Perkins Engine 1206E-E70TTA Service Manual

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Operation and Maintenance Manual

SEBU8601-01

December 2010

1206E-E70TTA Industrial Engine

(Engine)

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. 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 the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this product Perkins recommends using Perkins

replacement parts.

Failure to heed this warning can lead to premature failures, product damage, personal injury or

death.

SEBU8601-01 3

Table of Contents

Foreword ................................................................. 4

Safety Section

Safety Messages .................................................... 5

General Hazard Information ................................... 7

Burn Prevention .................................................... 10

Fire Prevention and Explosion Prevention ............. 11

Crushing Prevention and Cutting Prevention ........ 13

Mounting and Dismounting ................................... 13

High Pressure Fuel Lines ..................................... 13

Before Starting Engine .......................................... 15

Engine Starting ..................................................... 15

Engine Stopping ................................................... 15

Maintenance In

Warranty S ect

Warranty Information .......................................... 125

terval Schedule ............................ 88

ion

Reference Information Section

Reference Materials ............................................ 129

Index Section

Index ............................... .................................... 130

Electrical System .................................................. 16

Engine Electronics ................................................ 17

Product Information Section

Model Views ......................................................... 19

Product Identiﬁcation Information ........................ 27

Operation Section

Lifting and Storage ................................................ 30

Gauges and Indicators .......................................... 34

Features and Controls .......................................... 36

Engine Diagnostics ............................................... 46

Engine Starting ..................................................... 58

Engine Operation .................................................. 61

Engine Stopping ................................................... 66

Cold Weather Operation ....................................... 68

Maintenance Section

Reﬁll Capacities .................................................... 72

Maintenance Recommendations .......................... 86

4 SEBU8601-01 Foreword

Foreword

Literature Information

This manual co lubrication and maintenance information. This manual should be stored in or near the engine area in a literatu study and keep it with the literature and engine information.

English is the primary language for all Perkins publications. The English used facilitates translation and consist

Some photographs or illustrations in this manual show detai from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improveme may have caused changes to your engine which are not included in this manual. Whenever a question arises re consult with your Perkins dealer or your Perkins distributor for the latest available information.

Safety

This safety section lists basic safety precautions. In addition, this section identiﬁes hazardous,

g situations. Read and understand the basic

warnin precautions listed in the safety section before operating or performing lubrication, maintenance and

on this product.

repair

ntains safety, operation instructions,

re holder or literature storage area. Read,

ency.

ls or attachments that may be different

nt and advancement of product design

garding your engine, or this manual, please

Recommended se appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine a Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequen speciﬁed in the Maintenance Interval Schedule may be necessary.

The maintenance schedule items are organized for a preventive maintenance management program. If the prevent periodic tune-up is not required. The implementation of a preventive maintenance management program should min avoidances resulting from reductions in unscheduled downtime and failures.

ive maintenance program is followed, a

imize operating costs through cost

rvice should be performed at the

lso governs the Maintenance Interval

t lubrication and maintenance than is

Maintenance Intervals

Perform maintenance on items at multiples of the original requirement. We recommend that the maintena near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part o

Your authorized Perkins dealer or your Perkins distrib maintenance schedule to meet the needs of your operating environment.

nce schedules be reproduced and displayed

f the engine's permanent record.

utor can assist you in adjusting your

Overhaul

Opera

Operating techniques outlined in this manual are basic techniques required to operate the engine more efﬁciently and economically. Skill and techniques deve engine and its capabilities.

The o Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and discussion of electronic diagnostic information.

tion

. They assist with developing the skills and

lop as the operator gains knowledge of the

peration section is a reference for operators.

stopping the engine. This section also includes a

Maintenance

e maintenance section is a guide to engine care.

Th The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance

tervals. Items in the maintenance schedule are

in referenced to detailed instructions that follow.

Major engine overhaul details are not covered in the Operation and Maintenance Manual except

e interval and the maintenance items in that

for th interval. Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer

r Perkins distributor offers a variety of options

or you regarding overhaul programs. If you experience a major engine failure, there are also numerous

r failure overhaul options available. Consult with

afte your Perkins dealer or your Perkins distributor for information regarding these options.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer,

th defects, and other reproductive harm. Battery

bir posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

SEBU8601-01 5

Safety Section

Safety Messages

Safety Section

i03937271

Safety Message s

There may be engine. The exact location and a description of the warning signs are reviewed in this section. Please become fam

Ensure that all of the warning signs are legible. Clean the warnin the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the warni other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the warning coulddropofftheengine.

Replace missing.Ifawarningsignisattachedtoapartofthe engine that is replaced, install a new warning sign on the rep provide new warning signs.

lacement part. Your Perkins distributor can

several speciﬁc warning signs on your

iliar with all warning signs.

g signs or replace the warning signs if

ng signs. Do not use solvents, gasoline, or

signs. The warning signs that are loosened

any warning sign that is damaged or

The Universal W positions. The warning labels are located on the front right side of the valve mechanism cover and located on the top of th

arning label (1) is located in two

e NOx reduction system NRS.

(1) Universal Warning

Do not operate or work on this equipment unless

ave read and understand the instructions

you h and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or

the warnings could result in serious injury

heed or death.

Illustration 1

ypical example

g01154807

6 SEBU8601-01 Safety Section Safety Messages

Illustration 2

(1) Universal warning

(2) Ether

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.

g02305279

Illustration 3

Typical example

g01154809

The ether warning label (2) is located on the top of thereductionsystem(NRS).

SEBU8601-01 7

Safety Section

General Hazard Information

Illustration 4

(2) Ether (3) Hand (High Pressure

(3) Hand (High Pressure)

Contact with high pressure fuel may cause ﬂuid penetration and burn hazards. High pressure fuel spray may cause a ﬁre hazard. Failure to follow these inspe ction, maintenance and service instructions may cause personal injury or death.

Illustration 5

Typical example

g01154858

g02305282

i03566024

General Hazard Information

Illustration 6

Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired. Attach the warning tags to the engine and to each operator control station. When it is appropriate, disconnect the starting controls.

g00104545

The warning label for the Hand (High Pressure) (3) is located on a high-pressure fuel line.

Do not allow unauthorized personnel on the engine, or around the engine when the engine is being serviced.

Tampering with the engine installation or tampering

•

with the OEM supplied wiring can be dangerous. Personal injury, death and/or engine damage could result.

8 SEBU8601-01 Safety Section General Hazard Information

Vent the engine

•

engine is operated in an enclosed area.

If the engine i

•

secondary brake or the parking brake systems unless the vehicle is blocked or unless the vehicle is restraine

Wear a hard hat, protective glasses, and other

•

protective

When work is performed around an engine that is

•

operating, to help prevent damage to hearing.

Do not wear

•

on controls or on other parts of the engine.

Ensure tha

•

securedinplaceontheengine.

Never put

•

Glass containers can break.

Use all cl

•

Report all necessary repairs.

•

eaning solutions with care.

exhaust to the outside when the

s not running, do not release the

equipment, as required.

wear protective devices for ears in order

loose clothing or jewelry that can snag

t all protective guards and all covers are

maintenance ﬂuids into glass containers.

For initial sta

•

engine that has been serviced, make provisions to stop the engine if an overspeed occurs. This may be accomplish and/or the air supply to the engine.

Start the eng

•

Never short across the starting motor terminals or the batteries. This could bypass the engine neutral start syste damaged.

Engine exha which may be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If th engine exhaust to the outside.

Cautiousl prevent spraying or splashing of pressurized ﬂuids, hold a rag over the part that is being removed.

Filler caps

•

Grease ﬁt

•

Pressure taps

•

rt-up of a new engine or for starting an

ed by shutting off the fuel supply

ine from the operator's station (cab).

m and/or the electrical system could be

ust contains products of combustion

e engine is in an enclosed area, vent the

y remove the following parts. To help

tings

Unless other instructions are provided, perform the maintenance under the following conditions:

The engine is stopped. Ensure that the engine can

•

not be started.

Theprotectivelocksorthecontrolsareinthe

•

applied position.

Engage the secondary brakes or parking brakes.

•

the vehicle or restrain the vehicle before

Block

•

maintenance or repairs are performed.

onnect the batteries when maintenance

Disc

•

is performed or when the electrical system is serviced. Disconnect the battery ground leads.

the leads in order to help prevent sparks.

Ta p e

Disconnect the connector for the unit injector that

•

ocated on the valve cover base. This will help

is l prevent personal injury from the high voltage to the unit injectors. Do not come in contact with the unit

ector terminals while the engine is operating.

inj

Do not attempt any repairs or any adjustments to

•

e engine while the engine is operating.

Do not attempt any repairs that are not understood.

•

e the proper tools. Replace any equipment that

Us is damaged or repair the equipment.

Breathers

•

Drain pl

•

Use caution when cover plates are removed. Gradua bolts or nuts that are located at opposite ends of the cover plate or the device. Before removing the last t relieve any spring pressure or other pressure.

Illustration 7

Wear a hard hat, protective glasses, and other

•

protective equipment, as required.

When work is performed around an engine that is

•

operating, wear protective devices for ears in order to help prevent damage to hearing.

ugs

lly loosen, but do not remove the last two

wo bolts or nuts, pry the cover loose in order to

g00702020

SEBU8601-01 9

Safety Section

General Hazard Information

Do not wear loos

•

on controls or on other parts of the engine.

Ensure that al

•

securedinplaceontheengine.

Never put mai

•

Glass containers can break.

Use all clea

•

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.

Disconnect the batteries when maintenance

•

is performed or when the electrical system is serviced Tape the leads in order to help prevent sparks.

Do not att

•

Use the proper tools. Replace any equipment that is damaged or repair the equipment.

. Disconnect the battery ground leads.

empt any repairs that are not understood.

e clothing or jewelry that can snag

l protective guards and all covers are

ntenance ﬂuids into glass containers.

ning solutions with care.

Illustration 8

Always use a board or cardboard when you check for a leak. Leaking ﬂuid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If ﬂuid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

g00687600

Containing Fluid Spillage

Pressurized Air and Water

Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in person

When pressurized air and/or pressurized water is used f shoes, and eye protection. Eye protection includes goggles or a protective face shield.

The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum wate 275kPa(40psi).

al injury.

or cleaning, wear protective clothing, protective

r pressure for cleaning purposes must be below

Fluid Penetration

sure can be trapped in the hydraulic circuit long

Pres after the engine has been stopped. The pressure can cause hydraulic ﬂuid or items such as pipe plugs to

ape rapidly if the pressure is not relieved correctly.

esc

Do not remove any hydraulic components or parts

il pressure has been relieved or personal injury

unt may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved

personal injury may occur. Refer to the OEM

or information for any procedures that are required to relieve the hydraulic pressure.

NOTICE Care must be taken to ensure that ﬂuids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before opening any compartment or disassembling any component containing ﬂuids.

Dispose of all ﬂuids according to local regulations and mandates.

Asbestos Information

Illustration 9

g00702022

10 SEBU8601-01 Safety Section Burn Prevention

Perkins replac Perkins are asbestos free. Perkins recommends the use of only genuine Perkins replacement parts. Use the follow replacement parts that contain asbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos ﬁb to your health. The components that may contain asbestos ﬁbers are brake pads, brake bands, lining material, c asbestos that is used in these components is usually boundinaresinorsealedinsomeway.Normal handling i contains asbestos is generated.

If dust tha are several guidelines that should be followed:

Never use

•

Avoid brushing materials that contain asbestos.

•

Avoid grinding materials that contain asbestos.

•

ement parts that are shipped from

ing guidelines when you handle any

ers. Inhaling this dust can be hazardous

lutch plates, and some gaskets. The

s not hazardous unless airborne dust that

t may contain asbestos is present, there

compressed air for cleaning.

Dispose of Waste Properly

Illustration 10

Improperly disposing of waste can threaten the environment. Potentially harmful ﬂuids should be dispose

Always use leakproof containers when you drain ﬂuids. D drain, or into any source of water.

d of according to local regulations.

o not pour waste onto the ground, down a

g0070640

Use a wet

•

materials.

A vacuum

•

efﬁciency particulate air ﬁlter (HEPA) can also be used.

Use exhaust ventilation on permanent machining

•

jobs.

Wear an approved respirator if there is no other

•

way to control the dust.

Comply with applicable rules and regulations

•

for the work place. In the United States, use Occu (OSHA) requirements. These OSHA requirements can be found in “29 CFR 1910.1001”.

Obey environmental regulations for the disposal

•

of asbestos.

Stay away from areas that might have asbestos

•

particles in the air.

method in order to clean up asbestos

cleaner that is equipped with a high

pational Safety and Health Administration

i04156653

Burn Prevention

Do not touch any part of an operating engine system. The engine, the exhaust, and the engine aftertreatment system can reach temperatures as high as 650 °C (1202 °F) under normal operating conditions. If the engine or the engine aftertreatment system unexpectedly fails, the temperature of the gas at the diesel particulate ﬁlter (DPF) may increase to 900°C (1652°F).

At idle engine speed and/or zero vehicle speed, an operator can request a manual regeneration. Under this condition, the exhaust gas temperature can reach 650 °C (1202 °F). Otherwise automatic regeneration can produce exhaust gas temperatures as high as 450 °C (842 °F).

Allow the engine system to cool before any maintenance is performed. Relieve all pressure in the air system, in the hydraulic system, in the lubrication system, in the fuel system, or in the cooling system before any lines, ﬁttings, or related items are disconnected.

SEBU8601-01 11

Safety Section

Fire Prevention and Explosion Prevention

After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed on the engine fuel lines.

Allow the pressure to be purged in the air system, in the hydraulic system, in the lubrication system, or in the cooling system before any lines, ﬁttings, or related items are disconnected.

Induction System

Sulfuric Acid Burn Hazard may cause serious personal injury or death.

The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the a ppropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for ﬁrst aid that are noted on a material safety data sheet (MSDS) for sulfuric acid.

Cooling system cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.

conditioner contains alkali. Alkali can

Oils

Hot oil and hot lubricating components can cause personal injury. Do not allow hot oil to contact the skin. Also, d the skin.

o not allow hot components to contact

Batteries

Electrolyt injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries and connectors. Use of gloves is recommended.

e is an acid. Electrolyte can cause personal

. Wash hands after touching the batteries

i03652933

Fire Prevention an d Explosion Prevention

Coolant

When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant. The aftertreatment regeneration device (ARD) is connected to the coolant system and will contain hot coolant.

Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained.

Check that the coolant level after the engine has stopped and the engine has been allowed to cool.

Ensure that the ﬁller cap is cool before removing the ﬁller cap. The ﬁller cap must be cool enough to touch withabarehand.Removetheﬁller cap slowly in order to relieve pressure.

Illustration 11

All fuels, most lubricants, and some coolant mixtures are ﬂ ammable.

Flammable ﬂuids that are leaking or spilled onto hot surfaces or onto electrical components can cause a ﬁre. Fire may cause personal injury and property damage.

After the emergency stop button is operated ensure that you allow 15 minutes, before the engine covers are removed.

Determinewhethertheenginewillbeoperatedinan environment that allows combustible gases to be drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, property damage, or engine damage could result.

g00704000

12 SEBU8601-01 Safety Section Fire Prevention and Explosion Prevention

If the applicat

ion involves the presence of combustible gases, consult your Perkins dealer and/or your Perkins distributor for additional information about suitable prot

ection devices.

Remove all ﬂammable combustible materials or conductive m

aterials such as fuel, oil, and debris from the engine. Do not allow any ﬂammable combustible materials or conductive materials to accumulate on the engine.

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 ﬂa

mmable materials.

Do not expose the engine to any ﬂame.

Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in case of a line, a tube, or

a seal failure. Exhaust shields must be

installed correctly.

Do not wel

d on lines or tanks that contain ﬂammable

ﬂuids. Do not ﬂame cut lines or tanks that contain ﬂammable ﬂuid. Clean any such lines or tanks

thoroug

hly with a nonﬂammable solvent prior to

welding or ﬂame cutting.

Ensure that the

engine is stopped. Inspect all lines and hoses for wear or for deterioration. The hoses must be correctly routed. The lines and hoses must have adequate

support and secure clamps.

Oil ﬁlters and fuel ﬁlters must be correctly installed. The ﬁlter hou

sings must be tightened to the correct torque. Refer to the Disassembly and Assembly manual for more information.

Wiring m

ust be kept in good condition. All electrical wires must be correctly routed and securely attached. Check all electrical wires daily. Repair any wires

e loose or frayed before you operate the

that ar engine. Clean all electrical connections and tighten all electrical connections.

Eliminate all wiring that is unattached or unnecessary. Do not use any wires or cables that are smaller than

commended gauge. Do not bypass any fuses

the re and/or circuit breakers.

ng or sparking could cause a ﬁre. Secure

Arci connections, recommended wiring, and correctly maintained battery cables will help to prevent arcing

arking.

or sp

Contact with high pressure fuel may cause ﬂuid penetration and burn hazards. High pressure fu-

spray may cause a ﬁre hazard. Failure to fol-

el low these inspe ction, maintenance and service instructions may cause personal injury or death.

After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure to be

urged from the high pressure fuel lines before any

p service or repair is performed on the engine fuel lines.

Illustration 12

g00704059

Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open ﬂames or sparks. Always stop the engine before refueling.

Illustration 13

g00704135

SEBU8601-01 13

Safety Section

Crushing Prevention and Cutting Prevention

Gases from a bat ﬂames or sparks away from the top of a battery. Do not smoke in battery charging areas.

Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or ahydrometer

Incorrect jumper cable connections can cause an explosio the Operation Section of this manual for speciﬁc instructions.

Do not charge a frozen battery. This may cause an explosion.

The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the recommend covers when the engine is operated.

tery can explode. Keep any open

n that can result in injury. Refer to

ed cables, connections, and battery box

Fire Extinguisher

Make sure familiar with the operation of the ﬁre extinguisher. Inspect the ﬁre extinguisher and service the ﬁre extingu on the instruction plate.

that a ﬁre extinguisher is available. Be

isher regularly. Obey the recommendations

i02143194

Crushing Prevention and Cutting Preve

Support the component correctly when work beneath the component is performed.

Unless other maintenance instructions are provided, never attempt adjustments while the engine is running.

Stay clear of all rotating parts and of all moving parts. Lea is performed. After the maintenance is performed, reinstall the guards.

Keep objects away from moving fan blades. The fan blades will throw objects or cut objects.

When objects are struck, wear protective glasses in order to avoid injury to the eyes.

Chips or other debris may ﬂy off objects when objects are struck. Before objects are struck, ensure that no one will

ve the guards in place until maintenance

be injured by ﬂying debris.

ntion

Lines, Tubes and Hoses

Do not b 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:

•

Make sure that all clamps, guards, and heat shields ar will help to prevent vibration, rubbing against other parts, and excessive heat.

end high pressure lines. Do not strike high

High pressure fuel line or lines are removed.

ttings are damaged or leaking.

End ﬁ

Outer coverings are chafed or cut.

Wires are exposed.

er coverings are ballooning.

Out

Flexible part of the hoses are kinked.

Outer covers have embedded armoring.

d ﬁttings are displaced.

e installed correctly. During engine operation, this

i04016709

Mounting and Dismounting

Do not climb on the engine or the engine aftertreatment. The engine and aftertreatment have not been designed with mounting or dismounting locations.

Refer to the OEM for the location of foot and hand holds for your speciﬁc application.

i03550790

h Pressure Fuel Lines

Hig

Contact with high pressure fuel may cause ﬂuid

enetration and burn hazards. High pressure fu-

p el spray may cause a ﬁre hazard. Failure to follow these in spection, maintenance and service in-

tructions may cause personal injury or death.

14 SEBU8601-01 Safety Section High Pressure Fuel Lines

Illustration 14

(1)Highpressureline (2)Highpressureline (3)Highpressureline

(4) H ig h press u re line (5) H ig h press u re line (6) H ig h press u re line

The high pressure fuel lines are the fuel lines that are between the high pressure fuel pump and the high pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head. These fuel lines are different from fuel lines on other fuel systems.

This is because of the following items:

The high pressure fuel lines are constantly charged

•

with high pressure.

The internal pressures of the high pressure fuel

•

lines are higher than other types of fuel system.

The high pressure fuel lines are formed to shape

•

and then strengthened by a special process.

Do not step on the high pressure fuel lines. Do not deﬂect the high pressure fuel lines. Do not bend or strike the high pressure fuel lines. Deformation or damage of the high pressure fuel lines may cause a point of weakness and potential failure.

Do not check the high pressure fuel lines with the engine or the starting motor in operation. After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines.

Do not loosen the high pressure fuel lines in order to remove air from the fuel system. This procedure is not required.

g01877473

(7) High pressure fuel manifold (rail) (8) High pressure line (9) Fuel transfer line that is high pressure

Visually inspect the high pressure fuel lines before the engine is started. This inspection should be each day.

If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a ﬂuid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”.

Inspect the high pressure fuel lines for damage,

•

deformation, a nick, a cut, a crease, or a dent.

Donotoperatetheenginewithafuelleak.Ifthere

•

is a leak do not tighten the connection in order to stop the leak. The connection must only be tightened to the recommended torque. Refer to Disassembly and Assembly, “Fuel injection lines Remove and Fuel injection lines - Install”.

Ifthehighpressurefuellinesaretorquedcorrectly

•

and the high pressure fuel lines are leaking the high pressure fuel lines must be replaced.

Ensure that all clips on the high pressure fuel lines

•

are in place. Do not operate the engine with clips that are damaged, missing or loose.

Do not attach any other item to the high pressure

•

fuel lines.

Loosened high pressure fuel lines must be

•

replaced. Also removed high pressure fuel lines must be replaced. Refer to Disassembly and assembly manual, “ Fuel Injection Lines - Install”.

SEBU8601-01 15

Safety Section

Before Starting Engine

i02813489

Before Starting Engine

Before the ini serviced or repaired, make provision to shut the engine off, in order to stop an overspeed. This may be accomplis supply to the engine.

Overspeed s engines that are controlled electronically. If automatic shutdown does not occur, press the emergency stop buttonino

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is fr

If equipped, ensure that the lighting system for the engine is lights work correctly, if equipped.

All prot be installed if the engine must be started in order to perform service procedures. To help prevent an acciden around the parts carefully.

Do not b disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The

its are also provided in order to help prevent

circu engine damage.

See th adjustments.

tial start-up of an engine that is new,

hed by shutting off the air and/or fuel

hutdown should occur automatically for

rder to cut the fuel and/or air to the engine.

ee of personnel.

suitable for the conditions. Ensure that all

ective guards and all protective covers must

t that is caused by parts in rotation, work

ypass the automatic shutoff circuits. Do not

e Service Manual for repairs and for

i03996487

Engine Starting

All protective be installed if the engine must be started in order to perform service procedures. T o help prevent an accident that around the parts carefully.

Start the eng from the engine start switch.

Always star that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Kn to prevent major damage to the engine components. Knowing that the procedure will also help to prevent personal i

To ensure that the jacket water heater (if equipped) and/or the correctly, check the water temperature gauge. Also, check the oil temperature gauge during the heater operatio

Engine exhaust contains products of combustion which can engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the

Note: The engine is equipped with a device for cold

g. If the engine will be operated in very cold

startin conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with the cor operation.

These aid in each individual cylinder that heats the intake air in order to improve starting. Some Perkins engines may ha the ECM that allows a controlled ﬂow of ether into the engine. The ECM will disconnect the glow plugs

re the ether is introduced. This system would

befo be installed at the factory.

guards and all protective covers must

is caused by parts in rotation, work

ine from the operators compartment or

t the engine according to the procedure

owing that the correct procedure will help

njury.

lube oil heater (if equipped) is working

be harmful to your health. Always start the

engine exhaust to the outside.

rect type of starting aid for your region of

engines are equipped with a glow plug starting

ve a cold starting system that is controlled by

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.

