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

Perkins 1206EA-E70TTA Operation And Maintenance Manual

Industrial engine
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M0173087 (en-us)
July 2024
Operation and
Maintenance
Manual
1206EA-E70TTA Industrial Engine

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Summary of Contents for Perkins 1206EA-E70TTA

  • Page 1 M0173087 (en-us) July 2024 Operation and Maintenance Manual 1206EA-E70TTA Industrial 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

    M0173087 Table of Contents Table of Contents Cold Weather Operation ......... 71 Engine Stopping ..........76 Foreword ............4 Maintenance Section Safety Section Refill Capacities..........78 Safety Messages..........6 Maintenance Recommendations ....96 Additional Messages ......... 9 Maintenance Interval Schedule....... 99 General Hazard Information......

  • Page 4: Foreword

    State of arises regarding your engine, or this manual, please California to cause cancer, birth defects, consult with your Perkins dealer or your Perkins distributor for the latest available information. and other reproductive harm. WARNING – This product can...
  • Page 5 Perkins distributor offers various options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available. Consult with your Perkins dealer or your Perkins distributor for information regarding these options.

  • Page 6: Safety Section

    Replace any warning sign that is damaged or missing. If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Your Perkins distributor can provide new warning signs. Universal Warning...
  • Page 7 M0173087 Safety Section Safety Messages Illustration 2 g06785533 Typical example (1) Universal warning label on valve (2) Universal warning label on intake mechanism cover manifold The universal warning label is installed in two positions on the engine. On the valve mechanism cover and on the intake manifold, refer to illustration Ether Warning Do not use aerosol types of starting aids such as...
  • Page 8 M0173087 Safety Section Safety Messages The ether warning label is installed on the air cleaner close to the air intake. The location will depend on the application. In some applications, the ether label will be supplied loose for fitting by the engine installer.

  • Page 9: Additional Messages

    DEF could freeze and a message is attached to a part that is replaced, cause damage to the pump and lines. install a message on the replacement part. Replacement labels may be obtained from Perkins distributors.

  • Page 10: General Hazard Information

    M0173087 Safety Section General Hazard Information • Use all cleaning solutions with care. i08312804 General Hazard Information • Report all necessary repairs. Unless other instructions are provided, perform the maintenance under the following conditions: • The engine is stopped. Ensure that the engine cannot be started.
  • Page 11 Do not disassemble any hydraulic • Perkins recommend that you do not stand next to components or parts until pressure has been relieved an exposed running engine unless it is necessary or personal injury may occur.
  • Page 12 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 13 • 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 14: Burn Prevention

    M0173087 Safety Section Burn Prevention Always use leakproof containers when you drain After the engine has stopped, wait for 10 minutes to fluids. Do not pour waste onto the ground, down a allow the fuel pressure to be purged from the high- drain, or into any source of water.

  • Page 15: 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 16 M0173087 Safety Section Fire Prevention and Explosion Prevention Store fuels and lubricants in correctly marked containers away from unauthorized persons. Store oily rags and any flammable materials in protective containers. Do not smoke in areas that are used for storing flammable materials. Do not expose the engine to any flame.

  • Page 17: Crushing Prevention And Cutting Prevention

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

  • Page 18: Mounting And Dismounting

    M0173087 Safety Section Mounting and Dismounting When objects are struck, wear protective glasses to avoid injury to the eyes. Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure that no one will be injured by flying debris. i05768982 Mounting and Dismounting Do not climb on the engine or the engine...

  • Page 19: Before Starting Engine

    M0173087 Safety Section Before Starting Engine The high-pressure fuel lines are the fuel lines that are • Do not attach any other item to the high-pressure between the high-pressure fuel pump and the high- fuel lines. pressure fuel manifold and the fuel lines that are between the fuel manifold and fuel injectors.

  • Page 20: Engine Starting

    These engines are equipped with a glow plug starting aid in each cylinder which heats the intake air to improve starting. Some Perkins engines may have a cold starting system that is controlled by the ECM which allows a controlled flow of ether into the engine.
  • Page 21 M0173087 Safety Section Electrical System Grounding Practices Illustration 17 g06772560 Typical example (4) Ground to the battery (5) Ground to the engine block (6) Primary position for grounding Correct grounding for the engine electrical system is necessary for optimum engine performance and reliability.

