Perkins Engine 1506A-E88TA, 1506C-E88TA, 1506DE88TA Service Manual
Operation and
Maintenance
Manual
SEBU9070-01
July 2015
1506A-E88TA, 1506C-E88TA and 1506DE88TA Industrial Engines
LG (Engine)
PK9 (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
SEBU9070 3
Table of Contents
Table of Contents
Foreword.............................. ............................. 4
Safety Section
Safety Messages....................... ....................... 5
General Hazard Information............... .............. 7
Burn Prevention....................... ........................11
Fire Prevention and Explosion Prevention ... ...11
Crushing Prevention and Cutting Prevention . 13
Mounting and Dismounting............... .............. 13
Before Starting Engine ................. .................. 13
Engine Starting........................ ....................... 14
Engine Stopping ....................... ...................... 14
Refill Capacities....................... ....................... 47
Maintenance Recommendations.......... .......... 72
Maintenance Interval Schedule ........... ........... 75
Warranty Section
Warranty Information .................. .................. 101
Reference Information Section
Engine Ratings ....................... ...................... 102
Reference Materials .................. ................... 104
Index Section
Index............................... .............................. 107
Electrical System...................... ...................... 14
Engine Electronics..................... ..................... 15
Product Information Section
General Information.................... .................... 16
Product Identification Information.......... ......... 25
Operation Section
Lifting and Storage..................... ..................... 27
Features and Controls.................. .................. 30
Engine Diagnostics..................... .................... 38
Engine Starting........................ ....................... 40
Engine Operation...................... ...................... 43
Cold Weather Operation................. ................ 44
Engine Stopping ....................... ...................... 46
Maintenance Section
4
Foreword
SEBU9070
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.
SEBU9070
Safety Section
i06229776
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.
5
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 distributor can
provide new warning signs.
(1) Universal Warning
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.
Illustration 1 g01154807
Typical example
The Universal Warning label (1) is located in two
positions. The warning labels are located on the right
side of the valve mechanism cover and located on the
left side of the valve mechanism cover .
6 SEBU9070
Safety Section
Safety Messages
Illustration 2 g03732105
1506A and C
Illustration 3 g03863615
1506D
SEBU9070
7
Safety Section
General Hazard Information
i05943048
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:
8 SEBU9070
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:
SEBU9070 9
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.
Static Electricity Hazard when
Fueling with Ultra-low Sulfur Diesel
Fuel
The removal of sulfur and other compounds in ultralow sulfur diesel fuel (ULSD fuel) decreases the
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.
10 SEBU9070
Safety Section
General Hazard Information
• Never use compressed air for cleaning.
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 contents. Avoid death or serious injury from fire or explosion. Consult with
your fuel or fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices.
Inhalation
• 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.
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.
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.
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.
If dust that may contain asbestos is present, there are
several guidelines that should be followed:
SEBU9070 11
Safety Section
Burn Prevention
i05943062
Burn Prevention
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
air system, in the hydraulic system, in the lubrication
system, in the fuel system, or in the cooling system
before any lines, fittings, or related items are
disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check that the coolant level after the engine has
stopped and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
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
Skin may be irritated following repeated or prolonged
exposure to mineral and synthetic base oils. Refer to
your suppliers Material Safety Data Sheets for
detailed information. Hot oil and lubricating
components can cause personal injury. Do not allow
hot oil to contact the skin. Appropriate personal
protective equipment should be used
Diesel Fuel
Diesel may be irritating to the eyes, respiratory
system, and skin. Prolonged exposure to diesel may
cause various skin conditions. Appropriate personal
protective equipment should be used. Refer to
supplier Material safety Data sheets for detailed
information.
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.
i05945996
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.
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.
12 SEBU9070
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 installed correctly.
The filter housings must be tightened to the correct
torque. Refer to the Disassembly and Assembly
manual for more information.
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.
Illustration 11 g00704135
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.
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.
Ether
Ether is flammable and poisonous.
SEBU9070 13
Safety Section
Crushing Prevention and Cutting Prevention
Do not smoke while you are replacing an ether
cylinder or while you are using an ether spray.
