Perkins 2206J-E13TA Operation And Maintenance Manual
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Perkins 2206J-E13TA Operation And Maintenance Manual

Industrial engine
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SEBU9071-06 (en-us)
December 2020
Operation and
Maintenance
Manual
2206F-E13TA and 2206J-E13TA
Industrial Engine
PP3 (Engine)
PP4 (Engine)
TGK (Engine)

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Summary of Contents for Perkins 2206J-E13TA

  • Page 1 SEBU9071-06 (en-us) December 2020 Operation and Maintenance Manual 2206F-E13TA and 2206J-E13TA Industrial Engine PP3 (Engine) PP4 (Engine) TGK (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

    SEBU9071-06 Table of Contents Table of Contents Engine Stopping ..........64 Maintenance Section Foreword ............4 Refill Capacities..........65 Safety Section Maintenance Recommendations ....83 Safety Messages..........6 Maintenance Interval Schedule....... 86 Additional Messages ......... 8 Warranty Section General Hazard Information......9 Warranty Information........118 Burn 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 safety message that is damaged or missing. If a safety message is attached to a part of the engine that is replaced, install a new safety message on the replacement part. Your Perkins distributor can provide new safety messages.
  • Page 7 SEBU9071-06 Safety Section Safety Messages Illustration 1 g02292373 Universal Warning (1) Illustration 2 g01370904 One safety message is located on the left side of the engine. One safety message is located on the right side of the engine.

  • Page 8: Additional Messages

    Replace any message that is damaged, or missing. If exhaust cooler. a message is attached to a part that is replaced, install a message on the replacement part. Replacement labels may be obtained from Perkins distributors. Illustration 4 g03422039 Purge notice message...

  • Page 9: General Hazard Information

    SEBU9071-06 Safety Section General Hazard Information This notice should be located next to the battery • When working around an engine, the engine must disconnect switch. not be in operation. You may only be near a running engine to carry out maintenance procedures that require the engine to be in NOTICE Do not turn the battery power disconnect switch off...
  • Page 10 Refer to the OEM information for any procedures that are required to • Perkins recommend that you do not stand next to relieve the hydraulic pressure. an exposed running engine unless it is necessary when carrying out daily checks or maintenance procedures.
  • Page 11 Perkins equipment and replacement parts comply with applicable regulations and requirements where The removal of sulfur and other compounds in ultra- originally sold. Perkins recommends the use of only low sulfur diesel fuel (ULSD fuel) decreases the genuine Perkins replacement parts.
  • Page 12 • Wear an approved respirator if there is no other good hygiene, and adhering to safe work practices way to control the dust. when handling the equipment or parts. Perkins also recommends the following: • Comply with applicable rules and regulations for the work place.

  • Page 13: Burn Prevention

    SEBU9071-06 Safety Section Burn Prevention Always use leakproof containers when you drain Cooling system conditioner contains alkali. Alkali can fluids. Do not pour waste onto the ground, down a cause personal injury. Do not allow alkali to contact drain, or into any source of water. the skin, the eyes, or the mouth.

  • Page 14: Fire Prevention And Explosion Prevention

    Personal injury, property damage, or engine damage could result. If the application involves the presence of combustible gases, consult your Perkins dealer and/ or your Perkins distributor for additional information about suitable protection devices. Remove all flammable combustible materials or conductive materials such as fuel, oil, and debris from the engine.
  • Page 15 SEBU9071-06 Safety Section Fire Prevention and Explosion Prevention Illustration 11 g00704059 Illustration 12 g00704135 Use caution when you are refueling an engine. Do Gases from a battery can explode. Keep any open not smoke while you are refueling an engine. Do not flames or sparks away from the top of a battery.

  • Page 16: Crushing Prevention And Cutting Prevention

    Refer to the OEM for the location of foot and hand holds for your specific application. Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for replacement parts. i04257031 Replace the parts if any of the following conditions...

  • Page 17: Engine Starting

    SEBU9071-06 Safety Section Engine Starting • Allow the engine to run for five minutes to cool. i07828827 Engine Starting • Stop the engine. 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 Do not use aerosol types of starting aids such as...