If a warning tag is attached to the engine start switch, or to the controls DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.

i02234873

Engine St opp ing

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.

16 SEBU8601-01 Safety Section Electrical System

Use t he Emergen

cy Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency sto

p, DO NOT start the engine until the problem that caused the emergency stop has been corrected.

Stop the engine if an overspeed condition occurs during the initial start-up of a new engine or an engine that has bee

n overhauled.

To stop an electronically controlled engine, cut the power to the

engine and/or shutting off the air supply

to the engine.

i03903127

Electrical System

Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases that are produced by some batteries to ignite.

Grounding Practices

To help prevent sparks from igniting combustible gases that are produced by some batteries, the negative “−” cable should be connected last from the external power source to the primary position for grounding.

Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical connections before the engine is started. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for speciﬁc starting instructions.

Illustration 15

Typical examp le

(1) Ground to the battery (2) Primary position for grounding (3) Ground to the starting motor (4) Ground to the eng ine block

g02145392

SEBU8601-01 17

Safety Section

Engine Electronics

Illustration 16

example

Typical

(5) Ground to the battery (6) G round to the engine block (7) Primary position for grounding

Correct grounding for the engine electrical system is necessary for optimum engine performance

liability. Incorrect grounding will result in

and re uncontrolled electrical circuit paths and in unreliable electrical circuit paths.

g02145733

The power suppl connections for the engine electronics should always be from the isolator to the battery.

y connections and the ground

i03642610

Engine Electro nics

Tampering with the electronic system installation or the OEM wiring installation can be dangerous andcouldr engine damage.

Electrical Shock Hazard. The electronic unit injectors use DC voltage. The ECM sends this voltage to the electronic unit injectors. Do not come in contact with the harness connector for the electronic unit injectors while the engine is operating. Failure to follow this instruction could result in personal injury or death.

This engine has a comprehensive, programmable Engine Monitoring System. The Electronic Control Module (ECM) has the ability to monitor the engine operating conditions. If any of the engine parameters extend outside an allowable range, the ECM will initiate an immediate action.

The following actions are available for engine monitoring control:

esult in personal injury or death and/or

Uncontrolled electrical circuit paths can result in damage to the crankshaft bearing journal surfaces

o aluminum components.

and t

Engines that are installed without engine-to-frame

nd straps can be damaged by electrical

grou discharge.

nsure that the engine and the engine electrical

To e systems function correctly, an engine-to-frame ground strap with a direct path to the battery must be

d. This path may be provided by way of a direct

use engine ground to the frame.

e connections for the grounds should be tight and

Th free of corrosion. The engine alternator must be grounded to the negative “-” battery terminal with

ire that is adequate to handle the full charging

aw current of the alternator.

Warning

•

Derate

•

Shutdown

•

The following monitored engine operating conditions have the ability to limit engine speed and/or the engine power:

Engine Coolant Temperature

•

Engine Oil Pressure

•

Engine Speed

•

Intake Manifold Air Temperature

•

Engine Intake Throttle Valve Fault

•

Wastegate Regulator

•

18 SEBU8601-01 Safety Section Engine Electronics

Supply Voltage

•

Fuel Pressure in Manifold (Rail)

•

NOx Reduction System

•

Engine After

•

The Engine Monitoring package can vary for different engine mode 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 uni Together, the two controls will provide the engine monitoring function for the speciﬁc engine application. Refer to Tr Engine Monitoring System.

son with the Engine Monitoring System.

oubleshooting for more information on the

to Sensors

treatment System

ls and different engine applications.

SEBU8601-01 19

Product Information Section

Model Views

Product Information Section

Model Views

i03913230

Model View Illustrations

The following model views show typical features of the engine. Due to individual applications, your engine may appear different from the illustrations.

Note: Only major components are identiﬁed on the following illustrations.

20 SEBU8601-01 Product Information Section Model Views

Engine views

Illustration 17

Typical example

(1) Rear lifting eye (2) NOx reduction system NRS (3) Front lifting eye (4) Alternator

(5) Refrigerant compressor (6) High-pressure turbocharger (7) Low-pressure turbocharger (8) Engine oil drain

g02150184

(9) Flywheel housing (10) Flywheel (11) NRS cooler

SEBU8601-01 21

Product Information Section

Model Views

Illustration 18

Typical example

(12) Crankcase breather (13) Electronic con trol module (ECM ) (14) Starting motor (15) Oil ﬁlter

(16) Oil gauge (17) Oil ﬁller (18) Primary fuel ﬁlter (19) Secondary fuel ﬁlter

The location of the in-line fuel strainer (20) and the priming pump (21) will depend on the application.

g02150185

(20) In-line fuel strainer (21) Electric fuel priming pump

22 SEBU8601-01 Product Information Section Model Views

Illustration 19

Typical example

(22) Outlet connection to the air to air charge

cooler (23) Connection for the air inlet (24) Outlet c onnection for the coolant

(25) Housing for the water temperature

regulator (26) Water pump (27) Inlet connection for the Coolant

Engine Aftertreatment System

The following view shows typical features of the engine aftertreatment system. Due to individual applications, your system may appear different from the illustrations.

g02150187

(28) Vibration damper (29) Belt tensioner (30) B elt

SEBU8601-01 23

Product Information Section

Model Views

Illustration 20

example

Typical

(1) Diesel oxidation catalyst (DOC) (2) Sec uring clamp (3) Torca clamp (4) Diesel particulate ﬁlter (DPF) (5) Sec uring clamp

(6) Torca cla mp (7) Lifting eye (8) Air inlet for aftertreatment regeneration

device (ARD) (9) Connections for Coolant manifold

g02162626

(10) Lifting eye

24 SEBU8601-01 Product Information Section Model Views

Illustration 21

let to exhaust system

(11) Out

ertreatment regeneration device

(12) Aft

(13) Lif (14) Exh

ting eye

aust Inlet

Fuel Pump for Engine Aftertreatment System

Note: The fuel for the engine aftertreatment system is

ied by a designated fuel pump. The location of

suppl this pump can change depending on the application.

(15) Mou

Illustration 22

Typical examp le

(16) Fuel inlet (17) Electrical connector (18) Fuel supply line (19) Return to tank (20) Fuel inlet (21) Fuel inlet

g02162641

nting cradle

g02163775

SEBU8601-01 25

Product Information Section

Model Views

i03995541

Engine De script ion

The Perkins 12 following characteristics.

In-line 6 cyl

•

Four stroke cycle

•

Series turbocharged charge cooled

•

The 1206Ewith a low-pressure turbocharger and a high-pressure turbocharger.

Engine Speciﬁcations

Note: The front end of the engine is opposite the

ﬂywheel end of the engine. The left and the right sides of t end. The number 1 cylinder is the front cylinder.

06E-E70TTA industrial engine has the

inder

E70TTA industrial engine is equipped

he engine are determined from the ﬂywheel

Table 1

1206E-E70TTA Engine Speciﬁcations

Operating Range (rpm) 900 to 2800

Number of Cylinders 6 In-Line

Bore

Stroke 135 mm (5.31495 inch)

Power

Aspiration Turbocharged charge

Compression Ratio 16.5:1

Displacement

Firing Order

Rotation (ﬂywheel end) Counterclockwise

(1)

The operating rpm is dependent on the engine rating, the

application, and the conﬁguration of the throttle.

105 mm (4.13

225 kW (301.72 hp)

cooled

7.01 L (42

1-5-3-6-2-4

(1)

inch)

8in3)

Electronic Engine Features

The engine operating conditions are monitored. The Electronic Control Module (ECM) controls the response of the engine to these conditions and to the demands of the operator. These conditions and operator demands determine the precise control of fuel injection by the ECM. The electronic engine control system provides the following features:

Illustration 23

Cylinder and valve location

(A) Exhaust valves (B) Inlet valves

g01127295

Engine monitoring

•

Engine speed governing

•

Control of the injection pressure

•

Cold start strategy

•

Automatic air/fuel ratio control

•

Torque rise shaping

•

Injection timing control

•

System diagnostics

•

Aftertreatment Regeneration

•

For more information on electronic engine features, refer to the Operation and Maintenance Manual, “Features and Controls” topic (Operation Section).

26 SEBU8601-01 Product Information Section Model Views

Engine Diagnostics

Theenginehas that the engine systems are functioning correctly. The operator will be alerted to the condition by a “Stop or Warning” lamp horsepower and the vehicle speed may be limited. The electronic service tool may be used to display the diagnost

There are three types of diagnostic codes: active, logged, and

Most of the diagnostic codes are logged and stored in the ECM. F the Operation and Maintenance Manual, “Engine Diagnostics” topic (Operation Section).

The ECM provides an electronic governor that controls the injector output in order to maintain the desired e

Engine Co

The cooling system and lubrication system consists of the fo

•

llowing components:

Gear-driven centrifugal water pump

built-in diagnostics in order to ensure

. Under certain conditions, the engine

ic codes.

event.

or additional information, refer to

ngine rpm.

oling and Lubrication

Expected engin average power that is demanded. The average power that is demanded is based on fuel consumption of the engine ove operation at full throttle and/or operating at reduced throttle settings result in a lower average power demand. Redu the length of operating time before an engine overhaul is required.

e life is generally predicted by the

r a period of time. Reduced hours of

ced hours of operation will increase

Aftermarket Products and Perkins Engines

Perkins doe of non-Perkins ﬂuids and ﬁlters.

When auxil (ﬁlters, additives, catalysts,) which are made by other manufacturers are used on Perkins products, the Perkins w such use.

However, or use of other manufacturers devices, accessories, or consumables are NOT Perkins defects under the Perkins warranty.

s not warrant the quality or performance

iary devices, accessories, or consumables

arranty is not affected simply because of

failures that result from the installation

. Therefore, the defects are NOT covered

Water temperature regulator which regulates the

•

engine coolant temperature

Gear-driven rotor type oil pump

•

Oil coo

•

The engine lubricating oil is supplied by a rotor type oil pu engine lubricating oil is ﬁltered. The bypass valve can provide unrestricted ﬂow of lubrication oil to the en plugged.

Engi engine performance depend on adherence to proper operation and maintenance recommendations. Engi the use of recommended fuels, lubrication oils, and coolants. Refer to this Operation and Maintenance Man information on maintenance items.

ler

mp. The engine lubricating oil is cooled and the

gine if the oil ﬁlter element should become

ne efﬁciency, efﬁciency of emission controls, and

ne performance and efﬁciency also depend on

ual, “Maintenance Interval Schedule” for more

Engine Service Life

gine efﬁciency and maximum utilization of engine

En performance depend on the adherence to proper operation and maintenance recommendations. In

dition, use recommended fuels, coolants and

ad lubricants. Use the Operation and Maintenance Manual as a guide for required engine maintenance.

Aftertr

The aftertreatment system is approved for use by Perkin approved Perkins aftertreatment system must be used on a Perkins engine.

eatment System

s. In order to be emission-compliant only the

SEBU8601-01 27

Product Information Section

Product Identiﬁcation Information

Plate Locations and Film Locations

i03567854

Serial Number Plate (1)

Theengineserialnumberplateislocatedonthe left side of the cylinder block to the rear of the front engine mounting.

tion 25

Illustra

Serial number plate

g01094203

Illustration 24

Location of the serial number plate

Perkins engines are identiﬁed by an engine serial number.

An example of an engine number is BL*****U000001J.

*****

____________________ The list number for the engine

__________________________________________ Type of engine

____________________________ Built in the United Kingdom

000001

Perkins dealers or Perkins distributors need all of these numbers in order to determine the components that were included with the engine. This permits accurate identiﬁcation of replacement part numbers.

The numbers for fuel setting information for electronic engines are stored within the ﬂash ﬁle. These numbers can be read by using the electronic service tool.

___________________________ Engine Serial Number

_____________________________________ Year of Manufacture

g01890033

28 SEBU8601-01 Product Information Section Product Identiﬁcation Information

i03976148

Plate Locations and Film Locations (Engine Aftertreatment System)

Illustration 26

Typical example

The module arrangement exhaust plate is installed on the mounting plate (1). The location of the arrangement plate mounting plate can alter depending on the application.

Illustration 27

Module A rrangement Exhaust Plate

Record the information that is on the plate. This information identiﬁes the engine aftertreatment system. This information will be required by your Perkins dealer.

g02109493

g02151573

i03867276

Reference Numbers

Information for the following items may be needed to order parts. Locate the information for your engine. Record the information in the appropriate space. Make a copy of this list for a record. Keep the information for future reference.

Record for Reference

Engine Model _ ______________________________________________

Engine Serial number _____________________________________

Engine Low Idle rpm ______________________________________

Engine Full Load rpm _____________________________________

Primary Fuel Filter _________________________________________

Water Separator Element ________________________________

Secondary Fuel Filter Element __________________________

SEBU8601-01 29

Product Information Section

Product Identiﬁcation Information

Lubrication Oi

Auxiliary Oil Filter Element _______________________________

Total Lubrication System Capacity _____________________

Total Coolin

Air Cleaner Element _______________________________________

Drive Belt ____________________________________________________

Engine Afte

Part Number ________________________________________________

Serial Number _______ _______________________________________

l Filter Element

g System Capacity

rtreatment System

___________________________

_________________________

i03977815

Emissions Certiﬁcation Film

Label fo

r compliant engines

An emission label is installed on the front gear cover.

Note: A second emission label may be supplied with the engine. If necessary, the second emission label may be i equipment manufacturer.

nstalled on the application by the original

Illustration 28

Typical example

g02164223

30 SEBU8601-01 Operation Section Lifting and Storage

Operation Section

Lifting and Storage

Product Lifting (Engine)

i03977851

Some removals r obtain correct balance and safety.

To r em ove th e e are on the engine.

Lifting eyes engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting ﬁxtures obs that correct lifting devices are provided. Consult your Perkins dealer or your Perkins distributor for informatio lifting.

n regarding ﬁxtures for correct engine

equire lifting the ﬁxtures in order to

ngine ONLY, use the lifting eyes that

are designed and installed for speciﬁc

olete. If alterations are made, ensure

i03977852

Product Lifting (Clean Emission Module)

NOTICE Never bend the eyebolts and the brackets. Only load the eyeb ber that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes l

olts and the brackets under tension. Remem-

ess than 90 degrees.

Illustration 29

NOTICE

er bend the eyebolts and the brackets. Only load

Nev the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle

ween the supporting members and the object be-

bet comes less than 90 degrees.

en it is necessary to remove a component at an

Wh angle, only use a link bracket that is properly rated for the weight.

Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the engine. All

upporting members (chains and cables) should be

s parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted.

g01097527

When it is necessary to remove a component at an angle, the weight.

Use a h adjustable lifting beam to lift the Clean Emission Module. All supporting members (chains and cables) shou cables should be perpendicular to the top of the object that is being lifted.

Some removals may require lifting the ﬁxtures in order to obtain proper balance and safety.

only use a link bracket that is properly rated for

oist to remove heavy components. Use an

ld be parallel to each other. The chains and

SEBU8601-01 31

Operation Section

Lifting and Storage

Illustration 30

example

Typical

g02293733

To remove the Clean Emission Module (CEM), use

g eyes (1). Lifting eyes are designed and installed

liftin for the speciﬁc CEM arrangement. Do not use the lifting eyes for any other purpose than lifting the CEM.

Alterations to the lifting eyes and/or the CEM make the lifting eyes and the lifting ﬁxtures obsolete. If

ations are made, ensure that proper lifting

alter devices are provided. Consult your Perkins dealer, or your Perkins distributor for information regarding

es for proper CEM lifting.

ﬁxtur

32 SEBU8601-01 Operation Section Lifting and Storage

i04161429

Product Lifting

Illustration 31

Typical example

The lifting points (1) are for the application shown. A suitable lift truck will be required in order to lift the application.

The lifting eyes on the application will have blanking devices (2) installed.

Illustration 32

(A) Typical engine lifting eye (B) Typical CEM lifting eye

g02354678

g02354717

SEBU8601-01 33

Operation Section

Lifting and Storage

In order to lift Operation and Maintenance Manual, “Product Lifting (Clean Emission Module)”. In order to lift the engine, refer to this O “Product Lifting (Engine)”.

the clean emission module, refer to this

peration and Maintenance Manual,

i04084189

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 assist in preparing the engine for extended storage periods.

Condition for Storage

Theenginemustbestoredinawaterproofbuilding. 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 to extreme variations in temperature and humidity.

3. The engine oil w

order to store the engine. Provided the correct speciﬁcation of engine oil is used the engine canbestoredf correct speciﬁcation of engine oil refer to this Operation and Maintenance Manual, “Fluid recommendat

4. Remove the drive belt from the engine.

Sealed Coolant System

Ensure that ELC, or an antifreeze that meets “ASTM D6210” speciﬁcation.

Open Cooling System

Ensure tha opened. Allow the coolant to drain. Install the drain plugs. Place a vapor phase inhibitor into the system. The coola phase inhibitor has been introduced. The effect of the vapor phase inhibitor will be lost if the cooling system is open to

For maintenance procedures ref to this Operation and Main

the cooling system is ﬁlled with Perkins

t all cooling drain plugs have been

nt system must be sealed once the vapor

the atmosphere.

tenance Manual.

ill not need to be drained in

or up to 6 months. For the

ions”.

Aftertreatment

Storage Period

An engine can be stored for up to 6 months provided all the recommendation are adhered to.

Storage Procedure

Keep a record of the procedure that has been completed on the engine.

Note: Do not store an engine that has biodiesel in the fuel system.

1. Ensure that the engine is clean and dry.

a. If the engine has been operated using biodiesel,

the system must be drained and new ﬁlters installed. The fuel tank will require ﬂushing.

b. Fill the fuel system with an ultra low sulfur fuel.

For more information on acceptable fuels refer to this Operation and Maintenance Manual, “Fluid recommendations”. Operate the engine for 15 minutes in order to remove all biodiesel from the system.

No special procedures are required. The exhaust outlet of the aftertreatment should be capped. Before

g, the engine and the aftertreatment must be

storin enclosedinacover.

Month

The crankshaft must be rotated in order to change the sp the crankshaft more than 180 degrees. Visibly check for damage or corrosion to the engine and afte

Ensure that the engine and aftertreatment are cove procedure in the record for the engine.

ly Checks

ring loading on the valve train. Rotate

rtreatment.

red completely before storage. Log the

2. Drain any water from the primary ﬁlter water separator. Ensure that the fuel tank is full.

34 SEBU8601-01 Operation Section Gauges and Indicators

Gauges and Ind icators

i03979889

Gauges and Indicators

Your engine the gauges that are described. For more information about the gauge package, see the OEM information.

Gauges provide indications of engine performance. Ensure that the gauges are in good working order. Determine the gauges over a period.

Noticeab potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if t Determine and correct the cause of any signiﬁcant change in the readings. Consult your Perkins distrib

Some engine applications are equipped with Indicator Lamps. aid. There are two lamps. One lamp has an orange lens and the other lamp has a red lens.

These indicator lamps can be used in two ways:

The in

•

current operational status of the engine. The indicator lamps can also indicate that the engine has a f via the ignition switch.

The i

•

diagnostic codes. This system is activated by pressing the Flash Code button.

Refer to the Troubleshooting Guide, “Indicator Lamps” for further information.

If no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded, STOP the engine. Engine damage can result.

may not have the same gauges or all of

the normal operating range by observing

le changes in gauge readings indicate

he readings are within speciﬁcations.

utor for assistance.

Indicator lamps can be used as a diagnostic

dicatorlampscanbeusedtoidentifythe

ault. This system is automatically operated

ndicator lamps can be used to identify active

NOTICE

1. Remove the load

2. Stop the engine.

3. Check and maintain the oil level.

Jacket Water

Typical temperature range is 82° to 94°C

(179.6° to 169.2°F). This temperature range will vary ac temperature.

A 100 kPa (14.5 psi) radiator cap must be installed on the cooli for the cooling system is 108° C (226.4° F). This temperature is measured at the outlet for the water temp temperature is regulated by the engine sensors and the engine ECM. This programming cannot be altered. A engine coolant temperature is exceeded.

If the eng reduce the engine load. If high coolant temperatures are a frequent event, perform the following procedu

1. Reduce the load and the engine rpm.

2. Determine if the engine must be shut down

immediately or if the engine can be cooled by reduci

3. Inspect the cooling system for leaks. If necessary,

consul

load, the engine is running at high idle. The engine is runni lever is at the full throttle position with maximum rated load.

To help prevent engine damage, never exceed the high idle rpm. Overspeeding can result in serious damage to the engine. Operation at speeds exceeding high idle rpm should be kept to a minimum.

cordingtoengineloadandtheambient

ng system. The maximum temperature

erature regulator. The engine coolant

n engine derate can occur if the maximum

ine is operating above the normal range,

res:

ng the load.

t your Perkins distributor for assistance.

Tachometer – This gauge indicates engine

speed

ismovedtothefullthrottlepositionwithout

ng at the full load rpm when the throttle control

Coolant Temperature –

(rpm). When the throttle control lever

NOTICE

Engine Oil Pressure – The oil pressure should be greatest after a cold engine is

started. The typical engine oil pressure with SAE10W40is350to450kPa(50to65psi)atrated rpm.

A lower oil pressure is normal at low idle. If the load is stable and the gauge reading changes, perform the following procedure:

Ammeter – This gauge indicates the amount of charge or discharge in the battery charging circuit. Operation of the

indicator should be to the “+” side of “0” (zero).

Fuel Level – This gauge indicates the fuel level in the fuel tank. The fuel level gauge operates when the “START/ST OP” switch

is in the “on” position.

SEBU8601-01 35

Operation Section

Gauges and Indicators

Service Hour Meter – The gauge indicates

total operating hours of the engine.

Indicator Lam

Shutdown lamp

•

Warning lamp

•

Wait to star

•

Low oil pressure lamp

•

For information, refer to this manual, “Monitoring System (Table for the Indicator Lamps)” for the sequence o warning lamp.

The funct controlled at engine start-up.

The funct by the engine ECM. If low oil pressure is detected, the lamp will be illuminated. The reason for the

ation of the low-pressure lamp should be

illumin investigated immediately.

All lamp check that the lamps are functioning when the keyswitch is turned to the ON position. If any of the lamps s should be investigated immediately.

tlamp

f operation of the shutdown lamp and the

ion of the wait to start lamp is automatically

ion of the low oil pressure lamp is controlled

s will illuminate for 2 seconds in order to

tay illuminated, the reason for illumination

Aftertreatment Lamps

formation on the aftertreatment lamp, refer to

For in this Operation and Maintenance Manual, “Diesel Particulate Filter Regeneration”.

36 SEBU8601-01 Operation Section Features and Controls

Features and Controls

i03552521

Monitoring System (Engine)

Table 2

Warning

Lamp

ON ON

OFF OFF

ON OFF

ON FLASHING

FLASHING OFF

FLASH

ING

Shutdown

Lamp

Status

Lamp check When the engine start switch is turned to the

No faults There are

Active diagnostic fault

Derate and warning

Engine shutdown

“ON” position both lamps will illuminate for 2 seconds only.

An active diagnostic fault has been detected.

A serious active diagnostic fault has been detecte

One or more of the engine protection values has been ex

One or more of the engine protection values has been e fault has been detected.

Description of Lamp Status Engine Status

no active diagnostic faults. The engine is running

d and an engine derate has been invoked.

ceeded.

xceeded or a serious active diagnostic

The engine has not been started.

normally.

Theengineisrunning normally.