  • Page 22: Engine Electronics

    Note: Many of the engine control systems and Tampering with the electronic system installation or the OEM wiring installation can be dangerous display modules that are available for Perkins and could result in personal injury or death and/ engines will work in unison with the Engine or engine damage.

  • Page 23: Product Information Section

    M0173087 Product Information Section General Information Product Information Section General Information i10236447 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. Series Turbocharged Engine Illustration 18 g06787332 Typical example...
  • Page 24 M0173087 Product Information Section Model View Illustrations Illustration 19 g06787339 Typical example (8) Coolant pump (10) Crankshaft damper (12) Drive belt (9) Idle roller for drive belt (11) Belt tensioner...
  • Page 25 (24) Exhaust Back Pressure Regulator (15) Alternator (21) Flywheel (EBPR) (16) Refrigerant compressor (22) Flywheel housing Aftertreatment Systems There are two types of aftertreatment systems that the 1206EA-E70TTA engine could use. The type used will depend on engine rating /power.
  • Page 26 M0173087 Product Information Section Model View Illustrations Enclosed Type Clean Emission Module Open Type Clean Emission Module Illustration 21 g06791119 Typical example (1) Enclosed clean emission module The enclosed CEM contains three main parts the Diesel Oxidation Catalyst (DOC) Diesel Particulate Filter (DPF) and the Selective Catalytic Reduction Illustration 22 g06793134...
  • Page 27 M0173087 Product Information Section Model View Illustrations The open type CEM contains three main parts the Diesel Oxidation Catalyst (DOC) (1) Selective Catalytic Reduction (SCR) (3) and the Diesel Particulate Filter (DPF) (4). The open type CEM also has a mixer chamber (2). Pump Tank Unit (PTU) Illustration 23 g06791088...
  • Page 28 M0173087 Product Information Section Model View Illustrations Illustration 24 g06791094 Typical examples (1) Diesel Exhaust Fluid (DEF) Pump tank (4) Inlet air temperature sensor (8) Secondary fuel filters unit (5) NOx sensors (9) Fuel filter connection hose (2) Soot sensor control (6) Primary fuel filter (3) DEF heated line (7) Priming/transfer pump...
  • Page 29 M0173087 Product Information Section Model View Illustrations Illustration 27 g07757935 Typical example (C) Open Type CEM identification plate Illustration 25 g07118147 Typical example (A) CEM identification plate Illustration 28 g07757941 Typical example (D) Position of the SCR marking Illustration 26 g07116071 Typical example (B) Position of the SCR, DOC, and DPF marking...
  • Page 30 M0173087 Product Information Section Model View Illustrations Illustration 30 g07757953 Illustration 32 g07758023 Typical example Typical example (F) Position of the high-pressure turbocharger marking (J) Position of the ECM marking (G) Position of the low-pressure turbocharger marking Illustration 33 g07758030 Typical example (K) Position of the fuel manifold (rail) marking Illustration 31...
  • Page 31 (L) Position of the fuel injection pump marking (M) Position of the NOx Reduction System (NRS) cooler marking i10236454 Product Description (Engine and Aftertreatment) The Perkins 1206EA-E70TTA is a series turbocharged industrial engine and have the following characteristics. • In-line Six cylinder • Four stroke cycle •...
  • Page 32 Table 1 engine systems are functioning correctly. The operator will be alerted to the condition by a “Stop or 1206EA-E70TTA Series Turbocharged Engine Specifications Warning” lamp. Under certain conditions, the engine horsepower and the vehicle speed may be limited. Operating Range (rpm)
  • Page 33 “Overhaul Considerations” topic (Maintenance Section). 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) made by other manufacturers are used on Perkins products, the Perkins warranty is not affected simply because of such use.

  • Page 34: Product Identification Information

    Typical example serial number plate Clean Emissions Module (CEM) Illustration 37 g06773028 (1) Location of the engine serial number plate Perkins engines are identified by an engine serial number. An example of an engine number is VS*****U000001C. ***** The list number for the engine...
  • Page 35 M0173087 Product Information Section Plate Locations and Film Locations Illustration 41 g06394552 Typical example of a CEM identification plate Pump Tank Unit (PTU) Illustration 40 g06801650 Typical example of open type CEM The identification plate (2) is on the end of the CEM. Illustration 42 g06773071 Typical example...
  • Page 36 Typical example of a PTU serial plate Record the information on the CEM and PTU serial plates. The information will be required by your Perkins distributor to identify replacement part numbers. i07676597 Emissions Certification Film The label for the emissions is installed on the front gear cover.
  • Page 37 M0173087 Product Information Section Reference Information Lubrication Oil Filter Element Auxiliary Oil Filter Element (if equipped) Total Lubrication System Capacity Total Cooling System Capacity Air Cleaner Element Drive Belt Clean Emissions Module Part Number Serial Number Pump Tank Unit Part Number Serial Number...

