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

Perkins 1204J-E44TA Operation And Maintenance Manual

Industrial engines
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M0091784-05 (en-us)
July 2024
Operation and
Maintenance
Manual
1204J-E44TA and 1204J-E44TTA
Industrial Engines

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  • Page 1 M0091784-05 (en-us) July 2024 Operation and Maintenance Manual 1204J-E44TA and 1204J-E44TTA Industrial Engines...
  • 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

    M0091784-05 Table of Contents Table of Contents Cold Weather Operation ......... 79 Engine Stopping ..........84 Foreword ............4 Maintenance Section Safety Section Refill Capacities..........86 Safety Messages..........6 Maintenance Recommendations ....104 Additional Messages ........11 Maintenance Interval Schedule..... 107 General Hazard Information......11 Warranty Section 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 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. Universal Warning (1)
  • Page 7 M0091784-05 Safety Section Safety Messages Illustration 2 g06461623 Typical example (1) Universal Warning Hand (High Pressure) (2) 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 M0091784-05 Safety Section Safety Messages Illustration 3 g02382677 Typical example Illustration 4 g06461636 Typical example (2) Hand (High Pressure)
  • Page 9 M0091784-05 Safety Section Safety Messages 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 (3) Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals.
  • Page 10 M0091784-05 Safety Section Safety Messages Illustration 5 g01154809 Illustration 6 g06401834 Typical example (3) Ether Warning...

  • Page 11: Additional Messages

    Replacement labels may be obtained from Perkins Do not allow unauthorized personnel on the engine, distributors. or around the engine when the engine is being serviced.
  • Page 12 • Do not attempt any repairs that are not understood. Use the proper tools. Replace any • Perkins recommend that you do not stand next to equipment that is damaged or repair the an exposed running engine unless it is necessary equipment.
  • Page 13 M0091784-05 Safety Section General Hazard Information • Disconnect the batteries when maintenance is performed or when the electrical system is serviced. Disconnect the battery ground leads. Tape the leads to help prevent sparks. • Do not attempt any repairs that are not understood.
  • Page 14 (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 15: Burn Prevention

    M0091784-05 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 16 M0091784-05 Safety Section Burn Prevention After the engine has stopped, wait for 15 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 17: 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 18 M0091784-05 Safety Section Fire Prevention and Explosion Prevention Illustration 14 g00704059 Illustration 15 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 19: 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 20 M0091784-05 Safety Section High Pressure Fuel Lines Illustration 16 g06401872 (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 Do not check the high-pressure fuel lines with the between the high-pressure fuel pump and the high- engine or the starting motor in operation.

  • Page 21: Before Starting Engine

    M0091784-05 Safety Section Before Starting Engine • Do not operate the engine with a fuel leak. If there Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are is a leak, do not tighten the connection, to stop the provided in order to help prevent personal injury.

  • Page 22: Engine Stopping

    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 23: Engine Electronics

    M0091784-05 Safety Section Engine Electronics The power supply connections and the ground connections for the engine electronics should always be from the isolator to the battery. i07943840 Engine Electronics Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/ or engine damage.
  • Page 24 However, the monitoring system and the engine monitoring control will be similar for all engines. Note: Many of the engine control systems and display modules that are available for Perkins engines will work in unison with the Engine Monitoring System. Together, the two controls will provide the engine monitoring function for the specific engine application.

