Perkins 1206J-E70TA Operation And Maintenance Manual
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Perkins 1206J-E70TA Operation And Maintenance Manual

Perkins 1206J-E70TA Operation And Maintenance Manual

Industrial engines
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M0082024-06 (en-us)
April 2024
Operation and
Maintenance
Manual
1206J-E70TA and 1206J-E70TTA
Industrial Engines

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Summary of Contents for Perkins 1206J-E70TA

  • Page 1 M0082024-06 (en-us) April 2024 Operation and Maintenance Manual 1206J-E70TA and 1206J-E70TTA Industrial Engines...

  • Page 2: Important Safety Information

    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

    M0082024-06 Table of Contents Table of Contents Cold Weather Operation ......... 78 Engine Stopping ..........83 Foreword ............4 Maintenance Section Safety Section Refill Capacities..........85 Safety Messages..........6 Maintenance Recommendations ....103 Additional Messages ......... 9 Maintenance Interval Schedule..... 106 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: Maintenance Intervals

    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

    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 dealer or your Perkins distributor can provide new warning signs. Universal Warning 1...

  • Page 7: Ether Warning

    M0082024-06 Safety Section Safety Messages Illustration 2 g06224829 Typical example 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 2 Do not use aerosol types of starting aids such as ether.

  • Page 8: Hand (High Pressure)

    M0082024-06 Safety Section Safety Messages Illustration 4 g06400816 Typical example The ether warning label is installed on the air cleaner close to the air intake, refer to illustration 4 . 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

    The exact location of the messages and the a message is attached to a part that is replaced, description of the information are reviewed in this install a message on the replacement part. section. Become familiar with all messages. Replacement labels may be obtained from Perkins distributors.

  • Page 10: General Hazard Information

    M0082024-06 Safety Section General Hazard Information • Tampering with the engine installation or tampering with the OEM supplied wiring can be dangerous. Personal injury, death and/or engine damage could result. • Vent the engine exhaust to the outside when the engine is operated in an enclosed area.

  • Page 11: Pressurized Air And Water

    This action could bypass the engine neutral start system and/or the electrical system • Perkins recommend that you do not stand next to could be damaged. an exposed running engine unless it is necessary...

  • Page 12: Fluid Penetration

    M0082024-06 Safety Section General Hazard Information When pressurized air and/or pressurized water is Dispose of all fluids according to local regulations used for cleaning, wear protective clothing, protective and mandates. shoes, and eye protection. Eye protection includes goggles or a protective face shield. Static Electricity Hazard when Fueling with Ultra-low Sulfur Diesel The maximum air pressure for cleaning purposes...

  • Page 13: Asbestos Information

    (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 14: Dispose Of Waste Properly

    M0082024-06 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 15: Induction System

    M0082024-06 Safety Section Burn Prevention After the engine has stopped, wait for 10 minutes to Cooling system conditioner contains alkali. Alkali can allow the fuel pressure to be purged from the high- cause personal injury. Do not allow alkali to contact pressure fuel lines before any service or repair is the skin, the eyes, or the mouth.

  • Page 16: 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 17: Fire Extinguisher

    M0082024-06 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 18: 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 19 M0082024-06 Safety Section High Pressure Fuel Lines Illustration 16 g01877473 (1) High-pressure line (4) High-pressure line (7) High-pressure fuel manifold (rail) (2) High-pressure line (5) High-pressure line (8) High-pressure line (3) High-pressure line (6) High-pressure line (9) Fuel transfer line that is high pressure The high-pressure fuel lines are the fuel lines that are Do not loosen the high-pressure fuel lines to remove between the high-pressure fuel pump and the high-...

  • Page 20: Before Starting Engine

    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: Engine Stopping

    M0082024-06 Safety Section Engine Stopping Grounding Practices i02234873 Engine Stopping Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine components. Use the Emergency Stop Button (if equipped) ONLY in an emergency situation.