  • Page 38: Operation Section

    The chains and cables should be perpendicular to the top of the object that is being lifted. Perkins recommends that model-specific cradles are used to store and transport engines. Supporting engines on the sump/oil pan is not recommended under any circumstances.
  • Page 39 M0173087 Operation Section Product Lifting Engine and Clean Emission Module (CEM) Illustration 47 g06773179 Typical example (2) Lifting eyes for the CEM Refer to illustration 47 for the location of the lifting eyes to lift the CEM. The lifting eyes (2) are designed only to lift the CEM.
  • Page 40 The engine must be stored in a water proof building. The building must be kept at a constant temperature. Engines that are filled with Perkins ELC will have coolant protection to an ambient temperature of −36° C (−32.8° F). The engine must not be subjected...
  • Page 41 M0173087 Operation Section Engine and Aftertreatment Storage Period Monthly Checks An engine can be stored for up to 6 months provided The crankshaft must be rotated to change the spring all the recommendations are adhered to. loading on the valve train. Rotate the crankshaft more than 180 degrees.
  • Page 42 M0173087 Operation Section Engine and Aftertreatment 3. Ensure that the drive belt is correctly installed. Ensure that all engine coolant and engine oil has the correct specification and grade. Ensure that the coolant and the engine oil are at the correct level.

  • Page 43: Features And Controls

    M0173087 Operation Section Features and Controls Features and Controls Intake manifold air temperature – The intake manifold air temperature sensor indicates high intake air temperature. i10133133 Intake manifold pressure – The intake manifold Alarms and Shutoffs pressure sensor checks the rated pressure in the engine manifold.
  • Page 44 DEF system. Not allowing the engine Determine and correct the cause of any significant ECM time to store the information from the sensors change in the readings. Consult your Perkins dealer can damage to emission control system. or your Perkins distributor for assistance.
  • Page 45 3. Inspect the cooling system for leaks. If necessary, These indicator lamps can be used in two ways: consult your Perkins dealer or your Perkins distributor for assistance. • The indicator lamps can be used to identify the current operational status of the engine.
  • Page 46 M0173087 Operation Section Monitoring System The function of the low oil pressure lamp is controlled Ensure that the engine maintenance is carried out at by the engine ECM. If low oil pressure is detected, the correct intervals. A lack of maintenance can result in illumination of the warning lamp.
  • Page 47 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 48 M0173087 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 49 M0173087 Operation Section Sensors and Electrical Components Illustration 52 g06802854 Typical example with the CEM removed (9) Wastegate regulator solenoid (12) Fuel pressure sensor (15) Manifold inlet pressure sensor (10) Control valve for the NOx Reduction (13) NRS Differential pressure sensor (8) Solenoid for high-pressure fuel pump System (NRS) (14) Manifold inlet temperature...
  • Page 50 M0173087 Operation Section Sensors and Electrical Components Illustration 53 g06800962 Typical example (17) Alternator (19) Starting motor (21) Exhaust Back Pressure Regulator (18) Refrigerant compressor (20) Secondary speed/timing sensor (EBPR)
  • Page 51 M0173087 Operation Section Sensors and Electrical Components Illustration 54 g06800969 Typical example (22) Water in fuel switch (23) Inlet air temperature sensor Aftertreatment Components...
  • Page 52 M0173087 Operation Section Sensors and Electrical Components Illustration 55 g06800965 Typical example (1) Diesel Exhaust Fluid (DEF) Pump Tank (3) DEF heated line (5) Open type Clean Emission Module Unit (PTU) (4) NOx sensors (CEM) (2) Soot sensor control (6) Enclosed Clean Emission Module (CEM)
  • Page 53 M0173087 Operation Section Sensors and Electrical Components Enclosed Type Clean Emissions Module (CEM) Illustration 56 g06800941 Typical example (1) DEF injector (4) DPF temperature probe (7) Two probe temperature sensor (2) Soot sensor antenna (5) SCR temperature probe (3) Soot sensor antenna (6) Identification module...
  • Page 54 M0173087 Operation Section Sensors and Electrical Components Open Type Clean Emissions Module Illustration 58 g06238274 Typical example (2) DOC temperature probe (3) Three probe temperature sensor (4) SCR temperature probe (5) DEF injector (6) Soot sensor antenna (7) Soot sensor antenna (8) DPF temperature probe Illustration 57 g06237257...
  • Page 55 M0173087 Operation Section Sensors and Electrical Components Soot Sensors and NOx Sensors Illustration 59 g06239270 Typical example (1) Soot sensor (2) NOx sensors The location of the (1) soot sensor and the (2) NOx sensors will depend on the application. Pump Tank Unit (PTU) Illustration 60 g06802764...