  • Page 25: Product Information Section

    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. 1204J-E44TA Single Turbocharged Engine Illustration 19 g06462259 Typical example (1) Front lifting eye...
  • Page 26 M0091784-05 Product Information Section Model View Illustrations Illustration 20 g06462262 Typical example (12) Air intake (14) Water pump (16) Tensioner (13) Coolant outlet (15) Coolant intake (17) Belt...
  • Page 27 M0091784-05 Product Information Section Model View Illustrations Illustration 21 g06462264 Typical example (18) Alternator (21) Starter motor solenoid (24) Flywheel (19) Turbocharger wastegate (22) Starter motor (25) Flywheel housing (20) Turbocharger (23) Oil Drain Plug (26) Rear lifting eye...
  • Page 28 M0091784-05 Product Information Section Model View Illustrations 1204J-E44TTA Series Turbocharged Engine Illustration 22 g06462267 Typical example (1) Front lifting eye (5) Electronic Control Module (9) Air compressor (2) Crankcase breather (6) Priming/transfer fuel pump (10) High-pressure fuel pump (behind the air (3) Secondary fuel filter (7) Oil level gauge (dipstick) compressor)
  • Page 29 M0091784-05 Product Information Section Model View Illustrations Illustration 23 g06462270 Typical example (12) Air intake (15) Coolant intake (18) Belt (13) Coolant outlet (16) Refrigerant compressor (19) Turbocharger Wastegate Actuator (14) Water pump (17) Tensioner...
  • Page 30 M0091784-05 Product Information Section Model View Illustrations Illustration 24 g06462273 Typical example (20) Front lifting eye (24) Refrigerant compressor (28) Starter motor solenoid (21) High-pressure turbocharger (25) Oil filter (29) Flywheel (21) Alternator (26) Oil Drain Plug (30) Flywheel housing (23) Low-pressure turbocharger (27) Starter motor (31) Rear lifting eye...
  • Page 31 M0091784-05 Product Information Section Model View Illustrations Combined DPF and SCR with DOC Illustration 25 g06462572 Typical example (1) DPF (3) SCR (5) Inlet for Exhaust gas (2) Outlet for Exhaust gas (4) DOC...
  • Page 32 M0091784-05 Product Information Section Model View Illustrations Combined DOC and DPF with SCR Illustration 26 g06306483 Typical example (1) DPF (3) Inlet for Exhaust gas (5) Outlet for Exhaust gas (2) DOC (4) SCR...
  • Page 33 The Perkins 1204J-E44TA and the 1204J-E44TTA industrial engines have the following characteristics. • In-line 4 cylinder The 1204J industrial engine has two engine variants. The 1204J-E44TA is a single turbocharged engine. • 4 stroke cycle The engine model is ST. • Four valves per cylinder The 1204J-E44TTA is a series turbocharged engine.
  • Page 34 (A) Exhaust valves (B) Inlet valves • System diagnostics Table 1 • Low temperature regeneration 1204J-E44TA and 1204J-E44TTA Engine Specifications For more information on electronic engine features, Operating Range (rpm) 800 to 2200 refer to the Operation and Maintenance Manual, “Features and Controls”...
  • Page 35 Perkins aftertreatment system or approved operation and maintenance recommendations. In components must be used on a Perkins engine. addition, use recommended fuels, coolants, and lubricants. Use the Operation and Maintenance Clean Emission Module (CEM) Manual as a guide for required engine maintenance.
  • Page 36 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 37: Product Identification Information

    Diesel Particulate Filter (DPF) combined with Selective Catalytic Reduction (SCR) Illustration 29 g06464144 Location of serial number plate Perkins engines are identified by an engine serial number. An example of an engine number is ST*****U000001W. • ST Type of engine •...
  • Page 38 Illustration 32 g06464152 Typical example The plate (1) is installed after the DPF. Record all the information on the serial plate for your aftertreatment system. The information will be required by your Perkins distributors.
  • Page 39 M0091784-05 Product Information Section Reference Information 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 Diesel Exhaust Fluid (DEF) Filter Part Number (DEF) Tank Part Number Manifold Group DEF (DEF Tank Header Unit) Part Number...

  • Page 40: Operation Section

    M0091784-05 Operation Section Lifting and Storage Operation Section Lifting and Storage i07391117 Product Lifting (Aftertreatment Systems) Ensure that the correct clothing is worn, refer to this Operation and Maintenance Manual, “General Hazard Information”. There are two different types of Clean Emission Module (CEM) available.
  • Page 41 M0091784-05 Operation Section Aftertreatment Systems Diesel Oxidation Catalyst (DOC) with a combined Diesel Particulate Filter (DPF) and Selective Catalytic Reduction (SCR) Illustration 35 g06463879 Typical example The approximate weight of the CEM is up to 45 kg (99 lb). Two suitable double looped slings are required to lift the CEM.
  • Page 42 M0091784-05 Operation Section Aftertreatment Systems 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. Combined Diesel Oxidation Catalyst (DOC) with a Diesel Particulate Filter (DPF) and a separate Selective...
  • Page 43 There are several different designs of lifting eyes. Typical example 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.
  • Page 44 M0091784-05 Operation Section Product Lifting The front lifting eye for engine and aftertreatment is installed by three bolts. The design of the lifting eyes will allow access to lift the aftertreatment and engine. Engine Only Lifting Eyes Illustration 39 g03674679 The front lifting eye (3) for the engine only is installed by two bolts.
  • Page 45 For maintenance procedures refer to this Operation The building must be kept at a constant temperature. and Maintenance Manual. Engines that are filled with Perkins ELC will have coolant protection to an ambient temperature of Monthly Checks −36° C (−32.8° F). The engine must not be subjected to extreme variations in temperature or humidity.
  • Page 46 M0091784-05 Operation Section Engine and Aftertreatment 3. Ensure that all DEF lines and electrical connections are reconnected prior to storage, to prevent DEF crystals from forming. 4. Ensure that the DEF filler cap is correctly installed. Removal from Storage DEF has a limited life, refer to table 2 for the time and temperature range.

