involves the presence of the hoses are correctly routed. The lines and hoses combustible gases, consult your Perkins dealer and/ must have adequate support and secure clamps. If or your Perkins distributor for additional information any fuel lines or fuel hoses become kinked, the fuel about suitable protection devices.
  • Page 16 SEBU9063-07 Safety Section Fire Prevention and Explosion Prevention Illustration 12 g00704059 Illustration 13 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 17: Crushing Prevention And Cutting Prevention

    The engine and aftertreatment system have not been designed with Leaks can cause fires. Consult your Perkins dealer or mounting or dismounting locations. your Perkins distributor for replacement parts. Refer to the OEM for the location of foot and hand Replace the parts if any of the following conditions holds for your specific application.
  • Page 18 SEBU9063-07 Safety Section High Pressure Fuel Lines Illustration 14 g03404398 (1) High-pressure line (4) High-pressure line (7) Fuel transfer line that is high pressure (2) High-pressure line (5) High-pressure fuel manifold (rail) (3) High-pressure line (6) High-pressure line The high-pressure fuel lines are the fuel lines that are Visually inspect the high-pressure fuel lines before the engine is started.

  • Page 19: Before Starting Engine

    Some Perkins engines may have a cold starting system that is controlled by the ECM Do not bypass the automatic shutoff circuits. Do not which allows a controlled flow of ether into the disable the automatic shutoff circuits.

  • Page 20: Electrical System

    SEBU9063-07 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 21: Engine Electronics

    Engine Electronics 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...

  • Page 22: Product Information Section

    SEBU9063-07 Product Information Section General Information Product Information Section General Information i05673429 Model View Illustrations The following model views show typical features of the engine and the aftertreatment system. Due to individual applications, your engine, and your aftertreatment may appear different from the illustrations.
  • Page 23 SEBU9063-07 Product Information Section Model View Illustrations 1204F-E44TTA Series Turbocharged Engine Illustration 18 g03404422 Typical example (1) Front lifting eye (6) Priming/tranfer fuel pump (11) Oil sampling valve (2) Crankcase breather (7) In line fuel filter (12) High-pressure fuel pump (3) Secondary fuel filter (8) Oil level gauge (dipstick) (13) Oil filler...
  • Page 24 SEBU9063-07 Product Information Section Model View Illustrations Illustration 19 g03404423 Typical example (14) Air intake (16) Water pump (18) Tensioner (15) Coolant outlet (17) Coolant intake (19) Belt...
  • Page 25 SEBU9063-07 Product Information Section Model View Illustrations Illustration 20 g03404515 Typical example (20) Back pressure valve (25) Starter solenoid (30) Flywheel housing (21) High-pressure turbocharger (26) Starting motor (31) NOx reduction cooler (22) Low-pressure turbocharger (27) Starter relay (32) Rear lifting eye (23) Alternator (28) Oil drain tap (24) Refrigerant compressor...
  • Page 26 SEBU9063-07 Product Information Section Model View Illustrations DOC and SCR Illustration 21 g03416433 Typical example (1) SCR (3) Outlet for Exhaust gas (5) DOC (2) Identification module (4) Mixer (6) Inlet for Exhaust gas The identification module will be installed on all aftertreatment systems.
  • Page 27 SEBU9063-07 Product Information Section Model View Illustrations DOC DPF and SCR Illustration 22 g03713347 Typical example (1) Intake for exhaust gas (3) Mixer (5) Outlet for exhaust gas (2) DPF (4) SCR...
  • Page 28 The Perkins 1204F-E44TA and the 1204F-E44TTA The 1204F industrial engine has two engine variants. industrial engines have the following characteristics. The 1204F-E44TA is a single turbocharged engine. The 1204F-E44TTA is a series turbocharged engine • In-line 4 cylinder The 1204F-E44TA engine has a Diesel Oxidation •...
  • Page 29 (B) Inlet valves • Low temperature regeneration Table 1 For more information on electronic engine features, 1204F-E44TA and 1204F-E44TTA Engine Specifications refer to the Operation and Maintenance Manual, Operating Range (rpm) 800 to 2200 “Features and Controls” topic (Operation Section).
  • Page 30 The aftertreatment system is approved for use by When the DOC, DPFand SCR system is operating Perkins. In order to be emission-compliant only the with exhaust gas temperatures below 425° C approved Perkins aftertreatment system or approved (797° F) before key-off, the cooling and purging will components must be used on a Perkins engine.
  • Page 31 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 32: Product Identification Information

