Perkins Engine 1206F-E70TA, 1206F-E70TTA Service Manual

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Page 1

Operation and Maintenance Manual

SEBU8732

September 2013

1206F-E70TA and 1206F-E70TTA Industrial Engines

BM (Engine) BN (Engine)

Page 2

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.

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SEBU8732 3

Table of Contents

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

Safety Section

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

General Hazard Information ............... .............. 8

Burn Prevention....................... ........................11

Fire Prevention and Explosion Prevention ... .. 12

Crushing Prevention and Cutting Prevention . 14

Mounting and Dismounting............... .............. 14

High Pressure Fuel Lines ................ ............... 15

Before Starting Engine ................. .................. 16

Engine Starting ........................ ....................... 16

Maintenance Section

Refill Capacities....................... ....................... 74

Maintenance Recommendations.......... .......... 88

Maintenance Interval Schedule ........... ........... 91

Warranty Section

Warranty Information.................. .................. 127

Reference Information Section

Reference Materials .................. ................... 128

Index Section

Index............................... .............................. 131

Engine Stopping ....................... ...................... 17

Electrical System ...................... ...................... 17

Engine Electronics..................... ..................... 18

Product Information Section

General Information.................... .................... 20

Product Identification Information.......... ......... 29

Operation Section

Lifting and Storage..................... ..................... 32

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

Engine Diagnostics..................... .................... 58

Engine Starting ........................ ....................... 63

Engine Operation...................... ...................... 66

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

Engine Stopping ....................... ...................... 72

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4 Foreword

SEBU8732

Foreword

Literature Information

This manual contains safety, operation instructions, lubrication and maintenance information. This manual

should be stored in or near the engine area in a literature holder or literature storage area. Read, 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 consistency.

Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please 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, warning situations. Read and understand the basic

precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.

Operation

Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities.

The operation section is a reference for operators. Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information.

Maintenance

The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance intervals. Items in the maintenance schedule are

referenced to detailed instructions that follow.

Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary.

The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.

Maintenance Intervals

Perform maintenance on items at multiples of the original requirement. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained

as part of the engine's permanent record.

Your authorized Perkins dealer or your Perkins distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment.

Overhaul

Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that interval.

Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer or your Perkins distributor offers a variety of options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available. Consult with your Perkins dealer or your Perkins distributor for information regarding these options.

California Proposition 65 Warning

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

birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

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SEBU8732

Safety Section

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Safety Messages

There may be several specific warning signs on your engine. The exact location and a description of the warning signs are reviewed in this section. Please become familiar with all warning signs.

Ensure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if the words cannot be read or if the illustrations are not

visible. Use a cloth, water, and soap to clean the warning signs. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the

warning signs. The warning signs that are loosened could drop off the engine.

Safety Section

Safety Messages

Replace any warning sign that is damaged or missing. If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Your Perkins dealer or your Perkins distributor can provide new warning signs.

Universal Warning 1

Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death.

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6 SEBU8732 Safety Section

Safety Messages

Illustration 1 g03022899

Typical example

The universal warning label is install in two positions on the engine. On the valve mechanism cover and on the intake manifold, refer to illustration 1 .

Ether Warning 2

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

Illustration 2 g03023096

Typical example

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SEBU8732

The ether warning label is installed on the intake manifold, refer to illustration 2 .

Hand (High Pressure) 3

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

Safety Section

Safety Messages

Illustration 3 g03023097

Typical example

The hand high-pressure warning label is a rap around label installed on the main injection line, refer to illustration 3 .

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8 SEBU8732 Safety Section

General Hazard Information

i05192438

General Hazard Information

Illustration 4 g00104545

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 appropriate, disconnect the starting controls.

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.

• Vent the engine exhaust to the outside when the engine is operated in an enclosed area.

• If the engine is not running, do not release the secondary brake or the parking brake systems unless the vehicle is blocked or unless the vehicle is restrained.

• 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.

• Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine.

• Ensure that all protective guards and all covers are secured in place on the engine.

• Never put maintenance fluids into glass containers. Glass containers can break.

• Use all cleaning solutions with care.

• Report all necessary repairs.

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

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SEBU8732 9

Safety Section

General Hazard Information

• The engine is stopped. Ensure that the engine cannot be started.

• The protective locks or the controls are in the applied position.

• Engage the secondary brakes or parking brakes.

• Block the vehicle or restrain the vehicle before maintenance or repairs are performed.

• Disconnect the batteries when maintenance is performed or when the electrical system is serviced. Disconnect the battery ground leads. Tape the leads in order to help prevent sparks. If equipped, allow the diesel exhaust fluid to be purged before disconnecting the battery.

• If equipped, disconnect the connectors for the unit injectors that are located on the valve cover base. This action will help prevent personal injury from the high voltage to the unit injectors. Do not come in contact with the unit injector terminals while the engine is operating.

• Do not attempt any repairs or any adjustments to the engine while the engine is operating.

• Filler caps

• Grease fittings

• Pressure taps

• Breathers

• Drain plugs

Use caution when cover plates are removed. Gradually loosen, but do not remove the last two bolts or nuts that are located at opposite ends of the cover plate or the device. Before removing the last two bolts or nuts, pry the cover loose in order to relieve any spring pressure or other pressure.

• Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.

• For initial start-up of a new engine or for starting an engine that has been serviced, make provisions to stop the engine if an overspeed occurs. The stopping of the engine may be accomplished by shutting off the fuel supply and/or the air supply to the engine. Ensure that only the fuel supply line is shut off. Ensure that the fuel return line is open.

• Start the engine from the operators station (cab). Never short across the starting motor terminals or the batteries. This action could bypass the engine neutral start system and/or the electrical system could be damaged.

Engine exhaust contains products of combustion which may be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is in an enclosed area, vent the engine exhaust to the outside.

Cautiously remove the following parts. To help prevent spraying or splashing of pressurized fluids, hold a rag over the part that is being removed.

Illustration 5 g00702020

• 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.

• Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine.

• Ensure that all protective guards and all covers are secured in place on the engine.

• Never put maintenance fluids into glass containers. Glass containers can break.

• Use all cleaning solutions with care.

• Report all necessary repairs.

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

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10 SEBU8732 Safety Section

General Hazard Information

• 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. Disconnect the battery ground leads. Tape the leads in order to help prevent sparks.

• Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.

Pressurized Air and Water

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

When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective 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 water pressure for cleaning purposes must be below 275 kPa (40 psi).

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve the hydraulic pressure.

Illustration 6 g00687600

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.

Containing Fluid Spillage

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.

Inhalation

Illustration 7 g00702022

Exhaust

Use caution. Exhaust fumes can be hazardous to health. If you operate the equipment in an enclosed

area, adequate ventilation is necessary.

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SEBU8732 11

Safety Section

Burn Prevention

Asbestos Information

Perkins equipment and replacement parts that are shipped from Perkins engine company limited are asbestos free. Perkins recommends the use of only genuine Perkins replacement parts. Use the following guidelines when you handle any 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 fibers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous unless airborne dust that contains asbestos is generated.

If dust that may contain asbestos is present, there are several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestos materials.

• A vacuum cleaner that is equipped with a high 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 Occupational Safety and Health Administration (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.

Dispose of Waste Properly

Illustration 8 g00706404

Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations.

Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water.

i04891356

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.

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

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.

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12 SEBU8732 Safety Section

Fire Prevention and Explosion Prevention

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 appropriate 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.

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, aftertreatment system or to the engine 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.

i05408772

Fire Prevention and Explosion Prevention

Illustration 9 g00704000

All fuels, most lubricants, and some coolant mixtures are flammable.

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.

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 with a bare hand. Remove the filler cap slowly in order to relieve pressure.

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

Oils

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

Batteries

Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended.

Aftertreatment System

Allow the aftertreatment to cool down before any maintenance or repair is performed.

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

Determine whether the engine will be operated in an 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.

If the application involves the presence of combustible gases, consult your Perkins dealer and/ or your Perkins distributor for additional information about suitable protection devices.

Remove all flammable combustible materials or conductive materials such as fuel, oil, and debris from the engine. 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 flammable 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.

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SEBU8732 13

Safety Section

Fire Prevention and Explosion Prevention

Do not weld 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

thoroughly with a nonflammable solvent prior to welding or flame cutting.

Wiring must be kept in good condition. Ensure that all electrical wires are correctly installed and securely attached. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the 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 the recommended gauge. Do not bypass any fuses and/or circuit breakers.

Arcing or sparking could cause a fire. Secure connections, recommended wiring, and correctly maintained battery cables will help to prevent arcing or sparking.

Ensure that the engine is stopped. Inspect all lines and hoses for wear or for deterioration. Ensure that

the hoses are correctly routed. The lines and hoses must have adequate support and secure clamps.

Oil filters and fuel filters must be correctly installed. The filter housings must be tightened to the correct torque. Refer to the Disassembly and Assembly manual for more information.

Illustration 10 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.

Avoid static electricity risk when fueling. Ultra-low Sulfur Diesel fuel (ULSD fuel) poses a greater static ignition hazard than earlier diesel formulations with a higher sulfur content. Avoid death or serious injury from fire or explosion. Consult your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

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14 SEBU8732 Safety Section

Crushing Prevention and Cutting Prevention

• High-pressure fuel line or lines are removed.

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible parts of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, correct installation will help to prevent vibration, rubbing against other parts, and excessive heat.

i02143194

Illustration 11 g00704135

Gases from a battery can explode. Keep any open 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 a hydrometer.

Incorrect jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specific instructions.

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

The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the recommended cables, connections, and battery box covers when the engine is operated.

Fire Extinguisher

Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the instruction plate.

Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike highpressure 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:

Crushing Prevention and Cutting Prevention

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. Leave the guards in place until maintenance 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 be injured by flying debris.

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.

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Safety Section

High Pressure Fuel Lines

i03550790

High Pressure Fuel Lines

Illustration 12 g01877473

(1) High pressure line (2) High pressure line (3) High pressure 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

(4) High pressure line (5) High pressure line (6) High pressure line

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

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.

systems.

Do not check the high pressure fuel lines with the

This is because of the following items:

engine or the starting motor in operation. After the engine has stopped, you must wait for 10 minutes in

• The high pressure fuel lines are constantly charged with high pressure.

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.

• The internal pressures of the high pressure fuel lines are higher than other types of fuel system.

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

• The high pressure fuel lines are formed to shape

required.

and then strengthened by a special process.

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

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16 SEBU8732 Safety Section

Before Starting Engine

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.

• Do not operate the engine with a fuel leak. If there 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”.

• If the high pressure fuel lines are torqued correctly 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”.

i02813489

Before Starting Engine

Before the initial start-up of an engine that is new, serviced or repaired, make provision to shut the engine off, in order to stop an overspeed. This may be accomplished by shutting off the air and/or fuel supply to the engine.

Overspeed shutdown should occur automatically for engines that are controlled electronically. If automatic shutdown does not occur, press the emergency stop button in order to cut the fuel and/or air to the engine.

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 free of personnel.

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

All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.

Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are

provided in order to help prevent personal injury. The circuits are also provided in order to help prevent engine damage.

See the Service Manual for repairs and for adjustments.

i03996487

Engine Starting

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 NOTstart the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.

Start the engine from the operators compartment or from the engine start switch.

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

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

Engine exhaust contains products of combustion which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside.

Note: The engine is equipped with a device for cold starting. If the engine will be operated in very cold conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with the correct type of starting aid for your region of operation.

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Safety Section

Engine Stopping

These engines are equipped with a glow plug starting aid in each individual cylinder that heats the intake air in order to improve starting. Some Perkins engines may have a cold starting system that is controlled by the ECM that allows a controlled flow of ether into the

engine. The ECM will disconnect the glow plugs before the ether is introduced. This system would be installed at the factory.

i02234873

Engine Stopping

Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine components.

Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOTstart 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 been overhauled.

Grounding Practices

To stop an electronically controlled engine, cut the power to the engine and/or shutting off the air supply to the engine.

i04891806

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.

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 13 g01888534

Typical example

(1) Ground to battery (2) Ground to starting motor (3) Starting motor to engine block

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18 SEBU8732 Safety Section

Engine Electronics

i05192488

Engine Electronics

Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/or engine damage.

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.

Illustration 14 g03027396

Typical example

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

Correct grounding for the engine electrical system is necessary for optimum engine performance and reliability. Incorrect grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths.

Uncontrolled electrical circuit paths can result in damage to the crankshaft bearing journal surfaces and to aluminum components.

Engines that are installed without engine-to-frame ground straps can be damaged by electrical discharge.

To ensure that the engine and the engine electrical systems function correctly, an engine-to-frame ground strap with a direct path to the battery must be used. This path may be provided by way of a direct engine ground to the frame.

The connections for the grounds should be tight and free of corrosion. The engine alternator must be grounded to the negative “-” battery terminal. The wire used must be adequate to handle the full charging current of the alternator.

The power supply connections and the ground connections for the engine electronics should always be from the isolator to the battery.

This engine has a comprehensive, programmable Engine Monitoring System. The Electronic Control Module (ECM) monitors 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:

• Warning

• Derate

• Shutdown

The following monitored engine operating conditions and components can limit engine speed and/or the engine power:

• Engine Coolant Temperature

• Engine Oil Pressure

• Engine Speed

• Intake Manifold Air Temperature

• Wastegate Regulator

• Supply Voltage to Sensors

• Fuel Temperature

• Fuel Pressure in Manifold (Rail)

• NOxReduction System

• Engine Aftertreatment System

Page 19

SEBU8732 19

Safety Section

Engine Electronics

The Engine Monitoring package can vary for different engine models and different engine applications. However, the monitoring system and the engine monitoring control will be similar for all engines.

Note: Many of the engine control systems and display modules that are available for Perkins engines will work in unison with the Engine Monitoring System. Together, the two controls will provide the engine monitoring function for the specific engine application. Refer to the Troubleshooting for more information on the Engine Monitoring System.

Page 20

20 SEBU8732 Product Information Section

Model View Illustrations

Product Information Section

General Information

i05192513

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.

1206F-E70TA Single Turbocharged Engine with Installed Aftertreatment

Illustration 15 g03393436

Typical example

Page 21

SEBU8732 21

General Information

Model View Illustrations

1206F-E70TTA Engine Views with Series Turbochargers

Illustration 16 g03387645

Typical example

(1) Rear engine lifting eye (2) High-pressure turbocharger (3) Front engine lifting eye

(4) Alternator (5) Low-pressure turbocharger (6) Oil drain plug

(7) Back pressure valve

Page 22

22 SEBU8732 General Information

Model View Illustrations

Illustration 17 g03387666

Typical example

(8) Secondary fuel filter (9) Primary fuel filter (10) Crankcase breather (11) Engine Electronic Control Module

(ECM)

(12) Flywheel housing (13) Flywheel (14) Solenoid for starting motor (15) Starting motor (16) Oil filter

(17) Oil level gauge (Dipstick) (18) Oil drain tap (19) location for the oil sampling valve (20) High-pressure fuel pump

Page 23

SEBU8732 23

General Information

Model View Illustrations

Illustration 18 g03387667

Typical example

(21) NOx Reduction system (NRS) (22) Air intake (23) Coolant outlet

(24) Oil filler cap (25) Water pump (26) Coolant intake

(27) Crankshaft damper (28) Belt tensioner (29) Belt

Page 24

24 SEBU8732 General Information

Model View Illustrations

Off Engine Components

Illustration 19 g03387619

Items that can be supplied loose.