  • Page 22: Engine Electronics

    M0082024-06 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 23 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 24: Product Information Section

    M0082024-06 Product Information Section General Information Product Information Section General Information i07150844 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. Single Turbocharged Engine Illustration 19 g06236908 Typical example...
  • Page 25 M0082024-06 Product Information Section Model View Illustrations Illustration 20 g06236915 Typical example (10) Idle roller for drive belt (12) Crankshaft damper (14) Drive belt (11) Coolant pump (13) Belt tensioner...
  • Page 26 M0082024-06 Product Information Section Model View Illustrations Illustration 21 g06236918 Typical example (15) Rear lifting eyes for the application (18) Alternator (21) Oil drain valve (16) Back pressure valve (19) Refrigerant compressor (22) Flywheel housing (17) Front lifting eye for the application (20) Turbocharger (23) Flywheel...
  • Page 27 M0082024-06 Product Information Section Model View Illustrations Series Turbocharged Engine Illustration 22 g06236975 Typical example (1) Front lifting eye for engine only (3) Engine oil cooler (2) Rear lifting eye for engine only (4) High-pressure fuel pump...
  • Page 28 M0082024-06 Product Information Section Model View Illustrations Illustration 23 g06236982 Typical example (5) Air intake (7) NOx Reduction System (NRS) Valve (6) Coolant outlet (8) NRS cooler...
  • Page 29 M0082024-06 Product Information Section Model View Illustrations Illustration 24 g06237253 Typical example (9) High-pressure turbocharger (11) Oil drain plug (10) Low-pressure turbocharger (12) Back pressure valve Aftertreatment Systems There are two types of aftertreatment systems that the 1206J engines could use. The type used will depend on engine rating /power.
  • Page 30 M0082024-06 Product Information Section Model View Illustrations Enclosed Type Clean Emission Module Open Type Clean Emission Module Illustration 25 g06237255 Illustration 26 g06237257 Typical example Typical example (1) Enclosed clean emission module (1) Open type clean emission module The enclosed CEM contains three main parts the Diesel Oxidation Catalyst (DOC) Diesel Exhaust Filter (DPF) and the Selective Catalytic Reduction (SCR).
  • Page 31 M0082024-06 Product Information Section Model View Illustrations Illustration 27 g06238393 Typical example (2) DOC (3) Mixer (4) SCR (5) DPF Pump Tank Unit (PTU) Illustration 28 g06237309 Typical example (1) DEF Filler cap (2) PTU lifting eyes (3) DEF tank drain plug Off Engine Components...
  • Page 32 M0082024-06 Product Information Section Model View Illustrations Illustration 29 g06237277 Typical examples (1) Diesel Exhaust Fluid (DEF) Pump tank (4) Inlet air temperature sensor (8) Primary fuel filter unit (5) NOx sensors (9) Flexible exhaust pipe assembly (2) Soot sensor control (6) In-line fuel filter (10) Protection sleeve for flexible exhaust (3) DEF heated line...

  • Page 33: Product Description

    Product Description i10133090 Product Description (Engine and Aftertreatment) There are two variants of the Perkins 1206J industrial engine, the 1206J-E70TA is a single turbocharged engine and the engine prefix is VL. The 1206J-E70TTA is a series turbocharged engine and the prefix for this engine is VM.
  • Page 34 The electronic service tool may be used to display “Overhaul Considerations” topic (Maintenance the diagnostic codes. Section). There are three types of diagnostic codes: active, Aftermarket Products and Perkins logged, and event. Engines Perkins does not warrant the quality or performance of non-Perkins fluids and filters.

  • Page 35: Aftertreatment System

    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. However, failures that result from the installation or use of other manufacturers devices, accessories, or consumables are NOT Perkins defects.

  • Page 36: Product Identification Information

    Plate Locations and Film Locations Illustration 31 g03046077 Perkins engines are identified by an engine serial number. An example of an engine number is VL*****U000001C. ***** The list number for the engine Type of engine...
  • Page 37 M0082024-06 Product Information Section Plate Locations and Film Locations i07155370 Plate Locations and Film Locations (Aftertreatment System) Clean Emissions Module (CEM) Illustration 32 g01094203 Serial number plate Illustration 33 g06237359 Typical example The identification plate (1) is on the end of the CEM.
  • Page 38 Typical example of a PTU serial plate Record the information on the CEM and PTU serial Pump Tank Unit (PTU) plates. The information will be required by your Perkins dealer or 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 39: Reference Information