  • Page 47: Features And Controls

    M0091784-05 Operation Section Features and Controls Features and Controls Intake manifold pressure – The intake manifold pressure sensor checks the rated pressure in the engine manifold. i07867359 Fuel rail pressure – The fuel rail pressure sensor Alarms and Shutoffs measures the high pressure or low pressure in the fuel rail.
  • Page 48 Gauges and Indicators NOTICE Perkins strongly recommend the installation of the wait to disconnect lamp on all applications. Your engine may not have the same gauges or all the gauges that are described. For more information...
  • Page 49 Determine and correct the cause of any significant change in the readings. Consult your Perkins dealer If the engine is operating above the normal range, or your Perkins distributor for assistance.
  • Page 50 M0091784-05 Operation Section Monitoring System • Wait to start lamp (Glow plug warning lamp) Also available are mini power displays and performance monitors. These displays and monitors For information, refer to this manual, “Monitoring can show the operator the following engine System (Table for the Indicator Lamps)”...
  • Page 51 1. One or more of the shutdown values for diagnostic code. the engine protection strategy has been exceeded. Contact your Perkins dealer or your Perkins distributor. 2. A serious active diagnostic code has been detected. If installed, the audible warning will sound.
  • Page 52 M0091784-05 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 53 M0091784-05 Operation Section Sensors and Electrical Components Engine Views Illustration 42 g06289815 Typical example (1) Post NOx Reduction System (NRS) (5) Pre NRS Temperature Sensor (9) Oil Pressure Sensor Temperature Sensor (6) Electronic Control Module (ECM) (10) Fuel Temperature Sensor (2) Intake Manifold Air Temperature Sensor (7) Priming / Transfer pump (11) Suction Control Valve...
  • Page 54 M0091784-05 Operation Section Sensors and Electrical Components Illustration 43 g06289824 Typical example (13) Coolant Temperature Sensor (14) NOx Reduction System (NRS) Delta (15) Control Valve for the NRS Pressure Sensor (16) Wastegate Regulator...
  • Page 55 M0091784-05 Operation Section Sensors and Electrical Components Illustration 44 g06291298 Typical example (17) Alternator (20) Water in Fuel Switch (23) Secondary Speed/Timing Sensor (18) Starter Solenoid (21) Inlet Air Temperature Sensor (Camshaft Position Sensor) (19) Starter Relay (22) Starting Motor (24) Back Pressure Valve...
  • Page 56 M0091784-05 Operation Section Sensors and Electrical Components Illustration 45 g06291339 Typical example (26) Coolant Temperature Sensor (28) Electronic Control Module (ECM) (30) Intake Manifold Air Pressure Sensor (27) Fuel Rail Pressure Sensor (29) Intake Manifold Air Temperature Sensor Illustration 46 g06291447 Typical example (31) Fuel Metering Solenoid for the High-...
  • Page 57 M0091784-05 Operation Section Sensors and Electrical Components Illustration 47 g06314008 Typical example (36) Electronic Wastegate Actuator Aftertreatment Views • DOC Diesel Oxidation Catalyst • SCR Selective Catalytic Reduction • DPF Diesel Particulate Filter • DEF Diesel Exhaust Fluid...
  • Page 58 M0091784-05 Operation Section Sensors and Electrical Components Combined DPF with SCR and DOC Illustration 48 g06464214 Typical example (1) Soot Sensor Antenna (3) Soot Sensor Antenna (6) DPF Temperature Sensor (2) Identification / Temperature Sensor (4) DEF Injector Module (5) NOx Sensor Location...
  • Page 59 M0091784-05 Operation Section Sensors and Electrical Components Combined DOC and DPF with SCR Illustration 49 g06464237 Typical example (1) Identification / Temperature Sensor (3) DPF Temperature Sensor (6) NOx Sensor location Module (4) DOC Temperature Sensor (7) DEF Injector (2) Soot Sensor Antenna (5) SCR Temperature Sensor (8) Soot Sensor Antenna...
  • Page 60 M0091784-05 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 50 g06292320 Typical example (1) NOx Sensors (3) DEF Pump (5) Coolant Diverter Valve (2) DEF Tank level and Temperature Sensor (4) Heated DEF Lines (3 off)