(1) Clean emission module (2) Pump electronics tank unit (3) Heated line (4) Soot sensor control

(5) NOx sensors (6) In-line fuel filter (7) Priming/tranfer fuel pump (8) Primary fuel filter

(9) Flexible exhaust pipe assembly (9 A) Protection sleeve for flexible exhaust

pipe

(10) Inlet air temperature sensor

Note: Use the sleeve (9 A) for transportation only.

Page 25

SEBU8732 25

General Information

Model View Illustrations

Engine Aftertreatment System

Illustration 20 g03027726

Typical example

(1) Clean Emission Module (CEM) (2) Lifting eyes for CEM

(3) Exhaust intake connection (4) Exhaust outlet connection

(5) Diesel Exhaust Fluid (DEF) injector

Page 26

26 SEBU8732 General Information

Product Description

Illustration 21 g03034176

Typical example

(1) Pump Electronics Tank Unit (PETU) (2) Diesel Exhaust Fluid (DEF) tank filler cap (3) Coolant inlet

The size of the DEF tank will depend on the

(4) Coolant outlet (5) Dosing Control Module (DCU) (6) DEF Tank

• In-line Six cylinder

(7) Heated DEF line (8) Harness connections (9) DEF drain plug

application. For more information on the aftertreatment system, refer to this Operation and

• Four stroke cycle

Maintenance Manual, “Sensors and Electrical Components”.

i05192936

Product Description

(Engine and Aftertreatment)

• Four valves in each cylinder

• Series turbocharged charge cooled/or Single turbocharged charge cooled

• Aftertreatment System

The Clean Emissions Module (CEM) is constructed of three main items, the diesel oxidation catalyst, the Diesel Particulate Filter (DPF), and the Selective

There are two variants of the Perkins industrial engine, the 1206F-E70TA a single turbocharged

engine. This engine prefix is BM. The 1206F-E70TTA is a series turbocharged engine and the prefix for this engine is BN.

Catalytic Reduction (SCR). The SCR requires the use of Diesel Exhaust Fluid (DEF) to be injected into the system in order to lower the emissions from the engine. The (DEF) is stored and controlled by the pump electronic tank unit. The DEF tank can be

installed separate from the electronic pump unit. The Perkins 1206F-E70TA and the 1206F-E70TTA Industrial Engines have the following characteristics.

Page 27

SEBU8732 27

General Information

Product Description

For more information on DEF, refer this Operation and Maintenance Manual, “Fluid Recommendations”.

Engine Specifications

Note: The front end of the engine is opposite the

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

Illustration 22 g01127295

Cylinder and valve location

(A) Exhaust valves (B) Inlet valves

Table 1

1206F-TA Single Turbocharged Engine Specifications

16.4:1

(1)

)

(1)

(continued)

Operating Range (rpm)

Number of Cylinders

Bore 105 mm (4.13 inch)

Stroke 127 mm (5 inch)

Power

Aspiration Turbocharged charge cooled

Compression Ratio

Displacement 7.01 L (428 in

Firing Order

Rotation (flywheel end)

(1)

The operating rpm is dependent on the engine rating, the application, and the configuration of the throttle.

Table 2

1206F-70TTA Series Turbocharged Engine Specifications

Operating Range (rpm)

Number of Cylinders

Bore 105 mm (4.13 inch)

900 to 2800

6 In-Line

116 to 151 kW

(155.5 to 202.5 hp)

1-5-3-6-2-4

Counterclockwise

900 to 2800

6 In-Line

(Table 2, contd)

Stroke 135 mm (5.31495 inch)

Power

Aspiration Turbocharged charge cooled

Compression Ratio

Displacement 7.01 L (428 in

Firing Order

Rotation (flywheel end)

(1)

The operating rpm is dependent on the engine rating, the application, and the configuration of the throttle.

151 to 205 kW

(202.5 to 274.9 hp)

16.4:1

)

1-5-3-6-2-4

Counterclockwise

Electronic Engine Features

The engine and aftertreatment 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:

• 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

• NOx reduction system control

• Aftertreatment system control

The ECM provides an electronic governor that

controls the injector output in order to maintain the

desired engine speed.

For more information on electronic engine features,

refer to the Operation and Maintenance Manual,

“Features and Controls” topic (Operation Section).

Engine Diagnostics

The engine has built-in diagnostics in order to ensure

that the engine systems are functioning correctly. The

operator will be alerted to the condition by a “Stop or

Warning” lamp. Under certain conditions, the engine

horsepower and the vehicle speed may be limited.

The electronic service tool may be used to display the

diagnostic codes.

Page 28

28 SEBU8732 General Information

Product Description

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

Most of the diagnostic codes are logged and stored in the ECM. For additional information, refer to the

Operation and Maintenance Manual, “Engine Diagnostics” topic (Operation Section).

Engine Cooling and Lubrication

The cooling system and lubrication system consists of the following components:

• Gear-driven centrifugal water pump

• Water temperature regulator which regulates the

engine coolant temperature

• Gear-driven gerotor type oil pump

• Oil cooler

The engine lubricating oil is supplied by a gerotor type oil pump. The engine lubricating oil is cooled and the engine lubricating oil is filtered. The bypass valve can provide unrestricted flow of lubrication oil to the engine if the oil filter element should become plugged.

Engine efficiency, efficiency of emission controls, and engine performance depend on adherence to proper operation and maintenance recommendations. Engine performance and efficiency also depend on the use of recommended fuels, lubrication oils, and

coolants. Refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” for more

information on maintenance items.

When auxiliary devices, accessories, or consumables

(filters, additives, catalysts,) which are made by other

manufacturers are used on Perkins products, the

Perkins warranty is not affected simply because of

such use.

However, failures that result from the installation

or use of other manufacturers devices,

accessories, or consumables are NOT Perkins

defects. Therefore, the defects are NOT covered

under the Perkins warranty.

Aftertreatment System

The aftertreatment system is approved for use by

Perkins . In order to be emission-compliant only the

approved Perkins aftertreatment system must be

used on a Perkins engine.

Engine Service Life

Engine efficiency and maximum utilization of engine performance depend on the adherence to proper operation and maintenance recommendations. In addition, use recommended fuels, coolants, and

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

Expected engine life is generally predicted by the average power that is demanded. The average power that is demanded is based on fuel consumption of the engine over time. Reduced hours of operation at full throttle and/or operating at reduced throttle settings result in a lower average power demand. Reduced hours of operation will increase the length of operating time before an engine overhaul is required. For more information, refer to the Operation and Maintenance Manual, “Overhaul Considerations”

topic (Maintenance Section).

Aftermarket Products and Perkins Engines

Perkins does not warrant the quality or performance of non-Perkins fluids and filters.

Page 29

SEBU8732 29

Product Identification Information

Plate Locations and Film Locations

Product Identification Information

Plate Locations and Film Locations

i05193032

Serial Number Plate (1)

The engine serial number plate is located on the left

side of the cylinder block to the rear of the front

engine mounting.

Illustration 24 g01094203

Serial number plate

i05193060

Plate Locations and Film

Locations

(Aftertreatment System)

Illustration 23 g03046077

Perkins engines are identified by an engine serial number.

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

***** The list number for the engine

BN Type of engine

U Built in the United Kingdom

000001 Engine Serial Number

W Year of Manufacture

Perkins dealers or Perkins distributors need all of these numbers in order to determine the components

that were included with the engine. This information 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.

Clean Emission Module (CEM)

Illustration 25 g03047499

Typical example

The identification plate (1) is located on the intake

end of the CEM.

Page 30

30 SEBU8732 Product Identification Information

Emissions Certification Film

Illustration 26 g03388367

Typical example CEM identification plate

Pump Electronic Tank Unit (PETU)

Illustration 28 g03049116

Typical example PETU serial plate

Record the information on the CEM and PETU serial

plates. The information will be required by your

Perkins dealer or your Perkins distributor in order to

identify replacement part numbers.

i05193198

Emissions Certification Film

The label for the emission is installed on the front

gear cover.

Note: A second emission label will be supplied with

the engine. If necessary, the second emission label

will be installed on the application by the original

equipment manufacturer.

Illustration 27 g03419905

Typical example

The location of the PETU serial plate (2).

Page 31

SEBU8732 31

Product Identification Information

Reference Information

Secondary Fuel Filter Element

Lubrication Oil Filter Element

Auxiliary Oil Filter Element

Total Lubrication System Capacity

Total Cooling System Capacity

Air Cleaner Element

Drive Belt

Clean Emission Module

Part Number

Serial Number

Pump Electronics Tank Unit

Part Number

Illustration 29 g02443596

Typical example

i05362542

Reference Information

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.

Serial Number

Record for Reference

Engine Model

Engine Serial number

Engine Low Idle rpm

Engine Full Load rpm

In Line Fuel Filter

Primary Fuel Filter

Page 32

32 SEBU8732 Operation Section

Product Lifting

Operation Section

Lifting and Storage

i05350494

Product Lifting

NOTICE Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees.

When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight.

Read all the information within produce lifting before any lifting is attempted. Ensure that the correct set of lifting eyes for the assembly to be lifted have been selected.

Engine and Clean Emission Module (CEM)

Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the assembly. All supporting members (chains and cables) should be parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted.

Illustration 30 g03051657

Typical example

(1) Lifting eyes for engine and aftertreatment.

Refer to illustration 30 for the location of the lifting eyes in order to lift the assembly.

CEM Only

Ensure that the exhaust inlet for the CEM is not damaged during removal and installation. Do not

allow the weigh of the CEM to act on the exhaust inlet.

Page 33

SEBU8732 33

Lifting and Storage

Product Lifting

Illustration 31 g03051677

Typical example

(2) Lifting eyes for the CEM

Refer to illustration 31 for the location of the lifting eyes in order to lift the CEM. The lifting eyes (2) are designed only to lift the CEM. The lifting eyes (2) must not be used to lift any other parts of the application.

Note: If the CEM is removed from the application, the inlet and outlet connections must be protected in order to prevent damage.

Pump Electronics Tank Unit (PETU) Only

The tank on the PETU should be empty before the assembly is lifted.

Illustration 32 g03419909

Typical example

(3) Lifting eyes for PETU

Refer to illustration 32 for the location of the lifting eyes in order to lift the PETU.

Page 34

34 SEBU8732 Lifting and Storage

Product Storage

Engine Only

Condition for Storage

The engine must be stored in a water proof building. The building must be kept at a constant temperature. Engines that are filled with Perkins ELC will have coolant protection to an ambient temperature of

−36° C (−32.8° F). The engine must not be subjected to extreme variations in temperature and humidity.

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.

Illustration 33 g03051679

Typical example

(4) Lifting eyes for the engine

Refer to illustration 32 for the location of the lifting eyes in order to lift the engine.

i05193225

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.

Some applications, the engine can be equipped with delayed engine shutdown. Allow at least 2 minutes after the engine has stopped before you turn the battery disconnect switch to OFF. Disconnecting the battery power too soon will prevent purging of the DEF fluid lines after the engine is shut down. Also, during the 2 minutes the engine electronic control module is active storing information from the engine and aftertreatment sensors.

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.

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

3. The engine oil will not need to be drained in order to store the engine. Provided the correct specification of engine oil is used the engine can be stored for up to 6 months. For the correct specification of engine oil refer to this Operation and Maintenance Manual, “Fluid recommendations”.

4. Remove the drive belt from the engine.

Sealed Coolant System

Ensure that the cooling system is filled with Perkins ELC, or an antifreeze that meets ASTM D6210

specification.

Page 35

SEBU8732 35

Lifting and Storage

Product Storage

Open Cooling System

Ensure that all cooling drain plugs have been opened. Allow the coolant to drain. Install the drain plugs. Place a vapor phase inhibitor into the system. The coolant system must be sealed once the vapor phase inhibitor has been introduced. The effect of the vapor phase inhibitor will be lost if the cooling system is open to the atmosphere.

For maintenance procedures ref to this Operation and Maintenance Manual.

Monthly Checks

The crankshaft must be rotated in order to change the spring loading on the valve train. Rotate the crankshaft more than 180 degrees. Visibly check for damage or corrosion to the engine and aftertreatment.

Ensure that the engine and aftertreatment are covered completely before storage. Log the procedure in the record for the engine.

Aftertreatment

The engine must be allowed to perform a Diesel Exhaust Fluid (DEF) purge before the battery disconnect switch is turned off. Some applications, the engine can be equipped with delayed engine shutdown. Allow 2 minutes after the engine has stopped before disconnecting the battery disconnect switch.

The exhaust outlet of the aftertreatment must be capped. In order to prevent damage to the exhaust

outlet connection during storage, the weight of the CEM must not act on the exhaust outlet.

On removal from storage the DEF quality in the tank must be tested with a refractometer. The DEF in the

tank must meet the requirements defined in ISO 22241-1 and comply with table 3 .

1. If necessary, drain the tank and fill with DEF that meet ISO 22241-1.

2. Replace the DEF filter, refer to this Operation and Maintenance Manual, “Diesel Exhaust Fluid FilterClean/Replace”.

3. Ensure that the drive belt is correctly installed. Ensure that all engine coolant and engine oil has the correct specification and grade. Ensure that the coolant and the engine oil are at the correct level. Start the engine. If a fault becomes active turn off the engine, allow 2 minutes for the DEF system to purge, then restart the engine.

4. If the fault continues to stay active, refer to Troubleshooting for more information.

Table 3

Temperature Duration

10° C (50° F) 36 months

25° C (77° F) 18 months

30° C (86° F) 12 months

35° C (95° F)

(1)

At 35° C, significant degradation can occur. Check every batch before use.

(1)

6 months

DEF Tank Storage

1. Ensure normal engine shutdown, allow the DEF to

be purged. Do not disconnect the battery disconnect switch, allow 2 minutes after key off before disconnection.

2. Fill the tank with DEF that meet all the requirement defined in ISO 22241-1.

3. Ensure that all DEF lines and electrical connection are connected prior to prevent crystal from forming.

4. Ensure that the DEF filler cap is correctly installed.

Removal from Storage

DEF has a limited life, refer to table 3 for the time and temperature range. DEF that is outside this range

MUST be replaced.

Page 36

36 SEBU8732 Features and Controls

Alarms and Shutoffs

Features and Controls

i05416516

Alarms and Shutoffs

Shutoffs

The shutoffs are electrically operated or mechanically operated. The electrically operated shutoffs are controlled by the ECM.

Shutoffs are set at critical levels for the following items:

• Operating temperature

• Operating pressure

• Operating level

• Operating rpm

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

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

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

engine manifold.

Fuel rail pressure – The fuel rail pressure sensor measures the high pressure or low pressure in the fuel rail. The ECM will Check the pressure.

Engine oil pressure – The engine oil pressure 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 – The switch checks the air 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.

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

pump.

Note: The sensing element of the coolant temperature switch must be submerged in coolant in order to operate.

Engines may be equipped with alarms in order to alert the operator when undesirable operating conditions occur.

Be familiar with the following items:

• Types and locations of shutoff

• Conditions which cause each shutoff to function

• The resetting procedure that is required to restart

the engine

Alarms

The alarms are electrically operated. The operations of the alarms are controlled by the ECM.

The alarm is operated by a sensor or by a switch. When the sensor or the switch is activated, a signal is sent to the ECM. An event code is created by the ECM. The ECM will send a signal in order to illuminate the lamp.

Your engine may be equipped with the following sensors or switches:

Coolant temperature – The coolant temperature sensor indicates high jacket water coolant temperature.

Intake manifold air temperature – The intake manifold air temperature sensor indicates high intake air temperature.