  • Page 56: Engine Diagnostics

    The sequence of flashes represents the system diagnostic message. Count the first sequence of flashes in Perkins Electronic Engines have the capability to order to determine the first digit of the flash code. perform a self-diagnostics test. When the system...
  • Page 57 M0173087 Operation Section Engine Operation with Intermittent Diagnostic Codes Note: If the customer has selected “DERATE” and if The electronic service tool is required to alter the configuration parameters. there is a low oil pressure condition, the Electronic Control Module (ECM) will limit the engine power System Configuration Parameters until the problem is corrected.
  • Page 58 M0173087 Operation Section Configuration Parameters Table 4 System Configuration Parameters Configuration Parameters Record Engine Serial Number 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...
  • Page 59 M0173087 Operation Section Configuration Parameters (Table 5, contd) Engine Idle Shutdown Ambient Temperature Override Enable Status High Soot Load Aftertreatment Protection Enable Status Air Shutoff Throttle Lock Feature Installation Status PTO Mode Throttle Lock Engine Set Speed #1 Throttle Lock Engine Set Speed #2 Throttle Lock Increment Speed Ramp Rate Throttle Lock Decrement Speed Ramp Rate Throttle Lock Engine Set Speed Increment...
  • Page 60 M0173087 Operation Section Configuration Parameters (Table 5, contd) Engine Cooling Fan Minimum Air Flow Coolant Temperature Engine Cooling Fan Control Transmission Oil Temperature Input Enable Status Engine Cooling Fan Maximum Air Flow Transmission Oil Temperature 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...

  • Page 61: Engine Starting

    M0173087 Operation Section Engine Starting Engine Starting i08165229 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 62 M0173087 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 63 M0173087 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 64 M0173087 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 65: Engine Operation

    M0173087 Operation Section Engine Operation Engine Operation Carbon Dioxide (CO2) Emissions Emissions regulations require that the value of the emissions be reported to the end user. For this i10237242 engine, 727.598 g/kWh was determined to be the Engine Operation value during the EU type approval process. This value was recorded in EU type approval certificate.
  • Page 66 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 67: Aftertreatment Operation

    DEF injector. Any warning should be investigated immediately. Contact your Perkins distributor if further assistance is required. NOTICE Allow at least 2 minutes after shutting down the en- The system is equipped with a safe harbor mode.
  • Page 68 M0173087 Operation Section NOx Reduction System (NRS), Particulate Control Diagnostics (PCD) and Inducement Warning System • Notification Action taken by the system to alert NOTICE the operator of pending Inducement. It is essential to take prompt action to rectify any in- correct operation, use, or maintenance of the emis- •...
  • Page 69 Contact your Perkins distributor at level 1 warning, do not let the fault develop. The emission malfunction lamp will be on solid or flashing depending on customer display configuration in the application. Additional escalated annunciation used by customer to indicate inducement level if the emission lamp is configured to on solid at level 2 (mild) and level 2 (Severe).
  • Page 70 M0173087 Operation Section NOx Reduction System (NRS), Particulate Control Diagnostics (PCD) and Inducement Warning System • At Level 2 mild and Level 2 severe the low-level warning lamp for the DEF is active and the emission malfunction lamp will be solid or flash. An additional escalated annunciation will be enabled.