    M0082024-06 Product Information Section Reference Information Secondary Fuel Filter Element 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 40: 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 41 M0082024-06 Operation Section Product Lifting Engine and Clean Emissions Module (CEM) Illustration 40 g03051677 Typical example (2) Lifting eyes for the CEM Illustration 39 g07577915 Refer to illustration 40 for the location of the lifting Typical example eyes to lift the CEM. The lifting eyes (2) are designed (1) Lifting eyes for engine and aftertreatment.
  • Page 42 M0082024-06 Operation Section Product Lifting Open CEM Illustration 42 g03419909 Typical example (3) Lifting eyes for PTU. Refer to illustration 42 for the location of the lifting eyes to lift the PTU. Illustration 41 g06239792 Typical example Install a suitable sling in position (X) and install a suitable sling in position (Y).

  • Page 43: Product Storage

    Product Storage (Engine and Aftertreatment) Perkins are not responsible for damage which may occur when an engine is in storage after a period in service. Your Perkins dealer or your Perkins distributor can help with preparing the engine for extended storage...

  • Page 44: Condition For Storage

    The engine must be stored in a water proof building. and Maintenance Manual. The building must be kept at a constant temperature. Engines that are filled with Perkins ELC will have Monthly Checks coolant protection to an ambient temperature of −36°...
  • Page 45 M0082024-06 Operation Section Engine and Aftertreatment 1. If necessary, drain the tank and fill with DEF that meets ISO 22241-1. 2. Replace the DEF filter, refer to this Operation and Maintenance Manual, “Diesel Exhaust Fluid Filter- Clean/Replace”. 3. Ensure that the drive belt is correctly installed. Ensure that all engine coolant and engine oil has the correct specification and grade.

  • Page 46: Features And Controls

    M0082024-06 Operation Section Features and Controls Features and Controls Intake manifold pressure – The intake manifold pressure sensor checks the rated pressure in the engine manifold. i10133126 Fuel rail pressure – The fuel rail pressure sensor Alarms and Shutoffs measures the high pressure or low pressure in the fuel rail.

  • Page 47: Battery Disconnect Switch

    Determine and correct the cause of any significant change in the readings. Consult your Perkins dealer Some applications, the engine can be equipped with or your Perkins distributor for assistance.

  • Page 48: Indicator Lamps

    3. Inspect the cooling system for leaks. If necessary, consult your Perkins dealer or your Perkins distributor for assistance.

  • Page 49: Aftertreatment Lamps And Gauges

    M0082024-06 Operation Section Monitoring System The lamps will illuminate for 2 seconds to check that the lamps are functioning when the keyswitch is turned to the ON position. If any of the lamps stay illuminated, or a lamp fails to be illuminated the reason should be investigated immediately.

  • Page 50: Flash Codes

    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 51: Sensors And Electrical Components

    M0082024-06 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 52: Engine Components

    M0082024-06 Operation Section Sensors and Electrical Components Engine Components Illustration 46 g06237689 Typical example (1) Coolant temperature sensor (5) Electronic control module (9) Solenoid for high-pressure fuel pump (2) Injector harness connection (6) Primary speed/timing sensor (10) Fuel temperature sensor (3) Injector harness connection (7) Oil pressure sensor (4) Diagnostic connector...
  • Page 53 M0082024-06 Operation Section Sensors and Electrical Components Illustration 47 g06237690 Typical example (11) Wastegate regulator solenoid (13) Temperature sensor for the NRS (16) Manifold inlet pressure sensor (12) Control valve for the NOx Reduction (14) Fuel pressure sensor (17) Manifold inlet temperature System (NRS) (15) NRS Differential pressure sensor...
  • Page 54 M0082024-06 Operation Section Sensors and Electrical Components Illustration 48 g06237692 Typical example (18) Alternator (20) Starting motor (22) Back pressure valve (19) Refrigerant compressor (21) Secondary speed/timing sensor...
  • Page 55 M0082024-06 Operation Section Sensors and Electrical Components Illustration 49 g06237711 Typical example (23) Water in fuel switch (24) Inlet air temperature sensor Aftertreatment Components...
  • Page 56 M0082024-06 Operation Section Sensors and Electrical Components Illustration 50 g06237726...
  • Page 57 M0082024-06 Operation Section Sensors and Electrical Components Enclosed Type Clean Emissions Module (CEM) Illustration 51 g06237255 Typical example (1) Enclosed clean emissions module Illustration 52 g06238329 Typical example (2) DEF injector (3) Soot sensor antenna...
  • Page 58 M0082024-06 Operation Section Sensors and Electrical Components (4) Soot sensor antenna (6) SCR temperature probe (8) Two probe temperature sensor (5) DPF temperature probe (7) Identification module Open Type Clean Emissions Module Illustration 54 g06238274 Typical example (2) DOC temperature probe (3) Three probe temperature sensor (4) SCR temperature probe (5) DEF injector...
  • Page 59 M0082024-06 Operation Section Sensors and Electrical Components Soot Sensors and NOx Sensors Illustration 55 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 56 g06238439...