NOTICE When an alarm is activated, corrective measures must 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

alarm will continue until the condition is corrected. The alarm may need to be reset.

Note: If installed, the coolant level switch and the oil level switch are indicators. Both switches operate when the application is on level ground and the engine RPM at zero.

Clean Emission Module (CEM)

• Diesel Oxidation Catalyst (DOC)

• Selective Catalyst Reduction (SCR)

Soot Sensors – The soot sensors monitor the soot level within the CEM

NOx Sensors – Two NOx sensors monitor the NOx concentration within the exhaust gas before and after

the selective catalyst reduction module.

Temperature Sensors – A temperature sensor after the engine exhaust gas exit, after the DOC and

Page 37

SEBU8732 37

Features and Controls

Selective Catalytic Reduction Warning System

before the SCR module monitor the temperatures within the system.

Pump Electronics Tank Unit (PETU) Alarms and Shutoff

Diesel Exhaust Fluid (DEF) Level Sensor – The

DEF level sensor monitors the volume of fluid in the tank and signals the ECM if the level drops below a

given point.

Dosing Control Unit (DCU) – The DCU controls the injection of the DEF and will signal the ECM if the injection has been interrupted.

Testing

Turning the keyswitch to the ON position will check the indicator lights on the control panel. All the indicator lights will be illuminated for 2 seconds after the keyswitch is operated. Replace suspect bulbs immediately.

Refer to Troubleshooting for more information.

i05194082

Warning Strategy

The Electronic Control Module (ECM) will have either a world-wide warning strategy or a European union warning strategy enabled within the ECM software.

The European union warning strategy is comprised of two different options. The two options will give different response times for the operated to act and different de-rates to the engine. Only one option will be enabled.

DEF Level Warning Strategy

The DEF level world-wide warning strategy and the DEF level European union warning strategy both offer two options. Only one option will be enabled.

Warning Indicators

The warning indicators consist of a level gauge for the DEF, a low-level lamp for the DEF, an emission malfunction lamp, and the application stop lamp.

Selective Catalytic Reduction Warning System

The Selective Catalytic Reduction (SCR) system is a system used to reduce NOx emissions from the engine. Diesel Exhaust Fluid (DEF) is pumped from the DEF tank and is sprayed into the exhaust stream. The DEF reacts with the SCR catalyst to reduce NOx and leaves a nitrogen and water vapor.

NOTICE Stopping the engine immediately after the engine has been working under load can result in overheating of SCR components.

Refer to the Operation and Maintenance Manual, “Engine Stopping” procedure to allow the engine to cool and to prevent excessive temperatures in the turbocharger housing and the DEF injector.

NOTICE Allow at least 2 minutes after shutting down the engine before you turn the battery disconnect switch to OFF. Disconnecting the battery power too soon will prevent purging of the DEF lines after the engine is shut down.

Note: For information on DEF, refer to this Operation and Maintenance Manual, “Fluid Recommendations”.

Illustration 34 g03069862

(1) DEF gauge (A) Low-level warning lamp

Illustration 35 g02852336

Emission malfunction lamp

Warning Levels

The SCR has three levels of warning. Depending on the fault that has been detected and software enabled

will govern the time that the system will stay at each warning level.

Page 38

38 SEBU8732 Features and Controls

Selective Catalytic Reduction Warning System

Any warning should be investigated immediately, contact your Perkins dealer or your Perkins Distributor . The system is equipped with an override option. Once the override option has been used and the fault still exist, the engine will be locked in de-rate or shutdown mode.

World-Wide SCR Warnings

• At Level 1 the emission malfunction lamp will be on

solid.

• At Level 2 the emission malfunction lamp will flash.

• At Level 3 the emission malfunction lamp will flash

and the stop lamp will activate.

• At Level 3 the engine may shut down or operate at

1000 Revolutions Per Minute (RPM).

• At Level 3 cycling the keyswitch will give 20

minutes override at full power, before the shutdown or idle is triggered. The emission malfunction lamp will continue to flash .

Table 4

World-Wide

DEF Quality Tampering and Dosing Interruption

Normal operation Level 1 Level 2 Level 3 Override

Inducement Time First occurrence

The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then the repeat inducement time will be triggered. The override can only be used once

Repeat Inducement time

Inducement None None None

Notification None Emission malfunction

Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.

Table 5

Inducement Time First occurrence

None 2.5 Hours 70 minutes Shut down or idle

Until fault heals

None 5 minutes 5 minutes Shut down or idle

Until fault heals

lamp will be on solid

NOx Reduction System Fault

Normal operation Level 1 Level 2 Level 3 Override

None 35 Hours 60 minutes Shut down or idle

Emission malfunction lamp will flash

World-Wide

Emission malfunction lamp will flash The stop lamp will be on solid

Until fault heals

Cycling the keyswitch will give 20 minutes of full power

Emission malfunction lamp will flash

Cycling the keyswitch will give 20 minutes of full power

(continued)

Page 39

SEBU8732 39

Features and Controls

Selective Catalytic Reduction Warning System

(Table 5, contd)

Repeat Inducement time

Inducement None None None

Notification None Emission malfunction

Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.

None 48 minutes 20 minutes Shut down or idle

lamp will be on solid

Emission malfunction lamp will flash

World-Wide DEF Level Warnings

Two options are available but only one option will be enabled.

• The low-level warning lamp will operate when DEF

level reaches the trigger point of below 19 percent.

• At Level 1 the low-level warning lamp in the DEF

gauge will illuminate and the emission malfunction lamp will be on solid.

• At Level 2 the low-level warning lamp for the DEF

is active and the emission malfunction lamp will flash.

• At Level 3 all level 2 warning are operating, plus

the stop lamp will become activate. The engine will shut down or will only operate at 1000 RPM.

Until fault heals

Emission malfunction lamp will flash The stop lamp will activate

Cycling the keyswitch will give 20 minutes of full power

Emission malfunction lamp will flash

Filling the DEF tank will remove the warning from the system.

Table 6

World-Wide DEF Level Option 1

Inducement Trigger Above 19 percent Below 19 percent Below 12.5 percent 0 Percent reading Empty tank

Inducement None None None 25 percent torque de-

Notification None Low-level lamp

Table 7

Inducement Trigger Above 19 percent Below 19 percent Below 12.5 percent 6 Percent reading 0 Percent reading

Normal operation Initial indication Level 1 Level 2 Level 3

rate

illuminated

World-Wide DEF Level Option 2

Normal operation Initial indication Level 1 Level 2 Level 3

Low-level lamp illuminated Emission malfunction lamp on solid

Low-level lamp illuminated Emission malfunction lamp flashing

Shut down or idle only

Low-level lamp illuminated Emission malfunction lamp flashing Stop lamp on solid

(continued)

Page 40

40 SEBU8732 Features and Controls

Battery Disconnect Switch

(Table 7, contd)

Inducement None None None None Shut down or idle only

Notification None Low-level lamp

illuminated

i05408886

Battery Disconnect Switch

(If Equipped)

Allow at least 2 minutes after the engine has stopped before you turn the battery disconnect switch to OFF. Disconnecting the battery power too soon will prevent purging of the Diesel Exhaust Fluid (DEF) lines after the engine is shut down. Also, during the 2 minutes the engine Electronic Control Module (ECM) is active storing information from the engine and aftertreatment sensors.

Not allowing the DEF purge to be performed can damage the DEF system. Not allowing the engine ECM time to store the information from the sensors

can damage to emission control system.

Some applications, the engine can be equipped with a wait to disconnect lamp. The wait to disconnect lamp will be illuminated during engine operation and will be extinguished approximately 2 minutes after the engine has stopped.

Low-level lamp illuminated Emission malfunction lamp on solid

Low-level lamp illuminated Emission malfunction lamp flashing

Low-level lamp illuminated Emission malfunction lamp flashing Stop lamp on solid

NOTICE Never move the battery disconnect switch to the OFF position while the engine is operating. Serious damage to the electrical system could result.

Gauges and Indicators

Your engine may not have the same gauges or all of 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 normal operating range by observing the gauges over a period.

Noticeable changes in gauge readings indicate potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the readings are within specifications. Determine and correct the cause of any significant change in the readings. Consult your Perkins dealer or your Perkins distributor for assistance.

i05194972

Illustration 36 g03265058

Battery disconnect switch label

NOTICE Do not turn off the battery disconnect switch until the indicator lamp has turned off. If the switch is turned off when the indicator lamp is illuminated the Diesel Exhaust Fluid (DEF) system will not purge the DEF. If the DEF does not purge, DEF could freeze and damage the pump and lines.

Some engine applications are equipped with Indicator Lamps. Indicator lamps can be used as a diagnostic 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 indicator lamps can be used to identify the current operational status of the engine. The indicator lamps can also indicate that the engine has a fault. This system is automatically operated via the ignition switch.

• The indicator lamps can be used to identify active diagnostic codes. This system is activated by pressing the Flash Code button.

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

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

Page 41

SEBU8732 41

Features and Controls

Gauges and Indicators

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

started. The typical engine oil pressure with SAE10W40 is 350 to 450 kPa ( 50 to 65 psi) at rated rpm.

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

1. Remove the load.

2. Stop the engine.

3. Check and maintain the oil level.

Jacket Water Coolant Temperature –

Typical temperature range is 82° to 94°C

(179.6° to 169.2°F). This temperature range will vary according to engine load and the ambient temperature.

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

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/

STOP”” switch is in the ““on”” position.

Service Hour Meter – The gauge indicates total operating hours of the engine.

Indicator Lamps

• Shutdown lamp

• Warning lamp

• Low oil pressure lamp

• Wait to start lamp (Glow plug warning lamp)

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

The function of the wait to start lamp is automatically controlled at engine start-up.

If the engine is operating above the normal range, reduce the engine load. If high coolant temperatures are a frequent event, perform the following procedures:

1. Reduce the load on the engine.

2. Determine if the engine must be shut down

immediately or if the engine can be cooled by reducing the load.

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

consult your Perkins dealer or your Perkins distributor for assistance.

Tachometer – This gauge indicates

engine speed (rpm). When the throttle

control lever is moved to the full throttle position without load, the engine is running at high idle. The engine is running at the full load rpm when the throttle control lever is at the full throttle position with maximum rated load.

NOTICE 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.

The function of the low oil pressure lamp is controlled by the engine ECM. If low oil pressure is detected, the lamp will be illuminated. The reason for the illumination of the low-pressure lamp should be investigated immediately.

The glow plug warning lamp will flash in order to show that the engine is been held at low speed. This function will be performed at engine starting and the duration will depend on ambient temperature and engine temperature.

The lamps will illuminate for 2 seconds in order to check that the lamps are functioning when the keyswitch is turned to the ON position. If any of the lamps stay illuminated, or a lamp fails to be illuminated the reason should be investigated immediately.

Aftertreatment Lamps and gauges

All applications will require the following lamps and gauges:

• Emission malfunction lamp

• Action indicator lamp

• Gauge for Diesel Exhaust Fluid (DEF)

• Low warning lamp for DEF

• Wait to disconnect lamp (optional)

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42 SEBU8732 Features and Controls

Monitoring System

The wait to disconnect lamp will be illuminated during engine operation and will be extinguished approximately 2 minutes after the engine has stopped. Do not disconnect the battery disconnect switch during the period the lamp is illuminated. The diesel exhaust fluid system will be purged during this time. Also, during the 2 minutes the engine electronic control module is active storing information from the engine and aftertreatment sensors.

Note: The wait to disconnect lamp will not be checked at key on.

i05194981

Monitoring System

(Engine Indicators and Aftertreatment Indicators)

Engine Indicator Lamps

Note: When in operation the amber warning lamp has

three states, solid, flashing, and fast flashing. The sequence is to give a visual indication of the importance of the warning. Some application can have an audible warning installed.

Ensure that the engine maintenance is carried out at the correct intervals. A lack of maintenance can result

in illumination of the warning lamp. For the correct intervals of maintenance, refer to the Operation and Maintenance Manual, “Maintenance Interval

Schedule”.

Table 8

Indicator Lamp Table

Warning

Lamp

On On Lamp Check When the keyswitch is moved to the ON po-

Off Off No Faults With the engine in operation, there are no

On Solid Off Warning Level 1 warning The engine is operating normally but there is

Shutdown Action Indicator Lamp

If any of the indicators will not illuminate during indicator check, the fault must be investigated immediately

Lamp State Description of the Indication Engine Status

sition, the lamps come on for 2 seconds and the lamps will then go off.

If any Indicators stay illuminated or flash, the fault must be investigated immediately.

active warnings, diagnostic codes, or event codes.

The keyswitch is in the ON position but the engine has not yet been cranked.

The engine is operating with no detected faults.

one or more faults with the electronic management system for the engine.

As soon as possible the fault should be investigated.

(continued)

Page 43

SEBU8732 43

Features and Controls

Overspeed

(Table 8, contd)

Indicator Lamp Table

Warning

Lamp

Flashing Off Warning Level 2 warning The engine continues to be operated, but the

Flashing On Engine Shutdown Level 3 warning

Shutdown Action Indicator Lamp

Lamp State Description of the Indication Engine Status

level of importance of the warning has increased. Depending on the particular fault and the severity the engine may be de-rated. The engine could be damaged if continued to be operated.

Stop the engine. Investigate the code.

The engine is either shutdown or an engine If both the warning lamp and the shutdown lamp are in operation,this issue indicates one of the following conditions.

1. One or more of the shutdown values for the engine protection strategy has been exceeded.

2. A serious active diagnostic code has been detected.

If install, the audible warning will sound. After a short time period, the engine may shut down.

shutdown is imminent. One or more monitored

engine parameters have exceeded the limit for

an engine shutdown. This pattern of lamps can

be caused by the detection of a serious active

diagnostic code.

Contact your Perkins dealer or your Perkins

distributor.

Flash Codes

Some applications may support flash codes. A flash code can be viewed by an indicator lamp that when asked will flash in a particular sequence. The indicator lamp used to view the codes is the warning lamp, the lamp can then be refer to as a diagnostic lamp. For more information refer to this Operation and Maintenance Manual, “Diagnostic Lamp”.

Aftertreatment System

The aftertreatment indicators should illuminate at key on for 2 seconds in order to test the system. If any of the indicators do not illuminate, the fault must be

investigated immediately.

For more information on the illumination of the aftertreatment indicators refer to this Operation and

Maintenance Manual, “Selective Catalytic Reduction Warning System”.

i03554501

Overspeed

An overspeed is detected by the speed/timing sensors.

The default setting for an overspeed is 3000 rpm. The ECM will cut the power to the electronic unit injectors, until the rpm drops below 200 rpm of the overspeed setting. A diagnostic fault code will be logged into the ECM memory and a warning lamp will indicate a diagnostic fault code.

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

i05350563

Sensors and Electrical Components

The illustrations within the following sections are typical location of the sensors or electrical components for an industrial engine. Specific engines may appear different due to differences in applications.