  • Page 71: Cold Weather Operation

    This means that an engine can be shut down for aperiodof timeand the retained heat within the engine will allow the engine readily start. Perkins Diesel Engines can operate effectively in cold weather. During cold weather, the starting and • Install the correct specification of engine lubricant the operation of the diesel engine depends on the before the beginning of cold weather.
  • Page 72 80° C (176° F) minimum. Carbon 240 V dc. The output can be 750/1000W. Consult deposits on the valve stems will be kept at a your Perkins dealer or your Perkins distributor for minimum. The free operation of the valves and the more information.
  • Page 73 M0173087 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 74 M0173087 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 75 M0173087 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 76: Engine Stopping

    M0173087 Operation Section Engine Stopping Engine Stopping The OEM may have equipped the application with an emergency stop button. For more information about the emergency stop button, refer to the OEM information. i07161953 Ensure that any components for the external system Stopping the Engine that support the engine operation are secured after the engine is stopped.
  • Page 77 M0173087 Operation Section After Stopping Engine NOTICE Only use antifreeze/coolant mixtures recommended in this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic or in this Operation and Maintenance Manual, “Fluid Recom- mendations” topic. Failure to do so can cause engine damage.

  • Page 78: Maintenance Section

    These values are the approximate capacities for the crankcase oil sump (aluminum) which includes the standard factory in- DEF that is used in Perkins engines must meet the stalled oil filters. Engines with auxiliary oil filters will require ISO specification 22241-1 for quality. The ISO more oil.
  • Page 79 NOTICE If the engine is to be stored in, or shipped to an area Perkins recommend that all DEF taken from storage with below freezing temperatures, the cooling system should be checked to ensure that the DEF meets ISO must be either protected to the lowest outside tem- standard 22241-1.
  • Page 80 Additives must be added at the correct concentration. Water, additives, and glycol. Over concentration of additives can cause the inhibitors to drop out-of-solution. The deposits can Refer to Perkins Diesel Engines Fluids enable the following problems to occur: Recommendations, M0113102 for additional information that relates to coolant.
  • Page 81 NOTICE The Perkins industrial engines with a NOx reduc- Table 15 tion system must be operated with a minimum Propylene Glycol 30% volume glycol-water mixture, Perkins recom-...
  • Page 82 (if equipped) must be set to the HOT position. Refer agents with low amounts of nitrite. Perkins ELC has to the OEM to set the heater control. After the cooling been formulated with the correct amount of these...
  • Page 83 Perkins. NOTICE Do not mix types and brands of coolant. 6. Fill the cooling system with the Perkins Premixed Do not mix brands and types of SCAs. ELC. Operate the engine. Ensure that all coolant valves open then stop the engine. When cool Do not mix SCAs and Extenders.
  • Page 84 • Take a sample of the solution from the cooling “EMA Recommended Guideline on Diesel Engine system, drain the system. Oil”. In addition to Perkins definitions, there are other definitions that will be of assistance in purchasing • Allow the sample to sit for at least 30 minutes and lubricants.
  • Page 85 Failure to use the appropriate speci- support off-road applications, including Perkins fication of engine oil will also reduce the life of Engines. DO NOT use API FA-4 oil for Perkins your aftertreatment system. engines. These engine oils are not approved by...
  • Page 86 Aftermarket Oil Additives allows technicians to determine the amount of deterioration of the oil during use. This analysis Perkins does not recommend the use of aftermarket also allows technicians to verify the performance additives in oil. The use of aftermarket additives is...
  • Page 87 M0173087 Maintenance Section General Fuel Information • RME Rape Methyl Ester NOTICE The footnotes are a key part of the Perkins "Specifi- • SME Soy Methyl Ester cation for Distillate Diesel Fuel" Table. Read ALL of the footnotes. • EPA...
  • Page 88 M0173087 Maintenance Section General Fuel Information Table 22 "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 89 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 90 “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 91 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 92 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 93 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 94 500 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 95 M0173087 Maintenance Section General Fuel Information • Ensure that you use Perkins Advanced Efficiency Fuel Filters. Change your fuel filters per recommended service requirements or as needed. • Drain your water separators daily. • Drain your fuel tanks of sediment and water per the Operation and Maintenance Manual instructions.