  • Page 60: Engine Diagnostics

    The system provides the capability of Fault Logging. When the Electronic Control Module (ECM) generates an active diagnostic code, the code will be Perkins Electronic Engines have the capability to logged in the memory of the ECM. The codes that perform a self-diagnostics test. When the system...

  • Page 61: System Configuration Parameters

    M0082024-06 Operation Section Engine Operation with Intermittent Diagnostic Codes i01797063 Engine Operation with Intermittent Diagnostic Codes If a diagnostic lamp illuminates during normal engine operation and the diagnostic lamp shuts off, an intermittent fault may have occurred. If a fault has occurred, the fault will be logged into the memory of the Electronic Control Module (ECM).
  • Page 62 M0082024-06 Operation Section Configuration Parameters Table 5 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 63 M0082024-06 Operation Section Configuration Parameters (Table 6, 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 64 M0082024-06 Operation Section Configuration Parameters (Table 6, 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 65: Engine Starting

    M0082024-06 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 66: Starting With Jump Start Cables

    M0082024-06 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 67: After Starting Engine

    M0082024-06 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 68 M0082024-06 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 69: Engine Operation

    M0082024-06 Operation Section Engine Operation Engine Operation Carbon Dioxide (CO2) Emissions Emissions regulations require that the value of the CO2 emissions be reported to the end user. For this i07671708 engine, 727.598 g/kWh was determined to be the Engine Operation CO2 value during the EU type approval process.

  • Page 70: Fuel Conservation Practices

    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 71: 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 72 M0082024-06 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 73 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 74 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 75 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 76 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 77 M0082024-06 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 78: 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 79: Recommendations For The Coolant

    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 80: Radiator Restrictions

    M0082024-06 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 81: Fuel Related Components In Cold Weather

    M0082024-06 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 82 M0082024-06 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 83: Engine Stopping

    M0082024-06 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 84 M0082024-06 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 85: Maintenance Section

    Crankcase Oil Sump (3.56 US gal) (4.36 US gal) DEF that is used in Perkins engines must meet the These values are the approximate capacities for the crankcase ISO specification 22241-1 for quality. The ISO oil sump (aluminum) which includes the standard factory in- specification 22241-1 requirements are met by many stalled oil filters.

  • Page 86: General Coolant Information

    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 87 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 88: Coolant Recommendations

    NOTICE The Perkins industrial engines with a NOx reduc- Table 20 tion system must be operated with a minimum Propylene Glycol 30% volume glycol-water mixture, Perkins recom-...

  • Page 89: Elc Cooling System Maintenance

    (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 90 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 91: General Lubricant Information

    • 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 92: Engine Oil

    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 93: Oil Analysis

    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 94: Diesel Fuel Requirements

    M0082024-06 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 95 M0082024-06 Maintenance Section General Fuel Information Table 27 "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: Diesel Fuel Characteristics

    “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 M0082024-06 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 103: 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 104 M0082024-06 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 105: Severe Service Application

    • 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 106: Maintenance Interval Schedule

    M0082024-06 Maintenance Section Maintenance Interval Schedule “ Fuel Filter (In-Line) - Replace“ ....137 i10077446 Maintenance Interval Schedule “ Fuel System Primary Filter (Water Separator) Element - Replace“ ......139 “...