  • Page 61: 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 62 M0091784-05 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 63 M0091784-05 Operation Section Configuration Parameters (Table 4, 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 Customer Specified Parameters Customer specified parameters allow the engine to...
  • Page 64 M0091784-05 Operation Section Configuration Parameters (Table 5, contd) 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 Throttle Lock Engine Set Speed Increment Throttle Lock Engine Set Speed Decrement Monitoring Mode Shutdowns Monitoring Mode Derates...
  • Page 65 M0091784-05 Operation Section Configuration Parameters (Table 5, contd) Engine Cooling Fan Minimum Air Flow Transmission Oil Temperature Engine Cooling Fan Control Hydraulic Oil Temperature Input Enable Status Engine Cooling Fan Maximum Air Flow Hydraulic Oil Temperature Engine Cooling Fan Minimum Air Flow Hydraulic Oil Temperature Engine Cooling Fan Control Auxiliary #1 Temperature Input Enable Status Engine Cooling Fan Maximum Air Flow Auxiliary #1 Temperature Engine Cooling Fan Minimum Air Flow Auxiliary #1 Temperature...

  • Page 66: Engine Starting

    M0091784-05 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 67 M0091784-05 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 68 M0091784-05 Operation Section After Starting Engine Note: The engine ECM must be powered before the starting motor is operated or damage can occur. Improper jump start cable connections can cause 4. Start the engine in the normal operating an explosion resulting in personal injury. procedure.
  • Page 69 M0091784-05 Operation Section After Starting Engine Note: Gauge readings should be observed and the data should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge. Comparing data over time will also help detect abnormal operating developments.

  • Page 70: Engine Operation

    Family CO use of the engine emissions control system should Name Family Value (g/kWh) take place. Prompt action is critical to rectify any in- correct operation, use, or maintenance of the emis- 1204J-E44TA NRE6V04.4HTA 673.76 sions control system. 1204J-E44TTA NRE6V04.4HTA 673.76...
  • Page 71 The lamps and fault code will The efficiency of the engine can affect the fuel remain active until the problem is rectified. economy. Perkins design and technology in manufacturing provides maximum fuel efficiency in i01646335 all applications. Follow the recommended procedures...

  • Page 72: Aftertreatment Operation

    NOTICE Any warning should be investigated immediately. Allow at least 2 minutes after shutting down the en- Contact your Perkins dealer or your Perkins gine before you turn the battery disconnect switch to Distributor if further assistance is required. The OFF.
  • Page 73 M0091784-05 Operation Section Selective Catalytic Reduction Warning System • Inducement Categories The Inducements are • At Level 3 cycling the keyswitch will give 20 separated into categories. DEF Levels have minutes override at full power, before the inducement fault codes separate from the other shutdown or idle is triggered.
  • Page 74 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 8 World-Wide Reduced Performance Setting Category 2 Fault (Non-Tampering Dosing and Interruption)
  • Page 75 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 76 The stop lamp will activate Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop. Table 11 World-Wide Reduced Time Setting Category 2 Fault (Non-Tampering Dosing Interruption)
  • Page 77 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 Two options are available but only one option will be enabled.
  • Page 78 M0091784-05 Operation Section Selective Catalytic Reduction Warning System Table 14 World-Wide DEF Level Option 2 Normal operation Initial indication Level 1 Level 2 Level 3 Inducement Trigger Above 20 percent Below 20 percent Below 13.5 percent 7.5 Percent reading 3 Percent reading Inducement None None...

  • Page 79: Cold Weather Operation

    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 80 240 V ac. The output can be between 600W and deposit on the valve stems will be kept at a minimum. 750W. Consult your Perkins dealer or your Perkins The free operation of the valves and the valve distributor for more information.
  • Page 81 M0091784-05 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 82 M0091784-05 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 83 M0091784-05 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 84: Engine Stopping

    M0091784-05 Operation Section Engine Stopping Engine Stopping i07867848 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 85 M0091784-05 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 86: Maintenance Section