  • Page 96: 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 97 M0173087 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 98 • 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 99: Maintenance Interval Schedule

    M0173087 Maintenance Section Maintenance Interval Schedule “ Fuel System Primary Filter (Water Separator) i10237044 Element - Replace“ ......129 Maintenance Interval Schedule “...
  • Page 100 M0173087 Maintenance Section Maintenance Interval Schedule “ Diesel Exhaust Fluid Injector (Emission Related Component) - Replace“ ..... 115 Every 6000 Service Hours or 3 Years “...
  • Page 101 Aftercooler Core - Inspect Alternator - Inspect Note: Adjust the frequency of cleaning according to Perkins recommends a scheduled inspection of the the effects of the operating environment. alternator. Inspect the alternator for loose connections and correct battery charging. Check the...
  • Page 102 M0173087 Maintenance Section Battery - Replace 9. Connect the NEGATIVE “-” cable to the i05425759 NEGATIVE “-” battery terminal. Battery - Replace 10. Turn the battery disconnect switch to the ON position. i02747977 Battery Electrolyte Level - Batteries give off combustible gases which can explode.
  • Page 103 M0173087 Maintenance Section Battery or Battery Cable - Disconnect i05424317 i08773629 Battery or Battery Cable - Belt - Inspect Disconnect The battery cables or the batteries should not be removed with the battery cover in place. The bat- tery cover should be removed before any servic- ing is attempted.
  • Page 104 M0173087 Maintenance Section Belt Tensioner - Check i08773635 i10236748 Belt Tensioner - Check Coolant (Commercial Heavy- Duty) - Change Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist: • The engine overheats frequently. •...
  • Page 105 1. Flush the cooling system with clean water and a suitable cleaning agent to remove any debris. Refer to your Perkins dealer or distributor for suitable cleaning agents. 2. Install connection hose. Clean the drain plugs.
  • Page 106 M0173087 Maintenance Section Coolant (ELC) - Change 5. Start the engine. Inspect the cooling system for NOTICE leaks and for the correct operating temperature. Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components.
  • Page 107 1. Flush the cooling system with clean water and a engine. suitable cleaning agent to remove any debris. Refer to your Perkins dealer or distributor for 3. Maintain the coolant level at the maximum mark suitable cleaning agents. that is correct for your application.
  • Page 108 M0173087 Maintenance Section Coolant Level - Check 4. Clean the cooling system filler cap. Inspect the gasket that is on the cooling system filler cap. If the gasket that is on the cooling system filler cap is damaged, discard the old cooling system filler cap and install a new cooling system filler cap.
  • Page 109 M0173087 Maintenance Section Crankshaft Vibration Damper - Inspect 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 110 M0173087 Maintenance Section DEF Filler Screen (Emission Related Component) - Clean For information on removal of the crankshaft damper, 3. The filter screen can be cleaned in clean water and refer to Disassembly and Assembly, “Vibration dried using compressed air. Refer to this Damper and Pulley - Remove and Install”.
  • Page 111 M0173087 Maintenance Section DEF Manifold Filters (Emission Related Component) - Replace 8. Tighten clamp (2) to a torque of 4.5 ± 0.7 N·m (40 ± 6 lb in). 9. Install the DEF tank header, refer to Disassembly and Assembly, Manifold (DEF Heater) - Remove and Install.
  • Page 112 M0173087 Maintenance Section Diesel Exhaust Fluid (Emission Related Component) - Fill 6. Install the manifold, refer to Disassembly and Assembly, “Manifold (DEF Heater) - Remove and Install” for the correct procedure. i08775656 Diesel Exhaust Fluid (Emission Related Component) - Fill Refer to this Operation and Maintenance Manual, “Refill Capacities”...
  • Page 113 M0173087 Maintenance Section Diesel Exhaust Fluid Filter (Emission Related Component) - Replace Ensure that the correct specification Diesel Exhaust i08809919 Fluid (DEF) is used. Ensure the cleanliness of the Diesel Exhaust Fluid Filter DEF, refer to this Operation and Maintenance Manual, “Fluid Recommendations”...
  • Page 114 M0173087 Maintenance Section Diesel Exhaust Fluid Filter (Emission Related Component) - Replace Illustration 83 g06215916 Typical example 3. Use supplied tool (5) to remove filter element (2) from DEF pump assembly (1). 4. Install new filter element (2) into DEF pump assembly (1).
  • Page 115 M0173087 Maintenance Section Diesel Exhaust Fluid Injector (Emission Related Component) - Replace i08775698 i10236290 Diesel Exhaust Fluid Injector Diesel Exhaust Fluid Tank - (Emission Related Flush Component) - Replace Illustration 85 g06774313 Typical example Illustration 84 g06158030 Typical example If contamination of the Diesel Exhaust Fluid (DEF) is (1) DEF injector suspected, the DEF tank (3) will need to be drained (2) DEF connector...
  • Page 116 Periodic cleaning of the engine is recommended. If the DEF tank has been filled with another fluid Steam cleaning the engine will remove accumulated other than DEF, then contact your Perkins distributor. oil and grease. A clean engine provides the following benefits: i08397642 •...
  • Page 117 Note: The air filter system may not have been 2. Remove the end cap (1). Remove the air filter provided by Perkins. The procedure that follows is for element within the main body (2), if a secondary a typical air filter system. Refer to the OEM filter element is installed then, remove the information for the correct procedure.
  • Page 118 M0173087 Maintenance Section Engine Air Precleaner - Check/Clean Some engines are equipped with a differential gauge The service indicator may need to be replaced for inlet air pressure. The differential gauge for inlet frequently in environments that are severely dusty. air pressure displays the difference in the pressure that is measured before the air cleaner element and i10077461...
  • Page 119 For information on aftermarket products, refer to Operation and Maintenance Manual, “Engine Description”. Within that section, refer to the title “Aftermarket Products and Perkins Engines”. The breather element can be serviced from the top position or the breather element can be serviced from the bottom position.
  • Page 120 M0173087 Maintenance Section Type 1 5. Install a new filter element into the breather body (3). Ensure the correct position of the element, refer to illustration 91 . Align position (A) on the top cap to position (B) on the filter element. Illustration 90 g03090963 4.
  • Page 121 M0173087 Maintenance Section Type 1 Illustration 93 g02346498 Typical example (X) Alignment mark (Y) Alignment mark 1. Ensure that the outside body of the breather assembly is clean and free from damage. Place a Illustration 94 g03090968 container under the breather. Typical example (A) Alignment postion 2.
  • Page 122 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 95 g02346500 Typical example Inspect the breather outlet pipe (1) for damage.
  • Page 123 Engine Mounts - Inspect Note: The engine mounts may not have been supplied by Perkins. Refer to the Original Equipment Manufacturer (OEM) information for further details on the engine mounts and the correct bolt torque. Inspect the engine mounts for deterioration and for correct bolt torque.
  • Page 124 Refer to the OEM information for the istics and could result in the loss of power. recommended torques. When the engine mounts are supplied by Perkins the 2. Remove the oil filler cap and add oil, if necessary. maintenance procedure will be supplied in the Clean the oil filler cap.
  • Page 125 250 hours. Engine Oil and Filter - Change 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 126 Perkins oil filters are manufactured to Perkins specifi- cations. Use of an oil filter that is not recommended by Perkins could result in severe damage to the en- gine bearings, crankshaft, and so forth. As a result of the larger waste particles from unfiltered oil entering the engine lubricating system.
  • Page 127 M0173087 Maintenance Section Fan Clearance - Check 4. Install the new oil filter. Spin on the oil filter until the 4. Remove the engine oil level gauge to check the oil O ring contacts the sealing surface (1). Then level. Maintain the oil level between the “L” and “H” rotate the oil filter ¾...
  • Page 128 M0173087 Maintenance Section Fuel System - Prime Illustration 104 g07728426 Typical example Ensure that the cooling system is full before checking If the fan tip clearance requires adjustment, refer to the fan tip clearance. The fan tip clearance is the the Disassembly and Assembly manual for more distance between the tip of the fan blade (2) and the information.
  • Page 129 For ensure that the fuel system is free of air. DO NOT more information consult your Perkins distributor. loosen the high-pressure fuel lines in order to purge air from the fuel system. This procedure is not required.
  • Page 130 6. Tighten the vent screw (1) securely . Remove the wiring harness from connection (4). 7. Rotate filter (6) counterclockwise and remove the filter (6) and filter bowl (7) from filter base (5). Refer to your Perkins distributor for the correct tool.
  • Page 131 2. Lubricate the seals (8) with clean diesel fuel. Do NOT fill the bowl with fuel before the assembly is installed. 3. Only use tools recommended by Perkins distributor to install the filter assembly. Tighten the filter bowl (7). Turn the filter clockwise until the filter locks into position against the filter base.
  • Page 132 For 5. When fluid free from water comes from the primary more information consult your Perkins distributor. fuel filter, tighten the drain valve clockwise by hand pressure only. Remove the tube and remove the container.
  • Page 133 M0173087 Maintenance Section Fuel System Secondary Filter - Replace Illustration 109 g06792704 3. Install a suitable tube onto drain (4). Open the drain valve (3). Rotate the drain valve counterclockwise. Two full turns are required. Loosen vent screw (1). Illustration 110 g06592360 4.
  • Page 134 M0173087 Maintenance Section Fuel Tank Water and Sediment - Drain Install the Element 6. Prime the fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” for more information. i02348492 Fuel Tank Water and Sediment - Drain NOTICE Care must be taken to ensure that fluids are con- tained during performance of inspection, mainte-...
  • Page 135 M0173087 Maintenance Section Hoses and Clamps - Inspect/Replace Some fuel tanks use supply pipes that allow water Check for the following conditions: and sediment to settle below the end of the fuel supply pipe. Some fuel tanks use supply lines that •...
  • Page 136 Make repairs, if necessary. Radiator - Clean i07888480 Starting Motor - Inspect The radiator is not usually supplied by Perkins. The following text describes a typical cleaning procedure for the radiator. Refer to the OEM information for further information on cleaning the radiator.
  • Page 137 M0173087 Maintenance Section Turbocharger - Inspect 2. Remove the pipe from the high-pressure NOTICE turbocharger exhaust outlet and remove the air Turbocharger bearing failures can cause large quan- intake pipe to the turbocharger. Visually inspect tities of oil to enter the air intake and exhaust sys- tems.
  • Page 138 Excessive coolant leakage may indicate the need to replace the water pump. Remove the water pump. Refer to Disassembly and Assembly, “Water Pump - Remove and Install”. For more information, consult your Perkins distributor. Illustration 113 g06775153 Typical example • Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil Inspect the breather tube (1) for damage.
  • Page 139 M0173087 Maintenance Section Water Pump - Inspect Belts for multiple groove pulleys must be replaced as • Check the condition of the gauges. Replace any matched sets. If only one belt is replaced, the belt will gauges that are cracked. Replace any gauge that carry more load than the belts that are not replaced.
  • Page 140 M0173087 Maintenance Section Water Pump - Inspect Note: The water pump seals are lubricated by the coolant in the cooling system. It is normal for a small amount of leakage to occur. Refer to illustration 114 for the position of the weep hole and the vent hole. Visually inspect the water pump for leaks.

  • Page 141: 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 142: 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 143 M0173087 Reference Information Section Maintenance Log i05204675 Maintenance Log Table 24 Engine Model Customer Identifier Arrangement Number Serial Number Service Quantity Of Service Item Date Authorization Hours Fuel...
  • Page 144 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 145: Index

    M0173087 Index Section Index Coolant (ELC) - Change........ 106 Drain ............106 Additional Messages ......... 9 Fill .............. 107 After Starting Engine ........63 Flush ............107 After Stopping Engine ........76 Coolant Level - Check ........108 Aftercooler Core - Clean/Test (Air-To-Air Cooling System Supplemental Coolant Aftercooler) ..........
  • Page 146 M0173087 Index Section Engine Crankcase Breather Element Contamination Control Recommendations for (Emission Related Component) - Replace Fuels ............94 (Type 1)............118 Diesel Fuel Characteristics......90 Bottom Service .......... 120 Diesel Fuel Requirements ......87 Check the System........122 General Information........87 Top Service ..........119 Foreword ............
  • Page 147 Engine............34 Pump Tank Unit (PTU)......... 35 Important Safety Information......2 Product Description (Engine and Aftertreatment) ..........31 Aftermarket Products and Perkins Engines ............33 Lifting and Storage .......... 38 Aftertreatment System......... 33 Electronic Engine Features ......32 Engine Cooling and Lubrication ....32 Maintenance Interval Schedule.......
  • Page 148 M0173087 Index Section Particulate Control Diagnostics (PCD) and Inducement Warning System) .... 67 Warning Indicators........67 Warning Levels ..........67 Warning Strategy ......... 67 Self-Diagnostics ..........56 Sensors and Electrical Components....48 Aftertreatment Components ......51 Engine Components ........48 Severe Service Application ......
  • Page 149 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 150 M0173087 ©2024 Perkins Engines Company Limited All Rights Reserved July 2024...

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