• ECM Electronic Control Module

• RPM Revolutions Per Minute

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44 Features and Controls

Sensors and Electrical Components

Engine Components

SEBU8732

Illustration 37 g03389319

Typical example

(1) Coolant Temperature Sensor (2) Injector Connector for Number One and

Two Injectors

(3) Injector Connector for Number three and

Four Injectors

(4) Injector Connector for Number Five and

Six Injectors

(5) Fuel Pressure Sensor

(6) Inlet Manifold Air Temperature Sensor (7) Inlet Manifold Air Pressure Sensor (8) Glow Plug Connection (9) Diagnostic Connector (10) Electronic Control Module (11) Atmospheric Pressure Sensor

(Barometric Pressure sensor)

(12) Oil Pressure Sensor

(13) Primary Speed/Timing Sensor (14) Starter Solenoid (15) Starter relay (16) Starting Motor (17) Oil Level Switch (18) Fuel Temperature Sensor (19) Solenoid for High Pressure Fuel Pump

Page 45

SEBU8732

Features and Controls

Sensors and Electrical Components

Illustration 38 g03389322

Typical example

(20) Wastegate Regulator (21) Control Valve for the NOx Reduction

System (NRS)

(22) Temperature Sensor for the NRS (23) Intake Pressure for the NRS (24) Differential Pressure for the NRS

(25) Back Pressure Valve

Page 46

46 SEBU8732 Features and Controls

Sensors and Electrical Components

Illustration 39 g03389323

Typical example

(26) Alternator (27) Secondary Speed/Timing sensor (28) Exhaust Temperature Sensor

Page 47

SEBU8732

Features and Controls

Sensors and Electrical Components

Illustration 40 g03393046

Typical example

(29) Water in Fuel Switch (30) Inlet Air Temperature

Some applications do not require a diagnostic connector (9) installed in the engine wiring harness. The Inlet air temperature sensor (30) will be installed in the induction system between the air cleaner and the inlet manifold.

Illustration 41 g03058119

Typical example

(1) Coolant Temperature Sensor (2) Injector connector (3) Injector Connector

(4) Injector Connector (5) Fuel Pressure Sensor (6) Inlet Manifold TemperatureSensor

(7) Inlet Manifold Pressure Sensor (8) Glow Plug Connection

Page 48

48 SEBU8732 Features and Controls

Sensors and Electrical Components

Illustration 42 g03393011

Typical example

(9) Diagnostic connector (10) Electronic Control Module (11) Atmospheric Pressure Sensor (Barometric Pressure sensor) (12) Oil pressure sensor

Illustration 43 g03392999

Typical example

(13) Primary Speed/Timing Sensor

Page 49

SEBU8732 49

Features and Controls

Sensors and Electrical Components

Illustration 44 g03393000

Typical example

(14) Starter Solenoid (15) Starting Motor

(16) Starter Relay (17) Oil Level Switch

Illustration 45 g03393004

Typical example

(18) Fuel Temperature Sensor (19) Solenoid for High Pressure Fuel Pump

Page 50

50 SEBU8732 Features and Controls

Sensors and Electrical Components

Illustration 46 g03393005

Typical example

(20) Wastegate Regulator (21) Control Valve for NRS

(22) Temperature Sensor for the NRS (23) Intake Pressure for the NRS

(24) Differential Pressure for the NRS

Page 51

SEBU8732 51

Features and Controls

Sensors and Electrical Components

Illustration 47 g03393010

Typical example

(25) Back Pressure valve (26) Alternator

Page 52

52 SEBU8732 Features and Controls

Sensors and Electrical Components

Illustration 48 g03393006

Typical example

(27) Secondary Speed/Timing sensor (28) Exhaust Temperature Sensor

Page 53

SEBU8732 53

Features and Controls

Sensors and Electrical Components

Aftertreatment Components

Illustration 49 g03393078

Clean Emissions Module (CEM)

Illustration 50 g03393624

(1) Clean Emission Module (2) Gas Intake Temperature Sensor (3) Soot Sensor Antenna (4) Location for NOx Sensing Element (5) Soot Sensor Antenna (6) Diesel Exhaust Fluid Injector (7) Temperature Sensor Connector (8) Identification Module (9) Gas TemperatureSensor before Selective Catalytic Reduction

Page 54

54 Features and Controls

Sensors and Electrical Components

CEM Sensors

SEBU8732

Illustration 51 g03393632

(2) Gas Intake Temperature Sensor (3) Soot Sensor Antenna

Illustration 52 g03393634

(7) Temperature Sensor Connector (8) Identification Module

(4) Location for NOx Sensing Element (5) Soot Sensor Antenna

(9) Gas TemperatureSensor before

Selective Catalytic Reduction

(6) Diesel Exhaust Fluid Injector

Page 55

SEBU8732

Soot and NOx Sensors

Features and Controls

Sensors and Electrical Components

Illustration 53 g03393956

(10) Soot Sensor (11) NOx Sensors

The location of the soot sensor (10) and NOx sensor (11) will depend on the application.

Page 56

56 SEBU8732 Features and Controls

Sensors and Electrical Components

Pump Electronic Tank Unit (PETU)

Illustration 54 g03393959

(1) DEF Level Sensor and DEF Temperature

Sensor

(2) Coolant Diverter Valve

(3) Customer Connections (4) Dosing Control Module (5) Relays

(6) Voltage Limiting Protection Module

Page 57

SEBU8732

Features and Controls

Sensors and Electrical Components

Heated Line

Illustration 55 g03393960

Typical example

(7) Heated line

Page 58

58 SEBU8732 Engine Diagnostics

Self-Diagnostics

Engine Diagnostics

i05194988

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 Perkins electronic service tools.

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.

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.

i03554520

Diagnostic Lamp

A diagnostic lamp is used to indicate the existence of an active fault. A fault diagnostic code will remain active until the problem is repaired. The diagnostic code may be retrieved by using the electronic service tool.

i04907245

Diagnostic Flash Code Retrieval

Use the following procedure to retrieve the flash codes if the engine is equipped with a “DIAGNOSTIC” lamp:

1. Move the keyswitch from the on/off two times within 3 seconds.

2. The shutdown warning lamp will flash once.

3. A flashing YELLOW lamp indicates a 3-digit

diagnostic code for the engine. The sequence of flashes represents the system diagnostic message. Count the first sequence of flashes in order to determine the first digit of the flash code. After a two second pause, the second sequence of flashes will identify the second digit of the flash code. After the second pause, the third sequence of flashes will identify the flash code.

4. After the diagnostic codes have been displayed, the shutdown lamp will flash twice and the indicator lamp will start to flash the logged diagnostic codes.

5. After the logged diagnostic codes have been displayed, the shutdown lamp will flash three times in order to indication that the code sequences have finished.

Note: If there are no diagnostic codes or logged diagnostic codes, the system will flash the code 551.

i05406659

Fault Logging

The system provides the capability of Fault Logging. When the Electronic Control Module (ECM) generates an active diagnostic code, the code will be logged in the memory of the ECM. The codes that have been logged by the ECM can be identified by the electronic service tool. The active codes that have

been logged will be cleared when the fault has been rectified or the fault is no longer active. The following logged faults cannot be cleared from the memory of the ECM without using a factory password: Overspeed, low engine oil pressure, high engine coolant temperature, and aftertreatment codes.

i03554534

Engine Operation with Active Diagnostic Codes

If a diagnostic lamp illuminates during normal engine operation, the system has identified a situation that is not within the specification. Use electronic service tools to check the active diagnostic codes.

Page 59

SEBU8732 59

Engine Diagnostics

Engine Operation with Intermittent Diagnostic Codes

Note: If the customer has selected “DERATE” and if there is a low oil pressure condition, the Electronic Control Module (ECM) will limit the engine power until the problem is corrected. If the oil pressure is within the normal range, the engine may be operated at the rated speed and load. However, maintenance should be performed as soon as possible.

The active diagnostic code should be investigated. The cause of the problem should be corrected as soon as possible. If the cause of the active diagnostic code is repaired and there is only one active diagnostic code, the diagnostic lamp will turn off.

Operation of the engine and performance of the engine can be limited as a result of the active diagnostic code that is generated. Acceleration rates may be significantly slower. Refer to the Troubleshooting Guide for more information on the relationship between these active diagnostic codes and engine performance.

i01797063

Engine Operation with Intermittent Diagnostic Codes

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.

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

In most cases, it is not necessary to stop the engine because of an intermittent code. However, the

operator should retrieve the logged fault codes and the operator should reference the appropriate information in order to identify the nature of the event. The operator should log any observation that could have caused the lamp to light.

• Low power

• Limits of the engine speed

• Excessive smoke, etc

This information can be useful to help troubleshoot the situation. The information can also be used for

future reference. For more information on diagnostic codes, refer to the Troubleshooting Guide for this engine.

i05402551

Configuration Parameters

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

Page 60

60 SEBU8732 Engine Diagnostics

Configuration Parameters

Table 9

System Configuration Parameters

Configuration Parameters Record

Engine Serial Number

Factory Installed Aftertreatment #1 Identification Number

DPF #1 Soot Loading Sensing System Configuration Code

Limp Home Engine Speed Ramp Rate

System Operating Voltage Configuration

Rating Number

CAN Communication Protocol Write Security

Engine Emissions OperatorInducement Progress Configuration

Engine Emissions OperatorInducement Regulation Configuration

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 10

Customer Specified Parameters

Specified Parameters Record

Throttle Type Channel 1

Throttle Type Channel 2

IVS Channel 1

IVS Channel 2

Continuous Position Throttle Configuration 1

Continuous Position Throttle Configuration 2

Multi Position Throttle Switch Configuration

Throttle Arbitration

Equipment ID

Low Idle Speed

Delay Engine Shutdown

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

(continued)

Page 61

SEBU8732 61

Engine Diagnostics

Configuration Parameters

(Table 10, contd)

Engine Idle Shutdown Ambient Temperature Override Enable Status

High Soot Load Aftertreatment Protection Enable Status

Air Shutoff

Throttle Lock FeatureInstallation 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

Limp Home Desired Engine Speed

Engine Acceleration Rate

Engine Speed Decelerating Ramp Rate

Intermediate Engine Speed

Fan

Engine Fan Control

Engine Fan Type Configuration

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 Cooler Outlet Temperature

Engine Cooling Fan Control Coolant Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Coolant Temperature

(continued)

Page 62

62 SEBU8732 Engine Diagnostics

Configuration Parameters

(Table 10, contd)

Engine Cooling Fan Minimum Air Flow Coolant Temperature

Engine Cooling Fan Control Transmission Oil Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Transmission Oil Temperature

Engine Cooling Fan Minimum Air Flow Transmission Oil Temperature

Engine Cooling Fan Control Hydraulic Oil TemperatureInput 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

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

Remote Torque Speed Control Enable Status

Number of Engine Operating Mode Switches

Engine Operating Mode Configuration

Glow Plug Start Aid Installation Status

High Idle Configuration

Throttle Channel 1 Droop %

Throttle Channel 2 Droop %

TSC 1 Droop %

Min Max / All Speed Governing

Rated Speed Configuration

Page 63

SEBU8732 63

Engine Starting

Before Starting Engine

Engine Starting

i04935860

Before Starting Engine

Perform the required daily maintenance and other periodic maintenance before the engine is started. Inspect the engine compartment. This inspection can help prevent major repairs at a later date. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information.

• Ensure that the engine has an adequate fuel supply.

• Ensure that the engine has an adequate diesel exhaust fluid supply

• Open the fuel supply valve (if equipped).

NOTICE All valves in the fuel return line must be open and fuel supply lines must be open. Damage to the fuel system can occur if fuel lines are closed with the engine in operation.

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”.

i05360375

Cold Weather Starting

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

The ability to start the engine will be improved at temperatures below −18 °C (0 °F) from the use of a jacket water heater or extra battery capacity.

The following items provide a means of minimizing starting problems and fuel problems in cold weather: Engine oil pan 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 the engine speed during start-up.

1. Disengage any driven equipment.

Note: During key ON, the indicator lamps will be

illuminated for 2 seconds in order to check the lamp operation. If any of the indicator lamps do not illuminate check the bulb. If any indicator lamps stay illuminated or flash, refer to Troubleshooting, “Indicator Lamp Circuit - Test”.

2. Turn the keyswitch to the RUN position. Leave the keyswitch in the RUN position until the warning light for the glow plugs is extinguished.

Engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the outside.

• Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls.

• Reset all of the shutoffs or alarm components.

• Ensure that any driven equipment has been disengaged. Minimize electrical loads or remove any electrical loads.

3. When the warning light for the glow plugs is extinguished cycle the keyswitch. Turn the keyswitch to the OFF position and then to the START position in order to engage the electric starting motor and crank the engine.

Note: The operating period of the warning light for the glow plugs will change due to the ambient air temperature.

NOTICE 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 al-

low the starting motor to cool before attempting to start the engine again.

Page 64

64 SEBU8732 Engine Starting

Starting 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: After starting, the engine may be held at low speed for a duration between 1 and 25 seconds to allow engine systems to stabilize. The duration will depend on ambient temperature, time since last run and other factors. The glow plug warning lamp will flash in order to indicate that the engine is been held at low speed.

6. The engine should not be raced in order to speed up the warm-up process. Allow the engine to idle for 3 to 5 minutes, or allow the engine to idle until the water temperature indicator begins to rise. When idling after the engine has started in cold weather, increase the engine rpm from 1000 to 1200 rpm. This operation will warm up the engine more quickly.

7. Operate the engine at low load until all systems reach operating temperature. Check the gauges during the warm-up period.

Following a cold start white smoke can be seen from the tailpipe. This smoke is normal and caused by condensation leaving the exhaust system after warming up. The white smoke should clear following working of the engine.

i05354322

Note: The operating period of the warning light for the glow plugs will change due to the temperature of the engine.

NOTICE 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 al-

low the starting motor to cool before attempting to start the engine again.

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.

6. After starting, the engine may be held at low speed

for a duration between 1 and 25 seconds to allow engine systems to stabilize. The duration will depend on ambient temperature, time since last run and other factors. The glow plug warning light will flash in order to indicate that the engine is been held at low speed.

Starting the Engine

Note: Do not adjust the engine speed control during

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 keyswitch in the RUN position until the warning light for the glow plugs is extinguished.

Note: During the key on, the indicator lamps will be illuminated for 2 seconds in order to check lamp operation. If any of the lamps do not illuminate, check the bulb. If any indicator lamps stay illuminated or flash, refer to Troubleshooting, “Indicator Lamp Circuit - Test”.

i03663103

Starting with Jump Start Cables

Improper jump start cable connections can cause an explosion resulting in personal injury.

Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jump start

cable ends to contact each other or the engine.

Page 65

SEBU8732 65

Engine Starting

After Starting Engine

Note: If it is possible, first diagnose the reason for the starting failure. Refer to Troubleshooting, “Engine Will Not Crank and Engine Cranks But Will Not Start” for further information. Make any necessary repairs. If the engine will not start only due to the condition of the battery, either charge the battery, or start the engine by using another battery with jump start cables. The condition of the battery can be rechecked after the engine has been switched OFF.

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.

After jump starting, the alternator may not be able to fully recharge batteries that are severely discharged. The batteries must be replaced or charged to the proper voltage with a battery charger after the engine is stopped. Many batteries which are considered unusable are still rechargeable. Refer to Operation and Maintenance Manual, “Battery - Replace” and Testing and Adjusting Manual, “Battery - Test”.

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After Starting Engine

After starting, the engine may be held at low speed for a duration between 1 and 25 seconds to allow

engine systems to stabilize. The duration will depend on ambient temperature, time since last run and other factors.

Note: In ambient temperatures from 0 to 60°C (32 to 140°F), the warm-up time is approximately 3 minutes. In temperatures below 0°C (32°F), additional warm-up time may be required.

When the engine idles during warm-up, observe the following conditions:

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.

3. Connect one negative end of the jump start cable

to the negative cable terminal of the electrical source. Connect the other negative end of the jump start cable to the engine block or to the chassis ground. This procedure helps to prevent potential sparks from igniting the combustible gases that are produced by some batteries.

Note: The engine ECM must be powered before the starting motor is operated or damage can occur.

4. Start the engine in the normal operating procedure.

Refer to this Operation and Maintenance Manual, “Starting the Engine”.

5. Immediately after the engine is started, disconnect

the jump start cables in reverse order.

Do not check the high-pressure fuel lines with the engine or the starting motor in operation. 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”.

• Check for any fluid or for any air leaks at idle rpm and at one-half full rpm (no load on the engine) before operating the engine under load. This check may not possible in some applications.

• Allow the engine to idle for 3 to 5 minutes, or allow the engine to idle until the water temperature indicator begins to rise. Check all gauges during the warm-up period.

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

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66 SEBU8732 Engine Operation

Engine Operation

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Engine Operation

Proper operation and maintenance are key factors in obtaining the maximum life and economy of the engine. If the directions in the Operation and Maintenance Manual are followed, costs can be

minimized and engine service life can be maximized.

The time that is needed for the engine to reach 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 operating temperature. The engine will reach normal operating temperature sooner during a low engine speed (rpm) and during a low-power demand. This procedure is more effective than idling the engine 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 Particulate Filter (DPF). These issues are harmful to the engine.

The DPF may require the exhaust gas temperature to rise in order to remove the soot. If necessary, the back pressure valve operates in order to create the rise in temperature. In some applications, the operation of the back pressure valve will make the engine tone different.

The engine software will control the amount of DEF that will be required in order to keep the exhaust emission compliant.

This design of DPF will not require a service maintenance interval. The DPF can be expected to function properly for the useful life of the engine (emissions durability period), as defined by regulation, subject to prescribed maintenance requirements being followed.

i01646335

Engaging the Driven Equipment

1. Operate the engine at one-half of the rated rpm,

when possible.

2. Engage the driven equipment without a load on the

equipment, when possible.

Gauge readings should be observed and the data should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge. Comparing data over time will also help detect abnormal operating developments. Significant changes in the readings should be investigated.

Engine Operation and the Aftertreatment System

The exhaust gases and hydrocarbon particles from the engine first pass through Diesel Oxidation Catalyst (DOC). Some of the gasses and matter are oxidized as they pass through the DOC. The gasses then pass through the Diesel Particulate Filter (DPF). The DPF collects the soot and any ash that is produced by the combustion in the engine. During regeneration, the soot is converted into a gas and the ash remains in the DPF. The gasses finally pass through the Selective Catalytic Reduction (SCR). Before the gasses pass through the SCR, Diesel Exhaust Fluid (DEF) is injected into the gas stream. The DEF is stored and controlled by the Pump Electronic Tank Unit (PETU). The mixtures of DEF and the exhaust gas pass through the SCR reducing the NOx in the exhaust emissions.

Interrupted starts put excessive stress on the drive train. Interrupted starts also waste fuel. To get the driven equipment in motion, engage the clutch smoothly with no load on the equipment. This method should produce a start that is smooth and easy. The engine rpm should not increase and the clutch should not slip.

3. Ensure that the ranges of the gauges are normal

when the engine is operating at one-half of the rated rpm. Ensure that all gauges operate properly.

4. Increase the engine rpm to the rated rpm. Always

increase the engine rpm to the rated rpm before the load is applied.

5. Apply the load. Begin operating the engine at low

load. Check the gauges and equipment for proper operation. After normal oil pressure is reached and the temperature gauge begins to move, the engine may be operated at full load. Check the gauges and equipment frequently when the engine is operated under load.

Extended operation at low idle or at reduced load may cause increased oil consumption and carbon buildup in the cylinders. This carbon buildup results in a loss of power and/or poor performance.

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SEBU8732 67

Engine Operation

Fuel Conservation Practices

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Fuel Conservation Practices

The efficiency of the engine can affect the fuel economy. Perkins design and technology in manufacturing provides maximum fuel efficiency in all applications. Follow the recommended procedures in order to attain optimum performance for the life of the engine.

• Avoid spilling fuel.

Fuel expands when the fuel is warmed up. The fuel 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 Operations and Maintenance Manual, “Fuel Recommendations”for further information.

• Avoid unnecessary idling.

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

• Observe the service indicator frequently. Keep the air cleaner elements clean.

• Ensure that the turbocharger is operating correctly. For more information refer to this Operation and Maintenance Manual, “Turbocharger - Inspect”

• Maintain a good electrical system.

One faulty battery cell will overwork the alternator. This fault will consume excess power and excess fuel.

• The belt should be in good condition. Refer to the 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 system, when possible. Keep cooling system components clean and keep cooling system components in good repair. Never operate the engine without water temperature regulators. All of these items will help maintain operating temperatures.

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68 SEBU8732 Cold Weather Operation

Cold Weather Operation

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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 coldweather 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).

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

• Weather conditions

• Engine applications

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.

• Install the correct specification of engine lubricant before the beginning of cold weather. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” for the recommended viscosity of oil.

• Check all rubber parts (hoses, fan drive belts,) weekly.

• Check all electrical wiring and connections for any fraying or damaged insulation.

• Keep all batteries fully charged and warm by ensuring that the engine is allowed to operated at normal operating temperature.

• 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 Troubleshooting, “Glow Plug Starting AidTest”.

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.

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 property damage.

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

• For jump starting with cables in cold weather, refer to the Operation and Maintenance Manual, “Starting with Jump Start Cables.” for instructions.

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SEBU8732 69

Cold Weather Operation Cold Weather Operation

Viscosity of the Engine Lubrication Oil

Correct engine oil viscosity is essential. Oil viscosity affects lubrication properties and wear protection that the oil provides for 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.

In cold weather, check the coolant often for the correct glycol concentration in order to ensure

adequate freeze protection.

Engine Block Heaters

Engine block heaters (if equipped) heat the engine jacket water that surrounds the combustion chambers. This heat provides the following functions:

• Startability is improved.

• Warm up time is reduced.

An electric block heater can be activated once the engine is stopped. A block heater can be 110 V dc or

240 V dc. The output can be 750/1000W. Consult your Perkins dealer or your Perkins distributor for more information.

Recommendations for Coolant Warm Up

Warm up an engine that has cooled below normal operating temperatures due to inactivity. This warm

-up should be performed before the engine is

returned to full operation. During operation in very cold temperature conditions, damage to engine valve mechanisms can result from engine operation for short intervals. This damage can happen if the engine is started and the engine is stopped many 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 in the combustion chamber. This fuel and oil causes

soft carbon deposits to form on the valve stems. Generally, the deposits do not cause problems and the deposits are burned off during operation at normal engine operating temperatures.

When starting and stopping an engine many times without being operated in order to warm up completely, the carbon deposits become thicker. This starting and stopping can cause the following problems:

• Free operation of the valves is prevented.

• Valves become stuck.

• Pushrods may become bent.

• Other damage to valve train components can result.

Idling the Engine

After starting the engine, the engine speed will be governed for a maximum period of 25 seconds. When idling after the engine is started in cold weather, increase the engine rpm from 1000 to 1200 rpm. This idling will warm up the engine more quickly. Maintaining an elevated low idle speed for extended periods will be easier with the installation of a hand 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 minimum operating temperature. The minimum operating temperature is 80° C (176° F).

For this reason, when the engine is started, the engine must be operated until the coolant temperature is 80° C (176° F) minimum. Carbon deposits on the valve stems will be kept at a minimum 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 life of the engine will be generally extended. Lubrication will be improved. There will be less acid and less sludge in the oil. This condition will provide longer service life for the engine bearings, the piston rings, and other parts. However, limit unnecessary idle time to 10 minutes in order to reduce wear and

unnecessary fuel consumption.

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70 SEBU8732 Cold Weather Operation

Radiator Restrictions

The Water Temperature Regulator and Insulated Heater Lines

The engine is equipped with a water temperature regulator. When the engine coolant is below the correct operating temperature, jacket water circulates through the engine cylinder block and into the engine cylinder head. The coolant then returns to the cylinder block via an internal passage that bypasses the valve of the coolant temperature regulator. This return ensures that coolant flows around the engine under cold operating conditions. The water temperature regulator begins to open when the engine jacket water has reached the correct minimum operating temperature. As the jacket water coolant temperature rises above the minimum operating temperature, the water temperature regulator opens further allowing more coolant through the radiator to dissipate excess heat.

The progressive opening of the water temperature regulator operates the progressive closing of the bypass passage between the cylinder block and head. This action ensures maximum coolant flow to

the radiator in order to achieve maximum heat dissipation.

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

A cab heater is beneficial in very cold weather. The feed from the engine and the return lines from the cab should be insulated in order to reduce heat loss to the

outside air.

Recommendation for Crankcase Breather Protection

Crankcase ventilation gases contain a large quantity of water vapor. This water vapor can freeze in cold ambient conditions and can plug or damage the crankcase ventilation system. If the engine is operated in temperatures below −25° C (−13° F), measures must be taken to prevent freezing and plugging of the breather system. An open breather system will operate more effectively in temperatures below −25° C (−13° F). In extreme weather conditions insulating the breather hose will help to protect the system.

Consult with your Perkins dealer or your Perkins distributer for the recommended breather

components for operation from −25° to -40°C (−13° to -72.°F).

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Radiator Restrictions

Perkins discourages the use of airflow restriction devices that are mounted in front of radiators. Airflow

restriction can cause the following conditions:

• High exhaust temperatures

• Power loss

• Excessive fan usage

• Reduction in fuel economy

Reducing air flow over components will also affect under hood temperatures. Reducing air flow can increase surface temperatures during an aftertreatment regeneration and could affect component reliability.

Reducing air flow can increase surface temperatures during an aftertreatment regeneration and could affect component reliability.

If an airflow restriction device must be used, the device should have a permanent opening directly in

line with the fan hub. The device must have a minimum opening dimension of at least 770 cm

(120 in2).

A centered opening that is directly in line with the fan hub is specified in order to prevent an interrupted airflow on the fan blades. Interrupted airflow on the fan blades could cause a fan failure.

Perkins recommends a warning device for the inlet manifold temperature and/or the installation of an inlet air temperature gauge. The warning device for the inlet manifold temperature should be set at 75 °C (167 °F). The inlet manifold air temperature should not exceed 75 °C (167 °F). Temperatures that exceed this limit can cause power loss and potential engine damage.

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, “Fluid Recommendations”.

The following components provide a means of minimizing problems in cold weather:

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SEBU8732 71

Cold Weather Operation

Fuel Related Components in Cold Weather

• Glow plugs (if equipped)

• Engine coolant heaters, which may be an OEM option

• Fuel heaters, which may be an OEM option

• Fuel line insulation, which may be an OEM option

The cloud point is a temperature that allows wax crystals to form in the fuel. These crystals can cause the fuel filters to plug.

The pour point is the temperature when diesel fuel will thicken. The diesel fuel becomes more resistant to

flow through fuel lines, fuel filters,and fuel pumps.

Be aware of these facts when diesel fuel is purchased. Consider the average ambient air

temperature for the engine's application. Engines that are fueled in one climate may not operate well if the engines are moved to another climate. Problems can result due to changes in temperature.

Before troubleshooting for low power or for poor performance in the winter, check the fuel for waxing.

Low temperature fuels may be available for engine operation at temperatures below 0 °C (32 °F). These 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 Weather Operation and Fuel Related Components in Cold Weather”.

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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.

Drain the water and sediment from any fuel storage tank at the following intervals: weekly, service intervals and refueling of the fuel tank. Draining will help prevent water and/or sediment from being pumped from the fuel storage tank and into the engine fuel tank.

Fuel Filters

After you change the fuel filter, always prime the fuel system in order to remove air bubbles from the fuel system. Refer to the Operation and Maintenance Manual in the Maintenance Section for more

information on priming the fuel system.

The micron rating and the location of a primary fuel filter is important in cold-weather operation. The Inline filter, primary fuel filter, and the fuel supply line are the most common components that are affected by cold fuel.

Fuel Heaters

Note: The OEM may equip the application with fuel

heaters. If so, the temperature of the fuel must not exceed 73 °C (163 °F) at the fuel transfer pump. The fuel heater should be installed before the electric lift pump.

For more information about fuel heaters (if equipped), refer to the OEM information.

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Diesel Exhaust Fluid in Cold Weather

Due to the freezing point of Diesel Exhaust Fluid (DEF) the aftertreatment system is equipped with electrically heated DEF lines. The system also has a coolant heated element in the DEF tank. For

information on DEF refer to this Operation and Maintenance Manual, “Fluid Recommendations”.

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 pipe.

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

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72 SEBU8732 Engine Stopping

Stopping the Engine

Engine Stopping

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Stopping the Engine

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

Avoid accelerating the engine prior to shutting down the engine.

Avoiding hot engine shutdowns will maximize turbocharger shaft and bearing life. Also, selective catalytic reduction component 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 to low idle. Allow the engine to idle for 5 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 keyswitch to the OFF position. If necessary, refer to the instructions that are provided by the OEM.

Note: Some applications the engine will continue to operate after the keyswitch is turned to the OFF position. The engine will operate for a short time in order to allow engine components to cool.

3. Allow at least 2 minutes after the engine has

stopped before you turn the battery disconnect switch to OFF. Disconnecting the battery power too soon will prevent purging of the DEF fluid lines after the engine is shut down. Also, during the 2 minutes the engine electronic control module is active, storing information from the engine and aftertreatment sensors.

Delayed Engine Shutdown (if Equipped)

Note: There may be regulations that define the

requirements for the operator and/or support personnel to be present when the engine is running.

Leaving the machine unattended when the engine is running may result in personal injury or death. Before leaving the machine operator station, neutralize the travel controls, lower the work tools to the ground and deactivate all work tools, and place the lever for the hydraulic lockout control in the LOCKED position.

Leaving the engine unattended while running may result in property damage in the event of a malfunction.

Note: An authorized dealer can change the maximum run time value up to 30 minutes but the default setting is 10 minutes.

An override can be enabled so that the delayed engine shutdown will not operate. Overriding delayed engine shutdown may reduce engine and system component life. The override is operated by the keyswitch.

At any time during a delayed engine shutdown, the engine start switch may be turned to the ON position. The engine may be placed back into service.

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Emergency Stopping

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.

The delayed engine shutdown allows the engine to run for a time after the engine start switch is turned to the OFF position in order to cool the system components. The engine start switch key may be removed.

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SEBU8732 73

Engine Stopping

After Stopping Engine

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After Stopping Engine

Note: Before you check the engine oil, do not operate

the engine. Wait for at least 10 minutes after the engine has stopped in order to allow the engine oil to return to the oil pan.

• Diesel Exhaust Fluid (DEF) purge, do not disconnect the battery disconnect switch until the DEF purge has been completed. The procedure is automatically controlled and will take approximately 2 minutes.

• 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. If necessary, perform minor adjustments. Repair any leaks from the low-pressure fuel system and from the cooling, lubrication, or air systems. Replace any high-pressure fuel line that has leaked. Refer to Disassembly and Assembly Manual, “Fuel Injection Lines - Install”.

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.

• Allow the engine to cool. Check the coolant level.

• Check the coolant for correct antifreeze protection 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 instructions from the OEM.

• Check the crankcase oil level. Maintain the oil level between the “MIN” mark and the “MAX” mark on the engine oil level gauge.

• If the engine is equipped with a service hour meter, note the reading. Perform the maintenance that is in the Operation and Maintenance Manual, “Maintenance Interval Schedule”.

• Fill the fuel tank, in order to help prevent accumulation of moisture in the fuel. Do not overfill the fuel tank.