    M0091784-05 Maintenance Section Refill Capacities Maintenance Section Refill Capacities i09635208 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 87 M0091784-05 Maintenance Section Fluid Recommendations Diesel Exhaust Fluid (DEF) Refer to Perkins Diesel Engines Fluids Recommendations, M0113102 for additional information that relates to coolant. There are two different capacities of DEF tank available for the industrial engine 19 L (5 US gal) Water and 38 L (10 US gal).
  • Page 88 • Reduction of heat transfer specifications are published and evaluated by • Leakage of the water pump seal Perkins, use of PDO, glycerine, or other alternative coolants is not recommended in Perkins diesel • Plugging of radiators, coolers, and small passages engines.
  • Page 89 OEM to set the heater control. After the cooling agents with low amounts of nitrite. Perkins ELC has system is drained and the cooling system is refilled, been formulated with the correct amount of these...
  • Page 90 An SCA that is liquid may be needed at 500 hour Perkins. intervals. NOTICE 6. Fill the cooling system with the Perkins Premixed Do not mix types and brands of coolant. ELC. Operate the engine. Ensure that all coolant valves open then stop the engine. When cool Do not mix brands and types of SCAs.
  • Page 91 Use a non-foaming detergent to clean Example Of The Equation For Adding The SCA To The Heavy- Duty Coolant At The Initial Fill oil contamination, consult your Perkins dealer for suitable product. Total Volume of the Multiplication...
  • Page 92 “EMA Recommended Guideline on Diesel Engine Ash is the inert part of the particulate matter. The Oil”. In addition to Perkins definitions, there are other system is designed to collect this particulate matter. definitions that will be of assistance in purchasing There is a very small percentage of particulate matter lubricants.
  • Page 93 Lubricant Viscosity Recommendations Aftermarket Oil Additives for Direct Injection (DI) Diesel Engines Perkins does not recommend the use of aftermarket additives in oil. The use of aftermarket additives is The correct SAE viscosity grade of oil is determined not necessary to achieve the engines maximum by the minimum ambient temperature during cold service life or rated performance.
  • Page 94 Co-ordinating Fuel Research the table 26 . • ULSD Ultra Low Sulfur Diesel NOTICE The footnotes are a key part of the Perkins "Specifi- • RME Rape Methyl Ester cation for Distillate Diesel Fuel" Table. Read ALL of the footnotes.
  • Page 95 M0091784-05 Maintenance Section General Fuel Information Table 26 "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 96 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 97 “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 The viscosity of the fuel is significant because fuel serves as a lubricant for the fuel system components.
  • Page 98 Distillation existing local regulations for emissions. Distillation is an indication of the mixture of different Perkins 1200J series diesel engines have been hydrocarbons in the fuel. A high ratio of lightweight designed to operate only with Ultra Low Sulfur Diesel hydrocarbons can affect the characteristics of (ULSD) fuel.
  • Page 99 Protection Agency (EPA) and European Certification increased level of fuel dilution when using fuels. Perkins does not certify engines on any other biodiesel or biodiesel blends is related to the fuel. The user of the engine has the responsibility of typically lower volatility of biodiesel.
  • Page 100 Based on the feedstock NOTICE used these fuels are commonly referred to as Perkins does not warrant the quality or performance Biomass to liquid (BTL), Gas to liquid (GTL) and Coal of non-Perkins fluids and filters.
  • Page 101 500 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 102 Specification • Install desiccant type breathers of 4 µm or less DEF that is used in Perkins engines must meet the absolute efficiency with the ability to remove water ISO specification 22241-1 for quality. The ISO on bulk storage tanks.
  • Page 103 30° C (86° F) to 35° C (95° F) 6 months Above 35° C (95° F) test quality before use Perkins recommend that all DEF taken from storage should be checked to ensure that the DEF meets ISO standard 22241-1.

  • Page 104: 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 105 M0091784-05 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 106 • 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 107: Maintenance Interval Schedule

    M0091784-05 Maintenance Section Maintenance Interval Schedule “ Fuel System Secondary Filter - Replace“..142 i10210988 Maintenance Interval Schedule “ Battery Electrolyte Level - Check“ ... 110 “...
  • Page 108 M0091784-05 Maintenance Section Maintenance Interval Schedule “ Diesel Exhaust Fluid Filter (Emission Related Component) - Replace“ ..... 122 Every 3000 Service Hours or 2 Years “...

  • Page 109: 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 110: Battery Or Battery Cable - Disconnect

    M0091784-05 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 111: Belt - Inspect

    M0091784-05 Maintenance Section Belt - Inspect 2. Disconnect the negative battery terminal. Ensure To maximize the engine performance, inspect the belt (1) for wear and for cracking. Replace the belt if that the cable cannot contact the terminal. When the belt is worn or damaged. four 12 V batteries are involved, 2 negative connections must be disconnected.