Theengineisrunning but the engine has been derated.

Theengineisshutdown or shutdown is imminent.

i03979949

Moni

toring System

(Engine)

If the Shutdown mode has bee n selected and the warning indicator activates, engine shutdown may take as little as 20 seconds from the time the warning indicator is activated. Depending on the application, special precautions should be taken to avoid personal injury. The e ngine can be restarted following shutdown for emergency maneuvers, if necessary.

NOTICE

The Engine Monitoring System is not a guarantee

gainst catastrophic failures. Programmed delays

a and derate schedules are designed to minimize false alarms and provide time for the operator to stop the engine.

The following parameters are monitored:

Coolant temperature

•

Intake manifold air temperature

•

Intake manifold air pressure

•

Oil pressure

•

Pressure in the fuel rail

•

Fuel temperature

•

Fuel ﬁlter differential pressure

•

Water in fuel

•

Engine speed/timing

•

Atmospheric pressure (Barometric pressure)

•

The Inlet pressure and outlet pressure of the NOx

•

reduction system

The differential pressure w ithin the NOx reduction

•

system

SEBU8601-01 37

Operation Section

Features and Controls

Temperature of

•

The amount of soot in the Diesel particulate ﬁlter

•

the NOx reduction system

Programmable O ptions and Systems Operation

If the Warning/Derate/Shutdown mode has been selected an bring the engine to a stop whenever possible. Depending on the application, special precautions should be t

The engine can be programmed to the following modes:

“Warning”

The “Warning” lamp and the warning signal (orange lamp) turn “ON” and the warning signal is activated continu more of the engine parameters is not within normal operating range.

d the warning indicator activates,

aken to avoid personal injury.

ously in order to alert the operator that one or

If there is a sig temperature, there will be a two second delay in order to verify the condition.

For each of the programmed modes, refer to Troubleshooting Guide, “Indicator Lamps” for more information

For more information or assistance for repairs, consult you dealer.

nal for low oil pressure or for coolant

on Indicator Lamps.

r Perkins distributor or your Perkins

Instrument panels and Displays

In order to m instrument panels are available. These instrument panels can contain the aftertreatment lamps and the indicator The regeneration switch can be incorporate within the panel.

Also available are mini power displays and performance monitors. These displays and monitors can show t information.

The syst

•

onitor the engine a wide verity of

lamps and the gauges for the application.

he operator the following engine

em conﬁguration parameters

“Warning/Derate”

The “Di signal (red lamp) is activated. After the warning, the engine power will be derated. The warning lamp will begin t

The engine will be derated if the engine exceeds prese achieved by restricting the amount of fuel that is available for each injection. The amount of reduction of fu has caused the engine derate, typically up to a limit of 50%. This reduction in fuel results in a predetermined redu

agnostic” lamp turns “ON” and the warning

o ﬂash when the derating occurs.

t operational limits. The engine derate is

el is dependent on the severity of the fault that

ction in engine power.

“Warning/Derate/Shutdown”

The “Diagnostic” lamp turns “ON” and the warning signal (red lamp) is activated. After the warning,

engine power will be derated. The engine will

the continue at the rpm of the set derate until a shutdown of the engine occurs. The engine can be restarted

ter a shutdown for use in an emergency.

A shutdown of the engine may occur in as little

20 seconds. The engine can be restarted after

as ashutdownforuseinanemergency.However, thecauseoftheinitialshutdownmaystillexist.

he engine may shut down again in as little as 20

T seconds.

The customer speciﬁed p arameters

•

Diagnostic codes

•

Event c

•

Coolant temperature

•

Oil temperature

•

Oil pr

•

Intake temperature

•

Intake pressure

•

Atmo

•

Fuel temperature

•

odes

essure

spheric pressure

38 SEBU8601-01 Operation Section Features and Controls

i03979996

Sensors and Electrical Components

Sensor Locations

TheIllustrationwithinthesectionshowsthetypical locations of the sensors for a 1206E-70 Industrial Engine. Spe the illustration due to differences in applications.

ciﬁc engines may appear different from

Illustration 33

(1) Engine Intake Throttle Valve (2) Wastegate Regulator (3) Control Valve for the NOx Reduction

System (NRS)

(4) Temperature Sensor for the NOx

Reduction System

(5) Intake P ressure Sensor for the NOx

Reduction System (NRS)

(6) Differential Pressure Sensor for the NOx

Reduction System (NRS)

(7) Fuel Pres sure Sensor (Fuel Rail

Pressure Sens or) (8) Intake Manifold A ir Temperature Sensor (9) Intake M anifold Pressure Sens or (10) Electronic Control Module (ECM) (11) Atmos pheric Pressure Sensor

(Barometric Pressure Sensor) (12) Primary Speed/Timing Sensor (13) Starting Motor (14) Oil Pressure Sens or

g02150593

(15) Oil level Switch ( if Equ ipped) (16) Diagnostic Connector (17) Fuel Temperature Sensor (18) Solenoid for the High Pressure Fuel

Pump

(19) Coolant Temperature Sensor

SEBU8601-01 39

Operation Section

Features and Controls

Illustration 34

The location of the fuel ﬁlters will depend on the application.

(20) Differential Pressure Switch for the

Secondary Fuel Filter

(21) Water in Fuel Switch

(22) Secondary S peed/Timing S ensor (23) Fuel Priming Pump (24) Alternator

g02150594

(25) Refrigerant Compressor (if equipped)

40 SEBU8601-01 Operation Section Features and Controls

Illustration 35

(1) Engine Intake Throttle Valve (2) Wastegate Regulator (3) Control Valve for the NRS (4) Temperature Sensor for the NRS

ustration 36

Ill

(10) Electronic Control Module (EC M) (11) Atmospheric Pressure Sensor

(Barometric Pressure Sensor)

(5) Intake Pressure Sensor for the NRS (6) Differential Pressure Sensor for the NRS (7) Fuel Pres sure Sensor (Fuel Rail

Pressure Sens or)

(12) Primary Speed/Timing Sensor (13) Starting Motor (14) Oil Pressure Sens or

g02151173

(8) Intake Manifold Air Temperature Sensor (9) Intake M anifold Pressure Sens or

g02151174

(15) Oil Level Switch (if Equipped)

The oil level switch (15) will only operate with the application on level ground and the power in the

position. The engine must be at zero RPM. A

ON coolant level switch can be installed, this switch only operates at key on, and the application must be on

vel ground.

SEBU8601-01 41

Operation Section

Features and Controls

Illustration 37

(16) Diagnostic Connector (17) Fuel Temperature Sensor

stration 38

Illu

(20) Differential Pressure Switch for the

Secondary Fuel Filter

(18) Solenoid for the High Pressure Fuel

Pump

(21) Water in Fuel Switch (22) Secondary S peed/Timing S ensor

g02151327

(19) Coolant Temperature Sensor

g02151177

(23) Fuel Priming Pump

Programmable Monitoring System (PMS)

e Programmable Monitoring System determines

Th the level of action that is taken by the Engine Control Module (ECM) (10).In response to a condition that

n damage the engine. These conditions are

ca identiﬁed by the ECM from the signals that are produced from the following sensors.

Coolant Temperature Sensor

•

Intake Manifold Air Temperature Sensor

•

Intake Manifold Pressure Sensor

•

el Pressure Sensor

•

Engine Oil Pressure Sensor

•

Primary Speed/Timing Sensor

•

econdary Speed/Timing Sensor

•

42 SEBU8601-01 Operation Section Features and Controls

Fuel Temperatu

•

Temperature Sensor for the NRS

•

Intake Pressure Sensor for the NRS

•

Differentia

•

Sensors and

re Sensor

l Pressure Sensor for the NRS

i03928178

Electrical Components (Aftertreatment)

The follow engine aftertreatment system. Due to individual applications, your system may appear different from the illus

Glossary

•

ARD Aftertreatment Regeneration Device

•

ing view shows typical features of the

trations.

DOC Dies

•

el Oxidation Catalyst

SEBU8601-01 43

Operation Section

Features and Controls

Illustration 39

Typical example

(1) Soot sensor connection (2) Spa rk plug lead (3) ARD air pressure sensor (4) DOC pressure sensor (5) Pressure differential sensor (6) Relay (7) Soot sensor connection (8) DOC Temperature sensor (not shown) (9) Harness connector (10) Main fuel valve (If equipped) (11) Pilot fuel valve (12) Fuel pressure sensor (if equipped) (13) Fuel pressure sensor (pilot) (14) Aftertreatment device ID (15) Coil for spark plug (16) ARD air control valve (17) Location of s park plug (18) ARD exhaust gas temperature sensor

g02313693

44 SEBU8601-01 Operation Section Features and Controls

i03928179

Engine Shutoffs and Engine Alarms

Shutoffs

The shutoffs are electrically operated or mechanically operated. The electrically operated shutoffs are controlled

Shutoffs are set at critical levels for the following items:

Operating temperature

•

Operating pressure

•

Operatin

•

Operating rpm

•

The particular shutoff may need to be reset before the engine will start.

by the ECM.

g level

Intake manifol

manifold air temperature sensor indicates high intake air temperature.

Intake manifold pressure – The intake manifold pressure sensor checks the rated pressure in the engine manif

Fuel rail pressure – The fuel rail pressure sensor checks for h rail.

Engine oil p

sensor indicates when oil pressure drops below rated system pressure, at a set engine speed.

Engine overspeed – If, the engine rpm exceeds the overspeed setting the alarm will be activated.

Air ﬁlter restriction – Theswitchcheckstheair ﬁlter when the engine is operating.

User-deﬁned switch – This switch can shut down the engine remotely.

Water in fuel switch – This switch checks for water in the primary fuel ﬁlter when the engine is operating.

d air temperature – Th e intake

old.

igh pressure or low pressure in the fuel

ressure – The engine oil pressure

NOTICE Always determine the cause of the engine shutdown. Make necessary repairs before attempting to restart the eng

Be familiar with the following items:

•

Alar

The alarms are electrically operated. The operations of t

The alarm is operated by a sensor or by a switch. Whe is sent to the ECM. An event code is created by theECM.TheECMwillsendasignalinorderto il

Your engine may be equipped with the following se

Coolant temperature – The coolant temperature s temperature.

ine.

Types and locations of shutoff

tions which cause each shutoff to function

Condi

The resetting procedure that is required to restart

ngine

the e

he alarms are controlled by the ECM.

n the sensor or the switch is activated, a signal

luminate the lamp.

nsors or switches:

ensor indicates high jacket water coolant

Fuel temperature – The fuel temperature sensor monitors the pressurized fuel in the high-pressure fuel pum

Fuel differential pressure – This switch checks the pressu

Note: The sensing element of the coolant tempe in order to operate.

Engin to alert the operator when undesirable operating conditions occur.

When be taken before the situation becomes an emergency in order to avoid possible engine damage.

If corrective measures are not taken within a reasonable time, engine damage could result. The

arm will continue until the condition is corrected.

al The alarm may need to be reset.

oil level switch are indicators. Both switches operate when the application is on level ground and the

ngine RPM at zero.

re across the fuel ﬁlter.

rature switch must be submerged in coolant

es may be equipped with alarms in order

NOTICE

an alarm is activated, corrective measures must

te: If installed, the coolant level switch and the

SEBU8601-01 45

Operation Section

Features and Controls

Testing

Turning the ke the indicator lights on the control panel. All the indicator lights will be illuminated for 2 seconds after the keyswitch immediately.

Refer to Trou information.

yswitch to the ON position will check

is operated. Replace suspect bulbs

bleshooting, KENR9106 for more

i03554501

Overspeed

ECM ______________________Electronic Control Module

•

RPM ___________________ _____ Revolutions Per Minute

•

An oversp sensors.

The defa The ECM will cut the power to the electronic unit injectors, until the rpm drops below 200 rpm of the overspe logged into the ECM memory and a warning lamp will indicate a diagnostic fault code.

eed is detected by the speed/timing

ult setting for an overspeed is 3000 rpm.

ed setting. A diagnostic fault code will be

An overspeed can be set from 2600 rpm to 3000 rpm. This setting depends on the application.

46 SEBU8601-01 Operation Section Engine Diagnostics

Engine Diagnostics

i02651093

Self-Diagnostics

Perkins electronic engines have the capability to perform a self-diagnostics test. When the system detects an active problem, a diagnostic lamp is activated. Diagnostic codes will be stored in permanent memory in the Electronic Control Module (ECM). The diagnostic codes can be retrieved by using the electronic service tool. Refer to Troubleshooting , “Electronic Service Tools” for further information.

Some installations have electronic displays that provide direct readouts of the engine diagnostic codes. Refer to the manual that is provided by the OEM for more information on retrieving engine diagnostic codes. Alternatively refer to Troubleshooting , “Indicator Lamps” for further information.

i04036139

Diagnostic Flash Code Retrieval

In order to read the diagnostic ﬂash codes through the diagnostic lamp, cycle the key switch from off to on twice wit

The codes will be ﬂashing in sequence. For example if the ﬂash c ﬂash once, pause, ﬂash three times, pause, and ﬂash three times.

After the complete code has ﬂashed, a 3 second pause will take place before the next code will begin to ﬂash (if

Note: For more information refer to Troubles

hin 3 seconds.

ode equals 133, the diagnostic lamp will

another code is present).

hootingmanual.

Active codes represent problems that currently exist. These problems should be investigated ﬁrst.

Logged codes represent the following items:

Intermittent problems

•

Recorded events

•

Performance history

•

The problems may have been repaired since the logging of the code. These codes do not indicate that a repair is needed. The codes are guides or signals when a situation exists. Codes may be helpful to troubleshoot problems.

When the problems have been corrected, the corresponding logged fault codes should be cleared.

i02651107

Diagnostic Lamp

A diagnostic lamp is used to indicate the existence of

active fault. Refer to Troubleshooting , “Indicator

an Lamps” for more information. A fault diagnostic code will remain active until the problem is repaired.

he diagnostic code may be retrieved by using the

T electronic service tool. Refer to Troubleshooting , “Electronic Service Tools” for more information.

SEBU8601-01 47

Operation Section

Engine Diagnostics

Table 3

CDL Code

N/A No Diagnostic Code Detected N/A 551

1-2 Cylinder #1 Injector data incorrect 651-2

1-5 Cylinder #1 Injector current below normal 651-5

1-6 Cylinder #1 Injector current above normal 651-6

2-2 Cylinder #2 Injector data incorrect 652-2

2-5 Cylinder #2 Injector current below normal 652-5

2-6 Cylinder #2 Injector current above normal 652-6

3-2

3-5

3-6

4-2

4-5

4-6 Cylinder #4 Injector current above normal 654-6

5-2 Cylinder #5 Injector data incorrect 655-2

5-5

5-6 Cylinder #5 Injector current above normal 655-6

6-2 Cylinder #6 Injector data incorrect 656-2

6-5 Cylinder #6 Injector current below normal 656-5

6-6 Cylinder #6 Injector current above normal 656-6

18-5

18-6

41-3

41-4

91-2

91-3 Throttle Position Sensor voltage above normal 91-3

91-4 Throttle Position Sensor voltage below normal 91-4

91-8 Throttle Position Sensor abnormal frequency, pulse width, or period 91-08

100-3 Engine Oil Pressure Sensor voltage above normal 100-3

100-4 Engine Oil Pressure Sensor voltage below normal 100-4

100-21 Engine Oil Pressure Sensor data drifted low 100-21

110-3 Engine Coolant Temperature Sensor voltage above normal 110-3

110-4 Engine Coolant Temperature Sensor voltage below normal 110-4

168-2

168-3

168-4

172-3

172-4 Intake Manifold Air Temperature Sensor voltage below normal 105-4

Cylinder

Cylinder #3 Injector current below normal

Cylinder #3 Injector current above normal

Cylinder #4 Injector data incorrect

Cylinder #4 Injector current below normal

Cylinder #5 Injector current below normal 655-5

Fuel Control Valve current above normal

8 Volt DC Supply voltage above normal

8 Volt DC Supply voltage below normal

Throttle Position Sensor erratic, intermittent, or incorrect

Electrical System Voltage erratic, intermittent, or incorrect

Electrical System Voltage voltage above normal

Electrical System Voltage voltage Below normal

Intake Manifold Air Temperature Sensor voltage above normal

#3 Injector data incorrect 653-2

el Control Valve current below normal 1076-5

Description

J1939

Code

653-5

653-6

654-2

654-5

1076-6

678-3

678-4

91-2

168-2

168-3

168-4

105-3

Flash Code

111

112

113

114

115

116

517

154

157

168

511

133

(continued)

48 SEBU8601-01 Operation Section Engine Diagnostics

(Table 3, contd)

CDL Code Description

174-3

174-4

190-8

247-9

253-2 Personality Module erratic, intermittent, or incorrect 631-2 415

261-11 Engine Timing Offset fault 637-11 143

262-3 5 Volt Sensor DC Power Supply voltage above normal 3509-3

262-4 5 Volt Sensor DC Power Supply voltage below normal 3509-4

268-2 Programmed Parameter Fault erratic, intermittent, or incorrect 630-2 527

274-3

274-4 Atmospheric Pressure Sensor voltage below normal 108-4

274-13 Atmospheric Pressure Sensor calibration required 108-13

274-21 Atmospheric Pressure Sensor data drifted low 108-21

342-8 Secondary Engine Speed Sensor abnormal frequency, pulse width, or period 723-8 142

526-5 Turbo

526-6 Turbo Wastegate Drive current above normal 1188-6

535-3 Exhaust Temperature Sensor voltage above normal 3241-3

535-4 Exhaust Temperature Sensor voltage below normal 3241-4

774-2 Secondary Throttle Position S ensor erratic, intermittent, or incorrect 29-2

774-3 Secondary Throttle Position Sensor voltage above normal 29-3

774-4 Secondary Throttle Position Sensor voltage below normal 29-4

774-8 Secondary Throttle Position Sensor abnormal frequency, pulse width, or period 29-8

993-2 DPF Active Regeneration Inhibited Due to Inhibit Switch 3703-31

1262-2 Engine Throttle Actuator 1 Control Command not responding properly 3464-7

1634-2

1635-2

1639-9

1743-2

1785-3 Intake Manifold Pressure Sensor voltage above normal 3563-3

1785-4 Intake Manifold Pressure Sensor voltage below normal 3563-4

1785-13 Intake Manifold Pressure Sensor calibration required 3563-13

1785-21 Intake Manifold Pressure Sensor data drifted low 3563-21

1797-3 Fuel Rail Pressure Sensor voltage above normal 157-3

1797-4 Fuel Rail Pressure Sensor voltage below normal 157-4

1797-7 Fuel Rail Pressure Sensor not responding properly 157-7

1834-2 Ignition Key Switch loss of signal 158-2 429

2131-3

2131-4

Fuel Temperature Sensor voltage above normal

Fuel Temperature Sensor voltage below normal

Engine Speed Sensor abnormal frequency, pulse width, or period

SAE J1939 Data Link abnormal update rate

Atmospheric Pressure Sensor voltage above normal

Wastegate Drive current below normal

Idle Validation Switch #1 erratic, intermittent or incorrect

Idle Validation Switch #2 erratic, intermittent or incorrect

Machine Security System M odule abnormal update rate

Engine Operation Mode Selector Switch erratic, intermittent, or incorrect

5 Volt Sensor DC Power Supply #2 voltage above normal

5 Volt Sensor DC Power Supply #2 voltage below normal

J1939

Code

174-3

174-4

190-8 141

108-3

1188-

558-2 245

2970-2

1196-9

2882-2 144

3510-3

3510-4

Flash Code

165

514

516

152

177

185

155

246

197

159

528

(continued)

SEBU8601-01 49

Operation Section

Engine Diagnostics

(Table 3, contd)

CDL Code Description

2246-6

2417-5

2417-6

2452-3

2452-4 DPF #1 Intake Temperature Sensor voltage below normal 3242-4 224

2458-3 DPF #1 Differential Pressure Sensor : voltage above normal 3251-3 222

2458-4 DPF #1 Differential Pressure Sensor : voltage below normal 3251-4 222

2460-3 ARD Fuel Pressure #1 Sensor voltage above normal 3480-3 219

2460-4 ARD Fuel Pressure #1 Sensor voltage below normal 3480-4 219

2461-5 ARD Fuel Pressure #1 Control current below normal 3479-5

2461-6 ARD Fuel Pressure #1 Control current above normal 3479-6

2465-5

2465-6

2489-5

2489-6

2490-3

2490-4 ARD Air Pressure Control Actuator Position Sensor voltage below normal 3488-4

2498-3 ARD Supply Air Pressure Sensor voltage above normal 3837-3

2498-4 ARD Supply Air Pressure Sensor voltage below normal 3837-4

2498-13 ARD Supply Air Pressure Sensor calibration required 3837-13

2498-21 ARD Supply Air Pressure Sensor data drifted low 3837-21

2526-3 Air Inlet Temperature Sensor voltage above normal 172-3 232

2526-4 Air Inlet Temperature Sensor voltage below normal 172-4 232

3180-5 Aftertreatment #1 Ignition Transformer Secondary current below normal 4265-5

3180-6

3182-5

3182-6

3385-3

3385-4 Engine Exhaust Gas Recirculation Intake Pressure Sensor voltage below normal 3358-4

3385-13 Engine Exhaust Gas Recirculation Intake Pressure Sensor calibration required 3358-13

3385-21 Engine Exhaust Gas Recirculation Intake Pressure Sensor data drifted low 3358-21

3386-3

3386-4 Engine Exhaust Gas Recirculation Intake Pressure Sensor voltage below normal 412-4

Glow Plug Start Aid Relay current above normal

Ether Injection Control Solenoid current below normal

Ether Injection Control Solenoid current above normal

DPF #1 Intake Temperature Sensor voltage above normal

reatment #1 Ignition Transformer Primary current below normal 3484-5

Aftert

Aftertreatment #1 Ignition Transformer Primary current above normal

ARD Air Pressure Control Actuator current below normal

ARD Air Pressure Control Actuator current above normal

ARD Air Pressure Control Actuator Position Sensor voltage above normal

Aftertreatment #1 Ignition Transformer Secondary current above normal

Aftertreatment #1 Fuel Injector #1 Heater current below normal

Aftertreatment #1 Fuel Injector #1 Heater current above normal

Engine Exhaust Gas Recirculation Intake Pressure Sensor voltage above normal

J1939

Code

676-6 199

626-5

626-6

3242-3 224

3484-6

3487-5

3487-6

3488-3

4265-6

5425-5

5425-6

3358-3

412-3

Flash Code

233 233

216

243

211

212

244

215

231

227

(continued)

50 SEBU8601-01 Operation Section Engine Diagnostics

(Table 3, contd)

CDL Code Description

3397-2

3397-3

3397-4

3397-9

3397-12 DPF #1 Soot Loading Sensor failure 4783-12

3397-13 DPF #1 Soot Loading Sensor calibration required 4783-13

3397-19 DPF #1 Soot Loading Sensor data error 4783-19

3397-21 DPF #1 Soot Loading Sensor data drifted low 4783-21

3405-5 Engine Exhaust Gas Recirculation Valve Control current below normal 2791-5

3405-6 Engine Exhaust Gas Recirculation Valve Control current above normal 2791-6

3407-3 Engine Exhaust Gas Recirculation Valve Position Sensor voltage above normal 27-3

3407-4

3427-5

3427-6

3464-3

3464-4

3464-13 DPF #1 Intake Pressure Sensor calibration required 3609-13

3464-21 DPF #1 Intake Pressure Sensor data drifted low 3609-21

3468-2 Aftertreatment #1 Identiﬁcation Number Module erratic, intermittent, or incorrect 5576-2