  • Page 18: Engine Electronics

    To ensure that the engine and the engine electrical Note: Many of the engine control systems and systems function properly, an engine-to-frame display modules that are available for Perkins ground strap with a direct path to the battery must be Engines will work in unison with the Engine used.

  • Page 19: Product Information Section

    SEBU9071-06 Product Information Section General Information Product Information Section General Information i06838242 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. Engine views Illustration 13 g03809306 (1) Engine front lifting eye (6) NOx Reduction System (NRS) valve...
  • Page 20 SEBU9071-06 Product Information Section Model View Illustrations Illustration 14 g03809820 (16) Exhaust gas cooler (NRS) (22) Coolant pump (29) Flywheel housing (17) Turbocharger (23) Oil pump (30) Flywheel (18) Oil filler cap (24) Alternator (31) Oil sampling valve (19) Water temperature regulator valve (25) Coolant intake (32) Oil cooler (Thermostat)
  • Page 21 SEBU9071-06 Product Information Section Model View Illustrations Clean Emission Module Without Aftertreatment Regeneration Device (ARD) Illustration 15 g03809311 (1) Clean emission module (4) Mixer (7) Exhaust intake (2) Selective Catalytic Reduction (SCR) (5) Diesel Oxidation Catalyst (DOC) (8) Exhaust outlet (3) Diesel Exhaust Fluid (DEF) injector (6) Diesel Particulate Filter (DPF).
  • Page 22 SEBU9071-06 Product Information Section Model View Illustrations Clean Emission Module With ARD Illustration 16 g06044166 Typical example (1) Clean Emission Module (CEM) (4) DEF Injector (7) Aftertreatment Regeneration Device (2) Exhaust outlet (5) Diesel Particulate Filter (DPF) (ARD) (3) Selective Catalytic Reduction (SCR) (6) CEM sensors and fuel system (8) Exhaust Inlet...
  • Page 23 SEBU9071-06 Product Information Section Model View Illustrations Off Engine Components Illustration 17 g06136963 (1) Pump electronic unit (4) Flexible exhaust pipe (7) DEF tank header (2) Electric lift pump and primary fuel filter (5) DEF Heated lines (3) NOx sensors (6) ECM for aftertreatment Pump Electronic Tank Unit (PETU) Some DEF tanks are combined with the pump...
  • Page 24 (5) DEF tank i06839988 Illustration 19 g01387009 Product Description Cylinder and valve location (A) Exhaust valve (B) Inlet valve The Perkins 2206F-E13TA Industrial Engine has the Table 1 following characteristics: Engine Specifications • Four-stroke cycle Engine 2206F • Mechanically actuated, electronically controlled...
  • Page 25 ECM. The Engines electronic engine control system provides the following features: Perkins does not warrant the quality or performance • Engine speed governor of non-Perkins fluids and filters. • Automatic air/fuel ratio control...

  • Page 26: Product Identification Information

    SEBU9071-06 Product Information Section Product Identification Information Product Identification Information i06091255 Plate Locations and Film Locations Illustration 21 g01403841 Serial number plate The following information is stamped on the serial number plate: engine serial number, engine model and arrangement number. The engine information plate is located on top of the valve cover near the middle of the engine.
  • Page 27 CEM identification plate The CEM identification plate contains the following information: part number, serial number, change level and configuration ID code. This information may be needed by the Perkins distributor when inquiries are being made on the CEM. Illustration 25 g03049116...
  • Page 28 Product Information Section Emissions Certification Film Record the information on the CEM and PETU serial plates. The information will be required by your Perkins dealer or your Perkins distributor in order to identify replacement part numbers. i05951816 Emissions Certification Film Note: This information is pertinent in the United States, in Canada and in Europe.