  • Page 112: Clean Emissions Module Support - Inspect

    M0091784-05 Maintenance Section Clean Emissions Module Support - Inspect Ensure that the belt tensioner (2) is securely installed. Visually inspect the belt tensioner for damage. Check that the pulley on the tensioner rotates freely and that the bearing is not loose. Some engines have an idler pulley (1).
  • Page 113 Contaminants may cause rapid wear and shortened For information regarding the disposal and the component life. recycling of used coolant, consult your Perkins dealer or Perkins distributor. NOTICE Flush Care must be taken to ensure that fluids are con- tained during performance of inspection, mainte- nance, testing, adjusting and repair of the product.
  • Page 114 2. Start and run the engine at low idle. Increase the suitable cleaning agent to remove any debris. engine rpm to high idle. Operate the engine to Refer to your Perkins dealer or distributor for open the engine thermostat. This operation will suitable cleaning agents.
  • Page 115 To open the cooling system filler cap, For information regarding the disposal and the stop the engine and wait until the cooling system recycling of used coolant, consult your Perkins dealer components are cool. Loosen the cooling system or Perkins distributor.

  • Page 116: Coolant Level - Check

    M0091784-05 Maintenance Section Coolant Level - Check 2. Start and run the engine at low idle. Increase the engine rpm to high idle. Operate the engine to open the engine thermostat. An open thermostat will allow any air in the system to be purged. Decrease the engine speed to low idle.

  • Page 117: Def Filler Screen (Emission Related Component) - Clean

    M0091784-05 Maintenance Section DEF Filler Screen (Emission Related Component) - Clean Test for SCA Concentration 3. Add the correct amount of SCA. Refer to the Operation and Maintenance Manual, “Refill Heavy-Duty Coolant/Antifreeze and SCA Capacities and Recommendations” for more information on SCA requirements. NOTICE 4.
  • Page 118 M0091784-05 Maintenance Section DEF Filler Screen (Emission Related Component) - Clean Type 1 DEF filler Screen 5. Install filler screen (3) into DEF tank neck adapter (4). Press filler screen into neck adapter and ensure that tabs (2) are located correctly. Install cap (1).
  • Page 119 M0091784-05 Maintenance Section DEF Manifold Filters (Emission Related Component) - Replace Type 1 Manifold (DEF Heater) 4. If the filler screen cannot be cleaned or the filler screen is damaged, then the filler screen must be replaced. 5. Install filler screen (3) into DEF tank neck adapter (4).
  • Page 120 M0091784-05 Maintenance Section DEF Manifold Filters (Emission Related Component) - Replace Illustration 67 g07722287 Illustration 66 g07722286 2. Remove outer filter (2) from DEF manifold (1). Discard the old outer filter (2). Illustration 68 g07722292 3. Pull locking clip (6) outwards and remove the DEF filter (3) from DEF pickup tube (4).

  • Page 121: Diesel Exhaust Fluid (Emission Related Component) - Fill

    M0091784-05 Maintenance Section Diesel Exhaust Fluid (Emission Related Component) - Fill 6. Install the manifold, refer to Disassembly and 1. Before filling the DEF tank, ensure that the DEF Assembly, “Manifold (DEF Heater) - Remove and lines have been purged. Purging of the DEF lines Install”...
  • Page 122 M0091784-05 Maintenance Section Diesel Exhaust Fluid Filter (Emission Related Component) - Replace i07350316 Diesel Exhaust Fluid Filter (Emission Related Component) - Replace Personal injury can result from improper han- dling of chemicals. Make sure you use all the necessary protective equipment required to do the job.
  • Page 123 M0091784-05 Maintenance Section Diesel Exhaust Fluid Injector (Emission Related Component) - Replace i07868558 Diesel Exhaust Fluid Injector (Emission Related Component) - Replace Illustration 71 g06215916 Typical example 3. Use supplied tool (5) to remove filter element (2) from DEF pump assembly (1). 4.