3468-8

3468-14

3511-3

3511-4 Engine Exhaust Gas Recirculation Outlet Pressure Sensor voltage below normal 5019-4

3511-13 Engine Exhaust Gas Recirculation Outlet Pressure Sensor calibration required 5019-13

3511-21 Engine Exhaust Gas Recirculation Outlet Pressure Sensor data drifted low 5019-21

3514-5 Engine Throttle Actuator C ontrol Command current below normal 3464-5

3514-6 Engine Throttle Actuator Control Command current above normal 3464-6

3515-3 Engine Throttle Valve Position Sensor voltage above normal 51-3

3515-4

E172-1 High Air Filter Restriction - Warning 107-15 151

E232-1 High Fuel/Water Separator Water Level - Warning 97-17

E360-1 Low Engine Oil Pressure - Warning 100-17

E360-3 Low Engine Oil Pressure - Shutdown 100-01

DPF #1 Soot Loading Sensor : Erratic, Intermittent, or Incorrect

DPF #1 Soot Loading Sensor : Voltage Above Normal

DPF #1 Soot Loading Sensor : Voltage Below Normal

DPF #1 Soot Loading Sensor abnormal update rate

Engine

Aftertreatment Fuel Pump Relay current below normal

Aftertreatment Fuel Pump Relay current above normal

DPF #1 Intake Pressure Sensor voltage above normal

DPF #1 Intake Pressure Sensor voltage below normal

Aftertreatment #1 Identiﬁcation Number Module abnormal frequency, pulse wi

Aftertreatment #1 Identiﬁcation Number Module special instruction

Engine Exhaust Gas Recirculation Outlet Pressure Sensor voltage above normal

Engine Throttle Valve Position Sensor voltage below normal

Exhaust Gas Recirculation Valve Position Sensor voltage below normal 27-4

dth, or period

Event Codes

J1939

Code

4783-2

4783-3

4783-4

4783-9

5423-5 218

5423-6 218

3609-3

3609-4

5576-8

5576-14

5019-3

51-4

Flash Code

226

228

229

223

247

252

157

(continued)

SEBU8601-01 51

Operation Section

Engine Diagnostics

(Table 3, contd)

CDL Code Description

E361-1

E361-2

E361-3

E362-1

E363-1 High Fuel Supply Temperature - Warning 174-15

E363-2 High Fuel Supply Temperature - Derate 174-16

E396-2 High Fuel Rail Pressure - Warning 157-16

E398-2 Low Fuel Rail Pressure - Warning 157-18

E499-3

E539-1

E539-2 High Intake Manifold Air Temperature - Derate 105-16

E593-2 Aftertreatment Insufﬁcient Temperature to Complete Regeneration - Derate 3711-31 214

E991-3

E992-3

E995-2 High DPF #1 Soot Loading - Derate 3719-16

E995-3 High DPF #1 Soot Loading - Shutdown 3719-0

E997-1 High DPF #1 Ash Loading - Warning 3720-15

E997-2 High DPF #1 Ash Loading - Derate 3720-16

E1008-2 High DPF #1 Intake Temperature - Derate 3242-16 224

E1014-2 Low DPF #1 Intake Temperature - Derate 3242-18 224

E1022-1 Low ARD Fuel Pressure #1 - Warning 3480-17

E1022-2

E1025-2

E1026-2

E1041-2

E1044-2

E1045-2 Low Intake Manifold Pressure - Derate 102-18

E1050-1 High Aftertreatment #1 Fuel Pressure #1 - Warning 3480-15

E1050-2 High Aftertreatment #1 Fuel Pressure #1 - Derate 3480-16

E1070-1 Aftertreatment Fuel Injector #1 not responding - Warning 3556-7

E1092-1 High Engine Exhaust Gas Recirculation Temperature - Warning 412-15 227

E1092-2 High Engine Exhaust Gas Recirculation Temperature - Derate 412-16 227

E1121-2

E1154-2

E1156-1 High DPF #1 Intake Pressure - Warning 3609-15

E1170-2 Low Aftertreatment #1 Secondary Air Pressure - Derate 3837-18

High Engine Coolant Temperature - Warning

High Engine Coolant Temperature - Derate

High Engine Coolant Temperature - Shutdown

Engine Overspeed - Warning

Fuel Rail #1 Pressure Leak - Shutdown

High Intake Manifold Air Temperature - Warning

DPF Active Regeneration Inhibited Due to Permanent System Lockout Shutdown

DPF Ac Shutdown

Aftertreatment #1 Loss of Ignition - Derate

Aftertreatment #1 Loss of Combustion - Derate

ARD Air Pressure Control Actuator Not Responding To Command - Derate

High Intake Manifold Pressure - Derate

Engine Exhaust Gas Recirculation Valve Control Not Responding to Command

- Derate

Low DPF #1 Intake Pressure - Warning

tive Regeneration Inhibited Due to Temporary System Lockout -

ow ARD Fuel Pressure #1 - Derate 3480-18

J1939

Code

110-15

110-16

110-0

190-15 141

1239-0

105-15

3715-31

3714-31

3473-31 244

3474-31

3487-7 211

102-16

2791-7 228

3609-18

Flash Code

168

165

159

133

226

219

197

219

223

(continued)

52 SEBU8601-01 Operation Section Engine Diagnostics

(Table 3, contd)

CDL Code Description

E1264-3

E1305-1

E1319-2

E2143-3

High Pressure Common Rail Fuel Pressure Relief Valve Active - Shutdown

Initial Assembly Aftertreatment #1 Regeneration Required - Warning

Engine Exhaust Gas Recirculation Mass Flow Rate Not Responding - Derate

Low Engine Coolant Level - Shutdown

J1939

Code

5571-0 159

3483-11

2659-7

111-01 169

Flash Code

i01902949

Fault Logg

The system provides the capability of Fault Logging. When the Electronic Control Module (ECM) generate be logged in the memory of the ECM. The codes that have been logged by the ECM can be identiﬁed by the el have been logged will be cleared when the fault has been rectiﬁed or the fault is no longer active. The foll the memory of the ECM without using a factory password: Overspeed, low engine oil pressure, and high en

s an active diagnostic code, the code will

ectronic service tool. The active codes that

owing logged faults can not be cleared from

gine coolant temperature.

ing

i03554534

Engine Ope

ration with Active

Diagnostic Codes

If a diagnostic lamp illuminates during normal engine operatio is not within the speciﬁcation. Use electronic service toolstochecktheactivediagnosticcodes.

Note: If the customer has selected “DERATE” and if there is a low oil pressure condition, the Electronic Control until the problem is corrected. If the oil pressure is within the normal range, the engine may be operated at the r should be performed as soon as possible.

The act The cause of the problem should be corrected as soon as possible. If the cause of the active diagnostic code i diagnostic code, the diagnostic lamp will turn off.

Opera engine can be limited as a result of the active diagnostic code that is generated. Acceleration rate Troubleshooting Guide for more information on the relationship between these active diagnostic codes and e

n, the system has identiﬁed a situation that

Module (ECM) will limit the engine power

ated speed and load. However, maintenance

ive diagnostic code should be investigated.

s repaired and there is only one active

tion of the engine and performance of the

s may be signiﬁcantly slower. Refer to the

ngine performance.

SEBU8601-01 53

Operation Section

Engine Diagnostics

i01902995

Engine O peration with Intermittent

If a diagnostic lamp illuminates during normal engine operation and the diagnostic lamp shuts off, an intermitte occurred, the fault will be logged into the memory of the Electronic Control Module (ECM).

In most cases, it is not necessary to stop the engine because of an intermittent code. However, the operator s and the operator should reference the appropriate information in order to identify the nature of the event. The operat have caused the lamp to light.

nt fault may have occurred. If a fault has

hould retrieve the logged fault codes

or should log any observation that could

Diagnostic Codes

Low power

•

Limits of the engine speed

•

Excessive smoke, etc

•

This inf the situation. The information can also be used for future reference. For more information on diagnostic codes, engine.

ormation can be useful to help troubleshoot

refer to the Troubleshooting Guide for this

i03905586

Conﬁguration Parameters

The engine electronic control module (ECM) has two types of conﬁguration parameters. The system conﬁguration parameters and the customer speciﬁed parameters.

The electronic service tool is required in order to alter the conﬁguration parameters.

System Conﬁguration Parameters

System conﬁguration parameters affect the emissions of the engine or the power of the engine. System conﬁguration parameters are programmed at the factory. Normally, system conﬁguration parameters would never require changing through the life of the engine. System conﬁguration parameters must be reprogrammed if an ECM is replaced. System conﬁguration parameters do not require reprogrammed if the ECM software is changed. Factory passwords are required to change these parameters.

54 SEBU8601-01 Operation Section Engine Diagnostics

Table 4

System Conﬁguration Parameters

Conﬁguration Parameters Record

Engine Serial Number

Delayed Eng

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

ine Shutdown

Customer Speciﬁed Parameters

Customer speciﬁed parameters allow the engine to be conﬁgured to the exact needs of the application.

The electronic service tool is required in order to alter the customer conﬁguration parameters.

Customer parameters may be changed repeatedly as operational requirements change.

Table 5

Customer Speciﬁed Parameters

Speciﬁed Parameters Record

ttle Type Channel 1

Thro

Throttle Type Channel 2

Continuous Position Throttle Conﬁguration 1

Continuous Position Throttle Conﬁguration 2

Multi Position Throttle Switch Conﬁguration

Throttle Arbitration

quipment ID

Low Idle Speed

Ether Solenoid Conﬁguration

Engine Idle Shutdown Minimum Ambient Air Temperature

Engine Idle Shutdown Maximum Ambient Air Temperature

Engine Idle Shutdown Enable Status

Engine Idle Shutdown Delay Time

Engine Idle Shutdown Ambient Temperature Override Enable Status

Delayed Engine Shutdown Maximum Time

High Soot Load Aftertreatment Protection Enable Status

Key off regen enable status

Key Off Aftertreatment Regeneration Maximum Time

(continued)

SEBU8601-01 55

Operation Section

Engine Diagnostics

(Table 5, contd)

Multiple Engines on J1939

Air Shutoff

ARD Auto Regeneration Enable Status

Throttle Lock Feature Installation Status

PTO Mode

Throttle Lock Engine Set Speed #1

Throttle Lock Engine Set Speed #2

Throttle Lock Increment Speed Ramp Rate

Throttle Lock Decrement Speed Ramp Rate

Throttle Lock Engine Set Speed Increment

Throttle Lock Engine Set Speed Decrement

Monitoring Mode Shutdowns

Monitoring Mode Derates

ome Desired Engine Speed

Limp H

Engine Acceleration Rate

Engine Speed Decelerating Ramp Rate

Intermediate Engine Speed

Fan

Engine Fan Control

ine Fan Type Conﬁguration

Eng

Engine Cooling Fan Pulley Ratio

Engine Cooling Fan Temperature Error Increasing Hysteresis

Engine Cooling Fan Temperature Error Decreasing Hysteresis

Engine Cooling Fan Current Ramp Rate

Engine Cooling Fan Speed

Top Engine Fan Speed

Minimum Desired Engine Cooling Fan Speed

Engine Cooling Fan Solenoid Minimum Current

Engine Cooling Fan Solenoid Maximum Current

Engine cooling Fan solenoid Dither Frequency

Engine Cooling Fan Solenoid Dither Amplitude

Fan Temperatures

Engine Fan Control Charge Air Cooler Outlet Temperature Input Enable

Engine Cooling Fan Maximum Air Flow Charge Air Cooler Outlet Temperature

Engine Cooling Fan Minimum Air Flow Charge Air C ooler Outlet Temperature

Engine Cooling Fan Control Coolant Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Coolant Temperature

(continued)

56 SEBU8601-01 Operation Section Engine Diagnostics

(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 Cool

Engine Cooling Fan Control Hydraulic Oil Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Hydraulic Oil Temperature

Engine Cooling Fan Minimum Air Flow Hydraulic Oil Temperature

Engine Cooling Fan Control Auxiliary #1 Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Auxiliary #1 Temperature

Engine Cooling Fan Minimum Air Flow Auxiliary #1 Temperature

Engine Cooling Fan Control Auxiliary #2 Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Auxiliary #2 Temperature

Engine Cooling Fan Minimum Air Flow Auxiliary #2 Temperature

Reversing Fan

Engine Fan Reversing Feature

Engine Fan Reverse Operation Early Termination Enable Status

Engine Fan Manual Purge

Engine Fan Suspend Purge

gine Fan Purge Cycle Interval

Engine Fan Purge Cycle Duration

Other Parameters

Maintenance Indicator Mode

Maintenance Level 1 Cycle Interval Hours

Coolant Level Sensor

Air Filter Restriction Switch Installation Status

Air Filter Restriction Switch Conﬁguration

Fuel/Water Separator Switch Installation Status

User Deﬁned Switch Installation Status

Auxiliary Temperature Sensor Installation Status

Auxiliary Pressure Sensor Installation Status

Engine Overspeed Setpoint

Fuel Filter Differential Pressure Switch Conﬁg

Diesel Particulate Filter Regeneration Force/ Inhibit Switch Installation

Diesel Particulate Filter Regeneration Inhibit Indicator Installation

Diesel Particulate Filter Soot Loading Indicator Installation

High Exhaust System Temperature Indicator Installation

Auxiliary Temp #2

ing Fan Minimum Air Flow Transmission Oil Temperature

(continued)

SEBU8601-01 57

Operation Section

Engine Diagnostics

(Table 5, contd)

Remote Torque Speed Control Enable Status

Number of Engine Operating Mode Switches

Engine Operating Mode Conﬁguration

58 SEBU8601-01 Operation Section Engine Starting

Engine Starting

i03648917

Before Starting Engine

Perform the periodic maintenance before the engine is started. Inspect the engine compartment. This inspection can help preve Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information.

Ensure that the engine has an adequate fuel

•

supply.

Open the fuel supply valve (if equipped).

•

All valv supply lines must be open. Damage to the fuel system can occure if fuel lines are closed with the engine in operat

If the engine has not been started for several weeks, fuel may have drained from the fuel system. Air may have entered the ﬁlter housing. Also, when fuel ﬁlters have been changed, some air pockets will be trapped in the engine. In these instances, prime the fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” for more information on priming the fuel system. Also, check that the fuel speciﬁcation is correct and that the fuel condition is correct. Refer to the Operation and Maintenance Manual, “Fuel Recommendations”.

required daily maintenance and other

nt major repairs at a later date. Refer to the

NOTICE

es in the fuel return line must be open and fuel

ion.

i04084389

Starting the Eng ine

Note: Do not ad

start-up. The electronic control module (ECM) will control the engine speed during start-up.

Starting the Engine

1. Disengage any equipment that is driven by the

engine.

2. Turn the keyswitch to the RUN position. Leave the keyswitchintheRUNpositionuntilthewarning light for t

Note: During the key on, the indicator lamps will be illumi operation. If any of the lamps do not illuminate, replace the bulb.

3. When the warning light for the glow plugs is

Note: Th

the glow plugs will change due to the temperature of the engine.

Do not engage the starting motor when ﬂywheel is turning. Do not start the engine under load.

If the engine fails to start within 30 seconds, release the starter switch or button and wait two minutes to allo start the engine again.

nated for 2 seconds in order to check lamp

extinguished, turn the keyswitch to the START positio motor and crank the engine.

e operating period of the warning light for

w the starting motor to cool before attempting to

justtheenginespeedcontrolduring

he glow plugs is extinguished.

n in order to engage the electric starting

NOTICE

ine exhaust contains products of c ombustion

Eng which may be harmful to your he alth. Always start and operate the engine in a well ventilated area

d, if in an enclosed area, vent the exhaust to the

an outside.

not start the engine or move any of the controls

•

if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or

othecontrols.

Reset all of the shutoffs or alarm components.

•

Ensure that any driven equipment has been

•

disengaged. Minimize electrical loads or remove any electrical loads.

4. Allo

5. Rep

w the keyswitch to return to the RUN position

after the engine starts.

eat step 2 through step 4 if the engine fails

to start.

i03570564

Cold Weather Starting

Do not use aerosol types of starting aids such as ether. Such use could result i n an explosion and personal injury.

SEBU8601-01 59

Operation Section

Engine Starting

Startability w

−18 °C (0 °F) from the use of a jacket water heater or extra battery capacity.

When Group 2 diesel fuel is used, the following items provide a means of minimizing starting problems and fuel prob heaters, jacket water heaters, fuel heaters, and fuel line insulation.

Use the procedure that follows for cold weather starting.

Note: Do not adjust the engine speed control during start-up. The electronic control module (ECM) will control th

1. Disengage any driven equipment.

2. Turn the keyswitch to the RUN position. Leave the

keyswitch in the RUN position until the warning light for

Do not engage the starting motor when ﬂywheel is turning

If the engine fails to start within 30 seconds, release the star allow the starting motor to cool before attempting to start the engine again.

illbeimprovedattemperaturesbelow

lems in cold weather: Engine oil pan

e engine speed during start-up.

the glow plugs is extinguished.

NOTICE

. Do not start the engine under load.

ter switch or button and wait two minutes to

7. Operate the eng reach operating temperature. Check the gauges during the warm-up period.

ine at low load until all systems

i03663103

Starting with Jump Start Cables

Improper jump start cable connections can cause an explosi

Prevent sparks near the batteries. Sparks could cause vap cable ends to contact each other or the engine.

Note: If

the starting failure. Refer to Troubleshooting, “Engine Will Not Crank and Engine Cranks But Will Not Start” for furt If the engine will not start only due to the condition of the battery, either charge the battery, or start the engine cables. The condition of the battery can be rechecked after the eng

on resulting in personal injury.

ors to explode. Do not allow jump start

it is possible, ﬁrst diagnose the reason for

her information. Make any necessary repairs.

by using another battery with jump start

inehasbeenswitchedOFF.

3. When the warning light for the glow plugs is extinguished turn the keyswitch to the START

ion in order to engage the electric starting

posit motor and crank the engine.

: The operating period of the warning light for

Note

the glow plugs will change due to the temperature of the engine.

4. Allow the keyswitch to return to the RUN position after the engine starts.

5. Repeat step 2 through step 4 if the engine fails to start.

Note: The engine should not be “raced” in order to speed up the warm up process.

6. Allow the engine to idle for three to ﬁve minutes, or allow the engine to idle until the water temperature

dicator begins to rise. When idling after the

in engine has started in cold weather, increase the engine rpm from 1000 to 1200 rpm. This will

rm up the engine more quickly. Maintaining

wa an elevated low idle speed for extended periods will be easier with the installation of a hand

hrottle. Allow the white smoke to disperse before

t proceeding with normal operation.

NOTICE Using a battery source with the same voltage as the electric starting motor. Use ONLY equal voltage for jump starting. The use of higher voltage will damage the electrical system.

Do not reverse the battery cables. The alternator can be damaged. Attach ground cable last and remove ﬁrst.

Turn all electrical accessories OFF before attaching the jump start cables.

Ensure that the main power switch is in the OFF position before attaching the jump start cables to the engine being started.

1. Turn the start switch on the stalled engine to the

OFF position. Turn off all the engine's accessories.

2. Connect one positive end of the jump start cable

to the positive cable terminal of the discharged battery. Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source.

60 SEBU8601-01 Operation Section Engine Starting

3. Connect one neg to the negative cable terminal of the electrical source. Connect the other negative end of the jump start cab chassis ground. This procedure helps to prevent potential sparks from igniting the combustible gases that ar

Note: The engine ECM must be powered before the starting mo

4. Start the engine in the normal operating procedure. Refer to thi “Starting the Engine”.

5. Immediate the jump start cables in reverse order.

After jump fully recharge batteries that are severely discharged. The batteries must be replaced or charged to the proper vo is stopped. Many batteries which are considered unusable are still rechargeable. Refer to Operation and Maint Testing and Adjusting Manual, “Battery - Test”.

tor is operated or damage can occur.

ly after the engine is started, disconnect

starting, the alternator may not be able to

ltage with a battery charger after the engine

enance Manual, “Battery - Replace” and

ative end of the jump start cable

le to the engine block or to the

e produced by some batteries.

s Operation and Maintenance Manual,

i02330138

After Starting Engine

Note: In ambie

(32 to 140°F), the warm-up time is approximately three minutes. In temperatures below 0°C (32°F), additional w

When the engine idles during warm-up, observe the following c

Do not check the high pressure fuel lines with the engine or t inspect the engine in operation, always use the proper inspection procedure in order to avoid a ﬂuid penet Maintenance Manual, “General hazard Information”.

Check for

•

and at one-half full rpm (no load on the engine) before operating the engine under load. This is not possible

Allow the engine to idle for three to ﬁve minutes, or

•

allow th indicator begins to rise. Check all gauges during the warm-up period.

nt temperatures from 0 to 60°C

arm-up time may be required.

onditions:

he starting motor in operation. If you

ration hazard. Refer to Operation and

any ﬂuid or for any air leaks at idle rpm

in some applications.

e engine to idle until the water temperature

Note: Gauge readings should be observed and the data should be recorded frequently while the engine will help to determine normal readings for each gauge. Comparing data over time will also help detec changes in the readings should be investigated.

is operating. Comparing the data over time

t abnormal operating developments. Signiﬁcant

SEBU8601-01 61

Operation Section

Engine Operation

i04156659

Engine Operation

Proper oper in obtaining the maximum life and economy of the engine. If the directions in the Operation and Maintenan minimized and engine service life can be maximized.

Thetimeth normal operating temperature can be less than the time taken for a walk-around inspection of the engine.

The engine can be operated at the rated rpm after the engine is started and after the engine reaches operati operating temperature sooner during a low engine speed (rpm) and during a low-power demand. This procedu at no load. The engine should reach operating temperature in a few minutes.

Avoid excess idling. Excessive idling causes carbon buildup, engine slobber, and soot loading of the Diesel engine.

Gauge should be recorded frequently while the engine is operating. Comparing the data over time will help t Comparing data over time will also help detect abnormal operating developments. Signiﬁcant

ges in the readings should be investigated.

chan

Redu

The Diesel Particulate Filter (DPF) and the

ertreatment Regeneration Device (ARD) work

Aft together in order to reduce particulate emissions. The DPF collects the soot and any ash that is produced by

combustion in the engine. During regeneration,

the the soot is converted into a gas which is released into the atmosphere. The Ash remains in the DPF until

e ash is cleaned out of the DPF.

The temperature of the DPF must be above a

rticular value in order for regeneration to occur.

pa The exhaust gas provides heat for the regeneration process. There are two types of regeneration:

Passive Regeneration – Is a chemical reaction within the system and the engine provides sufﬁcient

xhaust gas temperature for regeneration.

ation and maintenance are key factors

ce Manual are followed, costs can be

at is needed for the engine to reach

ng temperature. The engine will reach normal

re is more effective than idling the engine

Particulate Filter (DPF). This is harmful to the

readings should be observed and the data

o determine normal readings for each gauge.

ction of Particulate Emissions

Active Regener

does not provide sufﬁcient exhaust temperature for passive regeneration. The ARD operates in order to raise the temp regeneration process is complete, the ARD turns off.

The operator the ARD from dash lamps and the driver will be able to request a regeneration by using a switch. Refer to this Operat System” for more information.

ation – The engines duty cycle

erature of the exhaust gas. When the

will receive information on the status of

ion and Maintenance Manual, “Monitoring

Engine Operation and A ctive Regenerati

Your ARD may perform an active regeneration while your engin of the DPF, the engine may operate at idle for periods longer than 5 minutes.

e is at idle. During this active regeneration

i04084269

Diesel Particulate Filter Regeneration

The temperature of the exhaust gas and the temperature of the exhaust system components can reach up to 650 °C (1202 °F) during regeneration. An unexpected failure of the engine or an unexpected failure of the aftertreatment system may increase temperature at the diesel particulate ﬁlter to as high as 900 °C (1652 °F) gas temperature. This may result in ﬁre, burn, or explosion hazards, which may result in personal injury or death. Do not expose ﬂammable material or explosive atmospheres to exhaust gas or to exhaust system components during regeneration.