    Particulate Filter (DPF) and Selective Catalytic Reduction (SCR) DOC and SCR Serial Plate Illustration 25 g03404834 Location of serial number plate Perkins engines are identified by an engine serial number. An example of an engine number is MT*****U000001W. • MT Type of engine •...
  • Page 33 Record all the information on the serial plate for your i05673571 aftertreatment system. The information will be Emissions Certification Film required by your Perkins distributors. The label for the emission is installed on the front gear cover. Note: A second emission label will be supplied with the engine.
  • Page 34 SEBU9063-07 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 Aftertreatment Systems Clean Emission Module Part Number Clean Emission Module Serial Number Dosing Control Unit Part Number Diesel Exhaust Fluid (DEF) Filter Part Number (DEF) Tank Part Number...

  • Page 35: Operation Section

    SEBU9063-07 Operation Section Lifting and Storage Operation Section Lifting and Storage i07432596 Product Lifting (Aftertreatment Systems) NOTICE Always inspect lifting eyebolts and all other lifting equipment for damage before performing any lifting. Never bend the eyebolts and the brackets. Never perform product lifting if components are damaged.
  • Page 36 SEBU9063-07 Operation Section Aftertreatment Systems DOC and SCR Illustration 31 g03417158 Typical example There are two sizes of CEM that can be installed. A high powered CEM and a low powered CEM. The approximate weight of the high powered CEM is 47 kg (104 lb), the approximate weight of the low powered CEM is 42 kg (93 lb).
  • Page 37 SEBU9063-07 Operation Section Product Lifting Some applications may require a frame or jig to lift the CEM. A frame or jig must only be connected to the cradle of the CEM. Refer to the Original equipment manufacture for more information. DOC, DPF, and SCR Illustration 32 g03713453...
  • Page 38 There are several different designs of lifting eyes. The following sections give examples of lifting eyes on the engine, engine, and aftertreatment and factory installed radiator. Consult your Perkins distributor for information regarding fixtures for proper engine lifting. Engine and Aftertreatment Lifting Eyes...
  • Page 39 The engine must be stored in a water proof building. The building must be kept at a constant temperature. Engines that are filled with Perkins ELC will have coolant protection to an ambient temperature of −36° C (−32.8° F). The engine must not be subjected to extreme variations in temperature and humidity.
  • Page 40 2. Fill the tank with DEF that meet all the requirement Sealed Coolant System defined in ISO 22241-1. Ensure that the cooling system is filled with Perkins 3. Ensure that all DEF lines and electrical connection ELC, or an antifreeze that meets “ASTM D6210”...
  • Page 41 SEBU9063-07 Operation Section Engine and Aftertreatment DEF Storage Table 2 Temperature Duration 10° C (50° F) 36 months 25° C (77° F) 18 months 30° C (86° F) 12 months 35° C (95° F) 6 months At 35° C, significant degradation can occur. Check every batch before use.

  • Page 42: Features And Controls

    SEBU9063-07 Operation Section Features and Controls Features and Controls Fuel rail pressure – The fuel rail pressure sensor measures the high pressure or low pressure in the fuel rail. The ECM will Check the pressure. i05768989 Engine oil pressure – The engine oil pressure Alarms and Shutoffs sensor indicates when oil pressure drops below rated system pressure, at a set engine speed.
  • Page 43 SEBU9063-07 Operation Section Selective Catalytic Reduction Warning System • SCR Temperature Sensor The DEF level sensor, DEF temperature sensor, and the Dosing control unit all connect with the engine • Ammonia Sensor ECM. If the ECM determines that any of the signals are out of the specified range, an alarm will be Temperature Sensor before DOC –...
  • Page 44 World-Wide SCR Warning Any warning should be investigated immediately, contact your Perkins distributor. The system is equipped with an override option. Once the override • At Level 1 the emission malfunction lamp will be option has been used and the fault still exist, the on solid.
  • Page 45 The stop lamp will be on solid Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop. Table 4 World-Wide Reduced Performance Setting Category 2 Fault (Non-Tampering Dosing and Interruption)
  • Page 46 Emission malfunction lamp will be on solid lamp will flash lamp will flash lamp will flash The stop lamp will be on solid Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.
  • Page 47 The stop lamp will activate Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop. Table 7 World-Wide Reduced Time Setting Category 2 Fault (Non-Tampering Dosing Interruption)
  • Page 48 The stop lamp will activate Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop. World-Wide DEF Level Warnings • The low-level warning lamp will operate when DEF level reaches the trigger point of below 20 percent.
  • Page 49 NOTICE Noticeable changes in gauge readings indicate Perkins strongly recommend the installation of the potential gauge or engine problems. Problems may wait to disconnect lamp on all applications. also be indicated by gauge readings that change even if the readings are within specifications.
  • Page 50 3. Inspect the cooling system for leaks. If necessary, The function of the low oil pressure lamp is controlled consult your Perkins distributor for assistance. by the engine ECM. If low oil pressure is detected, the lamp will be illuminated. The reason for the illumination of the low-pressure lamp should be investigated immediately.
  • Page 51 SEBU9063-07 Operation Section Monitoring System All lamps will illuminate for 2 seconds in order to Note: The wait to disconnect lamp will not be check that the lamps are functioning when the checked at key on. The wait to disconnect lamp will keyswitch is turned to the ON position.
  • Page 52 1. One or more of the shutdown values for diagnostic code. the engine protection strategy has been Contact your Perkins dealer or your Perkins exceeded. distributor. 2. A serious active diagnostic code has been detected.
  • Page 53 SEBU9063-07 Operation Section Sensors and Electrical Components The default setting for an overspeed is 3000 rpm. The ECM will cut the power to the electronic unit injectors, until the rpm drops below 200 rpm of the overspeed setting. A diagnostic fault code will be logged into the ECM memory and a warning lamp will indicate a diagnostic fault code.
  • Page 54 SEBU9063-07 Operation Section Sensors and Electrical Components Engine Views Illustration 39 g03419999 Typical example (1) Coolant Temperature Sensor (6) Atmospheric Pressure Sensor (10) Fuel Temperature Sensor (2) Fuel Pressure Sensor (Fuel Rail (Barometric Pressure Sensor) (11) Fuel Metering Solenoid for the High Pressure Sensor) (7) Priming/ Transfer pump Pressure Fuel Pump...
  • Page 55 SEBU9063-07 Operation Section Sensors and Electrical Components Illustration 40 g03420017 Typical example (12) Wastegate Regulator (14) Control Valve for the NRS (16) Differential Pressure Sensor for the (13) Inlet Pressure Sensor for the NOx (15) Temperature Sensor for the NRS Reduction System (NRS)
  • Page 56 SEBU9063-07 Operation Section Sensors and Electrical Components Illustration 41 g03420076 Typical example (17) Alternator (21) Low Oil Level Switch (if Equipped) (24) Secondary Speed/Timing Sensor (18) Starter Solenoid (22) Inlet Air Temperature Sensor (Camshaft Position Sensor) (19) Starting Motor (23) Water in Fuel Switch (25) Back Pressure Valve (20) Starter Relay...
  • Page 57 SEBU9063-07 Operation Section Sensors and Electrical Components Illustration 42 g02413838 Typical example (1) Coolant Temperature Sensor (3) Intake Manifold Air Temperature Sensor (2) Fuel Pressure Sensor (Fuel Rail (4) Intake Manifold Pressure Sensor Pressure Sensor) (5) Electronic Control Module (ECM) Illustration 43 g03420558 Typical example...
  • Page 58 SEBU9063-07 Operation Section Sensors and Electrical Components Illustration 44 g03421140 Typical example (12) Wastegate Regulator (14) Control Valve for the NRS (16) Differential Pressure Sensor for the (13) Inlet Pressure Sensor for the NOx (15) Temperature Sensor for the NRS Reduction System (NRS) Illustration 45 g03421147...
  • Page 59 SEBU9063-07 Operation Section Sensors and Electrical Components Illustration 46 g03421154 Typical example (22) Inlet Air Temperature Sensor (24) Secondary Speed/Timing Sensor (25) Back Pressure Valve (23) Water in Fuel Switch (Camshaft Position Sensor) Aftertreatment Views • DOC Diesel Oxidation Catalyst •...
  • Page 60 SEBU9063-07 Operation Section Sensors and Electrical Components DOC and SCR Illustration 47 g03421173 Typical example (1) SCR Temperature Sensor (3) DEF Injector (2) Identification Module (4) DOC Temperature Sensor...
  • Page 61 SEBU9063-07 Operation Section Sensors and Electrical Components DOC, DPF, and SCR Illustration 48 g03713372 Typical example (1) SCR Temperature Sensor (4) DOC Temperature Sensor (7) DEF Injector (2) Soot Sensor Connection (5) Identification Module (8) NOx Sensor location (3) DPF Temperature Sensor (6) Soot Sensor Connection...
  • Page 62 SEBU9063-07 Operation Section Sensors and Electrical Components Note: The NOx sensor (8) can be installed in only one location, the location will depend on the application. Sensors and Aftertreatment Components Illustration 49 g03659936 Typical example (1) DEF Pump and electronic unit (3) DEF Tank level and Temperature Sensor (5) Ammonia Sensor and Control (2) Coolant Diverter Valve...

  • Page 63: Engine Diagnostics

    A flashing YELLOW lamp indicates a 3-digit code for the engine. The sequence of flashes represents the system diagnostic message. Count the first Perkins Electronic Engines have the capability to perform a self-diagnostics test. When the system sequence of flashes in order to determine the first digit of the flash code.
  • Page 64 SEBU9063-07 Operation Section Engine Operation with Intermittent Diagnostic Codes System Configuration Parameters Operation of the engine and performance of the engine can be limited as a result of the active diagnostic code that is generated. Acceleration rates System configuration parameters affect the may be significantly slower.
  • Page 65 SEBU9063-07 Operation Section Configuration Parameters (Table 12, contd) Factory Installed Aftertreatment #1 Identification Number DPF #1 Soot Loading Sensing System Configuration Code Limp Home Engine Speed Ramp Rate System Operating Voltage Configuration Rating Number CAN Communication Protocol Write Security Engine Emissions Operator Inducement Progress Configuration Engine Emissions Operator Inducement Regulation Configuration Engine Emissions Operator Inducement Emergency Override Enable Status...
  • Page 66 SEBU9063-07 Operation Section Configuration Parameters (Table 13, contd) Delayed Engine Shutdown Enable Status Delayed Engine Shutdown Maximum Time High Soot Load Aftertreatment Protection Enable Status Air Shutoff Throttle Lock Feature Installation Status PTO Mode Throttle Lock Engine Set Speed #1 Throttle Lock Engine Set Speed #2 Throttle Lock Increment Speed Ramp Rate Throttle Lock Decrement Speed Ramp Rate...
  • Page 67 SEBU9063-07 Operation Section Configuration Parameters (Table 13, contd) Engine Fan Control Charge Air Cooler Outlet Temperature Input Enable Engine Cooling Fan Maximum Air Flow Charge Air Cooler Outlet Temperature Engine Cooling Fan Minimum Air Flow Charge Air Cooler Outlet Temperature Engine Cooling Fan Control Coolant Temperature Input Enable Status Engine Cooling Fan Maximum Air Flow Coolant Temperature Engine Cooling Fan Minimum Air Flow Coolant Temperature...
  • Page 68 SEBU9063-07 Operation Section Configuration Parameters (Table 13, contd) Min Max / All Speed Governing Rated Speed Configuration Droop No Load Fuel Offset PM1 Interval Engine Oil Level Sensor Installation Status Engine Change Air cooler #1 Outlet temperature Sensor Installation Status...

  • Page 69: Engine Starting

    SEBU9063-07 Operation Section Engine Starting Engine Starting i07677844 Cold Weather Starting i08171598 Before Starting Engine Do not use aerosol types of starting aids such as Perform the required daily maintenance and other ether. Such use could result in an explosion and periodic maintenance before the engine is started.
  • Page 70 SEBU9063-07 Operation Section Starting the Engine 5. Repeat step 2 through step 4 if the engine fails to 3. When the warning light for the glow plugs is start. extinguished, turn the keyswitch to the START position to engage the electric starting motor and Note: After starting, the engine may be held at low crank the engine.
  • Page 71 SEBU9063-07 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 72 SEBU9063-07 Operation Section After Starting Engine • Allow the engine to idle for 3 to 5 minutes, or allow the engine to idle until the water temperature indicator begins to rise. Check all gauges during the warm-up period. Constant speed engines should be allowed to operate at low idle for 3 minutes before used at operational speed.

  • Page 73: Engine Operation

    SEBU9063-07 Operation Section Engine Operation Engine Operation On DPF equipped aftertreatment system the DPF will reduce particulate emissions. The DPF collects the soot and any ash that is produced by the combustion in the engine. During regeneration, the soot is i06674826 converted into a gas which is released into the Engine Operation...
  • Page 74 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 to attain optimum performance for the life of the engine.

  • Page 75: Cold Weather Operation

    This means that an engine can be shut down for aperiodof timeand the retained heat within the engine will allow the engine readily start. Perkins Diesel Engines can operate effectively in cold weather. During cold weather, the starting and • Install the correct specification of engine lubricant the operation of the diesel engine depends on the before the beginning of cold weather.
  • Page 76 80° C (176° F) minimum. Carbon 240 V dc. The output can be 750/1000W. Consult deposits on the valve stems will be kept at a your Perkins dealer or your Perkins distributor for minimum. The free operation of the valves and the more information.
  • Page 77 SEBU9063-07 Operation Section Radiator Restrictions The Water Temperature Regulator and Consult with your Perkins dealer or your Perkins distributor for the recommended breather Insulated Heater Lines components for operation from −25° to -40°C (−13° to -72.°F). The engine is equipped with a water temperature regulator.
  • Page 78 SEBU9063-07 Operation Section Fuel Related Components in Cold Weather Following properties are used to define fuels low Fuel tanks should contain some provision for draining temperature capability: water and sediment from the bottom of the tanks. Some fuel tanks use supply pipes that allow water •...
  • Page 79 SEBU9063-07 Operation Section Diesel Exhaust Fluid in Cold Weather Note: At certain angles DEF can cover the DEF filler cap. If the DEF freezes, the DEF tank vent could block. A blocked vent in the DEF tank assembly will cause operational difficulties. For information on DEF refer to this Operation and Maintenance Manual, “Fluid Recommendations”.

  • Page 80: Engine Stopping

    SEBU9063-07 Operation Section Engine Stopping Engine Stopping i05774857 After Stopping Engine i05857035 Stopping the Engine Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel NOTICE Stopping the engine immediately after the engine has spray may cause a fire hazard. Failure to follow been working under load, can result in overheating these inspection, maintenance and service in- and accelerated wear of the engine components.
  • Page 81 SEBU9063-07 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 82: Maintenance Section

    SEBU9063-07 Maintenance Section Refill Capacities Maintenance Section Refill Capacities i05810113 Refill Capacities Lubrication System The refill capacities for the engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters. Auxiliary oil filter systems will require additional oil. Refer to the Original Equipment Manufacture (OEM) specifications for the capacity of the auxiliary oil filter.
  • Page 83 38 L (10 US gal). Diesel Fuel Requirements i07074302 Fluid Recommendations Perkins is not in a position to continuously evaluate (General Fuel Information) and monitor all worldwide distillate diesel fuel specifications that are published by governments and technological societies.
  • Page 84 SEBU9063-07 Maintenance Section General Fuel Information Table 16 "Perkins Specification for Distillate Diesel Fuel" Property UNITS Requirements “ASTM”Test “ISO/Other”Test Aromatics %Volume 35% maximum “D1319” “ISO 3837” %Weight 0.01% maximum “D482” “ISO 6245” Carbon Residue on 10% %Weight 0.35% maximum “D524”...
  • Page 85 “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 86 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 87 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 88 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 89 “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 90 500 ppm water or less. • Perkins recommends the use of bulk fuel filter / coalescer units which clean the fuel of both particulate contamination and water in a single...
  • Page 91 Specification water. Caution should be used when dispensing DEF near an engine that has recently been running. DEF that is used in Perkins engines must meet the Spilling DEF onto hot components will cause harmful vapors. ISO specification 22241-1 for quality. The ISO...
  • Page 92 SEBU9063-07 Maintenance Section Fluid Recommendations • Chromium Nickel Molybdenum (CrNiMo) NOTICE Never operate an engine without water temperature • Titanium regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the Non-metallic materials: proper operating temperature. Cooling system prob- lems develop without water...
  • Page 93 Until such standard/ specifications are published and evaluated by • Reduction of heat transfer Perkins, use of PDO, glycerine or other alternative coolants is not recommended in Perkins diesel • Leakage of the water pump seal engines.
  • Page 94 However, ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite. Perkins ELC has NOTICE been formulated with the correct amount of these The Perkins industrial engines with a NOx reduc-...
  • Page 95 An SCA that is liquid may be needed at 500 hour Perkins. intervals. 6. Fill the cooling system with the Perkins Premixed ELC. Operate the engine. Ensure that all coolant valves open then stop the engine. When cool check the coolant level.
  • Page 96 Table 24 the water. Use a non-foaming detergent to clean Example Of The Equation For Adding The SCA To The Heavy- oil contamination, consult your Perkins dealer for Duty Coolant At The Initial Fill suitable product. Total Volume of the...
  • Page 97 Fluid Recommendations “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 General Lubricant Information found in this publication, “Fluid Recommendations/...
  • Page 98 NOT designed to support off-road applications, including Perkins Supplemental heat is recommended for cold soaked Engines. DO NOT use API FA-4 oil for Perkins starts below the minimum ambient temperature. Supplemental heat may be required for cold soaked engines.
  • Page 99 SEBU9063-07 Maintenance Section Fluid Recommendations • At the specified interval, service the engine. Use new oil and install a new oil filter. • Perform maintenance at the intervals that are specified in the Operation and Maintenance Manual, “Maintenance Interval Schedule”. Oil analysis Some engines may be equipped with an oil sampling valve.

  • Page 100: 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 chassis frame or rail. off the engine. Allow the cooling system pressure cap to cool.
  • Page 101 SEBU9063-07 Maintenance Section Welding on Engines with Electronic Controls 1. Stop the engine. Turn the switched power to the OFF position. 2. Ensure that the fuel supply to the engine is turned off. 3. Disconnect the negative battery cable from the battery.
  • Page 102 • Failure to use recommended fuel, lubricants, and Refer to the standards for the engine or consult your coolant/antifreeze 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 103: Maintenance Interval Schedule

    SEBU9063-07 Maintenance Section Maintenance Interval Schedule “ Radiator - Clean” ......131 i07482989 Maintenance Interval Schedule Every 1000 Service Hours “...

  • Page 104: 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 The air-to-air aftercooler is OEM installed in many connections and correct battery charging. Check the applications. Please refer to the OEM specifications ammeter (if equipped) during engine operation in for information that is related to the aftercooler.

  • Page 105: Battery Or Battery Cable - Disconnect

    SEBU9063-07 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 106: Belt - Inspect

    SEBU9063-07 Maintenance Section Belt - Inspect 2. Disconnect the negative battery terminal. Ensure • Inspect the belt for cracks, splits, glazing, grease, displacement of the cord and evidence of fluid that the cable cannot contact the terminal. When contamination. four 12 V batteries are involved, 2 negative connections must be disconnected.

  • Page 107: Coolant (Deac) - Change

    SEBU9063-07 Maintenance Section Clean Emissions Module Support - Inspect i07711014 Clean Emissions Module Support - Inspect Illustration 56 g03723522 Typical example There are three mounts on the Clean Emissions • The oil has entered the cooling system and the Modules (CEM) that must be inspected. coolant is contaminated.
  • Page 108 Do not install the cooling system filler cap. 1. Flush the cooling system with clean water and a suitable cleaning agent in order to remove any debris. Refer to your Perkins dealer or distributor for suitable cleaning agents.

  • Page 109: Coolant (Elc) - Change

    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 110: Coolant Level - Check

    Allow the water to drain. Flush the cooling system with In order for Perkins ELC to achieve 12000 hours an clean water. Install the connection hose. extender must be added at 6000 hours. For a suitable extender, contact your Perkins dealer or 6.

  • Page 111: Def Filler Screen - Clean

    SEBU9063-07 Maintenance Section DEF Filler Screen - Clean i07508019 NOTICE When any servicing or repair of the engine cooling DEF Filler Screen - Clean system is performed, the procedure must be per- formed with the engine on level ground. This proce- dure will allow you to check accurately the coolant level.

  • Page 112: Diesel Exhaust Fluid - Fill

    SEBU9063-07 Maintenance Section DEF Manifold Filters - Replace 5. Install filter screen (3) into DEF tank neck adapter i06216651 (4). Press filter screen into neck adapter and Diesel Exhaust Fluid - Fill ensure that tabs (2) are located correctly. Install cap (1).

  • Page 113: Diesel Exhaust Fluid Filter - Clean/Replace

    SEBU9063-07 Maintenance Section Diesel Exhaust Fluid Filter - Clean/Replace 2. Ensure that the DEF cap (1) and the surrounding area is clean and free from dirt. Ensure that all equipment use in filling the tank is clean and free from dirt. 3.

  • Page 114: Diesel Exhaust Fluid Tank - Flush

    SEBU9063-07 Maintenance Section Diesel Exhaust Fluid Tank - Flush 3. Replace the DEF filter. Refer to Operation and i07417986 Maintenance Manual, “Diesel Exhaust Fluid Filter - Diesel Exhaust Fluid Tank - Clean/Replace” for the correct procedure. Flush Note: This filter is to be used for the flushing process only.

  • Page 115: Engine - Clean

    A clean engine provides the following Note: The air filter system may not have been benefits: provided by Perkins. The procedure that follows, is for a typical air filter system. Refer to the OEM • Easy detection of fluid leaks information for the correct procedure.
  • Page 116 SEBU9063-07 Maintenance Section Engine Air Cleaner Service Indicator - Inspect Air Cleaners 4. Remove primary air filter element (3) and if equipped, remove the secondary air filter element Some application can have dual elements. The dual (Not Shown). Discard all old air filter elements. air cleaner contains a primary air cleaner element and a secondary air cleaner element.

  • Page 117: Engine Air Precleaner - Check/Clean

    (1) Wing nut Description”. Within that section, refer to the title (2) Cover “Aftermarket Products and Perkins Engines”. (3) Body Remove wing nut (1) and cover (2). Check for an accumulation of dirt and debris in body (3). Clean the body, if necessary.
  • Page 118 SEBU9063-07 Maintenance Section Engine Crankcase Breather Element - Replace Note: The cut away from section (5) in the cap allows access to the seal. 4. Remove the old seal (4) and install a new seal. 5. Install a new filter element into the breather body (3) and orient the filter element so that position (A) is aligned.

  • Page 119: Engine Oil Level - Check

    Any engine mount that shows deterioration should be replaced. Refer to the OEM information for the recommended torques. When the engine mounts are supplied by Perkins the maintenance procedure will be supplied in the Disassembly and Assembly manual for your engine.

  • Page 120: 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 121 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, as a result of the larger...
  • Page 122 SEBU9063-07 Maintenance Section Engine Oil and Filter - Change 6. Install the new oil filter. Spin on the oil filter (4) until NOTICE the O ring contacts the sealing surface (2). Then Do not fill the oil filters with oil before installing them. rotate the oil filter ¾...

  • Page 123: Fan Clearance - Check

    SEBU9063-07 Maintenance Section Fan Clearance - Check 4. Remove the engine oil level gauge to check the oil level. Maintain the oil level between “L” and “H” marks on the engine oil level gauge. Do not fill the crankcase above the “H” mark. i05685634 Fan Clearance - Check Commissioning Information...
  • Page 124 SEBU9063-07 Maintenance Section Fan Clearance - Check 5. Operate the engine, allow the engine to reach normal operating temperature. Stop the engine. Check the coolant level, refer to this Operation and Maintenance Manual, “Coolant Level - Check” for more information. 6.

  • Page 125: Fuel System - Prime

    SEBU9063-07 Maintenance Section Fuel Filter (In-Line) - Replace 3. Fan tip clearance at position (2) and (3) must be 2. Release the hose clips (3) and remove the hose 14 ± 2 mm (0.55 ± 0.079 inch). lines from the in-line fuel filter. Remove the in-line filter.

  • Page 126: Fuel System Primary Filter (Water Separator)

    SEBU9063-07 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 3. The keyswitch will allow the electric priming pump NOTICE to operate. Operate the electric priming pump. The Ensure that the engine is stopped before any servic- ECM will stop the pump after 2 minutes. ing or repair is performed.
  • Page 127 SEBU9063-07 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 8. Rotate filter bowl (6) counterclockwise and remove 9. Rotate the filter element (5) counterclockwise and the filter bowl from assembly. remove the filter element . Clean the filter bowl. Install the New Filter Element Illustration 81 g03858640...

  • Page 128: Fuel System Primary Filter/Water Separator

    SEBU9063-07 Maintenance Section Fuel System Primary Filter/Water Separator - Drain 5. The secondary filter element must be replaced at the same time as the primary filter element. Also, the in-line filter must be changed. Refer to the Operation and Maintenance Manual , “Fuel System Filter - Replace”.
  • Page 129 SEBU9063-07 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 130: Hoses And Clamps - Inspect/Replace

    SEBU9063-07 Maintenance Section Fuel Tank Water and Sediment - Drain 3. Do not use a tool in order to install the filter Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close the assembly.

  • Page 131: Radiator - Clean

    SEBU9063-07 Maintenance Section Radiator - Clean Inspect all hoses for leaks that are caused by the following conditions: Pressurized System: Hot coolant can cause seri- • Cracking ous burns. To open the cooling system filler cap, stop the engine and wait until the cooling system •...

  • Page 132: Turbocharger - Inspect

    Clean both sides of the core. Wash the core Test” for more information on the checking procedure with detergent and hot water. Thoroughly rinse the and for specifications consult your Perkins dealer or core with clean water. your Perkins distributor for assistance.
  • Page 133 SEBU9063-07 Maintenance Section Turbocharger - Inspect A visual inspection of the turbocharger or 5. Install the air intake pipe and the exhaust outlet turbochargers can minimize unscheduled downtime. pipe to the turbocharger housing. Ensure that all A visual inspection of the turbocharger or clamps are installed correctly and that all clamps turbochargers can also reduce the chance for are tightened securely.

  • Page 134: Walk-Around Ins Pection

    SEBU9063-07 Maintenance Section Walk-Around Inspection 2. Remove the pipe from the high-pressure 7. Install the air intake pipe and the exhaust outlet turbocharger exhaust outlet and remove the air pipe to the turbocharger housing. Ensure that all intake pipe to the turbocharger. Visually inspect clamps are installed correctly and that all clamps the piping for the presence of oil.
  • Page 135 Remove and Install”. For more information, consult are in place and that the clips are not loose. your Perkins dealer or your Perkins distributor. • Inspect the rest of the fuel system for leaks. Look • Inspect the lubrication system for leaks at the front for loose fuel line clamps.

  • Page 136: Water Pump - Inspect

    SEBU9063-07 Maintenance Section Water Pump - Inspect • Check the condition of the gauges. Replace any Note: The water pump seals are lubricated by the gauges that are cracked. Replace any gauge that coolant in the cooling system. It is normal for a small cannot be calibrated.

  • Page 137: 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 138: 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 139 SEBU9063-07 Reference Information Section Maintenance Log i05204675 Maintenance Log Table 28 Engine Model Customer Identifier Arrangement Number Serial Number Service Quantity Of Service Item Date Authorization Hours Fuel...
  • Page 140 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 141: Index

    SEBU9063-07 Index Section Index Fill ...............110 Flush ............110 After Starting Engine ........71 Coolant Extender (ELC) - Add .......110 After Stopping Engine ........80 Coolant Level - Check ........110 Aftercooler Core - Clean/Test (Air-To-Air Crushing Prevention and Cutting Prevention.. 17 Aftercooler) ..........
  • Page 142 SEBU9063-07 Index Section Engine Operation ..........73 Fuel System - Prime........125 Elevated Idle for Aftertreatment....73 Fuel System Primary Filter (Water Reduction of Particulate Emissions..... 73 Separator) Element - Replace..... 126 Engine Operation with Active Diagnostic Install the New Filter Element....127 Codes ............
  • Page 143 Warning Strategy ......... 43 Engine Serial Number Plate (1)....32 Self-Diagnostics ..........63 Product Description ......... 28 Sensors and Electrical Components....53 Aftermarket Products and Perkins Aftertreatment Views ........59 Engines ............31 Engine Views ..........54 Aftertreatment System......... 30 Sensors and Aftertreatment Components...
  • Page 144 SEBU9063-07 Index Section Locations that have Explosive Atmospheres) ..........70 Stopping the Engine ........80 System Pressure Release......100 Coolant System ......... 100 Engine Oil ..........100 Fuel System..........100 Table of Contents ..........3 Turbocharger - Inspect ........132 Engine Install with High Pressure and Low Pressure Turbochargers ......
  • Page 145 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 146 SEBU9063 ©2020 Perkins Engines Company Limited All Rights Reserved December 2020...

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