  • Page 124: Diesel Exhaust Fluid Tank - Flush

    M0091784-05 Maintenance Section Diesel Exhaust Fluid Tank - Flush i10210007 Diesel Exhaust Fluid Tank - Flush Required Tools Table 29 Required Tools Part Description Tool Part Number Plugs Flushing Procedure 1. Turn the key switch to the OFF position. The key switch must be OFF to allow the Diesel Exhaust Fluid (DEF) pump to purge, ensuring the system is free of pressurized DEF.
  • Page 125 M0091784-05 Maintenance Section Diesel Exhaust Fluid Tank - Flush 8. Reinstall the manifold (DEF heater) into the DEF tank. Refer to Disassembly and Assembly, “Manifold (DEF Heater) - Remove and Install” for the correct procedure. 9. Replace any DEF system components that were removed due to contamination.

  • Page 126: 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 127: Engine Air Cleaner Service Indicator - Inspect

    M0091784-05 Maintenance Section Engine Air Cleaner Service Indicator - Inspect If the air cleaner element becomes plugged, the air 3. If equipped install the new secondary filter can split the material of the air cleaner element. element. Install the primary filter element. Unfiltered air will drastically accelerate internal 4.

  • Page 128: Engine Air Precleaner - Check/Clean

    M0091784-05 Maintenance Section Engine Air Precleaner - Check/Clean Test the Service Indicator i08412716 Engine Crankcase Breather Service indicators are important instruments. Element (Emission Related • Check for ease of resetting. The service indicator should reset in less than three pushes. Component) - Replace (Type 2) •...
  • Page 129 M0091784-05 Maintenance Section Type 2 Illustration 79 g06623961 Illustration 80 g01884135 Typical example (B) Alignment position Note: The cut away from section (5) in the cap allows 1. Ensure that dirt cannot enter the breather access to the seal. assembly. Ensure that the outside body of the breather assembly is clean and free from damage.

  • Page 130: Engine Crankcase Breather Element (Emission Related Component) - Replace

    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 82 g02416001 (1) Connection to breather cap for the engine...
  • Page 131 M0091784-05 Maintenance Section Type 1 2. Rotate the cap (1) counterclockwise into the unlocked position. Remove the cap from the body of the breather (3). Note: The cap (1) is tightened or loosened by hand. If the cap (1) is difficult to remove, use a suitable tool to apply a suitable force to assist the removal of the cap (1).

  • Page 132: Engine Oil Sample - Obtain

    Clean the oil filler cap. Install the oil filler cap. recommended torques. If an increase in the oil level is noticed, refer to When the engine mounts are supplied by Perkins the Troubleshooting, “Oil Contains Fuel”. maintenance procedure will be supplied in the Disassembly and Assembly manual for your engine.

  • Page 133: Engine Oil And Filter - Change

    250 hours. If the engine is operated in severe service conditions, Perkins recommends the use of engine oil sampling. Refer to this Operation and Maintenance Manual, Engine Oil sample - Obtain for more information.
  • Page 134 Perkins oil filters are manufactured to Perkins specifi- cations. Use of an oil filter that is not recommended by Perkins could result in severe damage to the en- gine bearings, crankshaft, as a result of the larger waste particles from unfiltered oil entering the engine lubricating system.
  • Page 135 M0091784-05 Maintenance Section Engine Oil and Filter - Change Horizontal Oil Filter 6. Install the new oil filter. Spin on the oil filter (4) until the O ring contacts the sealing surface (2). Then rotate the oil filter ¾ of a full turn. Remove the container and disposal of the waste oil in accordance with local regulations.

  • Page 136: Fan Clearance - Check

    M0091784-05 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 137 M0091784-05 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 138: Fuel System - Prime

    M0091784-05 Maintenance Section Fuel System - Prime 3. Fan tip clearance at position (2) and (3) must be Note: Operating the engine for this period will help ensure that the fuel system is free of air.DO NOT 14 ± 2 mm (0.55 ± 0.079 inch). loosen the high-pressure fuel lines to purge air from the fuel system.
  • Page 139 For 7. Tighten the vent screw (1) to a torque of 2.5 N·m more information consult your Perkins distributor. (22 lb in). If necessary, tighten the vent screw on the secondary fuel filter. Tighten to a torque of Remove the Element (Type 1) 2.5 N·m (22 lb in).
  • Page 140 M0091784-05 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 2. Place a suitable container under the water separator to catch any fuel that might spill. Clean up any spilled fuel. Clean the outside body of the filter assembly. Illustration 97 g06463169 9.
  • Page 141 M0091784-05 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace Install the New Filter Element (Type 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 142: Fuel System Primary Filter/Water Separator

    M0091784-05 Maintenance Section Fuel System Primary Filter/Water Separator - Drain 4. Remove the container and dispose of the fuel in a safe place. 5. The secondary filter element must be replaced at the same time as the primary filter element. Refer to the Operation and Maintenance Manual, “Fuel System Secondary Filter - Replace”.
  • Page 143 (General Fuel Information) of this OMM. It is recom- mended that new fuel filters are installed every 250 service hours in severe operating conditions. For more information consult your Perkins distributor. Remove the Element 1. Turn the fuel supply valve (if equipped) to the OFF position before performing this maintenance.
  • Page 144 M0091784-05 Maintenance Section Fuel System Secondary Filter - Replace Install the Element Illustration 102 g07555883 7. Rotate the filter element (5) counterclockwise and Illustration 103 g07555940 remove the filter element. Clean the filter bowl. 1. Locate the thread (7) on the filter element onto the threads (8) in the bottom of the filter bowl (2).

  • Page 145: Hoses And Clamps - Inspect/Replace

    M0091784-05 Maintenance Section Fuel Tank Water and Sediment - Drain 6. Prime the fuel system. Refer to the Operation and Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel Maintenance Manual, “Fuel System - Prime” for supply pipe.

  • Page 146: Radiator - Clean

    M0091784-05 Maintenance Section Radiator - Clean Check for the following conditions: 3. Drain the coolant from the cooling system to a level that is below the hose that is being replaced. • End fittings that are damaged or leaking 4. Remove the hose clamps. •...

  • Page 147: Starting Motor - Inspect

    Clean the core from the front and rear. Test” for more information on the checking procedure and for specifications consult your Perkins dealer or Use a degreaser and steam for removal of oil and your Perkins distributor for assistance.
  • Page 148 M0091784-05 Maintenance Section Turbocharger - Inspect Single Turbocharger 5. Install the air intake pipe and the exhaust outlet pipe to the turbocharger housing. Ensure that all clamps are installed correctly and that all clamps are tightened securely. For more information, refer to Systems Operation, Testing, and Adjusting, “Turbocharger - Inspect”.

  • Page 149: Walk-Around Inspection

    M0091784-05 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 150 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 151: Water Pump - Inspect

    M0091784-05 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 152: Warranty Section

    1 through Tier 4 marine auxiliary engines < 37 kW, Warranty supplement - Emission warranty parts but excluding locomotive and other marine available at the Perkins engines website. Consult engines) operated and serviced in the state of your authorized Perkins distributor to determine if...

  • Page 153: 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 154 M0091784-05 Reference Information Section Maintenance Log i05204675 Maintenance Log Table 30 Engine Model Customer Identifier Arrangement Number Serial Number Service Quantity Of Service Item Date Authorization Hours Fuel...
  • Page 155 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 156: Index

    M0091784-05 Index Section Index Flush ............113 Coolant (ELC) - Change.........114 Additional Messages ........11 Drain ............115 After Starting Engine ........68 Fill ...............115 After Stopping Engine ........84 Flush ............115 Aftercooler Core - Clean/Test (Air-To-Air Coolant Level - Check ........116 Aftercooler) ..........109 Cooling System Supplemental Coolant Aftercooler Core - Inspect ......
  • Page 157 M0091784-05 Index Section Engine Air Cleaner Service Indicator - Fluid Recommendations (Diesel Exhaust Inspect ............127 Fluid (DEF)) ..........102 Test the Service Indicator ......128 General Information........102 Engine Air Precleaner - Check/Clean ... 128 Fluid Recommendations (General Fuel Engine Crankcase Breather Element Information) ...........
  • Page 158 Replace the Hoses and the Clamps ..146 Aftertreatment Systems ....... 37 Engine Serial Number Plate (1)....37 Product Description......... 33 Important Safety Information......2 Aftermarket Products and Perkins Engines ............36 Aftertreatment System......... 35 Electronic Engine Features ......34 Lifting and Storage .......... 40 Engine Cooling and Lubrication ....
  • Page 159 M0091784-05 Index Section Reference Material (Extended Service Contract)............155 Walk-Around Inspection ........ 149 Reference Materials ........153 Engine Aftertreatment........ 151 Refill Capacities..........86 High-Pressure Fuel Lines ......150 Cooling System..........86 Inspect the Engine for Leaks and Loose Diesel Exhaust Fluid (DEF) ......87 Connections ..........
  • Page 161 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 162 M0091784 ©2024 Perkins Engines Company Limited All Rights Reserved July 2024...

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