  • Page 107: Maintenance Interval Schedule

    M0082024-06 Maintenance Section Maintenance Interval Schedule “ Alternator and Fan Belts - Replace“ ..108 Every 3000 Service Hours or 1 Year “ Cooling System Supplemental Coolant Additive (SCA) - Test/Add“ ......118 Every 3000 Service Hours or 2 Years “...

  • Page 108: 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 109: Battery Or Battery Cable - Disconnect

    M0082024-06 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 110: Belt - Inspect

    M0082024-06 Maintenance Section Belt - Inspect 2. Disconnect the negative battery terminal. Ensure • Inspect the belt for cracks, splits, glazing, grease, displacement of the cord and evidence of fluid that the cable cannot contact the terminal. When contamination. four 12 V batteries are involved, 2 negative connections must be disconnected.

  • Page 111: Coolant (Commercial Heavy-Duty) - Change

    M0082024-06 Maintenance Section Coolant (Commercial Heavy-Duty) - Change i07679030 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. • Foaming is observed. •...
  • Page 112 (Maintenance Section) for more information on suitable cleaning agent to remove any debris. cooling system specifications. Refer to your Perkins dealer or distributor for 2. Start and run the engine at low idle. Increase the suitable cleaning agents. engine rpm to high idle. Operate the engine to 2.

  • Page 113: Coolant (Elc) - Change

    M0082024-06 Maintenance Section Coolant (ELC) - Change Drain 3. Maintain the coolant level at the maximum mark that is correct for your application. 4. Clean the cooling system filler cap. Inspect the gasket that is on the cooling system filler cap. If Pressurized System: Hot coolant can cause seri- the gasket that is on the cooling system filler cap is ous burns.
  • Page 114 M0082024-06 Maintenance Section Coolant (ELC) - Change For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or Perkins distributor. Flush 1. Flush the cooling system with clean water to remove any debris. 2. Install the connection hose. Clean the drain plugs and install the drain plugs.

  • Page 115: Coolant Change

    M0082024-06 Maintenance Section Coolant - Change 2. Start and run the engine at low idle. Increase the • The fuel has entered the cooling system and the coolant is contaminated. 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.
  • Page 116 1. Flush the cooling system with clean water and a Allow the coolant to drain into a suitable container. suitable cleaning agent to remove any debris. Refer to your Perkins dealer or distributor for 3. Properly dispose of the drained material. Obey suitable cleaning agents.

  • Page 117: Coolant Level - Check

    M0082024-06 Maintenance Section Coolant Level - Check 3. Maintain the coolant level at the maximum mark NOTICE that is correct for your application. Do not fill the cooling system faster than 10 L (2.64 US gal) per minute to avoid air locks. 4.

  • Page 118: Test For Sca Concentration

    M0082024-06 Maintenance Section Cooling System Supplemental Coolant Additive (SCA) - Test/Add Test for SCA Concentration Heavy-Duty Coolant/Antifreeze and SCA NOTICE Do not exceed the recommended six percent supple- mental coolant additive concentration. Use a Coolant Conditioner Test Kit to check the concentration of the SCA.

  • Page 119: Crankshaft Vibration Damper - Inspect

    M0082024-06 Maintenance Section Crankshaft Vibration Damper - Inspect 3. Add the correct amount of SCA. Refer to the For information on removal of the crankshaft damper, refer to Disassembly and Assembly, “Vibration Operation and Maintenance Manual, “Refill Damper and Pulley - Remove and Install”. Capacities and Recommendations”...
  • Page 120 M0082024-06 Maintenance Section DEF Manifold Filters (Emission Related Component) - Replace 3. The filter screen can be cleaned in clean water and dried using compressed air. Refer to this Operation and Maintenance Manual, “General Hazard Information” for information on using compressed air.
  • Page 121 M0082024-06 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 122: Diesel Exhaust Fluid (Emission Related Component) - Fill

    M0082024-06 Maintenance Section Diesel Exhaust Fluid (Emission Related Component) - Fill 6. Install the manifold, refer to Disassembly and Ensure that the correct specification Diesel Exhaust Fluid (DEF) is used. Ensure the cleanliness of the Assembly, “Manifold (DEF Heater) - Remove and DEF, refer to this Operation and Maintenance Install”...
  • Page 123 M0082024-06 Maintenance Section Diesel Exhaust Fluid Filter (Emission Related Component) - Replace i07678995 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 124: Diesel Exhaust Fluid Tank - Flush

    M0082024-06 Maintenance Section Diesel Exhaust Fluid Tank - Flush i10135218 Diesel Exhaust Fluid Tank - Flush Illustration 84 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 125: Engine - Clean

    If the DEF tank has been filled with another fluid Periodic cleaning of the engine is recommended. other than DEF, then contact your Perkins distributor. Steam cleaning the engine will remove accumulated oil and grease. A clean engine provides the following...

  • Page 126: Engine Air Cleaner Element - Replace

    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 127: Engine Crankcase Breather Element (Emission Related Component) - Replace

    M0082024-06 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 128 M0082024-06 Maintenance Section Type 2 1. Ensure that dirt cannot enter the breather NOTICE assembly. Ensure that the outside body of the Ensure that the engine is stopped before any servic- breather assembly is clean and free from damage. ing or repair is performed. Place a container under the breather assembly.

  • Page 129: Check The System

    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 130: Top Service

    M0082024-06 Maintenance Section Type 1 Top Service Illustration 94 g03090963 4. Remove the old seal (4) and install a new seal. Note: The cut away from section (5) in the top cap allows access to the seal. Illustration 93 g03090965 1.

  • Page 131: Bottom Service

    M0082024-06 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 95 . Align position (A) on the top cap to position (B) on the filter element. Illustration 97 g02346498 Typical example...

  • Page 132: Engine Mounts - Inspect

    Note: The engine mounts may not have been 5. Align position (A) on the top cap to position (B) on supplied by Perkins. Refer to the Original Equipment the filter element. Refer to illustration 98 . Manufacturer (OEM) information for further details on the engine mounts and the correct bolt torque.

  • Page 133: Engine Oil Level - Check

    M0082024-06 Maintenance Section Engine Oil Level - Check When the engine mounts are supplied by Perkins the If an increase in the oil level is noticed, refer to Troubleshooting, “Oil Contains Fuel”. maintenance procedure will be supplied in the Disassembly and Assembly manual for your engine.

  • Page 134: Engine Oil And Filter - Change

    250 hours. If the engine is operated in severe service conditions, i07074312 Perkins recommends the use of engine oil sampling. Refer to this Operation and Maintenance Manual, Engine Oil and Filter - Change Engine Oil sample - Obtain for more information.

  • Page 135: Replace The Oil Filter

    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 136: Fan Clearance - Check

    M0082024-06 Maintenance Section Fan Clearance - Check 2. Start the engine and run the engine at “LOW IDLE” for 2 minutes. Perform this procedure to ensure that the lubrication system has oil and that the oil filters are filled. Inspect the oil filter for oil leaks. 3.

  • Page 137: Fuel Filter (In-Line) - Replace

    M0082024-06 Maintenance Section Fuel Filter (In-Line) - Replace 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 138: Fuel System - Prime

    M0082024-06 Maintenance Section Fuel System - Prime Note: Refer to Systems Operation, Testing, and i05774864 Adjusting, “Cleanliness of Fuel System Fuel System - Prime Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system. Note: Refer to Systems Operation, Testing, and NOTICE Adjusting, “Cleanliness of Fuel System...

  • Page 139: Fuel System Primary Filter (Water Separator)

    “Fluid Recommendations” (General Fuel Information) of this OMM. It is recom- 6. Remove the tube from the drain valve. mended that new fuel filters are installed every 250 service hours in severe operating conditions. For more information consult your Perkins distributor.
  • Page 140 M0082024-06 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 7. Tighten the vent screw (1) to a torque of 2.5 N·m 9. Rotate the filter element (5) counterclockwise and (22 lb in). If necessary, tighten the vent screw on remove the filter element .