• Fill the DEF tank, a low level of DEF in the tank can result in engine de-rate.

NOTICE Only use antifreeze/coolant mixtures recommended in this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic or in this Operation and Maintenance Manual, “Fluid Recommendations” topic. Failure to do so can cause engine damage.

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74 Maintenance Section

Refill Capacities

SEBU8732

Maintenance Section

Refill Capacities

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Refill Capacities

Lubrication System

The refill capacities for the engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters. Auxiliary oil filter systems will require additional oil. Refer to the 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 11

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 filters will require additional oil. Refer to the OEM specifications 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

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 12

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)

Minimum Maximum

13.5 L

(3.56 US gal)

16.5 L

(4.36 US gal)

Liters

15 L

(3.96 US gal)

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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 Frequently check the specific gravity of the coolant for proper freeze protection or for anti-boil protection.

Clean the cooling system for the following reasons:

• Contamination of the cooling system

• Overheating of the engine

• Foaming of the coolant

NOTICE 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.

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

Water is used in the cooling system in order to transfer heat.

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SEBU8732

Refill Capacities

Fluid Recommendations

Distilled water or deionized water is recommended for use in engine cooling systems.

DO NOT use the following types of water in cooling 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

13 .

Table 13

Acceptable Water

Property

Chloride (Cl) 40 mg/L

Sulfate (SO

Total Hardness

Total Solids

Acidity pH of 5.5 to 9.0

) 100 mg/L

Maximum Limit

170 mg/L

340 mg/L

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

• Local water utility company

• Agricultural agent

• Independent laboratory

Additives

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 −13 °C (8.6 °F).

Most conventional antifreezes use ethylene glycol. Propylene glycol may also be used. In a 1:1 mixture with water, ethylene and propylene glycol provide similar protection against freezing and boiling. Refer to Table 14 and refer to table 15 .

Table 14

Ethylene Glycol

Concentration Freeze Protection

50 Percent

60 Percent

−36 °C (−33 °F)

−51 °C (−60 °F)

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. Over concentration 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

• Leakage of the water pump seal

• Plugging of radiators, coolers, and small passages

NOTICE 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 15

Propylene Glycol

Concentration Freeze Protection

50 Percent

−29 °C (−20 °F)

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

Coolant Recommendations

• ELC Extended Life Coolant

• SCA Supplement Coolant Additive

• ASTM American Society for Testing and

Materials

The following two coolants are used in Perkins diesel engines:

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76 SEBU8732 Refill Capacities

Fluid Recommendations

Preferred – Perkins 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.

Perkins recommends a 1:1 mixture of water and glycol. This mixture of water and glycol will provide

optimum heavy-duty performance as an antifreeze. This ratio may be increased to 1:2 water to glycol if extra freezing protection is required.

A mixture of SCA inhibitor and water is acceptable but will not give the same level of corrosion, boiling and, freezing protection as ELC. Perkins recommends a 6 percent to 8 percent concentration of SCA in those cooling systems. Distilled water or deionized water is preferred. Water which has the recommended properties may be used.

Table 16

Coolant Service Life

Coolant Type

Perkins ELC

Commercial Heavy-Duty Anti-

freeze that meets ASTM

Commercial SCA inhibitor and

(1)

Use the interval that occurs first. The cooling system must also be flushed out at this time.

D6210

Water

3000 Service Hours or Two Year

3000 Service Hours or One Year

Service Life

6,000 Service Hours or Three

Years

(1)

The anti-corrosion package for ELC is different from the anti-corrosion package for other coolants. ELC is an ethylene glycol base coolant. However, ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite. Perkins ELC has been formulated with the correct amount of these

additives in order to provide superior corrosion protection for all metals in engine cooling systems.

ELC is available in a premixed cooling solution with distilled water. ELC is a 1:1 mixture. The Premixed

ELC provides freeze protection to −36 °C (−33 °F). The Premixed ELC is recommended for the initial fill

of the cooling system. The Premixed ELC is also recommended for topping off the cooling system.

Containers of several sizes are available. Consult your Perkins distributor for the part numbers.

ELC Cooling System Maintenance

Correct additions to the Extended Life Coolant

NOTICE 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

recommended concentration of ELC. Lowering the proportion of antifreeze lowers the proportion of additive. This will lower the ability of the coolant to protect the system from pitting, from cavitation, from erosion, and from deposits.

NOTICE Do not use a conventional coolant to top-off a cooling system that is filled with Extended Life Coolant (ELC).

Do not use standard supplemental coolant additive (SCA).

ELC

Perkins provides ELC for use in the following applications:

• Heavy-duty spark ignited gas engines

• Heavy-duty diesel engines

• Automotive applications

When using Perkins ELC, do not use standard SCA's or SCA filters.

ELC Cooling System Cleaning

Note: If the cooling system is already using ELC,

cleaning agents are not required to be used at the specified coolant change interval. Cleaning agents are only required if the system has been contaminated by the addition of some other type of coolant or by cooling system damage.

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Fluid Recommendations

Clean water is the only cleaning agent that is required when ELC is drained from the cooling system.

Before the cooling system is filled, the heater control (if equipped) must be set to the HOT position. Refer to the OEM in order to set the heater control. After the

cooling system is drained and the cooling system is refilled, operate the engine until the coolant level reaches the normal operating temperature and until the coolant level stabilizes. As needed, add the

coolant mixture in order to fill the system to the specified level.

Changing to Perkins ELC

To change from heavy-duty antifreeze to the Perkins ELC, perform the following steps:

NOTICE Care must be taken to ensure that all fluids are contained during performance of inspection, maintenance, testing, adjusting and the 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.

Note: The cooling system cleaner must be thoroughly flushed from the cooling system. Cooling system cleaner that is left in the system will contaminate the coolant. The cleaner may also corrode the cooling system.

8. Repeat Steps 6 and repeat steps 7 until the system is completely clean.

9. Fill the cooling system with the Perkins Premixed ELC.

ELC Cooling System Contamination

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:

1. Drain the coolant into a suitable container.

2. Dispose of the coolant according to local

regulations.

3. Flush the system with clean water in order to remove any debris.

4. Use an appropriate cleaner to clean the system. Follow the instruction on the label.

5. Drain the cleaner into a suitable container. Flush the cooling system with clean water.

6. Fill the cooling system with clean water and operate the engine until the engine is warmed to 49° to 66°C (120° to 150°F).

NOTICE 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 completely flush the cooling system with clear water. Continue to flush the system until all the signs of the cleaning agent are gone.

• 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.

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

7. Drain the cooling system into a suitable container and flush the cooling system with clean water.

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78 SEBU8732 Refill Capacities

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

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. A hydrometer should not be used.

Perkins engine cooling systems should be tested at 500 hour 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.

Adding the SCA to Heavy-Duty Coolant at the Initial Fill

Use the equation that is in Table 17 to determine the amount of SCA that is required when the cooling system is initially filled.

Table 17

Equation For Adding The SCA To The Heavy-Duty Coolant At

The Initial Fill

V × 0.045 = X

V is the total volume of the cooling system.

X is the amount of SCA that is required.

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 19 to determine the amount of SCA that is required, if necessary:

Table 19

Equation For Adding The SCA To The Heavy-Duty Coolant For

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Maintenance

V × 0.014 = X

Table 20 is an example for using the equation that is in Table 19 .

Table 20

Example Of The Equation For Adding The SCA To The Heavy-

Total Volume of the Cooling System (V)

15 L (4 US gal) × 0.014 0.2 L (7 oz)

Duty Coolant For Maintenance

Multiplication

Factor

that is Required (X)

Amount of SCA

Cleaning the System of Heavy-Duty Antifreeze

• Clean the cooling system after used coolant is 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.

Table 18 is an example for using the equation that is in Table 17 .

Table 18

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

that is Required (X)

Amount of SCA

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). Cooling System Supplemental Coolant Additive (SCA) Test/Add.

i05196225

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

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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 56 g01987816

Typical API symbol

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.

In addition to Perkins definitions, 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

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

• 0.1 percent maximum sulfated ash

• 0.12 percent maximum phosphorous

• 0. 4 percent maximum sulfur

The chemical limits were developed in order to maintain the expected life of the engine aftertreatment system. The performance of the engine aftertreatment system can be adversely affected if oil that is not specified in table 21 is used.

The life of your 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 designed 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 21 has low ash

content.

Maintenance 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 monitor 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 Direct Injection (DI) Diesel Engines

NOTICE

Perkins require the use of the following specification of engine oil. Failure to use the appropriate specification of engine oil will reduce the life of your engine. Failure to use the appropriate specification of engine oil will also reduce the life of your aftertreatment system.

Table 21

Classifications for the 1200 Series Industrial Engine

Oil Specification

API CJ-4 ACEA E9 ECF-3

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

Refer to illustration 57 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine.

Refer to illustration 57 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated.

Generally, use the highest oil viscosity that is available to meet the requirement for the temperature

at start-up.

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80 SEBU8732 Refill Capacities

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• See the appropriate “Lubricant Viscosities”. Refer to the illustration 57 in order to find the correct oil viscosity grade for your engine.

• At the specified interval, service the engine. Use new oil and install a new oil filter.

• Perform maintenance at the intervals that are specified in the Operation and Maintenance Manual, “Maintenance Interval Schedule”.

Oil analysis

Some engines may be equipped with an oil sampling valve. If oil analysis is required, the oil sampling valve is used to obtain samples of the engine oil. The oil analysis will complement the preventive maintenance

program.

The oil analysis is a diagnostic tool that is used to determine oil performance and component wear rates. Contamination can be identified and measured

Illustration 57 g03329707

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. Cold soaked starts occur when the engine has not been operated for a period of time. This interval will allow the oil to become more viscous due

to cooler ambient temperatures.

by using oil analysis. The oil analysis includes the following tests:

• The Wear Rate Analysis monitors the wear of the engines metals. The amount of wear metal and type of wear metal that is in the oil is analyzed. The increase in the rate of engine wear metal in the 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.

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

finished 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:

• The Oil Condition Analysis determines the loss of the oils lubricating properties. An infrared analysis is used to compare the properties of new oil to the properties of the used oil sample. This analysis allows technicians to determine the amount of deterioration of the oil during use. This analysis also allows technicians to verify the performance of the oil according to the specification during the entire oil change interval.

i05195224

Fluid Recommendations

(Diesel Exhaust Fluid (DEF))

General Information

Diesel Exhaust Fluid (DEF) is a liquid that is injected into the aftertreatment system before Selective Catalytic Reduction (SCR). This system of injecting the DEF into the exhaust will reactor in the SCR

system. The Nitrogen Oxide (NOx) molecules in the exhaust are converted to elemental nitrogen and water, reduces the emission of the engine.

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Specification

DEF that is used in Perkins engines must meet the ISO specification 22241-1 for quality. The ISO specification 22241-1 requirements are met by many brands of DEF, including those that carry the AdBlue or API certification."

The document series ISO standard 22241 will give information on quality requirements, test methods, handling, transportation, storage, and refilling interface.

Spillage

DEF that has been split will crystallize when the water within the liquid evaporates. Spilt DEF will attack paint and metal. If DEF is split, wash the area with

water.

Filling the DEF Tank

The fill cap on the DEF tank must be colored blue. The DEF level is important, allowing the DEF tank to run dry or operate at a low level can affect the engine operation.

DEF Quality

The quality of DEF can be measured by using a refractometer. The DEF must comply with ISO standard 22241-1 with the urea solution of 32.5

percent.

Cleanliness

Contaminants can degrade the quality and life of DEF. Filtering DEF is recommended when dispensed into the DEF tank. Filters should be compatible with DEF and should be used exclusively with DEF. Check with the filter supplier to confirm compatibility with DEF before using. Mesh-type filters using compatible metals, such as stainless steel, are recommended.

Paper (cellulose) media and some synthetic filter media are not recommended because of degradation during use.

Care should be taken when dispensing DEF. Spills should be cleaned immediately. Machine or engine surfaces should be wiped clean and rinsed with water. Caution should be used when dispensing DEF near an engine that has recently been running. Spilling DEF onto hot components will cause harmful

vapors.

Storage

Table 22

Storage Temperature Expected DEF Life

Below 25° C (77° F) 18 months

25° C (77° F) to 30° C (86° F) 12 months

30° C (86° F) to 35° C (95° F) 6 months

Above 35° C (95° F) test quality before use

Perkins recommend that all DEF taken from storage should be checked to ensure the DEF meets ISO

standard 22241-1.

i05359636

Fluid Recommendations

(General Fuel Information)

• Glossary

• ISO International Standards Organization

• 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

• SME Soy Methyl Ester

• EPA Environmental Protection Agency of the United States

• PPM Parts Per Million

• DPF Diesel Particulate Filter

General Information

NOTICE Every attempt is made to provide accurate, up-to-date information. By use of this document you agree that Perkins Engines Company Limited is not responsible for errors or omissions.

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82 SEBU8732 Refill Capacities

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

Diesel Fuel Requirements

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

specifications that are published by governments and technological societies.

The Perkins Specification for Distillate Diesel Fuel provides a known reliable baseline in order to judge the expected performance of distillate diesel fuels that are derived from conventional sources.

Satisfactory engine performance is dependent on the use of a good quality fuel. The use of a good quality fuel will give the following results: long engine life and acceptable exhaust emissions levels . The fuel must meet the minimum requirements that are stated in the table 23 .

NOTICE The footnotes are of the key part Perkins Specification for Distillate Diesel Fuel Table. Read ALL of the footnotes.

Table 23

Perkins Specification for Distillate Diesel Fuel

Property UNITS Requirements ASTMTest ISOTest

Aromatics %Volume 35% maximum D1319 ISO3837

Ash %Weight 0.01% maximum D482 ISO6245

Carbon Residue on 10% Bottoms

Cetane Number

Cloud Point °C The cloud point must not ex-

Copper Strip Corrosion

Density at 15 °C (59 °F)

Distillation °C 10% at 282 °C (539.6 °F)

Flash Point °C legal limit D93 ISO2719

Thermal Stability

(2)

%Weight 0.35% maximum D524 ISO4262

kg/m

(3)

40 minimum D613/D6890 ISO5165

ceed the lowest expected ambient temperature.

No. 3 maximum D130 ISO2160

801 minimum and 876 maximum

maximum 90% at 360 °C (680 °F) maximum

Minimum of 80% reflectance after aging for 180 minutes at 150 °C (302 °F)

D2500 ISO3015

No equivalent test ISO 3675ISO 12185

D86 ISO3405

D6468 No equivalent test

(1)

(continued)

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(Table 23, contd)

Pour Point °C 6 °C (42.8 °F) minimum be-

low ambient temperature

(1)

Sulfur

Kinematic Viscosity

Water and sediment % weight 0.1% maximum D1796 ISO3734

Water % weight 0.1% maximum D1744 No equivalent test

Sediment % weight 0.05% maximum D473 ISO3735

Gums and Resins

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

(1)

(2)

(3)

(4)

(5)

(6)

This specification includes the requirements for Ultra Low Sulfur Diesel (ULSD). ULSD fuel will have ≤ 15 ppm (0.0015%) sulfur. Refer to ASTM D5453, ASTM D2622, or ISO 20846, ISO 20884 test methods. A fuel with a higher cetane number is recommended in order to operate at a higher altitude or in cold weather. “Via standards tables, the equivalent API gravity for the minimum density of 801 kg / m3(kilograms per cubic meter) is 45 and for the maximum density of 876 kg / m The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscosity requirement and the fuel should meet the maximumviscosity requirements at 40 °C (104 °F) of either the ASTM D445 test method or the ISO 3104 test method. If a fuel with 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 might require fuel heaters in order to lower the viscosity to “1.4 cSt” at the fuel injection pump. Follow the test conditions and procedures for gasoline (motor). The lubricity 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 D6079 High Frequency Reciprocating Rig (HFRR) test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in the fuel system.