Do not store ether cylinders in living areas or in the
engine compartment. Do not store ether cylinders in
direct sunlight or in temperatures above 49° C
(120° F). Keep ether cylinders away from open
flames or sparks.
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:
• 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.
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.
i05463929
Mounting and Dismounting
Do not climb on the engine. The engine has not been
designed with mounting or dismounting locations.
Refer to the Original Equipment Manufacture (OEM)
for the location of foot and hand holds for your
specific application.
i04257031
Before Starting Engine
NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.
• 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
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.
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.
Inspect the engine for potential hazards.
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.
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 properly, 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 start an engine when the governor linkage is
disconnected.
14 SEBU9070
Safety Section
Engine Starting
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.
i02583384
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 NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
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.
Start the engine from the operator's compartment or
from the engine start switch.
i01462046
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 NOT start the engine until the
problem that caused the emergency stop has been
corrected.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an engine
that has been overhauled. This may be accomplished
by shutting off the fuel supply to the engine and/or
shutting off the air supply to the engine.
To stop an electronically controlled engine, cut the
power to the engine.
i06230746
Electrical System
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 the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal injury.
To ensure that the jacket water heater (if equipped) is
working correctly, check the water temperature gauge
and/or 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 may be 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.
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 negative “−” terminal of
the starting motor. If the starting motor is not
equipped with a negative “−” terminal, connect the
cable to the engine block.
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.
SEBU9070 15
Safety Section
Engine Electronics
Grounding Practice
Illustration 12 g03864331
Typical example
(1) Battery to grounding stud
(2) Battery to starter to grounding stud
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 that is 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.
i05986490
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.
This engine has a comprehensive, programmable
Engine Monitoring System. The Engine Control
Module (ECM) will monitor the engine operating
conditions. If any of the engine parameters extend
outside an allowable range, the ECM will initiate an
immediate action.
The following actions are available for engine
monitoring control: WARNING, DERATE and
SHUTDOWN. These engine monitoring modes can
limit engine speed and/or the engine power.
Many of the parameters that are monitored by the
ECM can be programmed for the engine monitoring
functions. The following parameters can be monitored
as a part of the Engine Monitoring System:
• Operating Altitude
• Engine Coolant Level
• Engine Coolant Temperature
• Engine Oil Pressure
• Engine Speed
• Fuel Temperature
• Intake Manifold Air Temperature
• System Voltage
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
Manual for more information.
16 SEBU9070
Product Information Section
Model View Illustrations
Product Information
Section
General Information
i06230810
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.
1506A and C Engine and Radiator Views
Illustration 13 g03733708
Typical example
(1) Engine air cleaner service indicator
(2) Inspection guard
(3) Radiator
(4) Radiator pressure cap
(5) Air-to-air aftercooler
(6) Rain cap
(7) Air cleaner
(8) Vacuator valve (Dust valve)
SEBU9070 17
General Information
Model View Illustrations
1506A and C Engine Views
Illustration 14 g03734120
Typical example
(9) Cooling fan
(10) Oil filler cap
(11) Starting motor assembly
(12) Fuel priming pump
(13) Secondary fuel filter
(14) Primary fuel filter
(15) V Belts for fan
18 SEBU9070
General Information
Model View Illustrations
Illustration 15 g03734121
Typical example
(16) Rear lifting eye
(17) Coolant sampling valve
(18) Housing for coolant temperature
regulator
(19) Front lifting location
(20) Belt for coolant pump
(21) Crankshaft damper
(22) Idler for coolant belt
(23) Coolant pump
(24) Oil filter
(25) Oil gauge (Dipstick)
(26) Sample valve for engine oil
SEBU9070 19
General Information
Model View Illustrations
Illustration 16 g03734133
Typical example
(27) Turbocharger
(28) Alternator
(29) Oil pan
(30) Oil drain tap
(31) Flywheel housing
(32) Flywheel
20 SEBU9070
General Information
Model View Illustrations
Illustration 17 g03734135
Typical example
(33) Unit injector hydraulic pump
(34) Fuel transfer pump
(35) Crankcase breather
(36) Electronic control module
(37) Breather outlet hose
(38) Oil drain plug
1506D Engine Views
The following model views show typical features of
the engine. Due to individual applications, your
engine, may appear different from the illustrations.
SEBU9070 21
General Information
Model View Illustrations
Illustration 18 g03864374
Typical example
(1) Switch for air inlet heater
(2) Twin compressor
(3) Auto tensioner
(4) Multi V belt
22 SEBU9070
General Information
Product Description
Illustration 19 g03864386
Typical example
(5) Wastegate actuator
i06231479
Product Description
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
The 1506 industrial engine has three different
end. The number 1 cylinder is the front cylinder.
emissions ratings A, C, and D. The 1506 industrial
engine can be configured for variable speed
applications or constant speed applications.
The 1506A and C industrial engines have five
different ratings. Visually the engines will look similar
the difference is due to the software that is loaded
into the engine Electronic Control Module (ECM).
The 1506D may be configured differently, with an air
inlet heater, automatic tensioner for the drive belt, and
a turbocharger with a wastegate actuator.
The Perkins 1506A, 1506C and 1506D industrial
engines have the following characteristics:
• In-Line 6-cylinder
• Four-stroke cycle
• Hydraulically Actuated Electronic Unit Injection
Illustration 20 g00609479
Cylinder and valve location
(A) Exhaust valve
(B) Inlet valve
(HEUI)
• Turbocharged with air-to-air aftercooled (ATAAC)
SEBU9070 23
General Information
Product Description
Table 1
1506 Engine Specifications
Arrangement and Cylinders In-Line 6-cylinder
Bore 112.0 mm (4.41 inch)
Stroke 149.0 mm (5.87 inch)
Aspiration
Displacement 8.8 L (537 in
Firing Order
Rotation (flywheel end)
ATAAC
3
)
1-5-3-6-2-4
Counterclockwise
Electronic Engine Features
The engine operating conditions are monitored. The
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 speed governor
• Automatic air/fuel ratio control
• Torque rise shaping
• Injection timing control
Engine Diagnostics
The engine has built-in diagnostics in order to ensure
that all of the components are functioning properly. In
the event of a deviation from the programmed limits,
the operator will be alerted to the condition by a
“DIAGNOSTIC” 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 code.
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.
The ECM provides an electronic governor that
controls the injector output in order to maintain the
desired engine rpm.
Engine Cooling and Lubrication
The cooling system consists of the following
components:
• Centrifugal pump that is driven by a belt
• Cooling fan driven by belts
• Water temperature regulator which regulates the
engine coolant temperature
• System diagnostics
For more information on electronic engine features,
refer to the Operation and Maintenance Manual,
“Engine Diagnostics” topic.
Additional Features
The following additional features provide increased
engine fuel economy and serviceability:
• Cold starting capability
• Tampering detection
• Diagnostics
Hydraulic Electronic Unit Injectors
Hydraulically Actuated Electronic Unit Injectors
(HEUI) perform the following function:
• Atomizes the fuel
The unit injectors are controlled by the ECM which
uses the camshaft position, the engine speed signals,
and the inlet air pressure sensors. The ECM controls
when the fuel is injected into each cylinder. The rated
rpm is identified on the information plate.
• Oil cooler and radiator
The drive belt can be a multi V belt or a single V belt
design.
The engine lubricating oil that is supplied is cooled.
The engine lubricating oil is also filtered. Bypass
valves provide unrestricted flow of lubrication oil to
the engine components during the following
conditions:
• High oil viscosity
• Plugged oil cooler or plugged oil filter element
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.
24 SEBU9070
General Information
Product Description
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 a 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.
Aftermarket Products and Perkins
Engines
Perkins does not warrant the quality or performance
of non-Perkins fluids and filters.
When auxiliary devices, accessories, or consumables
(filters, additives, catalysts, ) which are made by other
manufacturers are used on Perkins products, the
Perkins warranty is not affected simply because of
such use.
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.
SEBU9070 25
Product Identification Information
Plate Locations and Film Locations
Product Identification
Information
Plate Locations and Film
Locations
Serial Number Plate 1
i05951766
Illustration 22 g01403841
Engine Identification
Illustration 21 g03735788
Typical example
(1) Location of engine serial plate.
Perkins engines are identified by serial numbers.
These numbers are shown on the engine serial
number plate. Perkins distributors need these
numbers in order to determine the components that
were included with the engine. This information
permits accurate identification of replacement part
numbers.
Perkins engines are identified by an engine serial
number.
A typical example of an engine serial number is
LGE F**** N00001W.
L Type of engine
G Application (Table 2 )
E Rating Type (Table 3 )
F Number of cylinders (Table 4 )
***** Fixed build number
N Built in the USA
00001 Engine Number
W Year of Manufacture
Table 2
Application
G Genset
Table 3
Type of engine (Diesel)
A TAG1
B TAG2
D TAG3
(continued)
26 SEBU9070
Product Identification Information
Emissions Certification Film
(Table 3, contd)
E TAG4
F TAG5
H TAG6
Table 4
Number of Cylinders
F 6
H 8
M 12
R 16
Perkins dealers and Perkins distributors require all
of these numbers in order to determine the
components that were included in the engine. This
information permits accurate identification of
replacement part numbers.
i05951816
Emissions Certification Film
Fan Drive Belt
Coolant Pump Belt
Note: This information is pertinent in the United
States, in Canada and in Europe.
The emissions label is located on the top of the valve
mechanism cover.
i05951812
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.
Record for Reference
Engine Model
Engine Serial Number
Engine RPM
Primary Fuel Filter
Secondary Fuel Filter Element
Lubrication Oil Filter Element
Total Lubrication System Capacity
Total Cooling System Capacity
Air Cleaner Element
SEBU9070 27
Operation Section
Product Lifting
Operation Section
Lifting and Storage
i05951830
Product Lifting
Illustration 24 g00103219
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.
Illustration 23 g03735832
The lifting eyes (1) are the lifting locations for lifting
the engine and radiator.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
Use a hoist to remove heavy components. Use an
adjustable lifting beam to lift the engine. All
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.
Some removals require lifting the fixtures in order to
obtain proper balance and safety.
Lifting eyes are designed and installed for the specific
engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure that
proper lifting devices are provided. Consult your
Perkins distributor for information regarding fixtures
for proper engine lifting.
i05951855
Product Storage
Your Perkins distributor can assist in preparing the
engine for extended storage periods.
28 SEBU9070
Lifting and Storage
Product Storage
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.
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. Also, rotate the
coolant pump pulley. Visibly check for damage or
corrosion to the engine.
Ensure that the engine is covered completely before
storage. Log the procedure in the record for the
engine.
Removal from Storage
1. Remove all covers from engine and air cleaner.
Check the condition of the air filter element.
b. Fill the fuel system with a correct specification
of 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. Change the engine oil and filter. Refer to this
Operation and Maintenance Manual, “Engine Oil
and Filter - Change”. Ensure that the engine is
operated after the oil and filter has been changed.
Ensure that engine oil pressure is correct before
stopping the engine.
4. For the correct specification of engine oil refer to
this Operation and Maintenance Manual, “Fluid
recommendations”.
5. Loosen the fan drive belts and loosen the coolant
pump belt. Refer to this Operation and
Maintenance Manual, “Belts - Inspect/Adjust” for
more information.
Sealed Coolant System
Ensure that the cooling system is filled with Perkins
ELC, or an antifreeze that meets “ASTM D6210”
specification.
2. Check the condition of the coolant pump belt and
the fan drive belts before tensioning the belts.
Tension the coolant pump belts and tension the fan
drive belts. Refer to this Operation and
Maintenance Manual, “Belts - Inspect/Adjust” for
more information.
3. Check the coolant level. Refer to Operation and
Maintenance Manual, “Coolant Level - Check”
4. Remove valve cover, refer to Disassembly and
Assembly, “Valve Mechanism Cover - Remove and
Install”. Lubricate the valve train. Install the valve
cover.
5. Replace the fuel filters. Refer to the following
section within the Operation and Maintenance
Manual.
• Fuel System Primary Filter (Water Separator)
Element - Replace
• Fuel System Secondary Filter - Replace
• Fuel System - Prime
6. Use a bar or a turning tool in order to turn the
engine in the normal direction of rotation. The
procedure ensures that no hydraulic locks or
resistance exist.
SEBU9070 29
Lifting and Storage
Product Storage
Illustration 25 g03774288
(1) Plug
7. If an engine is stored for more than 1 year, Perkins
recommends Pre lubrication of the engine in order
to avoid dry starting. Use a suitable pump in order
to put engine oil into the engine oil system.
The pump will need to create a minimum pressure
within the engine of 0.25 bar (3.6 psi). This
pressure is needed for 15 seconds in order to
lubricate the internal surfaces. Remove plug (1) in
order to connect to the engine oil system. The
connection required is 9/16" x 18 tpi. Ensure that
the correct oil specification is used, refer to this
Operation and Maintenance Manual, “Fluid
Recommendations” for more information. After the
engine internal surfaces have been lubricated,
remove connector and install plug (1). Tighten plug
to a torque of 30 N·m (265 lb in). Perkins
recommends that the procedure must be
performed in a minimum ambient temperature of
10° C (50° F).
8. Check engine oil level and visually inspect all
hoses and connections before starting the engine.
Start the engine, refer to this Operation and
Maintenance Manual, “Starting the Engine” for
more information.
After starting the engine and after correct operation
of the engine, stop the engine and check again the
engine oil level. Ensure that engine oil level is
correct.
30 SEBU9070
Features and Controls
Gauges and Indicators
Features and Controls
i05952344
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 literature that is
provided by the OEM.
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 of time.
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
distributor or the Perkins dealer for assistance.
Engine Oil Pressure – Typical oil
pressure for an engine at rated speed
with SAE 10W30 or with SAE 15W40 is
240 to 480 kPa (35 to 70 psi).
Engine Oil Temperature – This gauge
indicates the engine oil temperature. An
oil temperature that is higher than
normal indicates a heat problem in the lubrication
system and/or the cooling system. This problem
can damage the cylinder heads, the cylinder
liners, the pistons, and the crankshaft bearings.
Jacket Water Coolant Temperature –
Typical temperature range is 88 to 102 °C
(190 to 215 °F). The maximum allowable
temperature with the pressurized cooling system
is 105 °C (220 °F). Higher temperatures may
occur under certain conditions. The water
temperature reading may vary according to load.
The reading should never exceed the boiling
point for the pressurized system that is being
used.
If the engine is operating above the normal range or
steam becomes apparent, perform the following
procedure:
1. Reduce the engine load .
2. Inspect the cooling system for leaks.
3. Determine if the engine must be shut down
immediately or if the engine can be cooled by
reducing the load.
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.
4. Check the coolant level.
Tachometer – This gauge indicates
engine speed. 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.
Ammeter – This gauge indicates the
amount of charge or of discharge in the
battery charging circuit. Operation of the
indicator should be to the right side of ““0”” (zero).
Service Hour Meter – This gauge
indicates the total number of clock hours
of engine operation. Hours of operation
are logged in the ECM. A service tool is needed to
retrieve the hours from the ECM. A Service Hour
Meter may be installed on the engine.
Fuel Level – This gauge indicates the
level of fuel in the fuel tank. The fuel
level gauge registers the fuel level only
when the ignition switch is in the ON position.
Warning Indicators
There are two warning lamps available.
• Warning Lamp
• Shutdown Lamp
Instrument Panels and Displays
In order to monitor the engine a wide verity of
instrument panels are available. These instrument
panels can contain the indicator lamps and the
gauges for the application.
Also available are mini power displays and
performance monitors.
i05964915
Monitoring System The
engine has protection in three stages:
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