  • Page 141: Fuel System Primary Filter/Water Separator - Drain

    M0082024-06 Maintenance Section Fuel System Primary Filter/Water Separator - Drain 5. The secondary filter element must be replaced at the same time as the primary filter element. Also, the in-line filter must be changed. Refer to the Operation and Maintenance Manual, “Fuel System Filter - Replace”.
  • Page 142 (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 143: Install The Element

    M0082024-06 Maintenance Section Fuel System Secondary Filter - Replace Install the Element Illustration 111 g07555883 7. Rotate the filter element (5) counterclockwise and Illustration 112 g07555940 remove the filter element. Clean the filter bowl. 1. Locate the thread (7) in the filter element onto the threads (8).

  • Page 144: Fuel Tank Water And Sediment - Drain

    M0082024-06 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 145: Replace The Hoses And The Clamps

    M0082024-06 Maintenance Section Injector (Diesel Exhaust Fluid) (Emissions Related Component) - Replace 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.

  • Page 146: Radiator - Clean

    Repeat the cleaning, if necessary. Inspect the fins for damage. Bent fins may be opened The radiator is not usually supplied by Perkins. The with a “comb”. Inspect these items for good condition: following text describes a typical cleaning procedure Welds, mounting brackets, air lines, connections, for the radiator.

  • Page 147: Engine Installed With Single Turbocharger

    Turbocharger connections. Refer to the Systems Operation, Testing and Adjusting Manual, “Electric Starting System - Test” for more information on the checking procedure and for specifications consult your Perkins dealer or your Perkins distributor for assistance. i04922217 Turbocharger - Inspect Hot engine components can cause injury from burns.

  • Page 148: Walk-Around Inspection

    M0082024-06 Maintenance Section Walk-Around Inspection 5. Install the air intake pipe and the exhaust outlet 4. Check for obvious heat discoloration of the pipe to the turbocharger housing. Ensure that all turbocharger. Check for any loose bolts or any clamps are installed correctly and that all clamps missing bolts.
  • Page 149 Refer to Disassembly and Assembly, “Water Pump - Remove and Install”. For more information, consult tank daily to ensure that only clean fuel enters the your Perkins dealer or your Perkins distributor. fuel system. • Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters, and the rocker cover.

  • Page 150: Engine Aftertreatment

    M0082024-06 Maintenance Section Water Pump - Inspect • Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires. Check for any loose tie-wraps or missing tie-wraps. • Inspect the ground strap for a good connection and for good condition.

  • Page 151: 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 152: 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 153: Maintenance Log

    M0082024-06 Reference Information Section Maintenance Log i05204675 Maintenance Log Table 29 Engine Model Customer Identifier Arrangement Number Serial Number Service Quantity Of Service Item Date Authorization Hours Fuel...

  • Page 154: Reference Material

    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 155: Index

    M0082024-06 Index Section Index Coolant (Commercial Heavy-Duty) - Change ............111 Additional Messages ......... 9 Drain ............111 After Starting Engine ........67 Fill ...............112 After Stopping Engine ........83 Flush ............112 Aftercooler Core - Clean/Test (Air-To-Air Coolant (ELC) - Change.........113 Aftercooler) ..........
  • Page 156 M0082024-06 Index Section Test the Service Indicator ......127 Fluid Recommendations (General Fuel Engine Air Precleaner - Check/Clean ... 127 Information) ........... 93 Engine Crankcase Breather Element Contamination Control Recommendations for (Emission Related Component) - Replace Fuels ............101 (Type 1)............129 Diesel Fuel Characteristics......
  • Page 157 Injector (Diesel Exhaust Fluid) (Emissions Pump Tank Unit (PTU)......... 38 Related Component) - Replace....145 Product Description (Engine and Aftertreatment) ..........33 Aftermarket Products and Perkins Lifting and Storage .......... 40 Engines ............34 Aftertreatment System......... 35 Electronic Engine Features ......34 Engine Cooling and Lubrication ....
  • Page 158 M0082024-06 Index Section Universal Warning 1 ........6 Safety Section ........... 6 Selective Catalytic Reduction Warning System............71 Warning Indicators........71 Warning Levels ..........71 Warning Strategy ......... 71 Self-Diagnostics ..........60 Sensors and Electrical Components....51 Aftertreatment Components ......55 Engine Components ........

  • Page 159: Product Information

    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 160 M0082024 ©2024 Perkins Engines Company Limited All Rights Reserved April 2024...

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