Regeneration

Regeneration is the removal of soot from the Diesel Particulate Filter (DPF). The Aftertreatment Regeneration Device (ARD) is used to regenerate the DPF. The DPF traps both soot and ash. The ash is removed through a manual cleaning process. Refer to Operation and Maintenance Manual, “Diesel Particulate Filter - Clean” for more information on the service of the DPF.

Types of Regeneration

Passive Regeneration – Is a chemical reaction

within the system and the engine will create enough heat in order to regenerate the DPF.

62 SEBU8601-01 Operation Section Engine Operation

Active Regener

enough heat in order to regenerate the DPF. The ARD must be used to create the heat necessary to regenerate th

ation – The engine does not create

eDPF.

Lamps

Five dash lamps can be affected by the DPF regeneratio alter the operator.

temperatur

operate at level 2.

Note: In some situations, the DPF lamp may stay illumina illuminated DPF lamp indicates that a complete regeneration has not been performed. A complete regener 0%. If the DPF lamp stays illuminated, perform a regeneration without interruption until the soot level is reduc the DPF lamp.

lamp w lamp will ﬂash if regeneration is not activated. Also, the DPF lamp will be illuminated.

Note:

as a diagnostic lamp. For more information refer to this Operation and Maintenance Manual, “Diagnostic Lamp

and may shut down. Also, the DPF lamp will be

uminated.

ill

n. Also, the horn can be used in order to

High Exhaus Lamp (HEST) – The lamp is illuminated

when the ARD is activated and the exhaust

e is greater than 450 °C (842 °F).

DPF Lamp – This lamp provides a general indication of the soot load. The lamp is off when the so

ted when the soot load is below 90%. The

ation is when the soot level is reduced to

ed to 0%. A complete regeneration will reset

Amber o

lamp indicates that the soot load has increased. Regeneration is required. This

ill be illuminated at level 3 soot load and the

Amber or yellow Warning Lamp can be use

”.

Red Stop Lamp – This lamp indicates that

oot load is extremely high. The soot

the s load is at level 3. The engine will derate

t System Temperature

ot load is normal. The lamp will

r yellow Warning Lamp – This

Forced regener

•

Low speed automatic regeneration and enhanced automatic reg ECM. During this regeneration the operator will see the high exhaust system temperature lamp (HEST) illuminated

Low speed automatic – Low speed automatic regenerati automatically with the engine speed in a low idle condition or near low idle condition. In order for a low speed autom conditions must be met:

Soot level

•

the soot level monitor (if equipped).

Engine spe

•

The interlocks for the application will raise the

•

RPM to the regeneration to occur. The engine RPM will be from1000to1400RPM.

Refer to the OEM for the applications interlocks

•

required to be engaged before regeneration can take pla

Enhanced automatic regeneration – This mode of DPF re place at higher engine rpm and higher engine loads. In order for enhanced automatic regenerations to occur,

Soot level must be between level 2 and level 3 on

•

the so

Engine speed must be greater than 1400 rpm.

•

Minimum engine idle speed input must be set.

•

Setting the input will not allow engine speed to fall regeneration. If minimum low idle speed input is not available, regeneration will stop if engine speed drop

Refer to the OEM for the applications interlocks

•

req take place.

on allows for the DPF regeneration to start

ce.

generation allows for regeneration to take

the following conditions must be met:

ot level monitor (if equipped).

below 1000 rpm during enhanced automatic

s below 1000 rpm.

uired to be engaged before regeneration can

ation

eneration are controlled by the engine

atic regeneration to occur, the following

must be between level 1 and level 3 on

ed must be below 1400 rpm.

required engine speed in order for the

DPF Disable Lamp – This lamp is illuminated whenever the ARD disable

tch is activated or the system has been

swi

disabled by the engine ECM.

des of Regeneration

Low speed automatic

•

Enhanced automatic regeneration

•

ced regeneration – A forced regeneration is

For

initiated by pressing the regeneration switch. A forced regeneration is allowed during normal operation up

level 3. A forced regeneration can be performed

to in the low speed automatic window or the enhanced automatic regeneration window.

SEBU8601-01 63

Operation Section

Engine Operation

Regeneration Switch

Note: The MIDDLE position of the regeneration

switch is the default position for automatic modes of regeneration.

Note: Some OEMs may use other means of activating a forced regeneration such as touch screen interfaces.

Force Regeneration – Press in the top of the switch for 2 seconds in order to

begin regeneration. An indicator light on the switch will become active showing that the regeneration is active. The HEST lamp will become active showing that the regeneration is active. The high exhaust temperature indicator will deactivate after regeneration is completed or the regeneration has been disabled.

Disable Regeneration – Press in the

bottom of the switch for 2 seconds in order

to disable regeneration. An indicator light on the switch will become active. The disable indicator lamp will illuminate. The indicator will deactivate after the disable regeneration is completed.

Note: To re-enable the regeneration, cycle the engine start switch key or press and hold down the force regeneration switch for 2 seconds.

Note: If the engine start switch key is cycled while the regeneration system is disabled via the disable regeneration switch, press and hold the disable regeneration switch for 2 seconds to reinitiate the disable regeneration.

Soot Level Monitoring and Indicator Lamps

During the normal working cycle of the engine the ECM will control when the regeneration will occur. Operation of the engine is not recommended with theamberwarninglightﬂashing, or the red lamp illuminated. Operation of the engine at this level could damage the DPF.

64 SEBU8601-01 Operation Section Engine Operation

Table 6

Lamp Operation Action Require

HEST Lamp On The ARD is activated and the exhaust

DPF Lamp On The lamp provides a general indication

Amber Warning Lamp

RedStopLamp On

Lamp is now ﬂashing

temperature is greater than 450 °C (842 °F)

of the soot load. The lamp is off when thesootloadisnormal.Thelampwill operate at level 2 and above.

The lamp indicates that the soot load has increased. Regeneration is required.

The ﬂashing lamp will indicate that the engine has continued to be operated, regeneration is required.

The engine could be derated or the engine could be shut down.

None

A regeneration is required. In automatic mode the ECM will decide when to allow the regeneration. If the DPF lamp stays illuminated allow a regeneration without interruption. An uninterrupted regeneration will reset the DPF lamp.

A regeneration is required. Perform a forced regeneration, or allow the ECM control.

An urgent regeneration is required. If a regeneration is not allowed, the DPF couldbedamage.

Oncetheengineentresintoshutdown mode you must contact your Perkins dealer or your Perkins distributor. Yo u r

dealer or distributor will need to perform a service level regeneration. The DFP may

need to be replaced.

Some applications will be equipped with a monitoring gauge. Illustration 40 is an example of the levels of soot loading on a gauge.

Illustration 40

(1) Norm al operation level 1 (2) Level 2 with DPF lamp illuminated (3) level 3 with DP F lamp illuminated and amber warning lamp

illuminated.

g02153650

During the normal working cycle of the engine the ECM will control when the regeneration will occur. Regeneration will take place by low speed automatic regeneration or by enhanced automatic regeneration. Operation of the engine at level 3 and not allowing a regeneration to be performed could damage the DFP.

Soot Level and Engine Loading

ustration 41

Ill

(A) E ngine load factor (B) E ngine RPM (1) Low speed automatic regeneration (2) High s peed automatic regeneration (60-80% soot load) (3) High s peed automatic regeneration (80-100% soot load)

g02237313

In some circumstances high speed regeneration cannot occur. Allow the application to operate at

ower load factor in order to allow low speed

al regeneration to occur.

Illustration 41 is a guide to show engine RPM engine load and when regeneration can occur.

SEBU8601-01 65

Operation Section

Engine Operation

i04018232

Fuel Conservation Practices

The efﬁciency economy. Perkins design and technology in manufacturing provides maximum fuel efﬁciency in all applicat in order to attain optimum performance for the life of the engine.

Avoid spilling fuel.

•

Fuel expan may overﬂow from the fuel tank. Inspect fuel lines for leaks. Repair the fuel lines, as needed.

Be aware of the properties of the different fuels.

•

Use only the recommended fuels. Refer to the Operatio Recommendations”for further information.

Avoid unn

•

Shut off the engine rather than idle for long periods of time.

Observe the service indicator frequently. Keep the

•

air clea

Ensure that the turbocharger is operating correctly.

•

For mor Maintenance Manual , “Turbocharger - Inspect”

of the engine can affect the fuel

ions. Follow the recommended procedures

ds when the fuel is warmed up. The fuel

ns and Maintenance Manual, “Fuel

ecessary idling.

ner elements clean.

e information refer to this Operation and

ain a good electrical system.

Maint

•

One faulty battery cell will overwork the alternator.

ault will consume excess power and excess

This f fuel.

elt should be in good condition. Refer to the

The b

•

Systems Operation, Testing and Adjusting, “V-Belt Test” for further information.

Ensure that all of the connections of the hoses are

•

tight. The connections should not leak.

Ensure that the driven equipment is in good

•

working order.

Cold engines consume excess fuel. Utilize heat

•

from the jacket water system and the exhaust

stem, when possible. Keep cooling system

sy components clean and keep cooling system components in good repair. Never operate the

gine without water temperature regulators.

en All of these items will help maintain operating temperatures.

66 SEBU8601-01 Operation Section Engine Stopping

Engine Stopping

i02334873

Stopping the Engine

NOTICE Stopping the engine immediately after it has been working under load, can result in overheating and accelerated wear of the engine components.

Avoid accelerating the engine prior to shutting it down.

Avoiding hot engine shutdowns will maximize turbocharger shaft and bearing life.

Note: Individual applications will have different control systems. Ensure that the shutoff procedures are understood. Use the following general guidelines in order to stop the engine.

1. Remove the load from the engine. Reduce the

engine speed (rpm) to low idle. Allow the engine to idle for ﬁve minutes in order to cool the engine.

2. Stop the engine after the cool down period

according to the shutoff system on the engine and turn the ignition key switch to the OFF position. If necessary, refer to the instructions that are provided by the OEM.

i01903586

Emer

gency S topping

i03648931

After Stopping Engine

Note: Before y

the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan.

Contact wit penetration and burn hazards. High pressure fuel spray may cause a ﬁre hazard. Failure to follow these i structions may cause personal injury or death.

After the

•

10 minutes in order to allow the fuel pressure to be purged from the high pressure fuel lines before any servi fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system a systems. Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual,

Check the crankcase oil level. Maintain the oil level

•

betwee the engine oil level gauge.

If the e

•

note the reading. Perform the maintenance that is in the Operation and Maintenance Manual,

tenance Interval Schedule”.

“Main

ou check the engine oil, do not operate

h high pressure fuel may cause ﬂ uid

nspection, maintenance and service in-

engine has stopped, you must wait for

ce or repair is performed on the engine

nd from the cooling, lubrication or air

“Fuel Injection Lines - Install”.

n the “MIN” mark and the “MAX” mark on

ngine is equipped with a service hour meter,

NOTICE Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure.

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.

Ensure that any components for the external system that support the engine operation are secured after the engine is stopped.

Fill the fuel tank in order to help prevent

•

Only use antifreeze/coolant mixtures recommended in the is in this Operation and Maintenance Manual. Failure to do so can cause engine damage.

Pressurized System: Hot coolant can cause serious burns. To open the cooling system ﬁller cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.

•

mulation of moisture in the fuel. Do not overﬁll

accu the fuel tank.

NOTICE

Reﬁll Capacities and Recommendations topic that

Allow the engine to cool. Check the coolant level.

SEBU8601-01 67

Operation Section

Engine Stopping

Check the coola

•

and the correct corrosion protection. Add the correct coolant/water mixture, if necessary.

Perform all required periodic maintenance on all

•

driven equipment. This maintenance is outlined in the instruct

nt for correct antifreeze protection

ions from the OEM.

68 SEBU8601-01 Operation Section Cold Weather Operation

Cold Weather Operation

i04156731

Cold Weather Operation

Perkins Diesel Engines can operate effectively in cold weather. During cold weather, the starting and the operation of the diesel engine is dependent on the following items:

The type of fuel that is used

•

The viscosity of the engine oil

•

The operation of the glow plugs

•

Optional Cold starting aid

•

Battery condition

•

This section will cover the following information:

Potential problems that are caused by cold-weather

•

operation

Suggest steps which can be taken in order to

•

minimize starting problems and operating problems when the ambient air temperature is between 0° to−40 °C (32° to 40 °F).

Install the cor

•

before the beginning of cold weather.

Check all rubb

•

weekly.

Check all ele

•

fraying or damaged insulation.

Keep all bat

•

Fill the fuel tank at the end of each shift.

•

Check the air cleaners and the air intake daily.

•

Check the air intake more often when you operate in snow.

Ensure that the glow plugs are in working order.

•

Refer to Tr Tes t” .

Personal injury or property damage can result from alcohol or starting ﬂuids.

Alcohol or starting ﬂuids are highly ﬂammable and toxic and if improperly stored could result in injury or prope

rect speciﬁcation of engine lubricant

er parts (hoses, fan drive belts,)

ctrical wiring and connections for any

teries fully charged and warm.

oubleshooting, “Glow Plug Starting Aid-

rty damage.

The operation and maintenance of an engine in freezing temperatures is complex . This complexity is because of the following conditions:

Weather conditions

•

Engine applications

•

Recommendations from your Perkins dealer or your Perkins distributor are based on past proven practices. The information that is contained in this section provides guidelines for cold-weather operation.

Hints for Cold Weather Operation

If the engine will start, operate the engine until a

•

minimum operating temperature of 80° C (176° F) is achieved. Achieving operating temperature will help prevent the intake valves and exhaust valves from sticking.

The cooling system and the lubrication system

•

for the engine do not lose heat immediately upon shutdown. This means that an engine can be shut down for a period and the engine can still have the ability to start readily.

Do not use aerosol types of starting aids such as ether. Such use could result i n an explosion and personal injury.

Forjumpstartingwithcablesincoldweather,

•

refer to the Operation and Maintenance Manual, “Starting with Jump Start Cables.” for instructions.

Viscosity of the Engine Lubrication Oil

Correct engine oil viscosity is essential. Oil viscosity affects the amount of torque that is needed to crank the engine. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” for the recommended viscosity of oil.

Recommendations for the Coolant

Provide cooling system protection for the lowest expected outside temperature. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” for the recommended coolant mixture.

SEBU8601-01 69

Operation Section

Cold Weather Operation

In cold weather correct glycol concentration in order to ensure adequate freeze protection.

, check the coolant often for the

Engine Block Heaters

Engine block engine jacket water that surrounds the combustion chambers. This heat provides the following functions:

Startability is improved.

•

Warm up time

•

An electric block heater can be activated once the engine is s 240 V dc. The output can be 750/1000W. Consult your Perkins dealer or your Perkins distributor for more infor

Idling th

When idling after the engine is started in cold weather, rpm. This idling will warm up the engine more quickly. Maintaining an elevated low idle speed for extended periods throttle. The engine should not be “raced” in order to speed up the warm-up process.

While the engine is idling, the application of a light load (parasitic load) will assist in achieving the minimu operating temperature is 80° C (176° F).

heaters (if equipped) heat the

is reduced.

topped. A block heater can be 110 V dc or

mation.

e Engine

increase the engine rpm from 1000 to 1200

will be easier with the installation of a hand

m operating temperature. The minimum

When starting a times without being operated in order to warm up completely, the carbon deposits become thicker. This starting problems:

Free operati

•

Valves become stuck.

•

Pushrods may become bent.

•

Other damag

•

result.

For this re the engine must be operated until the coolant temperature is 80° C (176° F) minimum. Carbon deposits o and the free operation of the valves and the valve components will be maintained.

The engine must be thoroughly warmed in order to keep other engine parts in better condition. The service l Lubrication will be improved. There will be less acid and less sludge in the oil. This condition will provide longer s rings, and other parts. However, limit unnecessary idle time to10 minutes in order to reduce wear and unneces

ife of the engine will be generally extended.

ervice life for the engine bearings, the piston

sary fuel consumption.

nd stopping an engine many

and stopping can cause the following

on of the valves is prevented.

e to valve train components can

ason, when the engine is started,

n the valve stems will be kept at a minimum

The Water Temperature Regulator and Insula

ted Heater Lines

Recommendations for Cool ant Warm U

Warm up an engine that has cooled below normal opera

-up should be performed before the engine is returned to full operation. During operation in very

temperature conditions, damage to engine

cold valve mechanisms can result from engine operation for short intervals. This damage can happen if the

ne is started and the engine is stopped many

engi times without being operated in order to warm up completely.

When the engine is operated below normal operating temperatures, fuel and oil are not completely burned

he combustion chamber. This fuel and oil causes

in t soft carbon deposits to form on the valve stems. Generally, the deposits do not cause problems and

e deposits are burned off during operation at

th normal engine operating temperatures.

ting temperatures due to inactivity. This warn

The engine is equipped with a water temperature

ator. When the engine coolant is below the

regul correct operating temperature, jacket water circulates through the engine cylinder block and into the

e cylinder head. The coolant then returns to the

engin cylinder block via an internal passage that bypasses the valve of the coolant temperature regulator. This

res that coolant ﬂows around the engine under

ensu cold operating conditions. The water temperature regulator begins to open when the engine jacket

r has reached the correct minimum operating

wate temperature. As the jacket water coolant temperature rises above the minimum operating temperature, the

er temperature regulator opens further allowing

wat more coolant through the radiator to dissipate excess heat.

The progressive opening of the water temperature regulator operates the progressive closing of the

pass passage between the cylinder block and

by head. This action ensures maximum coolant ﬂow to the radiator in order to achieve maximum heat

ssipation.

70 SEBU8601-01 Operation Section Cold Weather Operation

Note: Do not res the air ﬂow can damage the fuel system. Perkins discourages the use of all air ﬂow restriction devices such a air ﬂow can result in the following: high exhaust temperatures, power loss, excessive fan usage, and reduction in

A cab heater is beneﬁcial in very cold weather. The feed from th cab should be insulated in order to reduce heat loss to the outside air.

trict the air ﬂow. Restriction of

s radiator shutters. Restriction of the

fuel economy.

eengineandthereturnlinesfromthe

Recommendation for Crankcase Breather Protection

Crankcase ventilation gases contain a large quantity of water vapor. This water vapor can freeze in cold ambie the crankcase ventilation system. If the engine is operated in temperatures below −25° C (−13° F), measures plugging of the breather system. Insulated hoses and a heated canister assembly should be installed.

Consult with your Perkins dealer or your Perkins distributer for the recommended breather compone (−13° to -72.°F).

nt conditions and can plug or damage

must be taken to prevent freezing and

nts for operation from −25° to -40°C

i02685960

Fuel and the Effect from Cold Weather

Note: Only use grades of fuel that are recommended

by Perkins. Refer to this Operation and Maintenance Manual, “Fl

The following components provide a means of minimizing

Glow plugs (if equipped)

•

Engine coolant heaters, which may be an OEM

•

option

Fuel heaters, which may be an OEM option

•

Fuel line

•

The cloud point is a temperature that allows wax crystal the fuel ﬁlters to plug.

The pour will thicken. The diesel fuel becomes more resistant to ﬂow through fuel lines, fuel ﬁlters,and fuel pumps.

uid Recommendations”.

problems in cold weather:

insulation, which may be an OEM option

s to form in the fuel. These crystals can cause

point is the temperature when diesel fuel

Be aware of these facts when diesel fuel is purchased. Consider the average ambient air temper are fueled in one climate may not operate well if the engines are moved to another climate. Problems can resul

Before troubleshooting for low power or for poor perfo

Low temperature fuels may be available for engine oper fuels limit the formation of wax in the fuel at low temperatures.

For more information on cold weather operation, refer to the Operation and Maintenance Manual, “Cold Wea Cold Weather”.

ature for the engine's application. Engines that

t due to changes in temperature.

rmance in the winter, check the fuel for waxing.

ation at temperatures below 0 °C (32 °F). These

ther Operation and Fuel Related Components in

SEBU8601-01 71

Operation Section

Cold Weather Operation

i02323237

Fuel Related Components in Cold Weather

Fuel Tanks

Condensation can form in partially ﬁlled fuel tanks. Top off the fuel tanks after you operate the engine.

Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks.

Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pip

Some fuel tanks use supply lines that take fuel directly equipped with this system, regular maintenance of the fuel system ﬁlter is important.

from the bottom of the tank. If the engine is

Drain the water and sediment from any fuel storage tank at the following intervals: weekly, service

ls, and refueling of the fuel tank. This will help

interva prevent water and/or sediment from being pumped from the fuel storage tank and into the engine fuel tank.

Fuel Fi

A primary fuel ﬁlter is installed between the fuel tank a the fuel ﬁlter, always prime the fuel system in order to remove air bubbles from the fuel system. Refer to the Maintenance Section for more information on priming the fuel system.

The location of a primary fuel ﬁlter is important in cold weather operation. The primary fuel ﬁlter and the fuel supp are affected by cold fuel.

lters

nd the engine fuel inlet. After you change

Operation and Maintenance Manual in the

ly line are the most common components that

Fuel Heaters

e: The OEM may equip the application with fuel

Not

heaters. If this is the case, the temperature of the fuel must not exceed 73 °C (163 °F) at the fuel transfer

pum

For more information about fuel heaters (if equipped),

fer to the OEM information.

72 SEBU8601-01 Maintenance Section Reﬁll Capacities

Maintenance Section

Reﬁll Capacities

i03995972

Reﬁll Capaci ties

Lubrication System

The reﬁll capacities for the engine crankcase reﬂect the approximate capacity of the crankcase or sump plus standard oil ﬁ lters. Auxiliary oil ﬁlter systems will require additional oil. Refer to the OEM speciﬁcations for the capacity of the auxiliary oil ﬁlter. Refer to the Operation and Maintenance Manual, “Maintenance Section” for more information on Lubricant Speciﬁcations.

Table 7

Engine

Reﬁll Capacities

Compartment or System

Crankcase Oil Sump

(1)

These values are the approximate capacities for the crankcase oil sump (aluminum) which includes the standard factory installed oil ﬁlters. Engines with auxiliary oil ﬁ lters will require additional oil. R efer to the OEM speciﬁc ations for the capacity of the auxiliary oil ﬁlter. The design of the oil pan can change the oil capacity of the oil pan.

(1)

Cooling System

Minimum Maximum

13.5 L

(3.56 US

gal)

16.5 L

(4.36 US

gal)

i03996594

Fluid Recommendations

General Coolant Information

NOTICE Never add coolant to an overheated engine. Engine damage could result. Allow the engine to cool ﬁrst.

NOTICE If the engine is to be stored in, or shipped to an area with below freezing temperatures, the cooling system must be either protected to the lowest outside temperature or drained completely to prevent damage.

NOTICE Frequen proper freeze protection or for anti-boil protection.

Clean the cooling system for the following reasons:

•

Never operate an engine without water temperature regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the proper operating temperature. Cooling system problems can develop without water temperature regulators.

tlycheckthespeciﬁc gravity of the coolant for

Contamination of the cooling system

Overheating of the engine

Foaming of the coolant

NOTICE

Refer to the OEM speciﬁcations for the External System capacity. This capacity information will be needed in order to determine the amount of coolant/antifreeze that is required for the Total Cooling System.

Table 8

Engine

Reﬁll Capacities

Compartment or System

Engine Only

External System Per OEM

(1)

The External System includes a radiator or an expansion tank with the following components: heat exchanger and piping. Refer to the OEM speciﬁcations. Enter the value for the capacity of the External System in this row.

(1)

Liters

15 L

3.96 US gal)

(

Many engine failures are related to the cooling system. The following problems are related to cooling system failures: Overheating, leakage of the water pump, and plugged radiators or heat exchangers.

These failures can be avoided with correct cooling system maintenance. Cooling system maintenance is as important as maintenance of the fuel system and the lubrication system. Quality of the coolant is as important as the quality of the fuel and the lubricating oil.

Coolant is normally composed of three elements: Water, additives, and glycol.

Water

Waterisusedinthecoolingsysteminorderto transfer heat.

SEBU8601-01 73

Maintenance Section

Reﬁll Capacities

Distilled wate recommended for use in engine cooling systems.

DO NOT use the f systems: Hard water, softened water that has been conditioned with salt, and sea water.

If distilled water or deionized water is not available, use water with the properties that are listed in Table 9.

Table 9

Property Maximum Limit

Chloride (Cl) 40 mg/L

Sulfate (SO4) 100 mg/L

Total Hardness 170 mg/L

Total Solids 340 mg/L

For a water analysis, consult one of the following sources:

Local water utility company

•

Agricultural agent

•

Independent laboratory

•

r or deionized water is

ollowing types of water in cooling

Acceptable

Acidity pH of 5.5 to 9.0

Water

Additives

Additives help to protect the metal surfaces of the cooling system. A lack of coolant additives or insufﬁcient amounts of additives enable the following conditions to occur:

Corrosion

•

Formation of mineral deposits

•

Rust

•

Scale

•

Foaming of the coolant

•

Many additives are depleted during engine operation. These additives must be replaced periodically.

Additives must be added at the correct concentration. Overconcentration of additives can cause the inhibitors to drop out-of-solution. The deposits can enable the following problems to occur:

Formation of gel compounds

•

Reduction of heat transfer

•

Plugging of rad

•

iators, coolers, and small passages

Glycol

Glycol in the coolant helps to provide protection against the following conditions:

Boiling

•

Freezing

•

Cavitation of the water pump

•

For optimum performance, Perkins recommends a 1:1 mixture of a water/glycol solution.

Note: Use a mixture that will provide protection against the lowest ambient temperature.

Note: 100 percent pure glycol will freeze at a temperature of −23 °C (−9°F).

Most conventional antifreezes use ethylene glycol. Propylene glycol may also be used. In a 1:1 mixture with wat similar protection against freezing and boiling. Refer to Table 10 and refer to table 11.

Table 10

Do not use propylene glycol in concentrations that exceed 50 percent glycol because of the reduced heat transfer capability of propylene glycol. Use ethylene glycol in conditions that require additional protection against boiling or freezing.

Table 11

To check the concentration of glycol in the coolant, measure the speciﬁc gravity of the coolant.

er, ethylene and propylene glycol provide

Ethylene Glycol

Concentration Freeze Protection

50 Percent −36 °C (−33 °F)

60 Percent

NOTICE

Propylene Glycol

Concentration Freeze Protection

50 Percent −29 °C (−20 °F)

−51 °C

(−60 °F)

Coolant Recommendations

ELC____________________________ Extended Life Coolant

•

SCA___________________ Supplement Coolant Additive

•

Leakage of the water pump seal

•

74 SEBU8601-01 Maintenance Section Reﬁll Capacities

ASTM_________

•

_________________________________

American

Society for Testing and Materials

The following

two coolants are used in Perkins diesel

engines:

Preferred – P

erkins ELC

Acceptable – A commercial heavy-duty antifreeze that meets “

ASTM D6210 ” speciﬁcations

NOTICE

The 1200 series industrial engines must be operated with a 1:1 mixture of water and glycol. This concentration allows the NOx reduction system to operate correctly at high ambient temperatures.

NOTICE Do not use a commercial coolant/antifreeze that only meets

the ASTM D3306 speciﬁcation. This type of coolant/antifreeze is made for light automotive applications.

s recommends a 1:1 mixture of water and

Perkin glycol. This mixture of water and glycol will provide optimum heavy-duty performance as an antifreeze. This ra

tiomaybeincreasedto1:2watertoglycolif

extra freezing protection is required.

ELC

Perkins provides ELC for use in the following applications

Heavy-duty spark ignited gas engines

•

Heavy-duty diesel engines

•

Automotive

•

The anti-corrosion package for ELC is different from the anti-co is an ethylene glycol base coolant. However, ELC contains organic corrosion inhibitors and antifoam agents wit has been formulated with the correct amount of these additives in order to provide superior corrosion protectio

ELC is available in a premixed cooling solution with distille ELC provides freeze protection to −36 °C (−33 °F). The Premixed ELC is recommended for the initial ﬁll of the recommended for topping off the cooling system.

Contain your Perkins distributor for the part numbers.

applications

rrosion package for other coolants. ELC

h low amounts of nitrite. Perkins ELC

n for all metals in engine cooling systems.

d water. ELC is a 1:1 mixture. The Premixed

cooling system. The Premixed ELC is also

ers of several sizes are available. Consult

ure of SCA inhibitor and water is acceptable but

Amixt will not give the same level of corrosion, boiling and, freezing protection as ELC. Perkins recommends a 6

nt to 8 percent concentration of SCA in those

perce cooling systems. Distilled water or deionized water is preferred. Water which has the recommended

erties may be used

prop

Table 12

Coolant Service Life

Coolant Type Service Life

Perkins ELC

mmercial Heavy-Duty

Antifreeze that meets

“ASTM D6210”

Commercial Heavy-Duty

Antifreeze that meets

“ASTM D6210”

Perkins POWERPART

SCA inhibitor

Commercial SCA inhibitor

and Water

(1)

Use the interval that occurs ﬁrst. The cooling system must

also be ﬂushed out at this time.

6,000 Service Hours or

Three Years

3000 Service Hours or

eYear

Two Years

One Year

(1)

ELC Cooling System M aintenance

Correc Coolant

Use only Perkins products for pre-mixed or concentrated coolants.

Mixing Extended Life Coolant with other products reduces the Extended Life Coolant service life. Failure to follow the recommendations can reduce cooling system components life unless appropriate corrective action is performed.

In order to maintain the correct balance between the antifreeze and the additives, you must maintain the the proportion of antifreeze lowers the proportion of additive. This will lower the ability of the coolant to pr erosion, and from deposits.

t additions to the Extended Life

NOTICE

recommended concentration of ELC. Lowering

otect the system from pitting, from cavitation, from

SEBU8601-01 75

Maintenance Section

Reﬁll Capacities

NOTICE Do not use a con system that is ﬁlled with Extended Life Coolant (ELC).

Do not use stan (SCA).

When using Pe or SCA ﬁlters.

ventional coolant to top-off a cooling

dard supplemental coolant additive

rkins ELC, do not use standard SCA's

ELC Cooling System Cleaning

Note: If the cooling system is already using ELC,

cleaning agents are not required to be used at the speciﬁ agents are only required if the system has been contaminated by the addition of some other type of coolant o

Clean water is the only cleaning agent that is required when ELC i

Before the cooling system is ﬁlled, the heater control (if equi to the OEM in order to set the heater control. After the cooling system is drained and the cooling system is reﬁll reaches the normal operating temperature and until the coolant level stabilizes. As needed, add the coo speciﬁed level.

Chang

ed coolant change interval. Cleaning

r by cooling system damage.

s drained from the cooling system.

pped) must be set to the hot position. Refer

ed, operate the engine until the coolant level

lantmixtureinordertoﬁll the system to the

ing to Perkins ELC

5. Drain the clean

the cooling system with clean water.

6. Fill the cooli operate the engine until the engine is warmed to 49° to 66°C (120° to 150°F).

Incorrect or incomplete ﬂushing of the cooling system can result in damage to copper and other metal components.

To avoid damage to the cooling system, make sure to completel Continue to ﬂush the system until all the signs of the cleaning agent are gone.

7. Drain the cooling system into a suitable container

Note: The cooling system cleaner must be thoroughly

ﬂushed from the cooling system. Cooling system cleaner coolant. The cleaner may also corrode the cooling system.

8. Repeat Steps 6 and repeat steps 7 until the

9. FillthecoolingsystemwiththePerkinsPremixed

y ﬂush the cooling system with clear water.

and ﬂushthecoolingsystemwithcleanwater.

that is left in the system will contaminate the

system is completely clean.

ELC.

er into a suitable container. Flush

ng system with clean water and

NOTICE

ELC Cooling System Contamination

To change from heavy-duty antifreeze to the Perkins ELC, p

Care must be taken to ensure that all ﬂuids are cont tenance, testing, adjusting and the repair of the product. Be prepared to collect the ﬂuidwithsuitable con assembling any component containing ﬂuids.

Dis mandates.

1. Drain the coolant into a suitable container.

2. Dispose of the coolant according to local

3. Flush the system with clean water in order to

4. Use Perkins cleaner to clean the system. Follow

erform the following steps:

NOTICE

ained during performance of inspection, main-

tainers before opening any compartment or dis-

pose of all ﬂuids according to local regulations and

regulations.

remove any debris.

the instruction on the label.

NOTICE Mixing ELC with other products reduces the effectiveness of the ELC and shortens the ELC service life. Use only Perkins Products for premixed or concentrate coolants. Failure to follow these recommendations can result in shortened cooling system component life.

ELC cooling systems can withstand contamination to a maximum of 10 percent of conventional heavy-duty antifreeze or SCA. If the contamination exceeds 10 percent of the total system capacity, perform ONE of the following procedures:

Drain the cooling system into a suitable container.

•

Dispose of the coolant according to local regulations. Flush the system with clean water. Fill the system with the Perkins ELC.

Drain a portion of the cooling system into a suitable

•

container according to local regulations. Then, ﬁll the cooling system with premixed ELC. This procedure should lower the contamination to less than 10 percent.

76 SEBU8601-01 Maintenance Section Reﬁll Capacities

Maintain the sy

•

stem as a conventional Heavy-Duty Coolant. Treat the system with an SCA. Change the coolant at the interval that is recommended for the conventio

nal Heavy-Duty Coolant.

Commercial Heavy -Duty Antifreeze and SCA

NOTICE Commercial Heavy-Duty Coolant which contains Amine as part of the corrosion protection system must not be used.

NOTICE Never operate an engine without water temperature regulator

s in the cooling system. Water temperature regulators help to maintain the engine coolant at the correct operating temperature. Cooling system problems can d

evelop without water temperature regula-

tors.

Check the antifreeze (glycol concentration) in order to

ensure adequate protection against boiling or freezing. Perkins recommends the use of a refractometer for checking the glycol concentration. Ahydro

meter should not be used.

Perkins engine cooling systems should be tested at 500 hou

r intervals for the concentration of SCA.

Additions of SCA are based on the results of the test. An SCA

that is liquid may be needed at 500 hour

intervals.

to Table 13 for part numbers and for quantities

Refer of SCA.

Table 13

Perkins Liquid SCA

Part Number

21825735 10

Quantity

Adding the SCA t o Heavy-Duty Coolant at the Initial Fill

Commercial heavy-duty antifreeze that meets “ASTM D4985” speciﬁcations MAY require an addition of SCA at the initial ﬁll. Read the label or the instructions that are provided by the OEM of the product.

Use the equation that is in T able 14 to determine the amount of Perkins SCA that is required when the cooling system is initially ﬁlled.

Table 14

Equation For Adding The SCA To The Heavy-Duty

Coolant At The Initial Fill

V×0.045=X

V i s the total volume of the cooling system.

X is the amount of SCA that is required.

Table 15 is an example for using the equation that is in Table 14.

Table 15

Example Of The Equation For Adding The SCA To

The Heavy-

Total Volume

of the Cooling

System (V)

15 L (4 US gal) × 0.045 0.7 L (24 oz)

Duty Coolant At The Initial Fill

Multiplication

Factor

Amount of

SCA that is

Required (X)

Adding The SCA to The Heavy-Duty Coolant For Maintenance

Heavy-duty antifreeze of all types REQUIRE periodic additions of an SCA.

Test the antifreeze periodically for the concentration of SCA. For the interval, refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section). Test the concentration of SCA.

Additions of SCA are based on the results of the test. The size of the cooling system determines the amount of SCA that is needed.

Use the equation that is in Table 16 to determine the amount of Perkins SCA that is required, if necessary:

Table 16

Equation For Adding The SCA To The Heavy-Duty

V i s the total volume of the cooling system.

X is the amount of SCA that is required.

Table 17 is an example for using the equation that is in Table 16.

Table 17

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant For Maintenance

Total Volume

of the Cooling

System (V)

15 L (4 US gal)

Coolant For Maintenance

V×0.014=X

Multiplication

Factor

×0.014

Amount of

SCA that is

Required (X)

0.2 L (7 oz)

SEBU8601-01 77

Maintenance Section

Reﬁll Capacities

Cleaning the Sy

stem of Heavy-Duty

Antifreeze

Perkins cooli to clean the cooling system of harmful scale and corrosion. Perkins cooling system cleaners dissolve min contamination, and sludge.

Clean the co

•

drained or before the cooling system is ﬁlled with new coolant.

Clean the cooling system whenever the coolant is

•

contaminated or whenever the coolant is foaming.

ng system cleaners are designed

eral scale, corrosion products, light oil

oling system after used coolant is

i04156282

Fluid Recommendations

General Lubricant Information

Because of government regulations regarding the certiﬁcation of exhaust emissions from the engine, the lubricant recommendations must be followed.

API_____________________ American Petroleum Institute

•

SAE___________________________________________ Society Of

•

Automotive Engineers Inc.

ACEA___________________ _______________Association des

•

Constructers European Automobiles.

ECF-3_______________________ Engine Crankcase Fluid

•

Licensing

The Engine Oil Licensing and Certiﬁcation System by the American Petroleum Institute (API) and the Association des Constructers European Automobilesand (ACRA) is recognized by Perkins. For detailed information about this system, see the latest edition of the “API publication No. 1509”. Engine oils that bear the API symbol are authorized by API.

Illustration 42

Typical API symbo l

g01987816

Terminology

Certain abbreviations follow the nomenclature of “SAE J754”. Some classiﬁcations follow “SAE J183” abbreviations, and some classiﬁcations follow the “EMA Recommended Guideline on Diesel Engine Oil”.InadditiontoPerkinsdeﬁnitions, there are other deﬁnitions that will be of assistance in purchasing lubricants. Recommended oil viscosities can be found in this publication, “Fluid Recommendations/Engine Oil” topic (Maintenance Section).

Engine Oil

Commercial Oils

NOTIC

Perkins require the use of the following speciﬁcation of engine oil. Failure to use the appropriate

ﬁcation of engine oil will reduce the life of

speci your engine. Failure to use the appropriate s peciﬁcation of engine oil will also reduce the life of

aftertreatment system.

your

Table 18

Classiﬁcations for the 1200 Series Industrial Engine

Oil Speciﬁcation

API CJ-4 ACEA E9 ECF-3

API CJ-4 and ACEA E9 oil categories have the following chemical limits:

1 percent maximum sulfated ash

•

0.12 percent maximum phosphorous

•

0. 4 percent maximum sulfur

•

78 SEBU8601-01 Maintenance Section Reﬁll Capacities

The chemical li

mits were developed in order to maintain the expected life of the engine aftertreatment system. The performance of the engine aftert

reatment system can be adversely

affected if oil that is not speciﬁed in table 18 is used.

Thelifeofyo

ur Aftertreatment system is deﬁned by the accumulation of ash on the surface of the ﬁlter. Ash is the inert part of the particulate matter. The system is de

signed in order to collect this particulate matter. There is a very small percentage of particulate matter that is left behind as the soot is burnt. This matter will

eventually block the ﬁlter, causing loss of performance and increased fuel consumption. Most of the ash comes from the engine oil which is gradually

consumed during normal operation. This ash is passes through the exhaust. To meet the designed life of the product, the use of the appropriate engine oil

is essential. The oil speciﬁcation that is

listed in table 18 has low ash content.

Maintena

nce intervals for engines that use biodiesel – The oil change interval can be adversely

affected by the use of biodiesel. Use oil analysis in order to m

onitor the condition of the engine oil. Use oil analysis also in order to determine the oil change interval that is optimum.

Note: These engine oils are not approved by Perkins and these engine oils must not be used:CC

, CD, CD-2, CF-4, CG-4, CH-4, and CI-4.

Lubricant Viscosity Recommendations for Dir

The correct SAE viscosity grade of oil is determined by the cold engine start-up, and the maximum ambient temperature during engine operation.

Refertoillustration43(minimumtemperature)in order to determine the required oil viscosity for star

Refertoillustration43(maximumtemperature)in orde the highest ambient temperature that is anticipated.

Gen available to meet the requirement for the temperature at start-up.

ect Injection (DI) Diesel Engines

minimum ambient temperature during

ting a cold engine.

r to select the oil viscosity for engine operation at

erally, use the highest oil viscosity that is

Illustration 43

Lubricant Viscosities

Supplemental heat is recommended for cold soaked starts below the minimum ambient temperature. Supplemental heat may be required for cold soaked starts that are above the minimum temperature that is stated, depending on the parasitic load and other factors. C old soaked starts occur wh en the engine has not been operated for a period of time. This interval will allow the oil to become more viscous due to cooler am bient temperatures.

g02210556

Aftermarket Oil Additives

Perkins does not recommend the use of aftermarket additives in oil. It is not necessary to use aftermarket additives in order to achieve the engines maximum service life or rated performance. Fully formulated, ﬁnished oils consist of base oils and of commercial additive packages. These additive packages are blended into the base oils at precise percentages in order to help provide ﬁnished oils with performance characteristics that meet industry standards.

There are no industry standard tests that evaluate the performance or the compatibility of aftermarket additives in ﬁnished oil. Aftermarket additives may not be compatible with the ﬁnished oils additive package, which could lower the performance of the ﬁnished oil. The aftermarket additive could fail to mix with the ﬁ nished oil. This failure could produce sludge in the crankcase. Perkins discourages the use of aftermarket additives in ﬁnished oils.

To achieve the best performance from a Perkins engine, conform to the following guidelines:

See the appropriate “Lubricant Viscosities”. Refer

•

totheillustration43inordertoﬁnd the correct oil viscosity grade for your engine.

At the speciﬁed interval, service the engine. Use

•

new oil and install a new oil ﬁlter.

SEBU8601-01 79

Maintenance Section

Reﬁll Capacities

Perform mainte

•

speciﬁed in the Operation and Maintenance Manual, “Maintenance Interval Schedule”.

nance at the intervals that are

Oil analysis

Some engines valve. If oil analysis is required, the oil sampling valve is used to obtain samples of the engine oil. The oil analysis wi program.

The oil anal determine oil performance and component wear rates. Contamination can be identiﬁed and measured by using oi following tests:

The Wear Ra

•

engines metals. The amount of wear metal and type of wear metal that is in the oil is analyzed. The increase oil is as important as the quantity of engine wear metal in the oil.

Tests are conducted in order to detect

•

contamination of the oil by water, glycol, or fuel.

The Oil Condition Analysis determines the loss of

•

the oils lubricating properties. An infrared analysis is used properties of the used oil sample. This analysis allows technicians to determine the amount of

oration of the oil during use. This analysis

deteri also allows technicians to verify the performance oftheoilaccordingtothespeciﬁcation during the

e oil change interval.

entir

may be equipped with an oil sampling

ll complement the preventive maintenance

ysis is a diagnostic tool that is used to

l analysis. The oil analysis includes the

te Analysis monitors the wear of the

in the rate of engine wear metal in the

to compare the properties of new oil to the

i04025688

Fluid Recommendations

Glossary

•

ISO International Standards Organization

•

SME Soy Methyl E

•

EPA Environmental Protection Agency of the

•

United States

PPM Parts Per Million

•

DPF Diesel Particulate Filter

•

ster

General Information

NOTICE Every attempt is made to provide accurate, up-to-date information. By use of this document you agree that Perkins En forerrorsoromissions.

These recommendations are subject to change without notice. Contact your local Perkins distributor for the most up-to-date recommendations.

gines Company Limited is not responsible

NOTICE

Diesel Fuel Requirements

Perkins is not in a position to continuously evaluate and monitor all worldwide distillate diesel fuel

cations that are published by governments and

speciﬁ technological societies.

The Per provides a known reliable baseline in order to judge the expected performance of distillate diesel fuels that a

Satisfactory engine performance is dependent on the use o fuel will give the following results: long engine life and acceptable exhaust emissions levels. The fuel must in the table 19.

The footnotes are of the key part Perkins Speciﬁcatio footnotes.

kins Speciﬁcation for Distillate Diesel Fuel

re derived from conventional sources.

f a good quality fuel. The use of a good quality

meet the minimum requirements that are stated

NOTICE

n for Distillate Diesel Fuel Table. Read ALL of the

ASTM American Society for Testing and Materials

•

HFRR High Frequency Reciprocating Rig for

•

Lubricity testing of diesel fuels

FAME Fatty Acid Methyl Esters

•

CFR Co-ordinating Fuel Research

•

ULSD Ultra Low Sulfur Diesel

•

RME Rape Methyl Ester

•

80 SEBU8601-01 Maintenance Section Reﬁll Capacities

Table 19

Perkins Speciﬁcation for Distillate Diesel Fuel

Property UNITS Requirements “ASTM”Test “ISO”Test

Aromatics %Volume 35% maximum D1319 “ISO”3837

Ash

Carbon Residue on

%Weight 0.01% maxim

%Weight 0.35% maximum

um D482

D524

10% Bottoms

Cetane Number

(2)

Cloud Point °C

40 minimum

The cloud point must

D613/D6890 “ISO”5165

D2500 not exceed the lowest expected ambient temperature.

Copper Strip

No. 3 maximum D130 “ISO”2160

Corrosion

Density at 15 °C (59 °F)

Distill

(3)

ation

Kg / M

°C 10% at 282 °C

801 minimum and 876 maximum

No equivalent test

D86 “ISO”3405 (539.6 °F) maximum 90% at 360 °C (680 °F) maximum

Flash Point °C legal limit D93 “ISO”2719

Thermal Stability

Minimum of 80%

D6468 No equivalent test reﬂectance after aging for 180 minutes at 150 °C (302 °F)

Pour Point

°C 6 °C (

42.8 °F) minimum

D97 below ambient temperature

(1)

Sulfur

Kinematic Viscosity

%mass 0.0

(4)

“MM”2“/S (cSt)” The viscosity of the

015

D5453/D26222 “ISO 20846 ”“ISO 20884”

D445 “ISO”3405 fuel that is delivered to the fuel injection pump. “1.4 minimum/4.5 maximum”

Water and sediment

Water

% weight 0.1% maximum

Sediment % weight 0.05% maximum

Gums and Resins

(5)

mg/100mL

10 mg per 100 mL

D1796

D1744 No equivalent test

D473

D381 maximum

(1)

“ISO”6245

“ISO”4262

“ISO”3015

“ISO 3675 ”“ISO 12185”

”3016

“ISO

“ISO”3734

“ISO”3735

“ISO”6246

(continued)

SEBU8601-01 81

Maintenance Section

Reﬁll Capacities

(Table 19, contd)

Lubricity corrected wear scar diam 60 °C (140 °F).

(1)

This speciﬁcation includes the requirements for Ultra Low Sulfur Diesel (ULSD). ULSD fuel will have ≤ 15 ppm (0.0015%) sulfur. Refer to

“ASTM D 54 53”, “ASTM D2622”, or “ISO 20846, ISO 20884” test methods.

(2)

A fuel with a higher cetane number is recommended in order to operate at a higher altitude or in cold weather.

(3)

“Via standar

maximum den

(4)

The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also m eet the minimum viscosity requirement and the fuel should meet the maximum viscosity requirements at 40 °C (104 °F) of either the “ASTM D445” test method or the “ISO 3104” test method. If a fuel w ith a low viscosity is used, cooling of the fuel may be required to maintain “1.4 cSt”or greater viscosity at the fuel injection pump. Fuels with a high viscosity m ight require fuel heaters in order to lower the v iscosity to “1.4 cSt” at the fuel injection pump.

(5)

Follow the test conditions and procedures for gasoline (motor).

(6)

The lubric High Frequ supplier. problems i

eter at

(6)

ds tables, the equivalent API gravity for the minimum density of 801 kg / m

sity of 876 kg / m

ity of a fuel is a concern with ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1 or ASTM D 6079

ency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel

Do not treat the fuel without consulting the fuel supplier. Some additives are not com patible. These additives can ca use

n the fuel system.

is 30”.

0.52 maximum D6079

“ISO”12156-1

(kilograms per cubic meter) is 45 and for the

Engines that are manufactured by Perkins are certiﬁed w

ith the fuel that is prescribed by the United States Environmental Protection Agency. Engines that are manufactured by Perkins are certiﬁed with the f

uel that is prescribed by the European Certiﬁcation. Perkins does not certify diesel engines on any other fuel.

Note: The owner and the operator of the engine has the responsibility of using the fuel that is prescribed by the EPA a

nd other appropriate regulatory agencies.

NOTICE Operating with fuels that do not meet the Perkins recommend

ations can cause the following effects: Starting difﬁculty, reduced fuel ﬁlter service life, poor combustion, deposits in the fuel injectors, signiﬁcantly reduce s

ervice life of the fuel system, deposits in the combustion chamber, and reduced service life of the engine.

NOTICE The Perkins 1200 series of diesel engine must be operated using Ultra Low Sulfur Diesel. The sulphur content of this fuel must be lower than 15 PPM. This fuel complies with the emissions regulations that are prescribed by the Environmental Protection Agency of the United States.

Illustration 44

g02157153

Illustration 44 is a representation of the label that will be installed by the fuel ﬁller cap on the fuel tank of the application.

The fuel speciﬁcations that are listed in the table 20 are released as acceptable to use on all 1200 series of engine.

82 SEBU8601-01 Maintenance Section Reﬁll Capacities

Table 20

Acceptable Fuel Speciﬁcation for the 1200 Series of Engines

Fuel Speciﬁcation Comments

EN590 European Automotive Diesel Fuel (DERV)

“ASDM D975 G

“ASTM D975 GRADE 2D S15” “North American Middle Distillate general purpose Diesel fuel

“JIS K2204” “Japanese D iesel Fuel” Must meet the requirements that are

“BS 2869: 2010 CLASS A2 or EU equivalent ” “EU Off R oad Diesel fuel. Acceptable from 2011 MUST have

(1)

All the fu

RADE 1D S15”

els must comply with the speciﬁcation in the table for the Perkins Spec iﬁ cation Distillate Diesel Fuel.

“North Amer PPM sulfur level”

with less than 15 PPM sulfur level”

stated in the section “Lubricity”.

less than 1

ican Light Distillate Diesel fuel with less than 15

0 PPM sulfur level”

(1)

Diesel Fu

el Characteristics

Cetane Number

Fuel that has a high cetane number will give a shorter ignition delay. A high cetane number will produce

a better ignition quality. Cetane numbers are derived for fuels against proportions of cetane and heptamethylnonane in the standard CFR engine. Refer t

o “ISO 5165” for the test method.

Cetane numbers in excess of 45 are normally

ed from current diesel fuel. However, a cetane

expect number of 40 may be experienced in some territories. The United States of America is one of the territories

an have a low cetane value. A m inimum cetane

that c value of 40 is required during average starting conditions. A fuel with higher cetane number is

mended for operations at high altitudes or in

recom cold-weather operations.

with a low cetane number can be the root cause

Fuel of problems during a cold start.

osity

Visc

Viscosity is the property of a liquid of offering

istance to shear or ﬂow. Viscosity decreases

res with increasing temperature. This decrease in viscosity follows a logarithmic relationship for normal

sil fuel. The common reference is to kinematic

fos viscosity. Kinematic viscosity is the quotient of the dynamic viscosity that is divided by the density. The

termination of kinematic viscosity is normally by

de readings from gravity ﬂow viscometers at standard temperatures. Refer to “ISO 3104” for the test

thod.

The visco

sity of the fuel is signiﬁcant because fuel serves as a lubricant for the fuel system components. Fuel must have sufﬁcient viscosity in order to lubricate the fuel

system in both extremely cold temperatures and extremely hot temperatures. If the kinematic viscosity of the fuel is lower than “1.4 cSt” at the fuel

on pump, damage to the fuel injection pump

injecti can occur. This damage can be excessive scufﬁng and seizure. Low viscosity may lead to difﬁcult hot

ting, stalling, and loss of performance. High

restar viscosity may result in seizure of the pump.

s recommends kinematic viscosities of 1.4 and

Perkin

4.5 mm2/sec that is delivered to the fuel injection pump. If a fuel with a low viscosity is used, cooling of

el may be required to maintain 1.4 cSt or greater

the fu viscosity at the fuel injection pump. Fuels with a high viscosity might require fuel heaters in order to lower

scosity to 4.5 cSt at the fuel injection pump.

the vi

Density

Density is the mass of the fuel per unit volume at a speciﬁc temperature. This parameter has a

ct inﬂuence on engine performance and a direct

dire inﬂuence on emissions. This inﬂuence determines from a heat output given injected volume of fuel. This

ameter is quoted in the following kg/m

par

at 15 °C

(59 °F).

kins recommends a density of 841 kg/m

Per

in order to obtain the correct power output. Lighter fuels are acceptable but these fuels will not produce the rated

wer.

Sulfur

The level of sulfur is governed by emissions legislations. Regional regulation, national regulations,

r international regulations can require a fuel with

o aspeciﬁc sulfur limit. The sulfur content of the fuel and the fuel quality must comply with all existing local

egulations for emissions.

SEBU8601-01 83

Maintenance Section

Reﬁll Capacities

Perkins 1200 se designed to operate only with ULSD. By using the test methods “ASTM D5453, ASTM D2622, or ISO 20846 ISO 2088 must be below 15 PPM (mg/kg) or 0.0015% mass.

Use of diese it in these engines will harm or permanently damage emissions control systems and/or shorten their service interv

ries diesel engines have been

4”, the content of sulfur in ULSD fuel

NOTICE

l fuel with higher than 15 PPM sulphur lim-

al.

Lubricity

Lubricity wear. The ﬂuids lubricity describes the ability of the ﬂuid to reduce the friction between surfaces that are under loa caused by friction. Fuel injection systems rely on the lubricating properties of the fuel. Until fuel sulfur limits were man believed to be a function of fuel viscosity.

The lubr ultra low sulfur fuel, and low aromatic fossil fuels. These fuels are made in order to meet stringent exhaus

is the capability of the fuel to prevent pump

d. This ability reduces the damage that is

dated, the fuels lubricity was generally

icity has particular signiﬁcance to the current

t emissions.

Recommendatio

Biodiesel is a fuel that can be deﬁned as mono-alkyl esters of fatt made from various feedstock. The most commonly available biodiesel in Europe is Rape Methyl Ester (REM). This b oil. Soy Methyl Ester (SME) is the most common biodiesel in the United States. This biodiesel is derived fro are the primary feedstocks. These fuels are together known as Fatty Acid Methyl Esters (FAME).

Raw pressed vegetable oils are NOT acceptable for use as a fuel in any concentration in compression engines. W the crankcase and the fuel tank. These fuels may not be compatible with many of the elastomers that areusedin In original forms, these oils are not suitable for use as a fuel in compression engines. Alternate base stocks fo cooking oils, or various other feedstocks. In order to use any of the products that are listed as fuel, the oil must be es

Fuel made of 100 percent FAME is generally referred to as B10

y acids. Biodiesel is a fuel that can be

iodiesel is derived from rapeseed

m soybean oil. Soybean oil or rapeseed oil

ithout esteriﬁcation, these oils solidify in

engines that are manufactured today.

r biodiesel may include animal tallow, waste

teriﬁed.

0 biodiesel or neat biodiesel.

n for Biodiesel

The lubricity of these fuels must not exceed wear scar

er of 0.52 mm (0.0205 inch). The fuel lubricity

diamet test must be performed on an HFRR, operated at 60 °C (140 °F). Refer to “ISO 12156-1 ”.

NOTIC The fuels system has been qualiﬁed with fuel having lubricity up to 0.52 mm (0.0205 inch) wear scar

eter as tested by “ISO 12156-1”. Fuel with higher

diam wear scar diameter than 0.52 mm (0.0205 inch) will lead to reduced service life and premature failure of

uel system.

the f

Fuel additives can enhance the lubricity of a fuel.

tact your fuel supplier for those circumstances

Con when fuel additives are required. Your fuel supplier can make recommendations for additives to use, and

the proper level of treatment.

for

Distillation

Distillation is an indication of the mixture of different hydrocarbons in the fuel. A high ratio of light weight

ydrocarbons can affect the characteristics of

h combustion.

Biodiesel can be blended with distillate diesel fuel. The blen available biodiesel blends are B5, which is 5 percent biodiesel and 95 percent distillate diesel fuel. B20, which i diesel fuel.

Note:

The U.S. distillate diesel fuel speciﬁcation “ASTM D975-

European distillate diesel fuel speciﬁcation EN590: 2010

Note: Engines that are manufactured by Perkins are c Protection Agency (EPA) and European Certiﬁcation fuels. Perkins does not certify engines on any other fue of using the correct fuel that is recommended by the manufacturer and allowed by the EPA and other app

Speciﬁcation Requirements

The neat biodiesel must conform to the latest “EN14214 or ASTM D6751” (in the USA). The

odiesel can only be blended in mixture of up to

bi 20% by volume in acceptable mineral diesel fuel meeting latest edition of “EN590 or ASTM D975 S15”

esignation.

ds can be used as fuel. The most commonly

s 20 percent biodiesel and 80 percent distillate

The percentages given are volume-based.

09a” includes up to B5 (5 percent) biodiesel.

includes up B7 (7 percent) biodiesel.

ertiﬁed by use of the prescribed Environmental

l. The user of the engine has the responsibility

ropriate regulatory agencies.

84 SEBU8601-01 Maintenance Section Reﬁll Capacities

In United State meet the requirements listed in the latest edition of “ASTM D7467” (B6 to B20) and must be of an API gravity of 30-

In North America biodiesel and biodiesel blends must be purch producers and BQ-9000 certiﬁed distributors.

In other are that is BQ-9000 accredited and certiﬁed, or that is accredited and certiﬁed by a comparable biodiesel quality bod standards is required.

Engine Ser

Aggressive properties of biodiesel fuel may cause debris in t properties of biodiesel will clean the fuel tank and fuel lines. This cleaning of the fuel system can prema recommend that after the initial usage of B20 biodiesel blended fuel the fuel ﬁlters must be replaced at 50 hour

Glycerides present in biodiesel fuel will also cause

ers to become blocked more quickly. Therefore

fuel ﬁlt the regular service interval should be reduced to 250 hours.

s Biodiesel blends of B6 to B20 must

45.

ased from the BQ-9000 accredited

as of the world, the use of biodiesel

y to meet similar biodiesel quality

vice Requirements

he fuel tank and fuel lines. The aggressive

turely block of the fuel ﬁlters. Perkins

Performance Re

Due to the lower energy content than the standard distillate fu of 2 to 4 percent. In addition, over time the power may deteriorate further due to deposits in the fuel injectors.

Biodiesel and biodiesel blends are known to cause an increase of which are deposits within the fuel injector. These deposits can cause a loss in power due to restricted or modiﬁed f issues associated with these deposits.

Note: Perk effective in cleaning and preventing the formation of deposits. Perkins Diesel Fuel Conditioner helps to limit de biodiesel and biodiesel blends. For more information refer to “Perkins Diesel Fuel System Cleaner”.

Biodiesel fuel contains metal contaminants (sodium, potassium, calcium, and/or magnesium) that form ash products ash can have an impact on the life and performance of aftertreatment emissions control devices and can accumul the need for more frequent ash service intervals and cause loss of performance

posit issues by improving the stability of

upon combustion in the diesel engine. The

ate in DPF . The ash accumulation may cause

lated Issues

el B20 will cause a power loss in order

in fuel system deposits, most signiﬁcant

uel injection or cause other functional

ins T400012 Fuel Cleaner is most

When biodiesel fuel is used, crank case oil and aftertreatment systems may be inﬂuenced. This

ce is due to the chemical composition and

inﬂuen characteristics of biodiesel fuel, such as density and volatility, and to chemical contaminants that can be

nt in this fuel, such as alkali and alkaline metals

prese (sodium, potassium, calcium, and magnesium).

case oil fuel dilution can be higher when

Crank

•

biodiesel or biodiesel blends are used. This increased level of fuel dilution when using biodiesel

odiesel blends is related to the typically lower

or bi volatility of biodiesel. In-cylinder emissions control strategies utilized in many of the industrial latest

ne designs may lead to a higher level of

engi biodiesel concentration in the sump. The long-term effect of biodiesel concentration in crankcase oil is

rently unknown.

cur

Perkins recommend the use of oil analysis in order

•

heck the quality of the engine oil if biodiesel

to c fuel is used. Ensure that the level of biodiesel in the fuel is noted when the oil sample is taken.

General Requirements

sel has poor oxidation stability, which can result

Biodie in long-term problems in the storage of biodiesel. Biodiesel fuel should be used within 6 months of

acture. Equipment should not be stored with

manuf the B20 biodiesel blends in the fuel system for longer than 3 months.

Due to poor oxidation stability and other potential issues, it is strongly recommended that engines with

ted operational time either not use B20 biodiesel

limi blends or, while accepting some risk, limit biodiesel blend to a maximum of B5. Examples of applications

should limit the use of biodiesel are the following:

that Standby Generator sets and certain emergency vehicles.

Perkins strongly recommended that seasonally operated engines have the fuel systems, including

ltanks,ﬂashed with conventional diesel fuel

fue before prolonged shutdown periods. An example of an application that should seasonally ﬂush the fuel

stem is a combine harvester.

Microbial contamination and growth can cause

rrosion in the fuel system and premature plugging

co of the fuel ﬁlter. Consult your supplier of fuel for assistance in selecting appropriate anti-microbial

dditive.

SEBU8601-01 85

Maintenance Section

Reﬁll Capacities

Water accelera growth. When biodiesel is compared to distillate fuels, water is naturally more likely to exist in the biodiesel. It and if necessary, drain the water separator.

Materials su zinc accelerate the oxidation process of the biodiesel fuel. The oxidation process can cause deposits formation t for fuel tanks and fuel lines.

Fuel for Col

The European standard “EN590” contains climate dependant options can be applied differently in each country. There are ﬁve classes that are given to arctic climates and severe

Fuel that complies with “EN590 ” CLASS 4 can be used at te Refer to “EN590” for a detailed discretion of the physical properties of the fuel.

The diesel fuel “ASTM D975 1-D” used in the United States of America may be used in very cold tempera

tures that are below −18 °C (−0.4 °F).

tes microbial contamination and

is therefore essential to check frequently

ch as brass, bronze, copper, led, tin, and

herefore these materials must not be used

d Weather Operation

requirements and a range of options. The

winterclimates.0,1,2,3,and4.

mperatures as low as −44 °C (−47.2 °F).

Perkins fuel cl form in the fuel system with the use of biodiesel and biodiesel blends. These deposits can create a loss of power and en

Once the fuel cleaner has been added to the fuel, the deposits after 30 hours of engine operation. For maximum results, continue to use the fuel cleaner for up to 80 hours. Pe on-going basis with no adverse impact on engine or fuel system durability.

Details instruction on the rate of which the fuel cleaner must be use are on the container.

Note: Perkins fuel cleaner is compatible with existing and U.S. EP A Tier 4 nonroad certiﬁed diesel engine emission c Perkins fuel system cleaner contains less than 15 ppm of sulfur and is acceptable for use with ULSD fuel.

eaner will remove deposits that can

gine performance.

within the fuel system are removed

rkins fuel cleaner can be used on an

ontrol catalysts and particulate ﬁlters.

Aftermarket Fuel Additives

Supplemental diesel fuel additives are not generally recommended. This recommendation is due to

ial damage to the fuel system or the engine.

potent Your fuel supplier or the fuel manufacturer will add the appropriate supplemental diesel fuel additives.

Perkins recognizes the fact that additives may be required in some special circumstances. Contact

uel supplier for those circumstances when

your f fuel additives are required. Your fuel supplier can recommend the appropriate fuel additive and the

ect level of treatment.

corr

Note: For the best results, your fuel supplier should

t the fuel when additives are required. The treated

trea fuel must meet the requirements that are stated in table 19.

Perkins Diesel Fuel System Cleaner

kins T400012 Fuel Cleaner is the only fuel

Per cleaner that is recommended by Perkins.

biodiesel or biodiesel blends of fuel are to be

If used, Perkins require the use of Perkins fuel cleaner. The use of the fuel is in order to remove

posits within the fuel system that is created

de with the use of biodiesel. For more information on the use of biodiesel and biodiesel blends refer to

Recommendation for Biodiesel”.

“

86 SEBU8601-01 Maintenance Section Maintenance Recommendations

Maintenance Recommendations

i03648938

System Pressure R elease

Coolant System

Pressurized system: Hot coolant can cause serious burn. T diator is cool. Then loosen cap slowly to relieve the pressure.

The engine can have the ability to auto start. Ensure that the power supply is isolated before any service or repai

To relieve the pressure from the coolant system, turn off the e to cool. Remove the cooling system pressure cap slowly in order to relieve pressure.

o open cap, stop engine, wait until ra-

risperformed.

ngine. Allow the cooling system pressure cap

Before any serv engine fuel lines, perform the following tasks:

1. Stop the engin

2. Wait for 10 minutes.

Do not loosen the high pressure fuel lines in order to remove air from the fuel system.

ice or repair is performed on the

Engine Oil

To relieve pressure from t he lubricating system, tu rn off the engine.

i04103081

Welding on Engines with Electronic Controls

NOTICE Because the strength of the frame may decrease, some manufacturers do not recommend welding onto a chassis frame or rail. Consult the OEM of the equipment or your Perkins dealer regarding welding on a chassis frame or rail.

Fuel System

To relieve the pressure from the fuel system, turn off the engine.

High Pressure Fuel Lines

This is because of the following differences:

The high pressure fuel lines are constantly charged

•

with high pressure.

Proper welding procedures are necessary in order to avoid damage to the engines ECM, sensors, and associated components. When possible, remove the component from the unit and then weld the component. If removal of the component is not possible, the following procedure must be followed when you weld on a unit equipped with an Electronic Engine. The following procedure is considered to be the safest procedure to weld on a component. This procedure should provide a minimum risk of damage to electronic components.

ICE

NOT Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can

use damage to the drive train bearings, hydraulic

ca components, electrical components, and other components.

Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close

s possible to the weld. This will help reduce the pos-

a sibility of damage.

ote: Perform the welding in areas that are free from

explosive hazards.

The internal pressures of the high pressure fuel

•

lines are higher than other types of fuel system.

1. Stop the engine. Turn the switched power to the

OFF position.

SEBU8601-01 87

Maintenance Section

Maintenance Recommendations

2. Ensure that the

fuel supply to the engine is turned

off.

3. Disconnect th

e negative battery cable from the battery. If a battery disconnect switch is provided, open the switch.

4. Disconnect all electronic components from the wiring harnesses. Include the following components

Electronic components for the driven equipment

•

ECM

•

Sensors

•

Electronically controlled valves

•

Relays

•

Aftertre

•

atment ID module

NOTICE Do not use electrical components (ECM or ECM sensors) or electronic component grounding points for groundi

ng the welder.

Illustration 45

Use the e the grou compon

(1) E ngine (2) Welding electrode (3) Ke ysw itch in the OFF position (4) Battery disconnect switch in the open position (5) Disconnected battery cables (6) Battery (7) Electrical/Electronic component (8) Minimum distance between the component that is being welded

(9) The component that is being welded (10) Current path of the welder (11) Ground clamp for the welder

xample above. The current ﬂow from the welder to

nd clamp of the welder will not damage any associated

ents.

and any electrical/electronic component

g01075639

5. Connect the welding ground cable directly to the part that will be welded. Place the ground

eascloseaspossibletotheweldinorderto

cabl reduce the possibility of welding current damage to the following components. Bearings, hydraulic

ponents, electrical components, and ground

com straps.

e: If electrical/electronic components are used

Not

as a ground for the welder, or electrical/electronic components are located between the welder ground

d the weld, current ﬂow from the welder could

an severely damage the component.

otect the wiring harness from welding debris

6. Pr and spatter.

se standard welding practices to weld the

7.U

materials.

88 SEBU8601-01 Maintenance Section Maintenance Interval Schedule

i03975515

Maintenance Interval Schedule

When Required

Battery - Replace .................................................. 90

Battery or Battery Cable - Disconnect .................. 91

Engine - Cle Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................. 101

Engine Air C

Inspect/Replace ................................................ 103

Engine Oil Sample - Obtain ................................ 108

Fuel Syste

Severe Service Application - Check .................... 119

Daily

Cooling System Coolant Level - Check ................ 97

Driven Equipment - Check .................................. 100

Engine Ai

Engine Air Precleaner - Check/Clean ................. 104

Engine Oil Level - Check .................................... 108

Fuel Sys

Drain .................................................................. 114

Walk-Around Inspection ...................................... 122

Every We

Hoses and Clamps - Inspect/Replace ................. 117

Every 5

Fuel Tank Water and Sediment - Drain ................ 116

Every

Belt - Inspect ......................................................... 92

e Oil and Filter - Change ........................... 109

Engin

Fan Clearance - Check ........................................ 110

an .................................................... 101

leaner Element (Single Element) -

m - Prime ............................................ 111

r Cleaner Service Indicator - Inspect ... 104

tem Primary Filter/Water Separator -

0 Service Hours or Weekly

500 Service Hours

Every 1500 Serv

Engine Crankcase Breather Element - Replace .. 105

Every 2000 Ser

Aftercooler Core - Inspect ..................................... 89

Engine Mount

Starting Motor - Inspect ...................................... 120

Turbocharger - Inspect ........................................ 120

Every 3000 S

Alternator - Inspect ............................................... 90

Alternator

Belt Tensioner - Inspect ........................................ 92

Radiator Pressure Cap - Clean/Replace ............. 119

and Fan Belts - Replace ....................... 90

Every 3000

Cooling System Coolant (Commercial Heavy-Duty) -

Change ............................................................... 93

Cooling System Water Temperature Regulator -

Replace ............................................................... 99

Every 40

Aftercooler Core - Clean/Test ............................... 89

Every 45

ARD Spark Plug - Clean/Inspect/Replace ............ 89

Every 5

Diesel Particulate Filter - Clean .......................... 100

Every

Cooling System Coolant (ELC) - Change ............. 95

Commi

Fan Clearance - Check ........................................ 110

00 Service Hours

000 Service Hours

12 000 Service Hours or 6 Years

ssioning

ice Hours

vice Hours

s - Inspect ..................................... 107

ervice Hours

ServiceHoursor2Years

Every 500 Service Hours or 1 Year

Battery Electrolyte Level - Check .......................... 91

Cooling System Supplemental Coolant Additive

) - Test/Add ................................................. 98

(SCA

Crankshaft Vibration Damper - Inspect ................. 99

Engine Air Cleaner Element (Dual Element) -

an/Replace .................................................. 101

Cle Engine Air Cleaner Element (Single Element) -

Inspect/Replace ................................................ 103

l System Primary Filter (Water Separator)

Fue

Element - Replace ............................................. 112

Fuel System Secondary Filter - Replace ............. 115

diator - Clean ................................................... 118

Every 1000 Service Hours

ter Pump - Inspect ......................................... 123

SEBU8601-01 89

Maintenance Section

ARD Spark Plug - Clean/Inspect/Replace

i03975571

ARD Spark Plug Clean/Inspec

ARD Aftertreatment Regeneration Device

•

If the engin position the ARD spark plug will continue to ﬁre. Turn the keyswitch to the OFF position before servicing the ARD spark p

eisrunning,orthekeyswitchisintheON

lug.

t/Replace

NOTICE

Illustration 46

1. Ensure that the power is in the “OFF” position and

that the engine was stopped. Remove any dirt or debris from the area around the spark plug. Remove wire harness (2) from spark plug (1).

2. Use a T40006 Socket in order to remove the

spark plug. Loosen the spark plug and use the socket to remove the spark plug by hand in order to detect problems with the threads. Discard the spark plug.

g01947378

Illustration 47

3. Use T400005 Plug Bore Brush in order to clean the ground electrode (3).

4. Install the new spark plug by hand. Tighten the spark plug to a torque of 47 N·m (34 lb ft).

5. Connect the wiring harness (2).

g02148769

i01807350

Aftercooler Core - Clean /Test (Air-To-Air Aftercooler)

The air-to-air aftercooler is OEM installed in many applications. Please refer to the OEM speciﬁcations for information that is related to the aftercooler.

i02322295

Aftercooler Core - Inspect

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

Inspect the aftercooler for these items: damaged ﬁ ns, corrosion, dirt, grease, insects, leaves, oil, and other debris. Clean the aftercooler, if necessary.

For air-to-air aftercoolers, use the same methods that are used for cleaning radiators.

90 SEBU8601-01 Maintenance Section Alternator - Inspect

i02680137

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at t he nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

After cleaning, start the engine and accelerate the engine to high idle rpm. This will help in the removal of debris and drying of the core. Stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary.

Inspect the ﬁns for damage. Bent ﬁns may be opened with a “comb”.

Note: If parts of the aftercooler system are repaired or replaced, a leak test is highly recommended.

Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps, and seals. Make repairs, if necessary.

Alternator and Fan Belts Replace

Refer to Disassembly and Assembly Manual , “ Alternator Belt - Remove and Install”.

i03559623

Battery - Replace

Batteries give off combustible gases which can explode. A spark can cause the combustible gases to igni jury or death.

Ensure p an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks near bat serviced.

te. This can result in severe personal in-

roper ventilation for batteries that are in

teries. Do not smoke when batteries are

311

i02322

Alternator - Inspect

ns recommends a scheduled inspection of

Perki the alternator. Inspect the alternator for loose connections and correct battery charging. Check the

ter (if equipped) during engine operation in

amme order to ensure correct battery performance and/or correct performance of the electrical system. Make

irs, as required.

repa

Check the alternator and the battery charger for

ect operation. If the batteries are correctly

corr charged, the ammeter reading should be very near zero. All batteries should be kept charged. The

teries should be kept warm because temperature

bat affects the cranking power. If the battery is too cold, the battery will not crank the engine. When the

gine is not run for long periods of time or if the

en engine is run for short periods, the batteries may not fully charge. A battery with a low charge will freeze

re easily than a battery with a full charge.

The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.

Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.

1. Switch the engine to the OFF position. Remove

all electrical loads.

2. Turn off any battery chargers. Disconnect any battery chargers.

3. Ensure that the battery disconnect switch is in the OFF position.

4. Disconnect the NEGATIVE “-” cable from the NEGATIVE “-” batte ry terminal.

5. Disconnect the POSITIVE “+” cable from the POSITIVE “+” battery terminal.

Note: Always recycle a battery. Never discard a battery. Dispose of used batteries to an appropriate recycling facility.

SEBU8601-01 91

Maintenance Section

Battery Electrolyte Level - Check

6. Remove the used

7. Install the new battery.

Note: Before the cables are connected, ensure that

the battery disconnect switch is in the OFF position.

8. Connect the POSITIVE “+” cable to the POSITIVE “+” battery terminal.

9. Connect the NEGATIVE “-” cable to the NEGATIVE “-” battery terminal.

10. Turn the battery disconnect switch to the ON position.

battery.

i02747977

Battery Electrolyte Level Check

When the when the engine is run for short periods, the batteries may not fully recharge. Ensure a full charge in order to help are correctly charged, the ammeter reading should be very near zero, when the engine is in operation.

engine is not run for long periods of time or

prevent the battery from freezing. If batteries

Thoroughly rin

se the battery case with clean water.

i02323088

Battery or Battery Cable Disconnect

The battery cables or the batteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.

Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.

1. Turn the start switch to the OFF position. Turn the

ignition switch (if equipped) to the OFF position and remove the key and all electrical loads.

2. Disconnect the negative battery terminal. Ensure that the cable cannot contact the terminal. When four 12 volt batteries are involved, two negative connection must be disconnected.

ad-acid batteries contain sulfuric acid which

All le can burn the skin and clothing. Always wear a face shield and protective clothing when working on or

batteries.

near

1. Remove the ﬁller caps. Maintain the electrolyte

l to the “FULL” mark on the battery.

leve

If the addition of water is necessary, use distilled

er. If distilled water is not available use clean

wat water that is low in minerals. Do not use artiﬁcially softened water.

2. Check the condition of the electrolyte with a suitable battery tester.

3. Install the caps.

ep the batteries clean.

4. Ke

Clean the battery case with one of the following

leaning solutions:

Use a solution of 0.1 kg (0.2 lb) baking soda

•

nd 1 L (1 qt) of clean water.

3. Remove the positive connection.

4. Clean all disconnected connection and battery

terminals.

5. Use a ﬁne grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal ofmaterialcancausetheclampstonotﬁt correctly. Coat the clamps and the terminals with a suitable silicone lubricant or petroleum jelly.

6. Tape the cable connections in order to help prevent accidental starting.

7. Proceed with necessary system repairs.

8. In order to connect the battery, connect the

positive connection before the negative connector.

Use a solution of ammonium hydroxide.

•

92 SEBU8601-01 Maintenance Section Belt - Inspect

i03973719

Belt-Inspect

NOTICE Ensure that the engine is stopped before any servicing or repair is performed.

Belt Tensioner - Inspect

Illustration 49

Typical examp le

i03557440

g01880953

Illustration 48

Typical example

g01906354

To maximize the engine performance, inspect the belt (1) for wear and for cracking. Replace the belt if the belt is worn or damaged.

Inspect the belt for cracks, splits, glazing, grease,

•

displacement of the cord and evidence of ﬂuid contamination.

The belt must be replaced if the following conditions are present.

The belt has a crack in more than one rib.

•

More than one section of the belt is displaced in

•

one rib of a maximum length of 50.8 mm (2 inch).

To replace the belt, refer to Disassembly and Assembly, “Alternator Belt - Remove and Install”. If necessary, replace the belt tensioner. Refer to Disassembly and Assembly, “Alternator Belt Remove and Install” for the correct procedure.

Remove the belt. Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install”.

Ensure that the belt tensioner is securely installed. Visually inspect the belt tensioner (1) for damage. Check that the pulley on the tensioner rotates freely and that the bearing is not loose. Some engines have a idler pulley (2). Ensure that the idler pulley is securely installed. Visually inspect the idler pulley for damage. Ensure that the idler pulley can rotate freely and that the bearing is not loose. If necessary, replace damaged components.

Install the belt. Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install”.

SEBU8601-01 93

Maintenance Section

Cooling System Coolant (Commercial Heavy-Duty) - Change

i04155927

Cooling System Coo lant (Commercial H

eavy-Duty) -

Change

Dispose of all ﬂuids according to Local regulations and mandates.

NOTICE Keep all

Contaminants may cause rapid wear and shortened compone

parts clean from contaminants.

nt life.

Drain

Pressurized S ous burns. To open the cooling system ﬁller cap, stop the engine and wait until the cooling system components a pressure cap slowly in order to relieve the pressure.

1. Stop the engine and allow the engine to cool.

Loosen the cooling system ﬁller cap slowly in order to rel system ﬁller cap.

ystem: Hot coolant can cause seri-

re cool. Loosen the cooling system

ieve any pressure. Remove the cooling

Clean the cooling system and ﬂush the cooling system before the recommended maintenance interval if the following conditions exist:

The engine overheats frequently.

•

Foaming of the coolant is observed.

•

The oil has entered the cooling system and the

•

coolant is contaminated.

The fuel has entered the cooling system and the

•

coolant is contaminated.

Note: When the cooling system is cleaned, only clean water is needed.

NOTICE When any servicing or repair of the engine cooling system is performed the procedure must be performed with the engine on level ground. This will allow you to accurately check the coolant level. This will also help in avoiding the risk of introducing an air lock into the coolant system.

Illustration 50

Typical examp le

g02350782

94 SEBU8601-01 Maintenance Section Cooling System Coolant (Commercial Heavy-Duty) - Change

Illustration 51

Typical example

g02350785

2. Open the drain cock or remove the drain plug (1)

on the engine. Also, remove the drain plug (2). Open the drain cock or remove the drain plug on the radiator.

Allow the coolant to drain.

NOTICE Dispose of used engine coolant or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Perkins to reclaim the coolant.

For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or your Perkins distributor.

4. Start and run th

e engine at low idle until the

temperature reaches 49 to 66 °C (120 to 150 °F).

5. Stop the engin

e and allow the engine to cool. Loosen the cooling system ﬁller cap slowly in order to relieve any pressure. Remove the cooling system ﬁller

cap. Open the drain cock or remove the drain plug on the engine. Open the drain cock or remove the drain plug on the radiator. Allow the water to

drain. Flush the cooling system with

clean water.

Fill

1. Close the dr

engine. Close the drain cock or install the drain plug on the radiator.

Do not ﬁll the cooling system faster than 5 L (1.3 US gal) per minute, in order to avoid air locks.

Cooling system air locks may result in engine damage.

2. Fill the Heavy-Duty Coolant. Add Supplemental Coolant Additive to the coolant. For the correct amount, refer t “Fluid Recommendations” topic (Maintenance Section) for more information on cooling system speciﬁ ﬁller cap.

3. Start the engine rpm to high idle. Operate the engine in order to open the engine thermostat. This will allow the engine speed to low idle. Stop the engine.

4. Main

tain the coolant level at the maximum mark

that is correct for your application.

ain cock or install the drain plug on the

NOTICE

cooling system with Commercial

o the Operation and Maintenance Manual,

cations. Do not install the cooling system

and run the engine at low idle. Increase

any air in the system to be purged. Decrease

Flush

1. Flush the cooling system with clean water in order

to remove any debris.

2. Close the drain cock or install the drain plug in the engine. Close the drain cock or install the drain plug on the radiator.

NOTICE Do not ﬁll the cooling system faster than 5 L (1.3 US gal) per minute, in order to avoid air locks.

Cooling system air locks may result in engine damage.

3. Fill the cooling system with clean water. Install the

cooling system ﬁller cap.

Illustration 52

Filler c ap

g00103639

SEBU8601-01 95

Maintenance Section

Cooling System Coolant (ELC) - Change

5. Clean the cooli

gasket. If the gasket is damaged, discard the old ﬁller cap and install a new ﬁller cap. If the gasket is not damaged in order to pressure test the ﬁller cap. The correct pressure is stamped on the face of the ﬁller cap. If the ﬁller cap install a new ﬁller cap.

6. Start the en

leaks and for correct operating temperature.

ng system ﬁller cap and inspect the

,useasuitablepressurizingpump

does not retain the correct pressure,

gine. Inspect the cooling system for

i04155851

Cooling Sys tem Coolant (ELC)

- Change

NOTICE Care must be taken to ensure that ﬂuids are contained during p ing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before opening any c nent containing ﬂuids.

erformance of inspection, maintenance, test-

ompartment or disassembling any compo-

NOTICE When any servi system is performed the procedure must be performed with the engine on level ground. Level ground will allow you to accu check will also help in avoiding the risk of introducing an air lock into the coolant system.

cing or repair of the engine cooling

rately check the coolant level. This

Drain

Pressurized System: Hot coolant can cause serious burns. To open the cooling system ﬁller cap, stop the en components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.

1. Stop the engine and allow the engine to cool.

Loosen t order to relieve any pressure. Remove the cooling system ﬁller cap.

gine and wait until the cooling system

he cooling system ﬁller cap slowly in

Dispos mandates.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Clean the cooling system and ﬂush the cooling syst interval if the following conditions exist:

•

Note: When the cooling system is cleaned, only clean water is needed when the ELC is drained and r

eofallﬂuids according to Local regulations and

NOTICE

em before the recommended maintenance

engine overheats frequently.

The

Foaming of the coolant is observed.

The oil has entered the cooling system and the coolant is contaminated.

The fuel has entered the cooling system and the coolant is contaminated.

eplaced.

Illustration 53

Typical examp le

g02350782

Note: Inspect the water pump and the water

emperature regulator after the cooling system

t has been drained. This inspection can be a good opportunity to replace the water pump, the water temperature regulator, and the hoses, if necessary.

96 SEBU8601-01 Maintenance Section Cooling System Coolant (ELC) - Change

Illustration 54

Typical example

g02350785

2. Open the drain cock or remove the drain plug (1) on the engine. Also remove the drain plug (2). Open the drain cock or remove the drain plug on the radiator.

Allow the coolant to drain.

4. Start and run th

e engine at low idle until the

temperature reaches 49 to 66 °C (120 to 150 °F).

5. Stop the engin

e and allow the engine to cool. Loosen the cooling system ﬁller cap slowly in order to relieve any pressure. Remove the cooling system ﬁller

cap. Open the drain cock or remove the drain plug on the engine. Open the drain cock or remove the drain plug on the radiator. Allow the water to

drain. Flush the cooling system with

clean water.

Fill

1. Close the dr

engine. Close the drain cock or install the drain plug on the radiator.

Do not ﬁll the cooling system faster than 5 L (1.3 US gal) per minute, in order to avoid air locks.

Cooling system air locks may result in engine damage.

2. Fill the Coolant (ELC). Refer to the Operation and Maintenance Manual, “Fluid Recommendations” topic ( on cooling system speciﬁcations. Do not install the cooling system ﬁller cap.

3. Start and run the engine at low idle. Increase the engine rpm to high idle. Operate the engine in ord procedure will allow any air in the system to be purged. Decrease the engine speed to low idle. Stop t

ain cock or install the drain plug on the

NOTICE

cooling system with Extended Life

Maintenance Section) for more information

er to open the engine thermostat. This

he engine.

For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or your Perkins distributor.

Flush

1. Flush the cooling system with clean water in order

to remove any debris.

2. Close the drain cock or install the drain plug in the engine. Close the drain cock or install the drain plug on the radiator.

NOTICE Do not ﬁll the cooling system faster than 5 L (1.3 US gal) per minute, in order to avoid air locks.

Cooling system air locks may result in engine damage.

3. Fill the cooling system with clean water. Install the

cooling system ﬁller cap.

4. Maintain the coolant level at the maximum mark is correct for your application.

that

Illustration 55

Filler c ap

g00103639

SEBU8601-01 97

Maintenance Section

Cooling System Coolant Level - Check

5. Clean the cooli gasket. If the gasket is damaged, discard the old ﬁller cap and install a new ﬁller cap. If the gasket is not damaged in order to pressure test the ﬁller cap. The correct pressure is stamped on the face of the ﬁller cap. If the ﬁller cap install a new ﬁller cap.

6. Start the en leaks and for correct operating temperature.

ng system ﬁller cap and inspect the

,useasuitablepressurizingpump

does not retain the correct pressure,

gine. Inspect the cooling system for

i03576064

Cooling System Coolant Level

- Check

Engines With a Coolant Recovery Tank

Note: The cooling system may not have been

provided by Perkins. The procedure that follows is for typical cooling systems. Refer to the OEM information for the correct procedures.

Check the coolant level when the engine is stopped and cool.

3. Pour the correc Refer to the Operation and Maintenance Manual, “Reﬁll Capacities and Recommendations” for information o coolant. Refer to the Operation and Maintenance Manual, “Reﬁll Capacities and Recommendations” for the cooli coolant recovery tank above “COLD FULL” mark.

Illustration 56

4. Clean ﬁller cap and the receptacle. Reinstall the ﬁller cap and inspect the cooling system for leaks.

Note: The coolant will expand as the coolant heats up during normal engine operation. The additional volume will be forced into the coolant recovery tank during engine operation. When the engine is stopped and cool, the coolant will return to the engine.

t coolant mixture into the tank.

nthecorrectmixtureandtypeof

ng system capacity. Do not ﬁll the

g00103639

Engines Without a Coolant Recovery Tank

Check the coolant level when the engine is stopped and cool.

1. Observe the coolant level in the coolant recovery tank. Maintain the coolant level to “COLD FULL” mark on the coolant recovery tank.

2. Loosen ﬁller cap slowly in order to relieve any

pressure. Remove the ﬁller cap.

Illustration 57

Cooling sy stem ﬁller cap

0285520

98 SEBU8601-01 Maintenance Section Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Add the SCA, If Necessary

1. Remove the cooling system ﬁller cap slowly in

order to relieve pressure.

2. Maintain the coolant level at the maximum mark that is correct for your application. If the engine is equipped with a sight glass, maintain the coolant level to the correct level in the sight glass.

3. Clean the cooling system ﬁller cap and inspect the gasket. If the gasket is damaged, discard the old ﬁller cap and install a new ﬁller cap. If the gasket is not damaged, use a suitable pressurizing pump in order to pressure test the ﬁller cap. The correct pressure is stamped on the face of the ﬁller cap. If the ﬁller cap does not retain the correct pressure, install a new ﬁller cap.

4. Inspect the cooling system for leaks.

NOTICE Do not exceed the recommended amount of supplemental coolant additive concentration. Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engine's heat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components. Excessive supplemental coolant additive concentration could also result in radiator tube blockage, overheating, and/or accelerated water pump seal wear. Never use both liquid supplemental coolant additive and the spin-on element (if equipped) at the same time. The use of those additives together could result in supplemental coolant additive concentration exceeding the recommended maximum.

Pressurized System: Hot coolant can cause serious burns. To open the cooling system ﬁller cap, stop th components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.

e engine and wait until the cooling system

948

i03644

Cooling System Supplemental Coolan

t Additive (SCA) -

Test/Ad d

Cooling system coolant additive contains alkali. To help prevent personal injury, avoid contact with the skin and the eyes. Do not drink cooling system coolant additive.

Test for SCA Concentration

Heavy-Duty Coolant/Antifreeze and SCA

NOTICE

not exceed the recommended six percent supple-

Do mental coolant additive concentration.

1. Slowly loosen the cooling system ﬁller cap in

order to relieve the pressure. Remove the cooling system ﬁller cap.

Note: Always discard drained ﬂuids according to local regulations.

2. If necessary, drain some coolant from the cooling

system into a suitable container in order to allow space for the extra SCA.

3. AddthecorrectamountofSCA.Refertothe

Operation and Maintenance Manual, “Reﬁll Capacities and Recommendations” for more information on SCA requirements.

Use a Coolant Conditioner Test Kit in order to check

he concentration of the SCA.

SEBU8601-01 99

Maintenance Section

Cooling System Water Temperature Regulator - Replace

4. Clean the cooli gasket. If the gasket is damaged, discard the old ﬁller cap and install a new ﬁller cap. If the gasket is not damaged in order to pressure test the ﬁller cap. The correct pressure is stamped on the face of the ﬁller cap. If the ﬁller cap install a new ﬁller cap.

Cooling Sy

ng system ﬁller cap and inspect the

,useasuitablepressurizingpump

does not retain the correct pressure,

i04020355

stem Water Temperature Regulator Replace

Replace t the water temperature regulator fails. This is a recommended preventive maintenance practice. Replaci the chances for unscheduled downtime. Refer to this Operation and Maintenance Manual, “Maintenance Interva interval.

A water partially opened position can cause overheating or overcooling of the engine.

he water temperature regulator before

ng the water temperature regulator reduces

l Schedule” for the proper maintenance

temperature regulator that fails in a

NOTICE Failuretorep on a regularly scheduled basis could cause severe engine damage.

Perkins engines incorporate a shunt design cooling system and require operating the engine with a water temperature

If the water temperature regulator is installed incorrectly, the damage. Ensure that the new water temperature regulator is installed in the original position. Ensure that the water te

Do not use liquid gasket material on the gasket or cylinder h

Refer to two articles in the Disassembly and Assembly

- Remove and Water Temperature Regulators Install” for the replacement procedure of the water tempera or your Perkins distributor.

Note: If replaced, drain the coolant from the cooling system to a level that is below the water temperature regulator

housin

lace your water temperature regulator

regulator installed.

engine may overheat, causing cylinder head

mperature regulator vent hole is open.

ead surface.

Manual, “Water Temperature Regulators

ture regulator, or consult your Perkins dealer

only the water temperature regulators are

A water temperature regulator that fails in the closed position can cause excessive overheating. Excessive

eating could result in cracking of the cylinder

overh head or piston seizure problems.

Awate position will cause the engine operating temperature to be too low during partial load operation. Low engi could cause an excessive carbon buildup inside the cylinders. This excessive carbon buildup could result in an of the cylinder liner.

r temperature regulator that fails in the open

ne operating temperatures during partial loads

accelerated wear of the piston rings and wear

i03634651

Crankshaft Vibration Damper

-Inspect

Viscous Damper

The viscous damper has a inertia weight that is locatedinsideaﬂuid ﬁlled case. The inertia weight moves in the case in order to limit torsional vibration.

Visually inspect the crankshaft damper. Ensure that the cooling ﬁns (1) on the crankshaft damper are clean and free from dirt.

100 SEBU8601-01 Maintenance Section Diesel Particulate Filter - Clean

Illustration 58

Typical example

Inspect the damper and replace the damper for any of the following reasons:

The d amper is dented, cracked, or leaking.

•

For information on removal of the crankshaft damper, refer to Disassembly and Assembly, “Vibration Damper and Pulley - Remove and Install”.

g01950241

i04087370

Diesel Particulate Filter - Clean

Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Mufﬂer. Failure to do so could result in personal injury.

Illustration 59

Typical examp le

DPF__________________________ Diesel Particulate Filter

•

Contact your Perkins dealer, or your Perkins distributor. New torca clamps (1) must be installed on the DPF.

For information on removal of the DPF, refer to Disassembly and Assembly, “DPF - Remove”. Also, refer to System Operation Testing and Adjusting, “Diesel Particulate Filter - Clean”.

Onlyultralowsufurdieselfuelcanbeusedinan

•

application that has an aftertreatment regeneration device. The use of other fuel will damage your engine system.

The engine must be operated on CJ-4 speciﬁcation

•

of engine oil.

g01949226

i02151646

Driven Equipment - Check

The mufﬂer, catalytic converter/mufﬂer, and diesel particulate ﬁlter will become extremely hot during engine operation. A hot mufﬂer, catalytic converter/mufﬂer and diesel particulate ﬁlter can cause serious burns. Allow adequate cooling time before workingonornearthemufﬂer, catalytic convert- er/mufﬂer and diesel particulate ﬁlter.

Refer to the OEM speciﬁcations for more information on the following maintenance recommendations for thedrivenequipment:

Inspection

•

Adjustment

•

Lubrication

•

Other maintenance recommendations

•

Perkins Engine 1206E-E70TTA Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual