SEBU9072
July 2015
Operation and
Maintenance
Manual
2206D-E13TA Industrial Engine
PK3 (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.
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Table of Contents |
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Foreword.............................. |
............................. 4 |
Safety Section |
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Safety Messages....................... ....................... |
5 |
General Hazard Information............... .............. |
6 |
Burn Prevention....................... ....................... |
10 |
Fire Prevention and Explosion Prevention ... .. 10
Crushing Prevention and Cutting Prevention . 12
Mounting and Dismounting............... .............. |
12 |
Before Starting Engine ................. .................. |
12 |
Engine Starting........................ ....................... |
13 |
Engine Stopping ....................... ...................... |
13 |
Electrical System...................... ...................... |
13 |
Engine Electronics..................... ..................... |
14 |
Product Information Section |
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General Information.................... .................... |
15 |
Product Identification Information.......... ......... |
18 |
Operation Section |
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Lifting and Storage..................... ..................... |
20 |
Features and Controls.................. .................. |
23 |
Engine Diagnostics..................... .................... |
28 |
Engine Starting........................ ....................... |
30 |
Engine Operation...................... ...................... |
34 |
Cold Weather Operation................. ................ |
36 |
Engine Stopping ....................... ...................... |
38 |
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3 |
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Table of Contents |
Refill Capacities....................... ....................... |
39 |
Maintenance Recommendations.......... |
.......... 54 |
Maintenance Interval Schedule........... |
........... 57 |
Warranty Section |
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Warranty Information................... |
................... 82 |
Reference Information Section |
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Reference Materials ........................................ |
83 |
Index Section |
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Index................................ ............................... |
86 |
Maintenance Section
4
Foreword
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.
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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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Safety Section
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Safety Messages
There may be several specific safety messages on your engine. The exact location and a description of the safety messages are reviewed in this section.
Become familiar with all safety messages.
Ensure that all of the safety messages are legible. Clean the safety messages or replace the safety messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water, and soap to clean the safety messages. Do not use
solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety messages. The safety messages that are loosened could drop off the engine.
Replace any safety message that is damaged or missing. If a safety message is attached to a part of the engine that is replaced, install a new safety message on the replacement part. Your Perkins distributor can provide new safety messages.
Illustration 1
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Safety Section
Safety Messages
g03859164
Typical example
6
Safety Section
General Hazard Information
Universal Warning (1)
Illustration 2 |
g01370904 |
One safety message is located on the left side of the engine. One safety message is located on the right side of the engine.
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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General Hazard Information
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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:
Illustration 3 |
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.
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•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.
•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.
7
Safety Section
General Hazard Information
•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.
Illustration 4 |
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:
8 |
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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 |
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hot water to be blown out. This action could result in |
Illustration 5 |
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personal injury. |
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Always use a board or cardboard when you check for |
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When pressurized air and/or pressurized water is |
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a leak. Leaking fluid that is under pressure can |
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used for cleaning, wear protective clothing, protective |
penetrate body tissue. Fluid penetration can cause |
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shoes, and eye protection. Eye protection includes |
serious injury and possible death. A pin hole leak can |
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goggles or a protective face shield. |
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cause severe injury. If fluid is injected into your skin, |
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The maximum air pressure for cleaning purposes |
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you must get treatment immediately. Seek treatment |
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from a doctor that is familiar with this type of injury. |
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must be below 205 kPa ( |
psi 30The maximum water ) |
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pressure for cleaning purposes must be below |
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Containing Fluid Spillage |
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275 kPa ( psi 40 |
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Care must be taken to ensure that fluids are |
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Fluid Penetration |
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contained during performance of inspection, |
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Pressure can be trapped in the hydraulic circuit long |
maintenance, testing, adjusting, and repair of the |
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product. Be prepared to collect the fluid with suitable |
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after the engine has been stopped. The pressure can |
containers before opening any compartment or |
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cause hydraulic fluid or items such as pipe plugs to |
disassembling any component containing fluids. |
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escape rapidly if the pressure is not relieved correctly. |
Dispose of all fluids according to local regulations and |
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Do not remove any hydraulic components or parts |
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mandates. |
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until pressure has been relieved or personal injury |
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Static Electricity Hazard when |
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may occur. Do not disassemble any hydraulic |
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components or parts until pressure has been relieved |
Fueling with Ultra-low Sulfur Diesel |
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or personal injury may occur. Refer to the OEM |
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information for any procedures that are required to |
Fuel |
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relieve the hydraulic pressure. |
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The removal of sulfur and other compounds in ultra- |
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low sulfur diesel fuel (ULSD fuel) decreases the |
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conductivity of ULSD and increases the ability of |
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ULSD to store static charge. Refineries may have |
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treated the fuel with a static dissipating additive. |
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Many factors can reduce the effectiveness of the |
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additive over time. Static charges can build up in |
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ULSD fuel while the fuel is flowing through fuel |
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delivery systems. Static electricity discharge when |
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combustible vapors are present could result in a fire |
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or explosion. Ensure that the entire system used to |
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refuel your machine (fuel supply tank, transfer pump, |
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transfer hose, nozzle, and others) is properly |
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grounded and bonded. Consult with your fuel or fuel |
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system supplier to ensure that the delivery system |
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complies with fueling standards for proper grounding |
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and bonding. |
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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
Illustration 6 |
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.
If dust that may contain asbestos is present, there are several guidelines that should be followed:
9
Safety Section
General Hazard Information
•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 “ CFR291910.1001
•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 7 |
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.
10
Safety Section
Burn Prevention
i06106969
Burn Prevention
Coolant
When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant. 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
The liquid in a battery is an electrolyte. Electrolyte is an acid that can cause personal injury. Do not allow electrolyte to contact the skin or the eyes.
Do not smoke while checking the battery electrolyte levels. Batteries give off flammable fumes which can explode.
Always wear protective glasses when you work with batteries. Wash hands after touching batteries. The use of gloves is recommended.
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Fire Prevention and Explosion
Prevention
Illustration 8 |
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.
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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.
Illustration 9 |
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.
11
Safety Section
Fire Prevention and Explosion Prevention
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 10 |
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.
Ether
Ether is flammable and poisonous.
12
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.
•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.
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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.
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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.
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Mounting and Dismounting
Do not climb on the engine. The engine has 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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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.
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.
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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.
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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.
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.
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.
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Safety Section
Engine Starting
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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. 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.
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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 “−” jump-start 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 jump-start cable to the engine block.
Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires before the engine is started. Repair all frayed electrical wires before the engine is started. Refer to the “Engine Starting” section of this Operation and Maintenance Manual for specific starting instructions.
Grounding Practices
Proper grounding for the engine electrical system is necessary for optimum engine performance and reliability. Improper grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths.
Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft bearing journal surfaces, and to aluminum components.
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Safety Section
Engine Electronics
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 properly, 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 starting motor ground, a starting motor ground to the frame, or a direct engine ground to the frame.
All grounds should be tight and free of corrosion. The engine alternator must be grounded to the negative “-” battery terminal with a wire that is adequate to handle the full charging current of the alternator.
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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.
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15 |
Product Information Section
Model View Illustrations
Product Information
Section
General Information
i06107001
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.
Illustration 11 |
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g03812155 |
(1) Refrigerant compressor |
(5) Crankshaft damper |
(9) Engine oil filter |
(2) Alternator |
(6) Coolant intake |
(10) Turbocharger |
(3) Belt tensioner |
(7) Oil cooler |
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(4) Fuel transfer pump |
(8) Secondary fuel filter |
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16 |
SEBU9072 |
General Information
Product Description
Illustration 12 |
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(11) Engine front lifting eye |
(16) Flywheel housing |
(12) Coolant outlet |
(17) Flywheel |
(13) Water temperature regulator housing |
(18) Starting motor |
(14) Engine rear lifting eye |
(19) Air intake |
(15) Electronic control module |
(20) Oil drain valve |
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i06109638 |
Product Description
The Perkins 2206D-E13TA Industrial Engine have the following characteristics:
•Four-stroke cycle
•Mechanically actuated, electronically controlled fuel injection system
•Turbocharged
•Air to air charged cooled
g03812156
(21)Oil gauge (dipstick)
(22)Air compressor
(23)Location for oil filler
(24)Engine crankcase breather
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.
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Illustration 13 |
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g01387009 |
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Cylinder and valve location |
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( |
ExhaustA valve ) |
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( |
InletB valve |
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Table 1 |
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Engine Specifications |
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Engine |
2206D |
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Arrangement and Cylinders |
In-Line 6 cylinder |
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Bore |
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130 mm ( |
inch5.1 |
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Stroke |
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157 mm ( |
inch6.2 |
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Aspiration |
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ATAAC(1) |
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Displacement |
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12.5 L ( |
cubic763 inch |
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Firing Order |
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1-5-3-6-2-4 |
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Rotation (flywheel end) |
Counterclockwise |
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(1) |
Air-to-air aftercooled |
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Electronic Engine Features
The engine is designed for electronic controls. The integral on board computer controls the operation of the engine. Current 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 speed governor
•Automatic air/fuel ratio control
•Torque rise shaping
•Injection timing control
•System diagnostics
17
General Information
Product Description
Additional Features
The following additional features provide increased engine fuel economy and serviceability:
•Cold starting capability
•Tampering detection
•Diagnostics
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 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. For more) information, refer to the Operation and
Maintenance Manual “ Overhaul Considerations ” topic. )
Aftermarket Products and Perkins
Engines
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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 NOTcovered under the Perkins warranty.
18
Product Identification Information
Plate Locations and Film Locations
Product Identification
Information
i06109784
Plate Locations and Film
Locations
Illustration 14 |
g03812733 |
Typical example
(1)Information plate
(2)Serial number plate
The engine serial number plate is located on the left side of the engine block.
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Illustration 15 |
g01403841 |
Serial number plate
The following information is stamped on the serial number plate: engine serial number, engine model and arrangement number.
The engine information plate is located on top of the valve cover near the middle of the engine.
The following information is on the information plate: engine serial number, engine model, engine arrangement number, maximum altitude of the engine that is necessary to achieve the rated power, horsepower, high idle, full load rpm, fuel settings and other information
i05951816
Emissions CertificationFilm
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.
i06109817
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.
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19 |
Product Identification Information
Reference Information
Record for Reference
Engine Model
Engine Serial number
Engine Low Idle rpm
Engine Full Load rpm
Primary Fuel Filter Element
Secondary Fuel Filters
Lubrication Oil Filter
Breather Fume Filter Element
Auxiliary Oil Filter
Total Lubrication System Capacity
Total Cooling System Capacity
Air Cleaner Element
Drive Belt
20
Operation Section
Product Lifting
Operation Section
Lifting and Storage
i06109876
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.
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 16 |
g03812766 |
(1) Engine lifting eyes
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i06109969
Product Storage
Your Perkins distributor can assist in preparing the engine for extended storage periods.
An engine can be stored for up to 6 months provided all the recommendation are adhered to.
Engine
1.Clean the engine of any dirt, rust, grease, and oil. Inspect the exterior. Paint areas that contain paint damage with a good quality paint.
2.Remove dirt from the air cleaners. Check all seals, gaskets, and the filter element for damage.
3.Apply lubricant to all points in this Operation and Maintenance Manual, “Maintenance Interval Schedule”.
4.Drain the crankcase oil. Replace the crankcase oil and change the oil filters. For the proper procedure, refer to this Operation and Maintenance Manual.
5.Add VCI oil to the crankcase oil. The volume of VCI oil in the crankcase oil should be 3 to 4 percent.
Note: If the engine crankcase is full, drain enough engine oil so the mixture can be added.
6.Remove the air filter elements. Turn the engine at cranking speed with the throttle control in FUEL OFF position. Use a sprayer to add a mixture of 50 percent VCI oil and 50 percent engine oil into the air inlet or turbocharger inlet.
Note: The mixture of VCI oil can be added to the inlet by removing the plug for checking turbocharger boost pressure. The minimum application rate for the VCI oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of engine displacement.
7.Use a sprayer to apply a mixture of 50 percent VCI oil and 50 percent crankcase oil into the exhaust openings. The minimum application rate for the oil mixture is 5.5 mL per L (3 oz per 1000 cu in) of engine displacement. Seal the exhaust pipe and seal any drain holes in the muffler.
8.Remove the fuel from the secondary fuel filter housing. Alternately, empty and reinstall the spinon fuel filter element in order to remove any dirt and water. Drain any sleeve metering fuel pump.
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Clean the primary fuel filter. Fill with calibration fluid or kerosene. Install the primary fuel filter and operate the priming pump. This procedure will send clean oil to the secondary filter and the engine.
Open the fuel tank drain valve in order to drain any water and dirt from the fuel tank. Apply a spray of
calibration fluid or kerosene at the rate of
30 mL per 30 L ( oz per1 7.50 gal US of fuel tank capacity in order to prevent rust in the fuel tank.
Add 0.15 mL per L ( oz per.02 1 gal US |
of |
commercial biocide such as Biobor JF |
to the fuel. |
Apply a small amount of oil to the threads on the fuel tank filler neck and install the cap. Seal all openings to the tank in order to prevent evaporation of the fuel and as a preservative.
9. Remove the fuel injectors. Apply 30 mL ( oz of1 the mixture of oils (50 percent VCI oil and 50 percent engine oil) into each cylinder.
Use a bar or a turning tool in order to turn over the engine slowly. This procedure puts the oil on the cylinder walls. Install all fuel injectors and tighten to the correct torque. Refer to Disassembly and Assembly Manual for more information.
10.Spray a thin amount of a mixture of 50 percent VCI oil and 50 percent engine oil onto the following components: flywheel, ring gear teeth and starter pinion. Install the covers in order to prevent evaporation of the vapors from the VCI oil.
11.Apply a heavy amount of Multipurpose Grease to all outside parts that move, such as rod threads, ball joints, linkage.
Note: Install all covers. Ensure that tape has been installed over all openings, air inlets, exhaust openings, the flywheel housing, the crankcase breathers, the dipstick tubes.
Ensure that all covers are airtight and weatherproof. Use a waterproof weather resistant tape such as Kendall No. 231 or an equivalent. Do not use duct tape. Duct tape will only seal for a short time.
12. Under most conditions, removing the batteries is the best procedure. As an alternative, place the batteries in storage. As needed, periodically charge the batteries while the batteries are in storage.
If the batteries are not removed, wash the tops of the batteries until the tops are clean. Apply an electrical charge to the batteries in order to obtain a specific gravity of 1.225.
Disconnect the battery terminals. Place a plastic cover over the batteries.
21
Lifting and Storage
Product Storage
13.Remove the drive belts from the engine
14.Place a waterproof cover over the engine. Ensure that the engine cover is secure. The cover should be loose enough to allow air to circulate around the engine in order to prevent damage from condensation.
15.Attach) a tag with the storage date to the engine.
16.Remove) the waterproof cover at 2 month or 3 month intervals in order to check the engine for corrosion. If the engine has signs of corrosion, repeat the protection procedure.
Coolant System
Completely) fill the cooling system before storage.
Refer to this Operation and Maintenance Manual
“ RecommendationsFluid for more information”about coolants.
Remove Engine from Storage
1.Remove all outside protective covers.
2.Change the oil and filters.
3.Check the condition of the fan and alternator belts. Replace the belts, if necessary. Refer to this
Operation and Maintenance Manual “ - Belts Inspect/Adjust/Replace for the correct procedure.
4.Replace the fuel filter elements.
5.Remove the plastic covers from the air cleaner elements.
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.
7.Before starting the engine, remove the valve cover or covers. Put a large amount of engine oil on the camshaft, cam followers, and valve mechanism in order to prevent damage to the mechanism.
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SEBU9072 |
Lifting and Storage
Product Storage
10. Before start-up, test the cooling system for a 3 percent to a 6 percent concentration of coolant conditioner. Add liquid coolant conditioner or a coolant conditioner element, if equipped.
Test the coolant mixture for proper nitrite level. If necessary, adjust the coolant mixture.
Prime the engine with clean diesel fuel before starting.
11. Ensure that the cooling system is clean. Ensure that the system is full. Ensure that the system has the correct amount of supplemental cooling system conditioner.
12. On the first day of operation, check the entire engine several times for leaks and correct operation.
Illustration 17 |
g03862125 |
Typical example |
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( plug1 |
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8.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 |
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within the engine of 0.25 bar ( |
psi3.This6 |
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pressure is needed for 15 seconds in order to |
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lubricate the internal surfaces. |
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Remove of the plug shown in illustration 17 in |
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order to connect to the engine oil system. The |
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connection required is 9/16" x 18 tpi. Ensure that |
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the correct oil specification is used, refer to this |
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, |
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Operation and Maintenance Manual “ |
Fluid |
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Recommendations for more information. After the |
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” |
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engine internal surfaces have been lubricated, |
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remove connector and install plug ( Tighten1 plug |
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to a torque of 30 N·m ( |
lb in265Perkins |
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recommends that the procedure must be |
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performed in a minimum ambient temperature of |
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10° C ( |
F 50° |
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9.Check the condition of all rubber hoses. Replace any worn hoses. Replace any damaged hoses.
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Features and Controls
i05422613
Battery Disconnect Switch
(If Equipped)
Illustration 18 |
g03422039 |
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.
NOTICE
Never move the battery disconnect switch to the OFF position while the engine is operating. Serious damage to the electrical system could result.
Battery Disconnect Switch – The battery disconnect switch can be used in order to disconnect the battery from the
engines electrical system. The key must be inserted into the battery disconnect switch before the battery disconnect switch can be turned.
ON – To activate the electrical system, insert the disconnect switch key and turn the battery disconnect switch
clockwise. The battery disconnect switch must be turned to the ON position before you start the engine.
OFF – To deactivate the electrical system, turn the battery disconnect switch counterclockwise to the OFF
position.
23
Features and Controls
Battery Disconnect Switch
The battery disconnect switch and the engine start switch perform different functions. The entire electrical system is disabled when you turn the battery disconnect switch to the OFF position. The battery remains connected to the electrical system when you turn the engine start switch to the OFF position.
Turn the battery disconnect switch to the OFF position and remove the key when you service the electrical system or any other engine components.
Turn the battery disconnect switch to the OFF position and remove the disconnect switch key after you operate the engine. This will prevent the battery from being discharged. The following problems can cause battery discharge:
•short circuits
•current draw via some components
•vandalism
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Monitoring System
The monitoring system is designed to alert the operator to an immediate problem.
The engine has protection in three stages:
•Warning
•Action Alert
•Shutdown
The engine protection may be overridden by the critical condition mode.
The Electronic Control Module (ECM) monitors the following parameters:
•Engine Temperatures
•Engine Pressures
•Engine Speed
If the parameters exceed a trip point for a period that is longer than the delay period, the ECM logs an
event code. The indicator switches to the ON position.
The following parameters are monitored for event codes:
24
Features and Controls
Monitoring System
•Lubricating Oil Pressure
•Coolant Temperature
•Overspeed
•Intake Manifold Temperature
•Intake Manifold Pressure
•Fuel Temperature
The temperature protection is disabled for a period when the engine is cranking in order to compensate for heat soak solutions.
The ECM has dedicated alarm outputs for each of the three stages of protection. There are also dedicated alarm outputs for oil pressure, coolant temperature, and overspeed events which are energized at any stage of protection.
Warning Alarm
The Warning alarm informs the user that the engine is approaching a critical condition.
If the engine is in the Warning condition, then the event will be logged in the memory of the ECM. An
event code will be transmitted over the Perkins Data link and the hard wired Warning output will be
energized. If the engine is in the Warning condition, the event code and output will remain while the
condition exists. The electronic service tool is used to remove the event code from the memory of the ECM.
The trip point for the Warning alarm will be set to a factory default in production. The electronic service tool may be used to alter the trip point for a Warning within predefined limits.
Action Alert
The Action Alert informs the OEM that the engine is approaching a critical condition. The engine should be stopped in a controlled manner. Further running of the engine may result in an immediate shutdown.
If the engine is in the Action Alert condition, the event will be logged in the memory of the ECM. An event
code will be transmitted over the Perkins Data link and the hard wired Action Alert will be energized. If
the engine is in the Action Alert condition, the event code and output will remain while the condition exists. The event code cannot be cleared from the memory of the ECM without using a factory password.
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Shutdown
If the engine reaches the Shutdown condition, one of the following events has occurred: low lubricating oil pressure, high coolant temperature, or overspeed.
The event will be logged in the memory of the ECM. The engine will be shut down. An event code will be
transmitted over the Perkins Data link and the hard wired Shutdown output will be energized. The
Shutdown condition will latch until the ECM is reset. The event code for the shutdown cannot be cleared from the memory of the ECM without using a factory
password.
Critical Protection Override
If the engine is in an application that is critical for safety, the protection system can be overridden in order to ensure the continuation of the power supply during engine fault conditions.
Critical Protection Override will be set by a switch input from the OEM. For example, switch to battery +
in order to disable a critical override. Critical Protection Override input can be enabled in the
electronic service tool by use of a factory password.
When the Critical Protection Override feature is active, the ECM will continue to run the engine in all
shutdown conditions except for Overspeed shutdown.
If the shutdown is overridden, an event code is generated. The ECM will log the event code. The
ECM will energize the following: Warning, Action Alert, Shutdown, oil pressure, coolant temperature and overspeed outputs as normal. The warranty of the engine will be invalidated if the engine is operated in the following conditions: active event code and Critical Protection Override mode.
Standard Warning Outputs
The ECM provides individual outputs in order to drive warning lamps or relays to indicate each of the following fault conditions:
•Diagnostic Fault
•Oil Pressure
•Coolant Temperature
•Overspeed
•Action Alert
•Warning
•Shutdown
If the ECM detects a warning for the coolant temperature , the output on the coolant temperature will be energized and the warning output will be energized. If the ECM detects a warning for the low oil pressure, the output on the oil pressure will be energized and the warning output will be energized.
SEBU9072 |
25 |
Features and Controls
Sensors and Electrical Components
If the Action Alert alarms are enabled and the ECM detects a coolant temperature condition, the output
on the coolant Temperature will be energized and the output on the Action Alert will be energized.
If the engine shuts down on low oil pressure the output on the low oil pressure will be energized and the output on the shutdown will be energized. If the engine shuts down on coolant temperature, or the engine shuts down on overspeed the dedicated output and the shutdown output will be energized.
Shutdown Reset
The cause of an engine shutdown must be investigated. Corrective action must be taken before the system is reset in order to operate the engine.
After an engine shutdown, operate the reset input of the ECM or power down the controller.
Powering down the electronic control module can be achieved by the operation of the keyswitch into sleep mode. The electronic control module can be powered down by isolating the power supply to the electronic control module.
Note: The ECM cannot be reset by using the Reset input until the engine has stopped.
Diagnostic
If there is a fault with an engine protection sensor on the engine, the engine activates a diagnostic code. The engine communicates the diagnostic code to the operator via the Diagnostic output. The diagnostic code provides an indication to the operator of a fault with the engine protection system. Running of the engine for a prolonged period in this condition may result in engine failure. The output is generally used to drive lamps or relays.
The following sensors are monitored in order to determine if the sensors are out of the normal range, an open circuit, or a short circuit:
•Atmosphere Pressure
•Lubricating Oil Pressure
•Inlet Manifold Pressure
•Inlet Manifold Temperature
•Fuel Temperature
•Coolant Temperature
•Engine Speed
•Desired Speed Input
The Diagnostic output differs from the Warning and Shutdown outputs. The Warning and Shutdown outputs refer to the operation of the engine. The Diagnostic output refers to the condition of the electronic system and software system.
A diagnostic fault may develop on the lubricating oil pressure or coolant temperature sensors. For example, if a Shutdown protection sensor has a fault, this will result in an engine shutdown, unless the system is in critical protection override. If a diagnostic fault occurs, with one of the engine speed sensors while the engine is running. The engine continues to run by using the other timing sensor for reference.
i06137289
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.
26 |
SEBU9072 |
Features and Controls
Sensors and Electrical Components
Illustration 19 |
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g03822008 |
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( |
Coolant1 temperature) sensor |
( |
Electronic4 control) module |
( |
Camshaft7 speed) timing sensor |
( |
Inlet2 manifold)pressure sensor |
( |
Starting5 motor) |
( |
Barometric8 pressure) sensor |
( |
Inlet3 air temperature) sensor |
( |
Oil6pressure sensor) |
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27 |
Features and Controls
Sensors and Electrical Components
Illustration 20 |
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g03822009 |
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( |
Alternator9 ) |
( |
1 |
Fuel1 temperature) sensor |
( |
Crankshaft10 speed timing) sensor |
( |
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Fuel12 pressure sensor ) |
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