  • Page 29: Operation Section

    SEBU9071-06 Operation Section Lifting and Storage Operation Section Engine, Clean Emission Module (CEM), and Radiator Lifting Lifting and Storage i07434807 Product Lifting NOTICE Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Re- member that the capacity of an eyebolt is less as the angle between the supporting members and the ob- ject becomes less than 90 degrees.
  • Page 30 SEBU9071-06 Operation Section Product Lifting Illustration 27 g03391555 Typical example Illustration 28 g03389702 load ring When lifting the engine, with a factory-mounted CEM (with or without a factory-mounted radiator) the following procedure must be used. 1. Remove bolts shown in illustration 26 and illustration 27 .
  • Page 31 SEBU9071-06 Operation Section Product Lifting The engine package center of gravity will change depending on the engine attachments. Adjust the spreader bar and chains as necessary to maintain a lift within 5 degrees of horizontal in all directions. The load ring part number is T401848. Engine Only Illustration 29 g03810206...
  • Page 32 (1) PETU lifting eyes i06092636 Product Storage (Engine and Aftertreatment) Your Perkins distributor can assist in preparing the engine for extended storage periods. Some applications, the engine can be equipped with delayed engine shutdown. Allow at least 2 minutes after the engine has stopped before you turn the battery disconnect switch to OFF.
  • Page 33 SEBU9071-06 Operation Section Engine and Aftertreatment 3. Apply lubricant to all points in this Operation and 9. Remove the fuel injectors. Apply 30 mL (1 oz) of Maintenance Manual, “Maintenance Interval the mixture of oils (50 percent VCI oil and 50 Schedule”.
  • Page 34 (1) Plugs forming. 4. Ensure that the DEF filler cap is correctly installed. 8. If an engine is stored for more than 1 year, Perkins recommends Pre lubrication of the engine in order Remove Engine from Storage to avoid dry starting. Use a suitable pump in order to put engine oil into the engine oil system.
  • Page 35 SEBU9071-06 Operation Section Engine and Aftertreatment 10. Before start-up, test the cooling system for a 3 percent to a 6 percent concentration of coolant conditioner. Add liquid coolant conditioner or a coolant conditioner element, if equipped. Test the coolant mixture for proper nitrite level. If necessary, adjust the coolant mixture.

  • Page 36: Features And Controls

    SEBU9071-06 Operation Section Features and Controls Features and Controls The battery disconnect switch and the engine start switch perform different functions. The entire electrical system is disabled when you turn the i05422613 battery disconnect switch to the OFF position. The battery remains connected to the electrical system Battery Disconnect Switch when you turn the engine start switch to the OFF...
  • Page 37 SEBU9071-06 Operation Section Sensors and Electrical Components Emission Malfunction Indicator – This indicator will illuminate when an emissions system related to DEF or SCR has failed. Refer to Operation and Maintenance Manual, “Selective Catalytic Reduction Warning System” for more information. i06840153 Sensors and Electrical Components...
  • Page 38 SEBU9071-06 Operation Section Sensors and Electrical Components Illustration 35 g03821530 (11) Coolant temperature sensor (13) Crankshaft timing sensor (15) Electric priming/transfer pump (12) Alternator (14) Fuel pressure sensor (16) Fuel temperature sensor...
  • Page 39 SEBU9071-06 Operation Section Sensors and Electrical Components Clean Emissions Module without (ARD) Illustration 36 g03821962 (1) Diesel Exhaust Filter (DPF) outlet (3) Diesel oxidation catalyst temperature (5) Temperature sensor probes pressure sensor sensor (6) Diesel exhaust fluid injector (2) DPF inlet pressure sensor (4) Aftertreatment identification module...
  • Page 40 SEBU9071-06 Operation Section Sensors and Electrical Components Clean Emissions Module with (ARD) Illustration 37 g06048751 Typical example (1) Diesel Exhaust Fluid (DEF) injector (5) DPF pressure sensor (9) Fuel pilot pressure sensor (2) Temperature sensor (6) Temperature sender (10) Fuel main pressure sensor (3) Coil for spark plug (7) 40-Pin connector (11) Identification Module...
  • Page 41 SEBU9071-06 Operation Section Sensors and Electrical Components Loose Aftertreatment Components Illustration 38 g03821970 (1) NOx sensors (4) Voltage load protection module (7) Coolant diverter valve (2) Diesel Exhaust Fluid (DEF) heated lines (5) DEF Tank heater and DEF level gauge (3) Dosing control unit (6) Relays...
  • Page 42 SEBU9071-06 Operation Section Sensors and Electrical Components Pump Electronic Tank Unit (PETU) Illustration 39 g06137439 Typical example (1) DEF Level Sensor and DEF Temperature (3) Customer Connections (6) Voltage Limiting Protection Module Sensor (4) Dosing Control Module (2) Coolant Diverter Valve (5) Relays...

  • Page 43: Engine Diagnostics

    The system provides the capability of Fault Logging. When the Electronic Control Module (ECM) generates an active diagnostic code, the code will be Perkins Electronic Engines have the capability to logged in the memory of the ECM. The codes that perform a self-diagnostics test. When the system...
  • Page 44 SEBU9071-06 Operation Section Engine Operation with Intermittent Diagnostic Codes i01797063 Engine Operation with Intermittent Diagnostic Codes If a diagnostic lamp illuminates during normal engine operation and the diagnostic lamp shuts off, an intermittent fault may have occurred. If a fault has occurred, the fault will be logged into the memory of the Electronic Control Module (ECM).
  • Page 45 SEBU9071-06 Operation Section Configuration Parameters Table 3 System Configuration Parameters Configuration Parameters Record Engine Serial Number Rating Full Load Setting Full Torque Setting ECM Software Release Date Customer Specified Parameters Customer specified parameters allow the engine to be configured to the exact needs of the application. The electronic service tool is required in order to alter the customer configuration parameters.
  • Page 46 SEBU9071-06 Operation Section Configuration Parameters (Table 4, contd) Transmission Default Torque Limit Reset Not Reset Air Filter Restriction Switch Installation Status Not Installed Air Filter Restriction Switch Configuration Normally Open Intermediate Engine Speed 1400. rpm Air Shutoff Disabled Air Intake Shutoff Detection Installation Status Not Installed Coolant Level Sensor Not Installed...
  • Page 47 SEBU9071-06 Operation Section Configuration Parameters (Table 4, contd) Engine Fan Manual Purge Disabled Engine Fan Suspend Purge Disabled Engine Fan Purge Cycle Interval 1200 sec Engine Fan Purge Cycle Duration 180.0sec Enabled Engine Fan Control Charge Air Cooler Outlet Temperature Input Enable Engine Cooling Fan Maximum Air Flow Charge Air Cooler Outlet 46.6°...

  • Page 48: Engine Starting

    SEBU9071-06 Operation Section Engine Starting Engine Starting • Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or i02109067 to the controls. Before Starting Engine •...
  • Page 49 SEBU9071-06 Operation Section Starting the Engine Note: If the engine has not been run for several During the key on, all warning lamps will illuminate weeks, fuel may have drained. Air may have moved for a few seconds, in order to test the circuits. If into the filter housing.
  • Page 50 1000 to 1200 rpm in order to raise 3. Start the engine. If the engine does not start, check engine temperature. Do not exceed the for a diagnostic code and consult your Perkins recommended rpm in order to increase the speed of distributor.
  • Page 51 SEBU9071-06 Operation Section After Starting Engine After jump starting, the alternator may not be able to NOTICE recharge fully batteries that are severely discharged. Never attempt to start an engine from an external The batteries must be replaced or charged to the power source such as electric welding equipment, proper voltage with a battery charger after the engine which has a voltage that is unsuitable for engine...

  • Page 52: Engine Operation

    SEBU9071-06 Operation Section Engine Operation Engine Operation This design of DPF will require a service maintenance interval. Refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information. The DPF can be i06101183 expected to function properly for the useful life of the engine (emissions durability period), as defined by Engine Operation regulation, subject to prescribed maintenance...
  • Page 53 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 54: Aftertreatment Operation

    SEBU9071-06 Operation Section Aftertreatment Operation Aftertreatment Operation HC Evap To evaporate Hydrocarbons that can accumulate in the DPF, when operating at cold exhaust temperatures regeneration is necessary. Running HC Evap regenerations protects the DPF i07512828 against possible thermal events. Diesel Particulate Filter Desulfation Regeneration To keep the SCR catalyst Regeneration free of sulfur, and the DEF injector and mixing tube...
  • Page 55 STOP lamp will illuminate solid. Regenerations may be locked out and require an Carbon Dioxide (CO ) Emissions authorized Perkins distributor to perform Statement regeneration with service tool. A fault code will be active for any DPF system-related Emissions regulations require that the value of the issue.
  • Page 56 SEBU9071-06 Operation Section Selective Catalytic Reduction Warning System Safe Harbor Mode (Worldwide) – Safe Harbor NOTICE Mode is a 20 minute engine run time period that the Stopping the engine immediately after the engine has engine can be operated with full power after reaching been working under load can result in overheating of a level 3 inducement.
  • Page 57 SEBU9071-06 Operation Section Selective Catalytic Reduction Warning System Illustration 43 g03676102 Illustration 45 g03676111 DEF Level Normal If the DEF level falls below 13.5%, a level 1 inducement event will occur. The check engine lamp Inducement Strategy for DEF Level and the emissions malfunction indicator lamp will illuminate.
  • Page 58 SEBU9071-06 Operation Section Selective Catalytic Reduction Warning System The check engine and emissions malfunction indicator lamp will illuminate for a level 1 inducement- related fault. There are two inducement categories. If the inducement is a result of a category 1 fault, then a level 1 inducement will occur for a duration of 36 hours.
  • Page 59 If set to “Shutdown” , the engine may be restarted, but will only run for 5 minutes at derated condition before shutting down again. This action will continue until the issue is resolved. Note: Contact your Perkins dealer for repairs if a fault occurs. Illustration 53 g03676174 Inducement Strategy for DEF Level If the DEF level is below 7.5%, a level 2 inducement...
  • Page 60 SEBU9071-06 Operation Section Selective Catalytic Reduction Warning System If the inducement is a result of a category 2 fault, then a level 1 inducement will occur for a duration of 10 hours. There is no repeat occurrence for category 2, level 1 inducement faults.
  • Page 61 "Shutdown", the engine may be restarted, but will only run for 5 minutes at derated condition before shutting down again. This action will continue until the issue is resolved. Note: Contact your Perkins dealer for repairs if a fault occurs.

  • Page 62: Cold Weather Operation

    • Fuel line insulation, which may be an OEM option could cause a fan failure. Winter and arctic grades of diesel fuel are available in Perkins recommends a warning device for the inlet the countries and territories with severe winters. For manifold temperature and/or the installation of an more information refer to the Operation and inlet air temperature gauge.
  • Page 63 37° C (100° F). Note: Heat exchanger type fuel heaters should have a bypass provision in order to prevent overheating of the fuel in warm-weather operation. For further information on fuel heaters, consult your Perkins distributor .

  • Page 64: Engine Stopping

    SEBU9071-06 Operation Section Engine Stopping Engine Stopping Note: Individual applications have different control systems. Ensure that the shutoff procedures are understood. Use the following general guidelines in order to stop the engine. i06832774 Stopping the Engine 1. Remove the load from the engine so that the engine has no more than 30% power.

  • Page 65: Maintenance Section

    SEBU9071-06 Maintenance Section Refill Capacities Maintenance Section Table 5 2206 Industrial Engine Approximate Refill Capacities Refill Capacities Oil Sump Quarts Liters Standard Oil Pan 33.8 qt 32 L i06093491 Deep Oil Pan 39.1 qt 37 L Refill Capacities Center Oil Pan 31.7 qt 30 L These values are approximate capacities for the crankcase oil...
  • Page 66 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 67 SEBU9071-06 Maintenance Section General Fuel Information Table 7 "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 0.20% maximum “D524”...
  • Page 68 EPA and other appropriate regulatory agencies. NOTICE Operating with fuels that do not meet the Perkins rec- ommendations can cause the following effects: Start- ing difficulty, reduced fuel filter service life, poor combustion, deposits in the fuel injectors, signifi- cantly reduce service life of the fuel system.
  • Page 69 Refer to the Recommendation for Biodiesel and Using B20 section of this “Operation and Maintenance Manual” Fluid Recommendations for more information. All the fuels must comply with the specification in the table for the Perkins Specification Distillate Diesel Fuel. Diesel Fuel Characteristics Perkins recommends kinematic viscosities of 1.4 and 4.5 mm2/sec that is delivered to the fuel injection...
  • Page 70 Protection Agency (EPA) and European Certification wear scar diameter than 0.52 mm (0.0205 inch) will fuels. Perkins does not certify engines on any other lead to reduced service life and premature failure of fuel. The user of the engine has the responsibility of the fuel system.
  • Page 71 Rancimant test), and sediment (ISO12937). For standby generator sets oxidation • Perkins recommend the use of oil analysis to stability of biodiesel blend must be 20 hours or more check the quality of the engine oil if biodiesel fuel as per EN 15751.
  • Page 72 Paraffinic diesel fuels are considered as acceptable to use as a directed replacement to petroleum diesel operate incorrectly. or as a blendstock for petroleum diesel fuel in Perkins Contact your fuel supplier for those circumstances diesel engines provided they meet latest edition of when fuel additives are required.
  • Page 73 • Perkins recommends the use of bulk fuel filter / Details instruction on the rate of which the fuel cleaner is to be used are on the container.
  • Page 74 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 75 SEBU9071-06 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 76 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 77 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 78 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 79 Table 15 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 80 “EMA Recommended Guideline on Diesel Engine performance and increased fuel consumption. Most Oil”. In addition to Perkins definitions, there are other of the ash comes from the engine oil which is definitions that will be of assistance in purchasing gradually consumed during normal operation.
  • Page 81 Note: API FA-4 oil is designed for use in selected on-highway applications and is NOT designed to support off-road applications, including Perkins Engines. DO NOT use API FA-4 oil for Perkins engines. These engine oils are not approved by Perkins and these engine oils must not be used: CC, CD, CD-2, CF-4, CG-4, CH-4, and CI-4.
  • Page 82 SEBU9071-06 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 83: Maintenance Recommendations

    Consult the OEM of the equip- To relieve the pressure from the coolant system, turn ment or your Perkins dealer regarding welding on a off the engine. Allow the cooling system pressure cap chassis frame or rail.
  • Page 84 (2) Welding electrode Refer to the standards for the engine or consult your (3) Keyswitch in the OFF position Perkins distributor to determine if the engine is (4) Battery disconnect switch in the open position operating within the defined parameters.
  • Page 85 Severe Service Application Due to individual applications, identification is not possible for all the factors which can contribute to severe service operation. Consult your Perkins distributor for the unique maintenance that is necessary for the engine. The operating environment, incorrect operating...

  • Page 86: Maintenance Interval Schedule

    SEBU9071-06 Maintenance Section Maintenance Interval Schedule “ Engine Oil Sample - Obtain” ....106 i07493264 Maintenance Interval Schedule Initial 500 Service Hours “ Engine Valve Lash - Check” ....108 When Required Every 500 Service Hours “...
  • Page 87 SEBU9071-06 Maintenance Section Maintenance Interval Schedule “Diesel Particulate Filter (Emission Related Component) - Clean” ..... . . 102 “Diesel Exhaust Fluid Injector (Emission Related Component) - Replace”...
  • Page 88 SEBU9071-06 Maintenance Section ARD Spark Plug (Emission Related Component) - Clean 2. Debris may have collected in the spark plug well. i07495700 Thoroughly remove any debris. Use compressed ARD Spark Plug (Emission air. The maximum air pressure for cleaning Related Component) - Clean purposes must be below 205 kPa (30 psi).
  • Page 89 All personnel should also stay clear of the air compressor when the engine is operating and the air compressor is exposed. Consult your Perkins distributor for assistance. Do not disconnect the air line from the air com- pressor governor without purging the air brake i07297207 and the auxiliary air systems.

  • Page 90: Battery - Recycle

    SEBU9071-06 Maintenance Section Air Tank Moisture and Sediment - Drain i00847451 i01878164 Air Tank Moisture and Battery - Replace Sediment - Drain (If Equipped) Batteries give off combustible gases which can Moisture and sediment in the air starting system can explode.

  • Page 91: Battery Or Battery Cable - Disconnect

    SEBU9071-06 Maintenance Section Battery Electrolyte Level - Check 8. Connect the cable from the NEGATIVE “-” terminal i05424317 on the starter motor to the NEGATIVE “-” battery Battery or Battery Cable - terminal. Disconnect i02747977 Battery Electrolyte Level - Check The battery cables or the batteries should not be removed with the battery cover in place.
  • Page 92 SEBU9071-06 Maintenance Section Belts - Inspect/Replace i06093624 Belts - Inspect/Replace (Multi Vee Belt) To maximize the engine performance, inspect the belt for wear and for cracking. Replace the belt if the belt is worn or damaged. • Inspect the belt for cracks, splits, glazing, grease, displacement of the cord and evidence of fluid contamination.
  • Page 93 NOTICE 4. Drain the cooling system. Perkins ELC must be using with an extender in order to achieve 12000 hours operation. For more informa- 5. Fill the cooling system with clean water and tion on a suitable extender contact your Perkins operate the engine until the engine is warmed to distributor.
  • Page 94 SEBU9071-06 Maintenance Section Coolant (ELC) - Change NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. 3. Fill the cooling system with clean water. Install the cooling system filler cap. 4.
  • Page 95 Coolant Extender (ELC) - Add In order for Perkins ELC to achieve 12000 hours an extender must be added at 6000 hours. For a suitable extender, contact your Perkins dealer or Perkins distributor.
  • Page 96 SEBU9071-06 Maintenance Section DEF Filler Screen (Emission Related Component) - Clean 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 97 SEBU9071-06 Maintenance Section DEF Manifold Filters (Emission Related Component) - Replace 3. The filter screen can be cleaned in clean water and dried using compressed air. Refer to this Operation and Maintenance Manual, “General Hazard Information” for information on using compressed air.
  • Page 98 SEBU9071-06 Maintenance Section Emissions Related Component Illustration 73 g03806581 Illustration 74 g03806583 Illustration 72 g03806580 4. Remove the suction filter (4) at the bottom of the header coils by pulling tabs (5). Replace with a 2. Remove band clamp (2) from filter base (1). new suction filter.
  • Page 99 SEBU9071-06 Maintenance Section Diesel Exhaust Fluid (Emission Related Component) - Fill 6. Install the retaining plate (6) and install screws (7). Tighten screws (7) to a torque of 1.1 N·m (9.8 lb in). 7. Install new outer filter (3) onto DEF tank header (1).
  • Page 100 SEBU9071-06 Maintenance Section Diesel Exhaust Fluid Filter (Emission Related Component) - Replace Caution should be used when dispensing DEF near an engine that has recently been running. Spilling DEF onto hot components may cause the release of ammonia vapors. Do not breathe ammonia vapors. Do not clean up any spills with bleach.
  • Page 101 SEBU9071-06 Maintenance Section Diesel Exhaust Fluid Injector (Emission Related Component) - Replace i07495343 Diesel Exhaust Fluid Injector (Emission Related Component) - Replace Illustration 79 g03332637 Typical Example 3. Insert the DEF filter removal tool (4) into the DEF filter (1) and remove the DEF filter (1). Note: Avoid twisting the DEF filter (1) upon removal.

  • Page 102: Engine - Clean

    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 103 SEBU9071-06 Maintenance Section Engine Air Cleaner Service Indicator - Inspect If the air cleaner element becomes plugged, the air 1. Clean the outer casing of the air cleaner before can split the material of the air cleaner element. removing the end cover (3). Unfiltered air will drastically accelerate internal engine wear.

  • Page 104: Clean

    SEBU9071-06 Maintenance Section Engine Crankcase Breather - Clean Note: When a new service indicator is installed, excessive force may crack the top of the service indicator. Tighten the service indicator to a torque of 2 N·m (18 lb in). i06102339 Engine Crankcase Breather - Clean Hot oil and hot components can cause personal...

  • Page 105: Inspect

    This will reduce the power that is devel- recommended torques. oped and also force air bubbles into the oil. These When the engine mounts are supplied by Perkins the bubbles (foam) can cause the following problems: re- maintenance procedure will be supplied in the duction of the oil's ability to lubricate, reduction of oil Disassembly and Assembly manual for your engine.
  • Page 106 Perkins recommends using a sampling valve in order Hot oil and hot components can cause personal to obtain oil samples. The quality and the consistency injury.
  • Page 107 Fill the Oil Pan cations. Use of an oil filter that is not recommended by Perkins could result in severe damage to the en- gine bearings, and crankshaft. As a result of the larg- 1. Remove the oil filler cap. Refer to this Operation er waste particles from unfiltered oil entering the and Maintenance Manual, “Fluid...
  • Page 108 NOTICE Only qualified service personel should perform this maintenance. Refer to the Service Manual or your au- thorized Perkins dealer or your Perkins distributor for the complete valve lash adjustment procedure. Operation of Perkins engines with incorrect valve lash can reduce engine efficiency, and also reduce engine component life.
  • Page 109 SEBU9071-06 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace The fuel system can also be primed by using the key switch. Turn the key to the ON position for 2 minutes. After 2 minutes the fuel system should be primed. If necessary, by cycling the key switch the system will prime again for 2 minutes.

  • Page 110: Fuel System Primary Filter/Water Separator - Drain

    SEBU9071-06 Maintenance Section Fuel System Primary Filter/Water Separator - Drain 10. Dispose of the fluid and old filter in accordance NOTICE with local regulations. The water separator is under suction during normal engine operation. Ensure that the drain valve is tight- ened securely to help prevent air from entering the i06096654 fuel system.

  • Page 111: Fuel Tank Water And Sediment - Drain

    SEBU9071-06 Maintenance Section Fuel Tank Water and Sediment - Drain i02348492 Fuel Tank Water and Sediment - Drain NOTICE Care must be taken to ensure that fluids are con- tained during performance of inspection, mainte- nance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable contain- ers before opening any compartment or disassem- bling any component containing fluids.
  • Page 112 SEBU9071-06 Maintenance Section Fumes Disposal Filter Element (Emission Related Component) - Replace Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank.
  • Page 113 SEBU9071-06 Maintenance Section If Equipped Cap A Cap B Illustration 92 g03814811 Illustration 93 g03814824 1. Remove cap (A) from breather body (7). Remove 1. Loosen clip (1) and remove hose (2). Loosen clip the filter element (6) from breather body. Discard (3) and remove hose (4).

  • Page 114: Hoses And Clamps - Inspect/Replace

    SEBU9071-06 Maintenance Section Grounding Stud - Inspect/Clean/Tighten 7. Install hose (4) and tighten clip (3) securely . Install i06103230 hose (2) and tighten clip (1) securely. Hoses and Clamps - Inspect/ Replace i05970985 Grounding Stud - Inspect/ Clean/Tighten Contact with high pressure fuel may cause fluid penetration and burn hazards.
  • Page 115 Overhaul Considerations The following text describes a typical method of replacing coolant hoses. Refer to the OEM information for further information on the coolant For an overhaul solution, contact your Perkins system and the hoses for the coolant system. distributor. i03901481...

  • Page 116: Starting Motor - Inspect

    Proper safeguards must be followed to help prevent accidents. Perkins recommends a scheduled inspection of the starting motor. If the starting motor fails, the engine i08254039 may not start in an emergency situation.
  • Page 117 Service Manual for the engine or consult your Perkins distributor . • Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters, and the valve cover.

  • Page 118: 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 119: 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 120 SEBU9071-06 Reference Information Section Maintenance Log i05204675 Maintenance Log Table 19 Engine Model Customer Identifier Arrangement Number Serial Number Service Quantity Of Service Item Date Authorization Hours Fuel...
  • Page 121 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 122: Index

    SEBU9071-06 Index Section Index Coolant Level - Check ........95 Cooling System Supplemental Coolant Additional Messages ......... 8 Additive (SCA) - Test/Add......95 After Starting Engine ........51 Add the SCA, If Necessary ......96 Extended Idle at Cold Ambient Test for SCA Concentration ......
  • Page 123 SEBU9071-06 Index Section Test the Service Indicator ......104 Overhaul ............5 Engine Crankcase Breather - Clean ..... 104 Safety............. 4 Engine Diagnostics ......... 43 Fuel and the Effect from Cold Weather ... 62 Engine Electronics........... 18 Fuel Conservation Practices ......53 Engine Mounts - Inspect........
  • Page 124 Power Take-Off Clutch - Check......115 Clean Emissions Module with (ARD) ..40 Product Description ......... 24 Clean Emissions Module without (ARD) ..39 Aftermarket Products and Perkins Engine Views ..........37 Engines ............25 Loose Aftertreatment Components ..... 41 Electronic Engine Features ......25 Severe Service Application ......
  • Page 125 SEBU9071-06 Index Section Starting the Engine ........49 Starting with Jump Start Cables (Do Not Use This Procedure in Hazardous Locations that have Explosive Atmospheres) ..........50 Stopping the Engine ........64 System Pressure Release....... 83 Coolant System ........... 83 Engine Oil ............
  • Page 127 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 128 SEBU9071 ©2020 Perkins Engines Company Limited All Rights Reserved December 2020...

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