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

Industrial engine
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SEBU8601-04 (en-us)
March 2021
Operation and
Maintenance
Manual
1206E-E70TTA Industrial Engine
BL (Engine)

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Summary of Contents for Perkins 1206E-E70TTA

  • Page 1 SEBU8601-04 (en-us) March 2021 Operation and Maintenance Manual 1206E-E70TTA Industrial Engine BL (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

    SEBU8601-04 Table of Contents Table of Contents Cold Weather Operation ......... 69 Maintenance Section Foreword ............4 Refill Capacities..........73 Safety Section Maintenance Recommendations ....89 Safety Messages..........6 Maintenance Interval Schedule....... 91 General Hazard Information......8 Warranty Section Burn Prevention..........12 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 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 SEBU8601-04 Safety Section Safety Messages Illustration 2 g02305279 (1) Universal warning (2) Ether Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury. Illustration 3 g01154809 Typical example The ether warning label (2) is located on the top of the reduction system (NRS).

  • Page 8: General Hazard Information

    SEBU8601-04 Safety Section General Hazard Information Illustration 4 g02305282 (2) Ether (3) Hand (High Pressure (3) Hand (High Pressure) The warning label for the Hand (High Pressure) (3) is located on a high-pressure fuel line. i08315538 Contact with high pressure fuel may cause fluid General Hazard Information penetration and burn hazards.
  • Page 9 SEBU8601-04 Safety Section General Hazard Information • Tampering with the engine installation or • Do not attempt any repairs that are not tampering with the OEM supplied wiring can be understood. Use the proper tools. Replace any dangerous. Personal injury, death and/or engine equipment that is damaged or repair the damage could result.
  • Page 10 SEBU8601-04 Safety Section General Hazard Information • When work is performed around an engine that is operating, wear protective devices for ears to help prevent damage to hearing. • Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine. •...
  • Page 11 (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 12: Burn Prevention

    SEBU8601-04 Safety Section Burn Prevention • Use exhaust ventilation on permanent machining At idle engine speed and/or zero vehicle speed, an operator can request a manual regeneration. Under jobs. this condition, the exhaust gas temperature can • Wear an approved respirator if there is no other reach 650 °C (1202 °F).

  • Page 13: Fire Prevention And Explosion Prevention

    SEBU8601-04 Safety Section Fire Prevention and Explosion Prevention Induction System Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth. Oils Sulfuric Acid Burn Hazard may cause serious personal injury or death.
  • Page 14 If the application involves the presence of Ensure that the engine is stopped. Inspect all lines combustible gases, consult your Perkins dealer and/ and hoses for wear or for deterioration. Ensure that the hoses are correctly routed. The lines and hoses or your Perkins distributor for additional information must have adequate support and secure clamps.

  • Page 15: Crushing Prevention And Cutting Prevention

    Do not bend high-pressure lines. Do not strike high- pressure lines. Do not install any lines that are damaged. Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for replacement parts. Replace the parts if any of the following conditions are present: •...

  • Page 16: Mounting And Dismounting

    SEBU8601-04 Safety Section Mounting and Dismounting When objects are struck, wear protective glasses in order to avoid injury to the eyes. Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure that no one will be injured by flying debris.

  • Page 17: Before Starting Engine

    SEBU8601-04 Safety Section Before Starting Engine The high-pressure fuel lines are the fuel lines that are • Do not attach any other item to the high-pressure between the high-pressure fuel pump and the high- fuel lines. pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head.

  • Page 18: Engine Starting

    These engines are equipped with a glow plug starting aid in each cylinder which heats the intake air to improve starting. Some Perkins engines may have a cold starting system that is controlled by the ECM which allows a controlled flow of ether into the engine.
  • Page 19 SEBU8601-04 Safety Section Electrical System Grounding Practices Illustration 16 g03027396 Typical example Illustration 15 g01888534 (5) Ground to the battery Typical example (6) Ground to the engine block (7) Primary position for grounding (1) Ground to battery (2) Ground to starting motor Correct grounding for the engine electrical system is (3) Starting motor to engine block necessary for optimum engine performance and...

  • Page 20: Engine Electronics

    Engine Electronics 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 21: Product Information Section

    SEBU8601-04 Product Information Section Model Views Product Information Section Model Views i03913230 Model View Illustrations The following model views show typical features of the engine. Due to individual applications, your engine may appear different from the illustrations. Note: Only major components are identified on the following illustrations.
  • Page 22 SEBU8601-04 Product Information Section Model View Illustrations (3) Front lifting eye (6) High-pressure turbocharger (9) Flywheel housing (4) Alternator (7) Low-pressure turbocharger (10) Flywheel (5) Refrigerant compressor (8) Engine oil drain (11) NRS cooler Illustration 18 g02150185 Typical example (12) Crankcase breather (16) Oil gauge (20) In-line fuel strainer (13) Electronic control module (ECM)
  • Page 23 SEBU8601-04 Product Information Section Model View Illustrations Illustration 19 g02150187 Typical example (22) Outlet connection to the air to air (25) Housing for the water temperature (28) Vibration damper charge cooler regulator (29) Belt tensioner (23) Connection for the air inlet (26) Water pump (30) Belt (24) Outlet connection for the coolant...
  • Page 24 SEBU8601-04 Product Information Section Model View Illustrations Illustration 20 g02162626 Typical example (1) Diesel oxidation catalyst (DOC) (5) Securing clamp (8) Air inlet for aftertreatment regeneration (2) Securing clamp (6) Torca clamp device (ARD) (3) Torca clamp (7) Lifting eye (9) Connections for Coolant manifold (4) Diesel particulate filter (DPF) (10) Lifting eye...
  • Page 25 SEBU8601-04 Product Information Section Model View Illustrations Illustration 21 g02162641 (11) Outlet to exhaust system (13) Lifting eye (15) Mounting cradle (12) Aftertreatment regeneration device (14) Exhaust Inlet Fuel Pump for Engine Aftertreatment System Note: The fuel for the engine aftertreatment system is supplied by a designated fuel pump.
  • Page 26 Aspiration Turbocharged charge cooled Engine Description Compression Ratio 16.5:1 Displacement 7.01 L (428 in The Perkins 1206E-E70TTA industrial engine has the Firing Order 1-5-3-6-2-4 following characteristics. Rotation (flywheel end) Counterclockwise • In-line 6 cylinder The operating rpm is dependent on the engine rating, the appli- cation, and the configuration of the throttle.
  • Page 27 The ECM provides an electronic governor that Engines controls the injector output in order to maintain the desired engine rpm. Perkins does not warrant the quality or performance of non-Perkins fluids and filters. Engine Cooling and Lubrication When auxiliary devices, accessories, or...

  • Page 28: Product Identification Information

    Plate Locations and Film Locations Illustration 24 g01890033 Location of the serial number plate Perkins engines are identified by an engine serial number. An example of an engine number is BL*****U000001J. ***** The list number for the engine Type of engine...
  • Page 29 SEBU8601-04 Product Information Section Plate Locations and Film Locations Illustration 25 g01094203 Serial number plate i03976148 Plate Locations and Film Locations (Engine Aftertreatment System) Illustration 26 g02151573 Typical example The module arrangement exhaust plate is installed on the mounting plate (1). The location of the arrangement plate mounting plate can alter depending on the application.
  • Page 30 Record the information that is on the plate. This equipment manufacturer. information identifies the engine aftertreatment system. This information will be required by your Perkins dealer. i03867276 Reference Numbers Information for the following items may be needed to order parts. Locate the information for your engine.
  • Page 31 SEBU8601-04 Product Information Section Emissions Certification Film Illustration 28 g02164223 Typical example...

  • Page 32: Operation Section

    If alterations are made, ensure that correct lifting devices are provided. Consult your Perkins dealer or your Perkins distributor for information regarding fixtures for correct engine lifting. i07434786...
  • Page 33 Alterations to the lifting eyes and/or the CEM make the lifting eyes and the lifting fixtures obsolete. If alterations are made, ensure that proper lifting devices are provided. Consult your Perkins dealer, or your Perkins distributor for information regarding fixtures for proper CEM lifting.
  • Page 34 SEBU8601-04 Operation Section Product Lifting i07434787 Product Lifting Illustration 31 g02354678 Typical example 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 the components are damaged.
  • Page 35 4. Remove the drive belt from the engine. i04084189 Product Storage Sealed Coolant System (Engine and Aftertreatment) Ensure that the cooling system is filled with Perkins ELC, or an antifreeze that meets “ASTM D6210” specification. Perkins are not responsible for damage which may Open Cooling System occur when an engine is in storage after a period in service.

  • Page 36: Gauges And Indicators

    Determine and correct the cause of any significant change in the readings. Consult your Perkins 1. Reduce the load and the engine rpm. distributor for assistance. 2. Determine if the engine must be shut down...
  • Page 37 SEBU8601-04 Operation Section Gauges and Indicators Indicator Lamps • Shutdown lamp • Warning lamp • Wait to start lamp • Low oil pressure 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 38: Features And Controls

    SEBU8601-04 Operation Section Features and Controls Features and Controls i03552521 Monitoring System (Engine) Table 2 Shutdown Warning Lamp Lamp Status Description of Lamp Status Engine Status Lamp Lamp check When the engine start switch is turned to the “ON” posi- The engine has not been tion both lamps will illuminate for 2 seconds only.
  • Page 39 SEBU8601-04 Operation Section Sensors and Electrical Components Programmable Options and For more information or assistance for repairs, consult your Perkins distributor or your Perkins Systems Operation dealer. Instrument panels and Displays If the Warning/Derate/Shutdown mode has been In order to monitor the engine a wide verity of selected and the warning indicator activates, instrument panels are available.
  • Page 40 SEBU8601-04 Operation Section Aftertreatment Illustration 33 g02313693 Typical example (1) Soot sensor connection (7) Soot sensor connection (13) Fuel pressure sensor (pilot) (2) Spark plug lead (8) DOC Temperature sensor (not shown) (14) Aftertreatment device ID (3) ARD air pressure sensor (9) Harness connector (15) Coil for spark plug (4) DOC pressure sensor...
  • Page 41 SEBU8601-04 Operation Section Sensors and Electrical Components i03979996 Sensors and Electrical Components Sensor Locations The Illustration within the section shows the typical locations of the sensors for a 1206E-70 Industrial Engine. Specific engines may appear different from the illustration due to differences in applications. Illustration 34 g02150593 (1) Engine Intake Throttle Valve...
  • Page 42 SEBU8601-04 Operation Section Sensors and Electrical Components Illustration 35 g02150594 The location of the fuel filters will depend on the application. (20) Differential Pressure Switch for the (22) Secondary Speed/Timing Sensor (25) Refrigerant Compressor (if equipped) Secondary Fuel Filter (23) Fuel Priming Pump (21) Water in Fuel Switch (24) Alternator...
  • Page 43 SEBU8601-04 Operation Section Sensors and Electrical Components Illustration 36 g02151173 (1) Engine Intake Throttle Valve (5) Intake Pressure Sensor for the NRS (8) Intake Manifold Air Temperature Sensor (2) Wastegate Regulator (6) Differential Pressure Sensor for the NRS (9) Intake Manifold Pressure Sensor (3) Control Valve for the NRS (7) Fuel Pressure Sensor (Fuel Rail (4) Temperature Sensor for the NRS...
  • Page 44 SEBU8601-04 Operation Section Sensors and Electrical Components Illustration 38 g02151327 (16) Diagnostic Connector (18) Solenoid for the High Pressure Fuel (19) Coolant Temperature Sensor (17) Fuel Temperature Sensor Pump Illustration 39 g02151177 (20) Differential Pressure Switch for the (21) Water in Fuel Switch (23) Fuel Priming Pump Secondary Fuel Filter (22) Secondary Speed/Timing Sensor...
  • Page 45 SEBU8601-04 Operation Section Engine Shutoffs and Engine Alarms • Primary Speed/Timing Sensor Your engine may be equipped with the following sensors or switches: • Secondary Speed/Timing Sensor Coolant temperature – The coolant temperature sensor indicates high jacket water coolant • Fuel Temperature Sensor temperature.
  • Page 46 SEBU8601-04 Operation Section Overspeed Note: If installed, the coolant level switch and the oil level switch are indicators. Both switches operate when the application is on level ground and the engine RPM at zero. Testing Turning the keyswitch to the ON position will check the indicator lights on the control panel.

  • Page 47: Engine Diagnostics

    Self-Diagnostics In order to read the diagnostic flash codes through the diagnostic lamp, cycle the key switch from off to Perkins electronic engines have the capability to on twice within 3 seconds. perform a self-diagnostics test. When the system detects an active problem, a diagnostic lamp is The codes will be flashing in sequence.
  • Page 48 SEBU8601-04 Operation Section Diagnostic Flash Code Retrieval Table 3 Description CDL Code J1939 Code Flash Code No Diagnostic Code Detected Cylinder #1 Injector data incorrect 651-2 Cylinder #1 Injector current below normal 651-5 Cylinder #1 Injector current above normal 651-6 Cylinder #2 Injector data incorrect 652-2 Cylinder #2 Injector current below normal...
  • Page 49 SEBU8601-04 Operation Section Diagnostic Flash Code Retrieval (Table 3, contd) Description CDL Code J1939 Code Flash Code Intake Manifold Air Temperature Sensor voltage above normal 172-3 105-3 Intake Manifold Air Temperature Sensor voltage below normal 105-4 172-4 Fuel Temperature Sensor voltage above normal 174-3 174-3 Fuel Temperature Sensor voltage below normal...
  • Page 50 SEBU8601-04 Operation Section Diagnostic Flash Code Retrieval (Table 3, contd) Description CDL Code J1939 Code Flash Code Fuel Rail Pressure Sensor voltage below normal 1797-4 157-4 Fuel Rail Pressure Sensor not responding properly 1797-7 157-7 Ignition Key Switch loss of signal 1834-2 158-2 5 Volt Sensor DC Power Supply #2 voltage above normal...
  • Page 51 SEBU8601-04 Operation Section Diagnostic Flash Code Retrieval (Table 3, contd) Description CDL Code J1939 Code Flash Code Engine Exhaust Gas Recirculation Intake Pressure Sensor data drifted low 3385-21 3358-21 Engine Exhaust Gas Recirculation Intake Pressure Sensor voltage above normal 3386-3 412-3 Engine Exhaust Gas Recirculation Intake Pressure Sensor voltage below normal 3386-4...
  • Page 52 SEBU8601-04 Operation Section Diagnostic Flash Code Retrieval (Table 3, contd) Description CDL Code J1939 Code Flash Code Low Engine Oil Pressure - Warning E360-1 100-17 Low Engine Oil Pressure - Shutdown E360-3 100-01 High Engine Coolant Temperature - Warning E361-1 110-15 High Engine Coolant Temperature - Derate E361-2...
  • Page 53 SEBU8601-04 Operation Section Fault Logging (Table 3, contd) Description CDL Code J1939 Code Flash Code Low DPF #1 Intake Pressure - Warning E1154-2 3609-18 High DPF #1 Intake Pressure - Warning E1156-1 3609-15 Low Aftertreatment #1 Secondary Air Pressure - Derate E1170-2 3837-18 High Pressure Common Rail Fuel Pressure Relief Valve Active - Shutdown...
  • Page 54 SEBU8601-04 Operation Section Configuration Parameters i03905586 Configuration Parameters The engine electronic control module (ECM) has two types of configuration parameters. The system configuration parameters and the customer specified parameters. The electronic service tool is required in order to alter the configuration parameters. System Configuration Parameters System configuration parameters affect the emissions of the engine or the power of the engine.
  • Page 55 SEBU8601-04 Operation Section Configuration Parameters (Table 5, contd) Throttle Type Channel 1 Throttle Type Channel 2 Continuous Position Throttle Configuration 1 Continuous Position Throttle Configuration 2 Multi Position Throttle Switch Configuration Throttle Arbitration Equipment ID Low Idle Speed Ether Solenoid Configuration Engine Idle Shutdown Minimum Ambient Air Temperature Engine Idle Shutdown Maximum Ambient Air Temperature Engine Idle Shutdown Enable Status...
  • Page 56 SEBU8601-04 Operation Section Configuration Parameters (Table 5, contd) Engine Fan Control Engine Fan Type Configuration Engine Cooling Fan Pulley Ratio Engine Cooling Fan Temperature Error Increasing Hysteresis Engine Cooling Fan Temperature Error Decreasing Hysteresis Engine Cooling Fan Current Ramp Rate Engine Cooling Fan Speed Top Engine Fan Speed Minimum Desired Engine Cooling Fan Speed...
  • Page 57 SEBU8601-04 Operation Section Configuration Parameters (Table 5, contd) Engine Fan Suspend Purge Engine Fan Purge Cycle Interval Engine Fan Purge Cycle Duration Other Parameters Maintenance Indicator Mode Maintenance Level 1 Cycle Interval Hours Coolant Level Sensor Air Filter Restriction Switch Installation Status Air Filter Restriction Switch Configuration Fuel/Water Separator Switch Installation Status User Defined Switch Installation Status...

  • Page 58: Engine Starting

    SEBU8601-04 Operation Section Engine Starting Engine Starting i08165241 Starting the Engine i03648917 Before Starting Engine Note: Do not adjust the engine speed control during start-up. The electronic control module (ECM) will control the engine speed during start-up. Perform the required daily maintenance and other periodic maintenance before the engine is started.
  • Page 59 SEBU8601-04 Operation Section Cold Weather Starting 6. After starting, the engine may be held at low speed NOTICE for a duration between 1 and 60 seconds to allow Do not engage the starting motor when flywheel is engine systems to stabilize. The duration will turning.
  • Page 60 SEBU8601-04 Operation Section Starting with Jump Start Cables i08134367 NOTICE Using a battery source with the same voltage as the Starting with Jump Start electric starting motor. Use ONLY equal voltage for jump starting. The use of higher voltage will damage Cables the electrical system.
  • Page 61 SEBU8601-04 Operation Section After Starting Engine Do not check the high-pressure fuel lines with the i02330138 engine or the starting motor in operation. If you After Starting Engine inspect the engine in operation, always use the correct inspection procedure to avoid a fluid penetration hazard.

  • Page 62: Engine Operation

    SEBU8601-04 Operation Section Engine Operation Engine Operation raise the temperature of the exhaust gas. When the regeneration process is complete, the ARD turns off. i04156659 The operator will receive information on the status of the ARD from dash lamps and the driver will be able Engine Operation to request a regeneration by using a switch.
  • Page 63 SEBU8601-04 Operation Section Diesel Particulate Filter Regeneration Low speed automatic regeneration and enhanced automatic regeneration are controlled by the engine ECM. During this regeneration the operator will see Lamps the high exhaust system temperature lamp (HEST) illuminated. Five dash lamps can be affected by the DPF regeneration.
  • Page 64 SEBU8601-04 Operation Section Diesel Particulate Filter Regeneration Note: Some OEMs may use other means of activating a forced regeneration such as touch screen interfaces. Force Regeneration – Press in the top of the switch for 2 seconds in order to begin regeneration.
  • Page 65 DPF could be damage. required. Once the engine entres into shutdown mode you must contact your Perkins dealer or your Red Stop Lamp The engine could be derated or the engine could Perkins distributor. Your dealer or distributor be shut down.
  • Page 66 SEBU8601-04 Operation Section Fuel Conservation Practices • Be aware of the properties of different fuels. Use only the recommended fuels. Refer to the Operations and Maintenance Manual, “Fuel Recommendations” for further information. • Avoid unnecessary idling. Shut off the engine rather than allowing the engine to idle for long periods of time.

  • Page 67: Engine Stopping

    SEBU8601-04 Operation Section Engine Stopping Engine Stopping i05784249 After Stopping Engine i06832774 Stopping the Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes. This period will 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 68 SEBU8601-04 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 69: 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 70 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 71 SEBU8601-04 Operation Section Fuel and the Effect from Cold Weather 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).
  • Page 72 SEBU8601-04 Operation Section Fuel Related Components in Cold Weather Winter and arctic grades of diesel fuel are available in For more information about fuel heaters (if equipped), the countries and territories with severe winters. For refer to the OEM information. more information refer to the Operation and Maintenance Manual, “Fuel For Cold-Weather Operation”...

  • Page 73: Maintenance Section

    Engine Only (3.96 US gal) External System Per OEM NOTICE Every attempt is made to provide accurate, up-to- date information. By use of this document you agree that Perkins Engines Company Limited is not respon- (continued) sible for errors or omissions.
  • Page 74 Contact your local Perkins distributor for the most up-to-date recommendations. Diesel Fuel Requirements Perkins is not in a position to continuously evaluate and monitor all worldwide distillate diesel fuel specifications that are published by governments and technological societies.
  • Page 75 Engines that are manufactured by Perkins are NOTICE certified with the fuel that is prescribed by the United Operating with fuels that do not meet the Perkins rec- States Environmental Protection Agency. Engines ommendations can cause the following effects: Start-...
  • Page 76 “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. Diesel Fuel Characteristics Fuel with a low cetane number can be the root cause of problems during a cold start.
  • Page 77 The lubricity has particular significance to the current ultra low sulfur fuel, and low aromatic fossil fuels. Perkins recommends kinematic viscosities of 1.4 and These fuels are made to meet stringent exhaust 4.5 mm2/sec that is delivered to the fuel injection emissions.
  • Page 78 The long-term effect of biodiesel Protection Agency (EPA) and European Certification concentration in crankcase oil is unknown fuels. Perkins does not certify engines on any other currently. fuel. The user of the engine has the responsibility of using the correct fuel that is recommended by the •...
  • Page 79 Renewable and Alternative Fuels Biodiesel fuel contains metal contaminants (sodium, potassium, calcium, and/or magnesium) that form Perkins supports development and use of renewable ash products upon combustion in the diesel engine. fuels through sustainability initiatives. In recent years The ash can have an impact on the life and...
  • Page 80 If biodiesel or biodiesel blends of fuel are to be used, Perkins require the use of Perkins fuel cleaner. The • Use high-quality fuels per recommended and use of the fuel is to remove deposits within the fuel required specifications system that is created with the use of biodiesel.
  • Page 81 SEBU8601-04 Maintenance Section Fluid Recommendations • Perkins recommends the use of bulk fuel filter / Consult your local Perkins distributor for additional information on Perkins designed and produced coalescer units which clean the fuel of both filtration products. particulate contamination and water in a single pass.
  • Page 82 If distilled water or deionized water is not available, use water with the properties that are listed in Table • Cavitation of the water pump 11 . Table 11 For optimum performance, Perkins recommends a Acceptable Water 1:1 mixture of a water/glycol solution. Property Maximum Limit Note: Use a mixture that will provide protection against the lowest ambient temperature.
  • Page 83 NOTICE contains organic corrosion inhibitors and antifoam The Perkins industrial engines with a NOx reduc- agents with low amounts of nitrite. Perkins ELC has tion system must be operated with a minimum been formulated with the correct amount of these...
  • Page 84 6. Fill the cooling system with the Perkins Premixed Clean water is the only cleaning agent that is ELC. Operate the engine. Ensure that all coolant required when ELC is drained from the cooling valves open then stop the engine.
  • Page 85 Equation For Adding The SCA To The Heavy-Duty Coolant At regulations. Flush the system with a 5 to 10 The Initial Fill percent solution of Perkins ELC. Fill the system V × 0.07 = X with the Perkins ELC. V is the total volume of the cooling system.
  • Page 86 “EMA Recommended Guideline on Diesel Engine Oil”. In addition to Perkins definitions, there are other • Allow the sample to sit for at least 30 minutes and definitions that will be of assistance in purchasing check for signs of oil and deposits.
  • Page 87 NOT designed to Aftermarket Oil Additives support off-road applications, including Perkins Engines. DO NOT use API FA-4 oil for Perkins Perkins does not recommend the use of aftermarket additives in oil. The use of aftermarket additives is engines.
  • Page 88 The aftermarket additive could fail to mix with the finished oil. This failure could produce sludge in the crankcase. Perkins discourages the use of aftermarket additives in finished oils. To achieve the best performance from a Perkins engine, conform to the following guidelines: •...

  • Page 89: 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 90 SEBU8601-04 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 91: Maintenance Interval Schedule

    SEBU8601-04 Maintenance Section Maintenance Interval Schedule “ Cooling System Supplemental Coolant Additive i08424489 (SCA) - Test/Add“ ......102 Maintenance Interval Schedule “...
  • Page 92 SEBU8601-04 Maintenance Section Maintenance Interval Schedule “ Radiator Pressure Cap - Clean/Replace“..124 Every 3000 Service Hours or 2 Years “ Cooling System Coolant (Commercial Heavy-Duty) - Change“ ....... . . 97 Every 4000 Service Hours “...
  • Page 93 SEBU8601-04 Maintenance Section ARD Spark Plug - Clean/Inspect/Replace i03975571 ARD Spark Plug - Clean/ Inspect/Replace • ARD Aftertreatment Regeneration Device NOTICE If the engine is running, or the keyswitch is in the ON position the ARD spark plug will continue to fire. Turn the keyswitch to the OFF position before servicing the ARD spark plug.

  • Page 94: Battery - Replace

    Alternator - Inspect 1. Switch the engine to the OFF position. Remove all electrical loads. Perkins recommends a scheduled inspection of the 2. Turn off any battery chargers. Disconnect any alternator. Inspect the alternator for loose battery chargers.

  • Page 95: Battery Or Battery Cable - Disconnect

    SEBU8601-04 Maintenance Section Battery Electrolyte Level - Check 10. Turn the battery disconnect switch to the ON i07819485 position. Battery or Battery Cable - Disconnect i02747977 Battery Electrolyte Level - Check The battery cables or the batteries should not be When the engine is not run for long periods of time or removed with the battery cover in place.
  • Page 96 SEBU8601-04 Maintenance Section Belt Tensioner - Inspect i03557440 Belt Tensioner - Inspect Illustration 48 g01906354 Typical example To maximize the engine performance, inspect the belt (1) for wear and for cracking. Replace the belt if the belt is worn or damaged. Illustration 49 g01880953 Typical example...
  • Page 97 SEBU8601-04 Maintenance Section Cooling System Coolant (Commercial Heavy-Duty) - Change Drain i04155927 Cooling System Coolant (Commercial Heavy-Duty) - Pressurized System: Hot coolant can cause seri- Change ous burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool.
  • Page 98 3. Start and run the engine at low idle. Increase the For information regarding the disposal and the engine rpm to high idle. Operate the engine in recycling of used coolant, consult your Perkins dealer order to open the engine thermostat. This will or your Perkins distributor.
  • Page 99 SEBU8601-04 Maintenance Section Cooling System Coolant (ELC) - Change • Foaming of the coolant is observed. • The oil has entered the cooling system and the coolant is contaminated. • The fuel has entered the cooling system and the coolant is contaminated. Note: When the cooling system is cleaned, only clean water is needed when the ELC is drained and replaced.
  • Page 100 Perkins to reclaim the coolant. For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or your Perkins distributor. Flush 1. Flush the cooling system with clean water in order to remove any debris.
  • Page 101 4. Maintain the coolant level at the maximum mark Note: The cooling system may not have been that is correct for your application. provided by Perkins. The procedure that follows is for typical cooling systems. Refer to the OEM information for the correct procedures.
  • Page 102 SEBU8601-04 Maintenance Section Cooling System Supplemental Coolant Additive (SCA) - Test/Add 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 103 SEBU8601-04 Maintenance Section Crankshaft Vibration Damper - Inspect Use a Coolant Conditioner Test Kit in order to check 4. Clean the cooling system filler cap and inspect the the concentration of the SCA. gasket. If the gasket is damaged, discard the old filler cap and install a new filler cap.

  • Page 104: Engine - Clean

    Diesel Particulate Filter Periodic cleaning of the engine is recommended. Steam cleaning the engine will remove accumulated Contact your Perkins dealer, or your Perkins oil and grease. A clean engine provides the following distributor. New torca clamps (1) must be installed on benefits: the DPF.

  • Page 105: Engine Air Cleaner Element (Dual Element) - Clean/Replace

    Servicing the Air Cleaner Elements Note: The air filter system may not have been provided by Perkins. The procedure that follows is for a typical air filter system. Refer to the OEM information for the correct procedure.
  • Page 106 SEBU8601-04 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace 2. The secondary air cleaner element should be Two methods may be used in order to clean the primary air cleaner element: removed and discarded for every three cleanings of the primary air cleaner element.

  • Page 107: Inspect/Replace

    SEBU8601-04 Maintenance Section Engine Air Cleaner Element (Single Element) - Inspect/Replace Cleaning from the clean side (inside) with NOTICE pressurized air is recommended prior to vacuum Never run the engine without an air cleaner element cleaning the dirty side (outside) of a primary air installed.
  • Page 108 SEBU8601-04 Maintenance Section Engine Air Precleaner - Check/Clean • The yellow diaphragm enters the red zone. Note: When the engine is operated in dusty applications, more frequent cleaning is required. • The red piston locks in the visible position. i08410458 Test the Service Indicator Engine Crankcase Breather Service indicators are important instruments.
  • Page 109 For information on aftermarket products, refer to Operation and Maintenance Manual, “Engine Description”. Within that section, refer to the title “Aftermarket Products and Perkins Engines”. The breather element can be serviced from the top position or the breather element can be serviced from the bottom position.
  • Page 110 SEBU8601-04 Maintenance Section Type 1 5. Install a new filter element into the breather body (3). Ensure the correct position of the element, refer to illustration 67 . Align position (A) on the top cap to position (B) on the filter element. Illustration 69 g02346498 Typical example...
  • Page 111 SEBU8601-04 Maintenance Section Engine Crankcase Breather Element - Replace 7. Install tube connection (1). Ensure that the retaining clips on the tube connection are correctly engaged. Remove the container. Check the System Illustration 71 g02346500 Illustration 70 g03090968 Typical example Typical example (A) Alignment postion Inspect the breather tube (1) for damage.
  • Page 112 For information on aftermarket products, refer to Operation and Maintenance Manual, “Engine Description”. Within that section, refer to the title “Aftermarket Products and Perkins Engines”. Illustration 73 g01884135 (B) Alignment position Note: The cut away from section (5) in the cap allows access to the seal.
  • Page 113 7. Remove the container. replaced. Refer to the OEM information for the recommended torques. Check the System When the engine mounts are supplied by Perkins the maintenance procedure will be supplied in the Disassembly and Assembly manual for your engine. i05300117...

  • Page 114: Engine Oil Sample - Obtain

    Do not allow hot oil or hot components to contact the skin. Perkins recommends using a sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when a sampling valve is NOTICE used.
  • Page 115 Use of an oil filter that is not recommended If the engine is operated in severe service conditions, by Perkins could result in severe damage to the en- Perkins recommends the use of engine oil sampling. gine bearings, crankshaft, and so forth. As a result of...
  • Page 116 SEBU8601-04 Maintenance Section Fan Clearance - Check 2. Start the engine and run the engine at “LOW IDLE” for 2 minutes. Perform this procedure to ensure that the lubrication system has oil and that the oil filters are filled. Inspect the oil filter for oil leaks. 3.

  • Page 117: Fuel System - Prime

    SEBU8601-04 Maintenance Section Fuel System - Prime Illustration 80 g01348394 Adjustment of the cover will change the clearance NOTICE (gap) between the edge of the cover and the tip of Do not crank the engine continuously for more than the fan blade. Ensure that the cover is centralized to 30 seconds.
  • Page 118 SEBU8601-04 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 2. Turn the keyswitch to the “RUN” position. Note: Refer to Systems Operation, Testing, and Adjusting, “Cleanliness of Fuel System 3. The keyswitch will allow the electric priming pump Components”...
  • Page 119 SEBU8601-04 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 6. Tighten the vent screw (1) securely . Remove the 8. Rotate the filter element counterclockwise and wiring harness from connection (4). remove the filter element (5). Clean the filter bowl. 7.

  • Page 120: Fuel System Primary Filter/Water Separator - Drain

    Operation and Maintenance Manual , “Fuel System Filter - Replace”. In-line Strainer The fuel system has an in-line strainer installed before the electric priming pump. Perkins recommended that the in-line strainer be replaced when required. The location of the in-line strainer will depend on the application.
  • Page 121 SEBU8601-04 Maintenance Section Fuel System Secondary Filter - Replace 6. Remove the filter bowl (2). Rotate the filter NOTICE assembly counterclockwise in order to remove the Ensure that the engine is stopped before any servic- assembly. Use a suitable tool in order to remove ing or repair is performed.
  • Page 122 SEBU8601-04 Maintenance Section Fuel Tank Water and Sediment - Drain 1. Locate the thread in the filter element (7) onto the Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes threads (8). Spin on the element. Do not tighten. through the fuel system and the fuel returns to the 2.

  • Page 123: Replace

    (if equipped). The coolant system and the hoses for the coolant system are not usually supplied by Perkins. The Contact with high pressure fuel may cause fluid following text describes a typical method of replacing penetration and burn hazards.

  • Page 124: Replace

    Repeat the cleaning, if necessary. Inspect the fins for damage. Bent fins may be opened The radiator is not usually supplied by Perkins. The with a “comb”. Inspect these items for good condition: following text describes a typical cleaning procedure Welds, mounting brackets, air lines, connections, for the radiator.
  • Page 125 • Extending the maintenance intervals Refer to the standards for the engine or consult your • Failure to use recommended fuel, lubricants and Perkins dealer or your Perkins distributor in order to coolant/antifreeze determine if the engine is operating within the defined parameters.

  • Page 126: Turbocharger - Inspect

    SEBU8601-04 Maintenance Section Turbocharger - Inspect i04103131 NOTICE Turbocharger bearing failures can cause large quan- Turbocharger - Inspect tities of oil to enter the air intake and exhaust sys- tems. Loss of engine lubricant can result in serious (High Pressure and Low engine damage.
  • Page 127 SEBU8601-04 Maintenance Section Walk-Around Inspection The presence of oil may be the result of extended 9. Fasten the air intake pipe and the exhaust outlet engine operation at low idle. The presence of oil pipe to the turbocharger housing. Ensure that all may also be the result of a restriction of the line for clamps are installed correctly and that all clamps the intake air (clogged air filters), which causes the...
  • Page 128 Remove and Install”. For more information, consult fuel lines that have leaked. your Perkins dealer or your Perkins distributor. Ensure that all clips on the high-pressure fuel lines • Inspect the lubrication system for leaks at the front are in place and that the clips are not loose.
  • Page 129 SEBU8601-04 Maintenance Section Water Pump - Inspect • Check the condition of the gauges. Replace any Note: If engine coolant enters the engine lubricating gauges that are cracked. Replace any gauge that system the lubricating oil and the engine oil filter must cannot be calibrated.

  • Page 130: Warranty Section

    Company limited suggested retail price for all • The costs in order to investigate complaints which warranted parts replaced, and labor charges based are not caused by a defect in Perkins Engine on Perkins Engine Company limited recommended Company limited material or Perkins Engine time allowance for the warranty repair and the Company limited workmanship.
  • Page 131 – You are responsible for initiating the warranty engine. process. The ARB suggests that you present your off-road engine to a Perkins dealer when a problem i05452329 exists. The warranty repairs should be completed by the dealer as expeditiously as possible.
  • Page 132 • EGR rate feedback and control system component to be identical in all material respects to the component described in Perkins application • Catalyst or Thermal Reactor System for certification for the warranty period.
  • Page 133 Perkins application for certification, Perkins will provide the following at no charge through a Perkins records covering the maintenance on your engine. dealer or other source approved by Perkins :...
  • Page 134 MATERIAL AND SERVICES, AS SPECIFIED HEREIN. PERKINS IS NOT RESPONSIBLE FOR For information on the use of Aftermarket Products INCIDENTAL OR CONSEQUENTIAL DAMAGES. and Perkins Engines, refer to this Operation and Maintenance Manual, “Engine Description”. i04711150 Regular maintenance intervals with a special...
  • Page 135 Erratic behavior of the engine may indicate a need for repair to the ECM. Your Perkins distributor/dealer is equipped with the necessary tools, personnel, and procedures in order to perform this service.

  • Page 136: Reference Information Section

    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 137: Index

    Emission Control Warranty for California .. 131 Manufactures Warranty Coverage .... 131 OWNER'S WARRANTY RESPONSIBILITIES........ 131 Electrical System..........18 Perkins Responsibilities ......133 Grounding Practices ........19 Warranty Period......... 132 Emergency Stopping........67 Cold Weather Operation ......... 69 Emissions Certification Film ......30 Hints for Cold-Weather Operation ....
  • Page 138 General Coolant Information ....... 81 Check the System........113 General Lubricant Information..... 86 Engine Description .......... 26 Fluid Recommendations (General Fuel Aftermarket Products and Perkins Information) ........... 73 Engines ............27 Contamination Control Recommendations for Electronic Engine Features ......26 Fuels ............80 Engine Cooling and Lubrication ....
  • Page 139 SEBU8601-04 Index Section Monitoring System (Engine)......38 Instrument panels and Displays ....39 Gauges and Indicators ........36 Programmable Options and Systems Aftertreatment Lamps ........37 Operation ........... 39 Indicator Lamps ........... 37 Mounting and Dismounting ......16 General Hazard Information......8 Containing Fluid Spillage......
  • Page 140 SEBU8601-04 Index Section Environmental Factors....... 125 Incorrect Maintenance Procedures ... 125 Incorrect Operating Procedures ....125 Starting Motor - Inspect ......... 125 Starting the Engine.......... 58 Starting the Engine ........58 Starting with Jump Start Cables (Do Not Use This Procedure in Hazardous Locations that have Explosive Atmospheres) ..........
  • Page 141 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 142 SEBU8601 ©2021 Perkins Engines Company Limited All Rights Reserved March 2021...

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