(5)

%mass 0.0015 D5453/D26222 ISO 20846ISO 20884

(4)

mm2/s (cSt) The viscosity of the fuel that

mg/100mL 10 mg per 100 mL

is 30”.

is delivered to the fuel injection pump. “1.4 minimum/

4.5 maximum”

maximum

0.52 maximum D6079 ISO12156-1

D97 ISO3016

D445 ISO3405

D381 ISO6246

Engines that are manufactured by Perkins are certified with the fuel that is prescribed by the United States Environmental Protection Agency . Engines that are manufactured by Perkins are certified with the fuel 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 and other appropriate regulatory agencies.

NOTICE Operating with fuels that do not meet the Perkins recommendations can cause the following effects: Starting difficulty, reduced fuel filter service life, poor combustion, deposits in the fuel injectors, significantly reduce service 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 58 g02157153

Illustration 58 is a representation of the label that will be installed next to the fuel filler cap on the fuel tank of the application.

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84 SEBU8732 Refill Capacities

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The fuel specifications that are listed in the table 24 are released as acceptable to use on all 1200 series of engine.

Table 24

Acceptable Fuel Specification for the 1200 Series of Engines

Fuel Specification Comments

EN590 European Automotive Diesel Fuel (DERV)

(1)

ASTM D975 GRADE 1D S15 “North American Light Distillate Diesel fuel with less than 15 PPM sulfur

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

JIS K2204 “Japanese Diesel Fuel” Must meet the requirements that are stated in

BS 2869: 2010 CLASS A2 or EU equivalent “EU Off Road Diesel fuel. Acceptable from 2011 MUST have less than

(1)

All the fuels must comply with the specification in the table for the Perkins Specification Distillate Diesel Fuel .

Diesel Fuel 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 to ISO 5165 for the test method.

Cetane numbers in excess of 45 are normally expected from current diesel fuel. However, a cetane number of 40 may be experienced in some territories. The United States of America is one of the territories

that can have a low cetane value. A minimum cetane value of 40 is required during average starting

conditions. A fuel with higher cetane number is recommended for operations at high altitudes or in cold-weather operations.

Fuel with a low cetane number can be the root cause

level”

than 15 PPM sulfur level”

the section “Lubricity”.

10 PPM sulfur level”

The viscosity 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 injection pump, damage to the fuel injection pump can occur. This damage can be excessive scuffing and seizure. Low viscosity may lead to difficult hot restarting, stalling, and loss of performance. High viscosity may result in seizure of the pump.

Perkins recommends kinematic viscosities of 1.4 and

4.5 mm2/sec that is delivered to the fuel injection pump. If a fuel with 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 might require fuel heaters in order to lower the viscosity to 4.5 cSt at the fuel injection

pump.

of problems during a cold start.

Density

Viscosity

Density is the mass of the fuel per unit volume at a

Viscosity is the property of a liquid of offering resistance to shear or flow. Viscosity decreases with increasing temperature. This decrease in viscosity follows a logarithmic relationship for normal fossil fuel. The common reference is to kinematic viscosity. Kinematic viscosity is the quotient of the dynamic viscosity that is divided by the density. The determination of kinematic viscosity is normally by readings from gravity flow viscometers at standard temperatures. Refer to ISO 3104 for the test method.

specific temperature. This parameter has a direct influence on engine performance and a direct influence on emissions. This influence determines

from a heat output given injected volume of fuel. This parameter is quoted in the following kg/m

at 15 °C

(59 °F).

Perkins recommends a density of 841 kg/m

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

power.

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Sulfur

The level of sulfur is governed by emissions legislations . Regional regulation, national regulations, or international regulations can require a fuel with a specific sulfur limit. The sulfur content of the fuel and the fuel quality must comply with all existing local regulations for emissions.

Perkins 1200 series diesel engines have been designed to operate only with ULSD. By using the test methods ASTM D5453, ASTM D2622, or ISO

20846 ISO 20884, the content of sulfur in ULSD fuel must be below 15 PPM (mg/kg) or 0.0015% mass.

NOTICE Use of diesel fuel with higher than 15 PPM sulphur limit in these engines will harm or permanently damage emissions control systems and/or shorten their service interval.

Lubricity

Lubricity is the capability of the fuel to prevent pump wear. The fluids lubricity describes the ability of the fluid to reduce the friction between surfaces that are

under load. This ability reduces the damage that is caused by friction. Fuel injection systems rely on the lubricating properties of the fuel. Until fuel sulfur limits were mandated, the fuels lubricity was generally believed to be a function of fuel viscosity.

The lubricity has particular significance to the current ultra low sulfur fuel, and low aromatic fossil fuels.

These fuels are made in order to meet stringent exhaust emissions.

The lubricity of these fuels must not exceed wear scar diameter of 0.52 mm (0.0205 inch). The fuel lubricity test must be performed on an HFRR, operated at 60 °C (140 °F). Refer to ISO 12156-1.

NOTICE The fuels system has been qualified with fuel having lubricity up to 0.52 mm (0.0205 inch) wear scar diameter as tested by ISO 12156-1. Fuel with higher wear scar diameter than 0.52 mm (0.0205 inch) will lead to reduced service life and premature failure of the fuel system.

Fuel additives can enhance the lubricity of a fuel. Contact your fuel supplier for those circumstances when fuel additives are required. Your fuel supplier can make recommendations for additives to use, and

for the proper level of treatment.

Distillation

Distillation is an indication of the mixture of different hydrocarbons in the fuel. A high ratio of light weight

hydrocarbons can affect the characteristics of combustion.

Recommendation for Biodiesel and Using B20

Biodiesel is a fuel that can be defined as mono-alkyl esters of fatty acids . Biodiesel is a fuel that can be made from various feedstock. The most commonly available biodiesel in Europe is Rape Methyl Ester (RME) . This biodiesel is derived from rapeseed oil . Soy Methyl Ester (SME) is the most common biodiesel in the United States. This biodiesel is

derived from soybean oil . Soybean oil or rapeseed oil are the primary feedstocks. These fuels are together known as Fatty Acid Methyl Esters (FAME) .

Raw pressed vegetable oils are NOTacceptable for use as a fuel in any concentration in compression engines . Without esterification, these oils solidify in the crankcase and the fuel tank. These fuels may not be compatible with many of the elastomers that are used in engines that are manufactured today. In original forms, these oils are not suitable for use as a fuel in compression engines . Alternate base stocks for biodiesel may include animal tallow , waste cooking oils , or various other feedstocks. In order to use any of the products that are listed as fuel, the oil must be esterified .

Fuel made of 100 percent FAME is generally referred to as B100 biodiesel or neat biodiesel.

Biodiesel can be blended with distillate diesel fuel. The blends can be used as fuel. The most commonly

available biodiesel blends are B5, which is 5 percent biodiesel and 95 percent distillate diesel fuel. B20, which is 20 percent biodiesel and 80 percent distillate diesel fuel.

Note: The percentages given are volume-based.

The U.S. distillate diesel fuel specification ASTM D975-09a includes up to B5 (5 percent) biodiesel.

European distillate diesel fuel specification EN590: 2010 includes up B7 (7 percent) biodiesel.

Note: Engines that are manufactured by Perkins are certified by use of the prescribed Environmental Protection Agency (EPA) and European Certification fuels. Perkins does not certify engines on any other fuel. The user of the engine has the responsibility of using the correct fuel that is recommended by the manufacturer and allowed by the EPA and other appropriate regulatory agencies.

Specification Requirements

The neat biodiesel must conform to the latest EN14214 or ASTM D6751 (in the USA). The

biodiesel can only be blended in mixture of up to 20% by volume in acceptable mineral diesel fuel meeting latest edition of EN590 or ASTM D975 S15

designation.

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86 SEBU8732 Refill Capacities

Fluid Recommendations

In United States Biodiesel blends of B6 to B20 must meet the requirements listed in the latest edition of

ASTM D7467 (B6 to B20) and must be of an API gravity of 30-45.

In North America biodiesel and biodiesel blends must be purchased from the BQ-9000 accredited

producers and BQ-9000 certified distributors.

In other areas of the world, the use of biodiesel that is BQ-9000 accredited and certified, or that is accredited and certified by a comparable biodiesel

quality body to meet similar biodiesel quality standards is required.

Engine Service Requirements

Aggressive properties of biodiesel fuel may cause debris in the fuel tank and fuel lines. The aggressive properties of biodiesel will clean the fuel tank and fuel lines. This cleaning of the fuel system can prematurely block of the fuel filters. Perkins recommend that after the initial usage of B20 biodiesel blended fuel the fuel filters must be replaced at 50 hours.

Glycerides present in biodiesel fuel will also cause fuel filters to become blocked more quickly. Therefore the regular service interval should be reduced to 250 hours.

When biodiesel fuel is used, crank case oil and aftertreatment systems may be influenced. This

influence is due to the chemical composition and characteristics of biodiesel fuel, such as density and volatility, and to chemical contaminants that can be present in this fuel, such as alkali and alkaline metals (sodium, potassium, calcium, and magnesium).

• Crankcase oil fuel dilution can be higher when

biodiesel or biodiesel blends are used. This increased level of fuel dilution when using biodiesel or biodiesel blends is related to the typically lower volatility of biodiesel. In-cylinder emissions control strategies utilized in many of the industrial latest engine designs may lead to a higher level of biodiesel concentration in the sump. The long-term effect of biodiesel concentration in crankcase oil is currently unknown.

• Perkins recommend the use of oil analysis in

order to check the quality of the engine oil if biodiesel fuel is used. Ensure that the level of biodiesel in the fuel is noted when the oil sample is taken.

Performance Related Issues

Due to the lower energy content than the standard distillate fuel B20 will cause a power loss in order 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 in fuel system deposits, most significant of

which are deposits within the fuel injector. These deposits can cause a loss in power due to restricted or modified fuel injection or cause other functional issues associated with these deposits.

Note: Perkins T400012 Fuel Cleaner is most effective in cleaning and preventing the formation of deposits. Perkins Diesel Fuel Conditioner helps to limit deposit issues by improving the stability of 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 upon combustion in the diesel engine. The ash can have an impact on the life and performance of aftertreatment emissions control devices and can

accumulate in DPF. The ash accumulation may cause the need for more frequent ash service intervals and cause loss of performance

General Requirements

Biodiesel has poor oxidation stability, which can result in long-term problems in the storage of biodiesel. Biodiesel fuel should be used within 6 months of

manufacture. Equipment should not be stored with 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 limited operational time either not use B20 biodiesel blends or, while accepting some risk, limit biodiesel blend to a maximum of B5. Examples of applications that should limit the use of biodiesel are the following: Standby Generator sets and certain emergency vehicles.

Perkins strongly recommended that seasonally operated engines have the fuel systems, including fuel tanks, flashed with conventional diesel fuel

before prolonged shutdown periods. An example of an application that should seasonally flush the fuel system is a combine harvester.

Microbial contamination and growth can cause corrosion in the fuel system and premature plugging of the fuel filter. Consult your supplier of fuel for assistance in selecting appropriate anti-microbial additive.

Water accelerates microbial contamination and growth. When biodiesel is compared to distillate fuels,

water is naturally more likely to exist in the biodiesel. It is therefore essential to check frequently and if necessary, drain the water separator.

Materials such as brass, bronze, copper, lead, tin, and zinc accelerate the oxidation process of the biodiesel fuel. The oxidation process can cause deposits formation therefore these materials must not be used for fuel tanks and fuel lines.

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SEBU8732 87

Refill Capacities

Fluid Recommendations

Fuel for Cold Weather Operation

The European standard EN590 contains climate dependant requirements and a range of options. The options can be applied differently in each country. There are five classes that are given to arctic climates and severe winter climates . 0, 1, 2, 3 and 4.

Fuel that complies with EN590 CLASS 4 can be used at temperatures as low as −44 °C (−47.2 °F). 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

temperatures that are below −18 °C (−0.4 °F).

Aftermarket Fuel Additives

Supplemental diesel fuel additives are not generally recommended . This recommendation is due to

potential damage to the fuel system or the engine. 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.

Note: Some anti-corrosion additives can lead to injector fouling, this fouling can cause the injector to operate incorrectly.

Once the fuel cleaner has been added to the fuel, the deposits within the fuel system are removed after 30

hours of engine operation. For maximum results, continue to use the fuel cleaner for up to 80 hours. Perkins fuel cleaner can be used on an 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. EPA Tier 4 nonroad certified diesel engine emission control catalysts and particulate filters. Perkins fuel system cleaner contains less than 15 ppm of sulfur and is acceptable for use with ULSD fuel.

Contact your fuel supplier for those circumstances when fuel additives are required. Your fuel supplier can recommend the appropriate fuel additive and the correct level of treatment.

Note: For the best results, your fuel supplier should treat the fuel when additives are required. The treated fuel must meet the requirements that are stated in table 23 .

Perkins Diesel Fuel System Cleaner

Perkins T400012 Fuel Cleaner is the only fuel cleaner that is recommended by Perkins .

If biodiesel or biodiesel blends of fuel are to be used, Perkins require the use of Perkins fuel cleaner. The

use of the fuel is in order to remove deposits within the fuel system that is created with the use of biodiesel. For more information on the use of

biodiesel and biodiesel blends refer to “Recommendation for Biodiesel and Using B20”.

Perkins fuel cleaner will remove deposits that can form in the fuel system with the use of biodiesel and biodiesel blends. These deposits can create a loss of power and engine performance.

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88 SEBU8732 Maintenance Recommendations

System Pressure Release

Maintenance Recommendations

i03648938

System Pressure Release

Coolant System

Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator 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 repair is performed.

To relieve the pressure from the coolant system, turn off the engine. Allow the cooling system pressure cap to cool. Remove the cooling system pressure cap slowly in order to relieve pressure.

Fuel System

To relieve the pressure from the fuel system, turn off the engine.

High Pressure Fuel Lines

systems.

1. Stop the engine.

2. Wait for 10 minutes.

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

Engine Oil

To relieve pressure from the lubricating system, turn off the engine.

i05359716

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.

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.

NOTICE Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can cause damage to the drive train bearings, hydraulic 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 as possible to the weld. This will help reduce the possibility of damage.

This is because of the following differences:

• 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.

Before any service or repair is performed on the engine fuel lines, perform the following tasks:

Note: Perform the welding in areas that are free from explosive hazards.

1. Stop the engine. Turn the switched power to the OFF position.

2. Ensure that the fuel supply to the engine is turned off.

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SEBU8732 89

Maintenance Recommendations

Welding on Engines with Electronic Controls

3. Disconnect the 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

• Electric operated fuel pump

• Electronically controlled valves

• Relays

• Aftertreatment ID module

NOTICE Do not use electrical components (ECM or ECM sensors) or electronic component grounding points for grounding the welder.

Illustration 59 g01075639

Use the example above. The current flow from the welder to the ground clamp of the welder will not damage any associated components.

(1) Engine (2) Welding electrode (3) Keyswitch 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

and any electrical/electronic component (9) The component that is being welded (10) Current path of the welder (11) Ground clamp for the welder

5. Connect the welding ground cable directly to the

part that will be welded. Place the ground cable as close as possible to the weld in order to reduce the possibility of welding current damage to the following components. Bearings, hydraulic components, electrical components, and ground straps.

Note: If electrical/electronic components are used as a ground for the welder, or electrical/electronic components are located between the welder ground and the weld, current flow from the welder could severely damage the component.

6. Protect the wiring harness from welding debris and

spatter.

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90 SEBU8732 Maintenance Recommendations

Severe Service Application

7. Use standard welding practices to weld the materials.

i05196263

Severe Service Application

Severe service is the application of an engine that exceeds the current published standards for that engine. Perkins maintains standards for the following engine parameters:

• Performance such as power range, speed range, and fuel consumption

• Fuel quality

• Operational Altitude

• Maintenance intervals

• Oil selection and maintenance

• Coolant type and maintenance

• Environmental qualities

Quality of the air – The engine may be exposed to extended operation in an environment that is dirty or dusty, unless the equipment is cleaned regularly. Mud, dirt, and dust can encase components. Maintenance can be very difficult. The buildup can contain corrosive chemicals.

Buildup – Compounds, elements, corrosive chemicals, and salt can damage some components.

Altitude – Problems can arise when the engine is operated at altitudes that are higher than the intended settings for that application. Necessary adjustments should be made.

Incorrect Operating Procedures

• Extended operation at low idle

• Frequent hot shutdowns

• Operating at excessive loads

• Operating at excessive speeds

• Operating outside the intended application

Incorrect Maintenance Procedures

• Installation

• The temperature of the fluid in the engine

Refer to the standards for the engine or consult your Perkins dealer or your Perkins distributor in order to determine if the engine is operating within the defined parameters.

Severe service operation can accelerate component wear. Engines that operate under severe conditions may need more frequent maintenance intervals in order to ensure maximum reliability and retention of full service life.

Due to individual applications, it is not possible to identify all of the factors which can contribute to severe service operation. Consult your Perkins dealer or your Perkins distributor for the unique maintenance that is necessary for the engine.

The operating environment, incorrect operating procedures, and incorrect maintenance procedures can be factors which contribute to a severe service

application.

Environmental Factors

Ambient temperatures – The engine may be

exposed to extended operation in extremely cold environments or hot environments. Valve

components can be damaged by carbon buildup if the engine is frequently started and stopped in very cold temperatures. Extremely hot intake air reduces engine performance.

• Extending the maintenance intervals

• Failure to use recommended fuel, lubricants, and coolant/antifreeze

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SEBU8732 91

Maintenance Recommendations

Maintenance Interval Schedule

i05196439

Maintenance Interval Schedule

When Required

“Battery - Replace”...................................................92

“Battery or Battery Cable - Disconnect”...................94

“Diesel Exhaust Fluid - Fill”................................... 100

“Engine - Clean”.................................................... 102

“Engine Air Cleaner Element (Dual Element) -

Inspect/Clean/Replace”........................................102

“Engine Air Cleaner Element (Single Element) -

Inspect/Replace”................................................... 104

“Engine Oil Sample - Obtain”.................................110

“Fuel System - Prime”............................................114

Daily

“Coolant Level - Check”...........................................99

“Driven Equipment - Check” ................................. 101

“Engine Air Cleaner Service Indicator - Inspect” .. 105

“Engine Air Precleaner - Check/Clean” ................106

“Engine Oil Level - Check”.....................................110

“Fuel System Primary Filter/Water Separator -

Drain” .....................................................................117

“Walk-Around Inspection”.....................................124

“Engine Oil and Filter - Change” ............................111

“Fuel Filter (In-Line) - Replace”..............................114

“Fuel System Primary Filter (Water Separator)

Element - Replace” ................................................115

“Fuel System Secondary Filter - Replace” ............118

“Radiator - Clean” ................................................. 122

Every 1000 Service Hours

“Belt Tensioner - Check” ..........................................94

“Belt - Inspect”..........................................................95

“Water Pump - Inspect”.........................................126

Every 1500 Service Hours

“Engine Crankcase Breather Element - Replace” 106

Every 2000 Service Hours

“Aftercooler Core - Inspect” .....................................92

“Engine Mounts - Inspect” ....................................109

“Starting Motor - Inspect” ...................................... 123

“Turbocharger - Inspect”.......................................123

Every 3000 Service Hours

“Alternator - Inspect” ................................................92

“Alternator and Fan Belts - Replace” .......................92

Every 3000 Service Hours or 2 Years

Every Week

“Hoses and Clamps - Inspect/Replace”................ 120

Every 50 Service Hours or Weekly

“Fuel Tank Water and Sediment - Drain” ...............119

Every 500 Service Hours

“Fan Clearance - Check” .......................................113

Every 500 Service Hours or 1 Year

“Battery Electrolyte Level - Check”..........................93

“Crankshaft Vibration Damper - Inspect” ..............100

“Engine Air Cleaner Element (Dual Element) -

Inspect/Clean/Replace”........................................102

“Engine Air Cleaner Element (Single Element) -

Inspect/Replace”................................................... 104

“Coolant (DEAC) - Change”.....................................95

Every 4000 Service Hours

“Aftercooler Core - Clean/Test”................................92

Every 5000 Service Hours

“Diesel Exhaust Fluid Filter - Clean/Replace” ...... 101

“Injector (Diesel Exhaust Fluid) - Replace”........... 121

Every 6000 Service Hours or 3 Years

“Coolant Extender (ELC) - Add” ..............................99

Every 12 000 Service Hours or 6 Years

“Coolant (ELC) - Change”........................................97

Page 92

92 SEBU8732 Maintenance Recommendations

Aftercooler Core - Clean/Test

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 fins, 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.

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 the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

i02322311

Alternator - Inspect

Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and correct battery charging. Check the ammeter (if equipped) during engine operation in order to ensure correct battery performance and/or correct performance of the electrical system. Make repairs, as required.

Check the alternator and the battery charger for correct operation. If the batteries are correctly charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries should be kept warm because temperature affects the cranking power. If the battery is too cold, the battery will not crank the engine. When the engine is not run for long periods of time or if the engine is run for short periods, the batteries may not fully charge. A battery with a low charge will freeze more easily than a battery with a full charge.

i02680137

Alternator and Fan Belts Replace

Refer to Disassembly and Assembly Manual, “Alternator Belt - Remove and Install”.

i05425759

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.

Battery - Replace

Batteries give off combustible gases which can explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death.

Ensure proper ventilation for batteries that are in an enclosure. Follow the proper procedures in or-

der to help prevent electrical arcs and/or sparks near batteries. Do not smoke when batteries are serviced.

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SEBU8732 93

Maintenance Recommendations

Battery Electrolyte Level - Check

i02747977

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.

Note: After the engine has stopped, allow 2 minutes in order for the diesel exhaust fluid lines to be purged before disconnecting the power.

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 “-” battery 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.

6. Remove the used battery.

7. Install the new battery.

Battery Electrolyte Level Check

When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from freezing. If batteries are correctly charged, the ammeter reading should be very near zero, when the engine is in operation.

All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a face shield and protective clothing when working on or near batteries.

1. Remove the filler caps. Maintain the electrolyte

level to the “FULL” mark on the battery.

If the addition of water is necessary, use distilled water. If distilled water is not available use clean

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.

4. Keep the batteries clean.

Clean the battery case with one of the following cleaning solutions:

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.

• Use a solution of 0.1 kg (0.2 lb) baking soda and 1 L (1 qt) of clean water.

• Use a solution of ammonium hydroxide .

Thoroughly rinse the battery case with clean water.

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94 SEBU8732 Maintenance Recommendations

Battery or Battery Cable - Disconnect

i05424317

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.

Note: After the engine has stopped, allow 2 minutes in order for the diesel exhaust fluid lines to be purged before disconnecting the power.

i04907925

Belt Tensioner - Check

2. Disconnect the negative battery terminal. Ensure

that the cable cannot contact the terminal. When four 12 V batteries are involved, 2 negative connections must be disconnected.

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 of material can cause the clamps to fit incorrectly. 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.

Illustration 60 g03074016

Typical example

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 an 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”.

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SEBU8732 95

Maintenance Recommendations

Belt - Inspect

i04907868

• The engine overheats frequently.

• Foaming 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.

NOTICE When any servicing or repair of the engine cooling system is performed, the procedure must be performed with the engine on level ground. Level ground will allow you to check accurately the coolant level. This procedure will also help in avoiding the risk of introducing an air lock into the coolant system.

Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This inspection is a good opportunity to replace the water pump, the water temperature regulator, and the hoses, if necessary.

Drain

Illustration 61 g03073936

Typical example

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.

i05197133

Coolant (DEAC) - Change

1. Stop the engine 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.

Note: Refer to Operation and Maintenance Manual, “General Hazard Information” for information on Containing Fluid Spillage.

• DEAC Diesel Engine Antifreeze Coolant

Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist:

Page 96

96 SEBU8732 Maintenance Recommendations

Coolant (DEAC) - Change

Alternative Drain Plug

The cylinder coolant can be drained from the plug below the oil cooler. Refer to illustration 64 . If the

alternative drain plug (3) is removed, the O ring seal must be replaced. Tighten the drain plug to a torque of 35 N·m (25 lb ft).

Illustration 62 g03461657

Illustration 63 g02350785

2. Remove connection hose (1) on the engine. Also remove the drain plug (2). Open the drain cock or remove the drain plug on the radiator.

Illustration 64 g03081697

Flush

1. Flush the cooling system with clean water and a

suitable cleaning agent in order to remove any debris. Refer to your Perkins dealer or distributor for suitable cleaning agents.

2. Install connection hose. Clean the drain plugs. Install the drain plugs. Tighten drain plug securely.

NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine damage.

3. Fill the cooling system with clean water and install

the cooling system filler cap.

Allow the coolant to drain into a suitable container.

3. Properly dispose of the drained material. Obey local regulations for the disposal of the material.

4. Start and run the engine at low idle for a minimum of 30 minutes. The coolant temperature should be at least 82 °C (180 °F).

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SEBU8732 97

Maintenance Recommendations

Coolant (ELC) - Change

NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components.

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

5. Stop the engine 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. Remove the connection hose or remove the cooling system drain plugs. Allow the water to drain. Flush the cooling system with clean water. Install the connection hose.

6. The drain plug O rings on the engine block must be

replaced. Clean the drain plugs and install new O ring seal. Install the drain plugs and tighten to a torque of 35 N·m (25 lb ft).

Fill

4. Clean the cooling system filler cap. Inspect the

gasket that is on the cooling system filler cap. If the gasket that is on the cooling system filler cap is damaged, discard the old cooling system filler cap and install a new cooling system filler cap. If the gasket that is on the cooling system filler cap is not damaged, perform a pressure test. If the cooling system filler cap does not retain the correct pressure, install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system for leaks and for the correct operating temperature.

i05197293

Coolant (ELC) - Change

NOTICE Perkins ELC must be using with an extender in order to achieve 12000 hours operation. For more information on a suitable extender contact your Perkins dealer or Perkins distributor.

NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine damage.

1. Fill the cooling system with the coolant/antifreeze.

Refer to this Operation and Maintenance Manual, “Refill Capacities and Recommendations” topic (Maintenance Section) for more information on cooling system specifications. Do not install the cooling system filler cap.

2. Start and run the engine at low idle. Increase the

engine rpm to high idle. Operate the engine in order to open the engine thermostat. This operation will allow any air in the system to be purged. Decrease the engine speed to low idle. Stop the engine.

3. Maintain the coolant level at the maximum mark

that is correct for your application.

Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist:

• The engine overheats frequently.

• Foaming is observed.

• 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 when the ELC is drained and replaced.

Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. Replace the water pump, the water temperature regulator, and the hoses, if necessary.

NOTICE Service or repair of the engine cooling system must be performed on level ground. The engine must be level in order to check the coolant level. The engine must be level in order to avoid the risk of introducing an air lock into the coolant system.

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98 SEBU8732 Maintenance Recommendations

Coolant (ELC) - Change

Drain

1. Stop the engine 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.

Illustration 65 g03461657

Illustration 66 g02350785

2. Remove connection hose (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.

For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or Perkins distributor.

Flush

1. Flush the cooling system with clean water in order

to remove any debris.

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SEBU8732 99

Maintenance Recommendations

Coolant Extender (ELC) - Add

4. Clean the cooling system filler cap. Inspect the

2. Install the connection hose. Clean the drain plugs

and install the drain plugs. Tighten the drain plugs securely.

NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute 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. Start and run the engine at low idle until the

temperature reaches 49 to 66 °C (120 to 150 °F).

gasket that is on the cooling system filler cap. If the gasket that is on the cooling system filler cap is damaged, discard the old cooling system filler cap and install a new cooling system filler cap. If the gasket that is on the cooling system filler cap is not damaged, pressure test the cooling system filler cap. The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap. If the cooling system filler cap does not retain the correct pressure, install a new cooling system filler cap.

5. Start the engine. Inspect the cooling system for leaks and for proper operating temperature.

i05197396

5. Stop the engine 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. Remove the connection hose and remove the cooling system drain plugs. Allow the water to drain. Flush the cooling system with clean water. Install the connection hose.

6. The drain plug O rings on the engine block must be replaced. Clean the drain plugs and install new O ring seal. Install the drain plugs and tighten to a torque of 35 N·m (25 lb ft).

Fill

NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine damage.

1. Fill the cooling system with Extended Life Coolant

(ELC). Refer to this Operation and Maintenance Manual, “Refill Capacities” topic (Maintenance Section) for more information on cooling system specifications. Do not install the cooling system filler cap.

2. Start and run the engine at low idle. Increase the

engine rpm to high idle. Operate the engine in order to open the engine thermostat. An open thermostat will allow any air in the system to be purged. Decrease the engine speed to low idle. Stop the engine.

Coolant Extender (ELC) - Add

In order for Perkins ELC to achieve 12000 hours an extender must be added at 6000 hours. For a suitable extender, contact your Perkins dealer or Perkins

distributor.

i05436397

Coolant Level - Check

Check the coolant level when the engine is stopped and cool.

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 procedure will allow you to check accurately the coolant level. This procedure will also help in avoiding the risk of introducing an air lock into the coolant system.

1. Remove the cooling system filler cap slowly in

order to relieve pressure.

3. Maintain the coolant level at the maximum mark that is correct for your application.

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100 SEBU8732 Maintenance Recommendations

Crankshaft Vibration Damper - Inspect

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.

Illustration 67 g02590196

Typical filler cap gaskets

3. Clean the cooling system filler cap and check the condition of the filler cap gaskets. Replace the cooling system filler cap if the filler cap gaskets are damaged. Reinstall the cooling system filler cap.

4. Inspect the cooling system for leaks.

Note: The Diesel Exhaust Fluid (DEF) tank requires

coolant flow around the tank. The Coolant Diverter Valve (CDV) will turn the flow on or off. If the coolant system has been filled with the CDV in the closed position, coolant level will drop because of the opening of the CDV.

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Crankshaft Vibration Damper Inspect

Illustration 68 g01950241

Typical example

Inspect the damper and replace the damper for any of the following reasons:

• The damper 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”.

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Diesel Exhaust Fluid - Fill

Refer to the original equipment manufacture information for the Diesel Exhaust Fluid (DEF) tank capacity.

Viscous Damper

The viscous damper has a inertia weight that is located inside a fluid 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.

Illustration 69 g03379943

Lockable type DEF Filler cap

Perkins Engine 1206F-E70TA, 1206F-E70TTA Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual