Perkins Engine 2206-E13 Service Manual

Operation and Maintenance Manual

SEBU8337-00

May 2008

2206-E13 Industrial Engine

(Engine)

TGB TGD

(Engine)

TGF

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.

SEBU8337 3

Table of Contents

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

Safety Section

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

General Hazard Information ................................... 6

Burn Prevention ...................................................... 7

Fire Prevention and Explosion Prevention .............. 8

Crushing Prevention and Cutting Prevention .......... 9

Mounting and Dismounting ................................... 10

Before Starting Engine .......................................... 10

Engine Starting ..................................................... 10

Engine Stopping .................................................... 11

Electrical System ................................................... 11

Warranty Secti

Warranty Information ............................................ 82

Index Section

Index ..................................................................... 83

Engine Electronics ................................................ 12

Product Information Section

General Information .... .......................................... 13

Model Views ......................................................... 14

Product Identiﬁcation Information ........................ 17

Operation Section

Lifting and Storage ................................................ 21

Gauges and Indic ators .......................................... 22

Features and Controls .......................................... 23

Engine Diagnostics ............................................... 29

Engine Starting ..................................................... 30

Engine Operation .................................................. 33

Engine Stopping ................................................... 34

Cold Weather Operation ....................................... 35

Maintenance Section

Reﬁll Capacities .................................................... 38

Maintenance Interval Schedule ............................ 54

4 SEBU8337 Foreword

Foreword

Literature Information

This manual con lubrication and maintenance information. This manual should be stored in or near the engine area in a literatur 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 consiste

Some photographs or illustrations in this manual show details from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvemen may have caused changes to your engine which are not included in this manual. Whenever a question arises reg 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 si precautions listed in the safety section before operating or performing lubrication, maintenance and repair on

this product.

tains safety, operation instructions,

e holder or literature storage area. Read,

ncy.

or attachments that may be different

t and advancement of product design

arding your engine, or this manual, please

tuations. Read and understand the basic

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

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

ive maintenance program is followed, a

mize operating costs through cost

rvice should be performed at the

lso governs the Maintenance Interval

t lubrication and maintenance than is

Maintenance Intervals

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

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

ce schedules be reproduced and displayed

the engine’s permanent record.

tor can assist you in adjusting your

Overhaul

Operatio

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

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

ey assist with developing the skills and

as the operator gains knowledge of the

ation section is a reference for operators.

pping the engine. This section also includes a

Maintenance

The mai The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance interv referenced to detailed instructions that follow.

ntenance section is a guide to engine care.

als. Items in the maintenance schedule are

Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the i interval. Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer or your P regarding overhaul programs. If you experience a major engine failure, there are also numerous after f your Perkins dealer or your Perkins distributor for information regarding these options.

nterval and the maintenance items in that

erkins distributor offers a variety of options

ailure overhaul options available. Consult with

California Proposition 65 Warning

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

defects, and other reproductive harm. Battery

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

SEBU8337 5

Safety Section

Safety Messages

Safety Section

i02767956

Safety Messages

Illustration 1

Location of safety message

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. Please 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 of 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.

g01384682

Universal Warning (1)

The safety message for the universal warning is locatedonbothsidesofthevalvecoverbase.

Illustration 2

g00934493

6 SEBU8337 Safety Section General Hazard Information

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.

i02328435

General Hazard Information

Keep the engine debris, oil, tools, and other items from the deck, from walkways, and from steps.

Never put maintenance ﬂuids into glass containers. Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleani

Report all necessary repairs.

Do not allow unauthorized personnel on the equipment.

Ensure that the power supply is disconnected before you work on the bus bar or the glow plugs.

Perform maintenance on the engine with the equipment in the servicing position. Refer to the OEM informat equipment in the servicing position.

free from foreign material. Remove

ng solutions with care.

ionfortheprocedureforplacingthe

Pressure Air and Water

Illustration 3

Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment.

Illustration 4

Wear a hard hat, protective glasses, and other protective equipment, as required.

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

Make sure that all protective guards and all covers are secured in place on the engine.

g00104545

g00702020

Pressurize and/or hot water to be blown out. This could result in personal injury.

The direct application of pressurized air or pressurized water to the body could result in personal injury.

When pressurized air and/or water is used for cleaning, and eye protection. Eye protection includes goggles oraprotectivefaceshield.

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

d air and/or water can cause debris

wear protective clothing, protective shoes,

sure for cleaning purposes must be below

Fluid Penetration

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

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

can be trapped in the hydraulic circuit long

pidly if the pressure is not relieved correctly.

ssure has been relieved or personal injury

nal injury may occur. Refer to the OEM

SEBU8337 7

Safety Section

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 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

Illustration 5

g00687600

a bare hand. Remove the ﬁllercapslowlyinorder to relieve pressure.

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 in order to ensure that ﬂuids are contained during performance of inspection, maintenance, testing, adjusting and repair of the engine. Make provision to collect the ﬂuidwitha suitable container before any compartment is opened or before any component is disassembled.

Only use the tools that are suitable for collecting

•

ﬂuids and equipment that is suitable for collecting ﬂuids.

Only use the tools that are suitable for containing

•

ﬂuids and equipment that is suitable for containing ﬂuids.

Obey all local regulations for the disposal of liquids.

i02088921

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

Oils

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

If the application has a makeup tank, remove the cap for the makeup tank after the engine has stopped. The ﬁller cap must be cool to the touch.

Batteries

The liquid in a battery is an electrolyte. Electrolyte is an acid that can cause personal injury. Do not allow electrolytetocontacttheskinortheeyes.

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.

Burn Pre

Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is perfo the appropriate system before any lines, ﬁttings or related items are disconnected.

rmed on the engine. Relieve all pressure in

vention

8 SEBU8337 Safety Section Fire Prevention and Explosion Prevention

i02813488

Fire Prevention and Explosion Prevention

on 6

Illustrati

All fuels, most lubricants, and some coolant mixtures are ﬂammabl

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

A ﬂash ﬁre may result if the covers for the engine crankcase are removed within ﬁfteen minutes after an emergen

Determine whether the engine will be operated in an environme drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, property

onto electrical components can cause

nt that allows combustible gases to be

damage, or engine damage could result.

g00704000

cy shutdown.

Exhaust shield

s (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 cor

rectly.

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 ﬂa

me cutting.

Wiring must be kept in good condition. All electrical wires must be

correctly routed and securely attached. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Cle

an all electrical connections and tighten

all electrical connections.

Eliminate a

ll 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 cir

cuit breakers.

Arcing or sparking could cause a ﬁre. Secure connectio

ns, recommended wiring, and correctly maintained battery cables will help to prevent arcing or sparking.

Inspect all lines and hoses for wear or for deterioration. The hoses must be correctly routed. The lines

and hoses must have adequate support and secure clamps. Tighten all connections to the recommended torque. Leaks can cause ﬁres.

Oil ﬁlters and fuel ﬁlters must be correctly installed. The ﬁlter housings must be tightened to the correct torque.

If the application involves the presence of combustible gases, co

nsult 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 engi

ne. 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 rag

sandanyﬂammable materials in protective containers. Do not smoke in areas that are used for storing ﬂammable materials.

Do not expose the engine to any ﬂame.

Illustration 7

g00704059

SEBU8337 9

Safety Section

Crushing Prevention and Cutting Prevention

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

Illustration 8

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 ahydrometer.

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

n you are refueling an engine. Do

e before refueling.

g00704135

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not install any lines that are bent or damaged. Do not clip any other items to the high pressure line

Repair any lines that are loose or damaged. Leaks can cause ﬁre Perkins distributor for repair or for replacement parts.

Check lines, your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recomm

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 ex

•

Outer coverings are ballooning.

•

Flexible part of the hoses are kinked.

•

Outer cover

•

End ﬁttings are displaced.

•

Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, this will help to parts, and excessive heat.

pressure lines. Do not strike high

s. Consult your Perkins dealer or your

tubes and hoses carefully. Do not use

ended torque.

posed.

s have embedded armoring.

prevent vibration, rubbing against other

i01359666

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

The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the 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.

Crushing P Cutting Prevention

Support the component properly when work beneath the compon

Unless other maintenance instructions are provided, never att running.

Stay clea parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, reinstal

Keep objects away from moving fan blades. The fan blades w

ent is performed.

empt adjustments while the engine is

r of all rotating parts and of all moving

l the guards.

ill throw objects or cut objects.

revention and

10 SEBU8337 Safety Section Mounting and Dismounting

When objects ar order to avoid injury to the eyes.

Chips or other are struck. Before objects are struck, ensure that no one will be injured by ﬂying debris.

e struck, wear protective glasses in

debris may ﬂy off objects when objects

i01372247

Mounting an d Dismounting

Inspect the steps, the handholds, and the work area before mounting the engine. Keep these items clean and keep these items in good repair.

Mount the engine and dismount the engine only at locations that have steps and/or handholds. Do not climb on the engine, and do not jump off the engine.

Face the engine in order to mount the engine or dismount the engine. Maintain a three-point contact with the steps and handholds. Use two feet and one hand or use one foot and two hands. Do not use any controls as handholds.

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

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

Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are provided in o circuits are also provided in order to help prevent engine damage.

See the Service Manual for repairs and for adjustments.

sure that the lighting system for the

rvice procedures. To help prevent an

rder to help prevent personal injury. The

i02583384

Engine Starting

Do not stand on components which cannot support your weight. Use an adequate ladder or use a work platform. Secure the climbing equipment so that the equipment will not move.

Do not carry tools or supplies when you mount the engine or when you dismount the engine. Use a hand line to raise and lower tools or supplies.

i02813489

Before Starting Engine

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

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

Inspect the engine for potential hazards.

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

Do not use aerosol types of starting aids such as ether. Such use could result i n 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.

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.

SEBU8337 11

Safety Section

Engine Stopping

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 en

gine is started in an enclosed area,

vent the engine exhaust to the outside.

Note: The eng

inemaybeequippedwithadevicefor 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.

i01462046

Engine Stopping

Stop the engine according to the procedure in the Operat Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine

Use the Emergency Stop Button (if equipped) ONLY in an emerg Stop Button for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem t corrected.

Stop the e during the initial start-up of a new engine or an engine that has been overhauled. This may be accomplished by shutt shutting off the air supply to the engine.

To st o p a power to the engine.

ion and Maintenance Manual, “Engine

components.

ency situation. Do not use the Emergency

hat caused the emergency stop has been

ngine if an overspeed condition occurs

ing off the fuel supply to the engine and/or

n electronically controlled engine, cut the

Check the elect

rical wires daily for wires that are loose or frayed. Tighten all loose electrical connections before the engine is started. Repair all frayed electr

ical wires before the engine is started. See the Operation and Maintenance Manual for speciﬁc starting instructions.

Grounding Practice

Illustration 9

Typical example

(1) Starting motor to engine block (2) Starting motor to battery negative

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.

g01403749

i02814681

Electrical System

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

To help prevent sparks from igniting combustible gases that are produced by some batteries, the negative “−” cable should be connected last from the external power source to the negative “−” terminal of the starting motor. If the starting motor is not equipped with a negative “−” terminal, connect the cable to the engine block.

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 with a wire that is adequate to handle the full charging current of the alternator.

12 SEBU8337 Safety Section Engine Electronics

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

y connections and the ground

i02773399

Engine Electron ics

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

This engine h Engine Monitoring System. The Engine Control Module (ECM) has the ability to monitor the engine operating c extend outside an allowable range, the ECM will initiate an immediate action.

The following actions are available for engine monitoring control: WARNING, ACTION ALERT, and SHUTDOWN.

ult in personal injury or death and/or

as a comprehensive, programmable

onditions. If any of the engine parameters

Many of the parameters that are monitored by the ECM can be p functions. The following parameters can be monitored as a part of the Engine Monitoring System:

Atmospheric Pressure

•

Intake Man

•

Coolant Temperature

•

Engine Oil Pressure

•

Crankshaf

•

Camshaft Position

•

Fuel Temperature

•

Intake Ma

•

System Voltage

•

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

rogrammed for the engine monitoring

ifold Air Pressure

tPosition

nifold Temperature

the monitoring system and the engine

SEBU8337 13

Product Information Section

General Information

Product Information Section

General Information

i01889424

Welding on Engines with Electronic Controls

NOTICE Proper welding procedures are necessary in order to avoid damage to the engine’s ECM, sensors, and associated components. When possible, remove the component from the unit and then weld the component. If removal of the component is not possible, the following procedure must be followed when you weld with a unit that is equipped with an Electronic Engine. The following procedure is considered to be the safest procedure to weld a component. This procedure should provide a minimum risk of damage to electronic components.

NOTICE Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can cause damage to the drive train bearings, hydraulic components, electrical components, and other components.

Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. This will help reduce the possibility of damage.

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

OFF position.

2. Disconnect the negative battery cable from the

battery. If a battery disconnect switch is provided, open the switch.

Illustration 10

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

(1) Engine (2) Welding rod (3) Keysw itch in the OFF position (4) Battery disconnect switch in the open position (5) Disconnected battery cables (6) Battery (7) Electrical/Electronic com ponent (8) Maximum distance between the component that is being

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

g00765012

4. Connect the welding ground cable directly to the

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

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

3. Disconnect the J1/P1 connectors from the ECM. Move the harness to a position that will not allow the harness to accidentally move back and make contact with any of the ECM pins.

5. Protect the wiring harness from welding debris and spatter.

6. Use standard welding practices to weld the materials.

14 SEBU8337 Product Information Section Model Views

Model Views

i02770579

Model View Illustrations

Illustration 11

Typical example

Left side engine view

(1) Connection for the breather (2) Electronic control module (ECM) (3) Fuel priming pump

(4) Secondary fuel ﬁlter (5) Pr imary f u el ﬁlter (6) Fuel pump

g01385634

(7) Crankshaft damper (8) Oil ﬁ ller

SEBU8337 15

Product Information Section

Model Views

Illustration 1 2

Typical example

Right side engine view

(9) Water temperature regulator housing (10) Alternator (11) Water pump

(12) Turbocharger (13) Oil ﬁlter (14) Oil drain plug

Engine Description

Table 1

2206 Engine Speciﬁcations

Cylinders and Arrangement In-line six cylinder

Bore 130 mm (5.2 inch)

Stroke 157 mm (6.2 inch)

Displacement

Firing Order

Rotation (ﬂywheel end) Counterclockwise

12.5 L (7

63 in3)

1-5-3-6-2-4

i02770677

g01385635

(15) Oil cooler (16) Exhaust manifold

The electronic engines that are covered by this manual have the following characteristics: direct fuel injection, electronic unit injection that is mechanically actuated, turbocharged, and air-to-air aftercooled (ATAAC).

The electronic engine control system provides the following functions: electronic governing, automatic air to fuel ratio control, injection timing control, and system diagnostics.

An electronic governor controls the output of the unit injectors in order to maintain the engine rpm that is desired.

16 SEBU8337 Product Information Section Model Views

Very high injec electronically controlled, mechanically actuated unit injectors. The injectors combine the pumping and the electronic fu injection. The unit injectors accurately control smoke limiting, white smoke, and engine acceleration rates.

There is one unit injector per cylinder. Individual unit injectors meter the fuel. The individual unit injectors also pump the done under high pressure. High injection pressures help to reduce fuel consumption and emissions. The use of th electronic control of injection timing. The injection timing varies with engine operating conditions. The engine perf areas:

Starting

•

Emissions

•

Noise

•

Fuel consu

•

The timing advance is achieved through precise control of controlled by adjusting the ﬁring duration. The information is provided to the Electronic Control Module (EC the camshaft position sensor. The information is for detection of cylinder position and engine speed.

tion pressures are produced by

el metering (duration and timing) during

fuel. The metering and the pumping is

is type of unit injector provides total

ormance is optimized in the following

mption

the injector ﬁring. Engine speed is

M) by the crankshaft position sensor and

Engine efﬁcien engine performance depend on adherence to proper operation and maintenance recommendations. This includes the u and lubrication oils.

cy, efﬁciency of emission controls, and

se of recommended fuels, coolants

Aftermarket Products and Perkins Engines

When auxiliary devices, accessories, or consumables (ﬁlters, add 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 oth accessories, or consumables are NOT Perkins defects. Therefore, the defects are NOT covered under the P

itives, catalysts, etc) which are made by

er manufacturers’ devices,

erkins warranty.

The engines have built-in diagnostics in order to ensure that all of the components are functioning and opera component deviation from the programmed limits, the operator will be alerted to the condition by a DIAGNOS panel. An electronic service tool that is provided by Perkins may be used to read the diagnostic codes. These co Refer to Operation and Maintenance Manual, “Engine Diagnostics” for additional information.

The cooling system consists of the following items: a centrifugal pump that is driven by a gear, water temper that incorporates a shunt system.

The eng type pump. The engine lubricating oil is cooled and ﬁltered. Bypass valves provide unrestricted ﬂow of lub viscosity is high or if either the oil cooler or the oil ﬁlter elements (paper cartridge) become plugged.

ting properly. In the event of a system

TIC lamp that is mounted on the control

des are logged and stored in the ECM.

ature regulator, an oil cooler, and a radiator

ine lubricating oil is supplied by a gear

rication oil to the engine parts when the oil

SEBU8337 17

Product Information Section

Product Identiﬁcation Information

i02770689

Plate Locations and Film Locations

Illustration 1 3

(1) Serial number plate

s engines are identiﬁed by serial numbers.

Perkin These numbers are shown on the engine serial number plate. Perkins distributors need these number were included with the engine. This permits accurate identiﬁcation of replacement part numbers.

s in order to determine the components that

g013856

18 SEBU8337 Product Information Section Product Identiﬁcation Information

Serial Number Plate (1)

Illustration 14

Typical exam ple

The engine serial number plate is located on the right side of the engine block.

g01403841

Tot a l Lu br ic at

ion System Capacity

_____________________

Total Cooling System Capacity _________________________

Air Cleaner Element _______________________________________

Fan Drive Belt

______________________________________________

Alternator Belt ______________________________________________

Engine serial number

_____________________________________

Designation _________________________________________________

Engine Rating ________ ______________________________________

i02563635

Reference Numbers

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

Record for Reference

Engine Model _______ ________________________________________

Engine Serial number _____________________________________

Engine rpm __________________________________________________

Primary Fuel Filter _________________________________________

Secondary Fuel Filter Element ___ _______________________

Lubrication Oil Filter Element ___________________________

SEBU8337 19

Product Information Section

Product Identiﬁcation Information

i02770895

Emissions Certiﬁcation Film

Illustration 1 5

Typical example

The emission certiﬁcation ﬁlm is located on the left hand side of the valve mechanism cover.

i02817239

Customer Speciﬁed Parameters

To record programmed speciﬁcations, use the following blanks.

Customer Passwords (If required).

First Password _______________________________________ ____

•

Second Password ________________________________ ______

•

Rating Selection (L-N) _____________________________ _____

Equipment ID ______________________________________________

g01385765

Programmable Monitoring System (PMS)

The Programmable Monitoring System determines the level of action that is taken by the ECM in response to a condition that can damage the engine. These conditions are identiﬁed by the ECM from the signals that are produced from the following sensors.

Inlet Manifold Temperature Sensor

•

Coolant Temperature Sensor

•

Engine Oil Pressure Sensor

•

Engine Crankshaft/Camshaft Sensors

•

Inlet Manifold Pressure Sensor

•

Fuel Temperature Sensor

•

20 SEBU8337 Product Information Section Product Identiﬁcation Information

Table 2

Event Code Parameter State Trip Point Delay Time

E162 High Boost Pressure

-1

-2

E360

-1

-2

-3

E361

-1 Warn Operator (1) On 104 °C (2190 °F) 60 seconds

-2 Action Alert (2) Always On 105 °C (221 °F) 10 seconds

-3 Engine Shutdown (3) Always On 108 °C (226 °F) 10 seconds

E362

-1

-2

-3

E363

-1

-2

E368

-1

-2 Action Alert (2) Always On 78 °C (172 °F) 10 seconds

Warn Operator (1) On 300 kPa (43.5 psi)

Action Alert (2) Always On

Low Engine Oil Pressure

Warn Operator (1) On 200 kPa (29 psi)

Action Alert (2) Always On

Engine Shutdown (3) Always On

High Engine Coolant Temperature

Engine Overs

Warn Operator (1) On

Action Alert (2) Always On

Engine Shutdown (3) Always On

High Fuel Supply Temperature

Warn Operator (1) On 60 °C (140 °F)

Action Alert (2) Always O n 68 °C (154 °F)

High Engine Intake Manifold Air Temperature

Warn Operator (1) On 75 °C (167 °F)

peed

Map 5 seconds

Map 2 seconds

2000 RPM 1 second

2050 RPM 0 second

2140 RPM 0 second

60 seconds

Refer to Troubleshooting , “System Conﬁ guration Parameters” for additional information for the Programmable Monitoring System.

SEBU8337 21

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

Product Lifting

Illustration 16

i02513632

g00103219

i02848873

Product St orag e

Refer to Perkin for information on engine storage.

There is three Level “A, B and C”.

Level “A ”

Level “A” will engines and 12 month protection for gas engines. This is for engines that are transported by a container or a truck. Le that are within the United kingdom and within Europe.

Level “B ”

This level is give protection under normal storage condition from −15° to +55°C (5° to 99°F) and “90%” relative hu transportation of items overseas.

s Engine Company limited, Stafford

different levels of engine storage.

give protection for 12 month for diesel

vel “A” is for the transportation of items

additional to level “A”. Level “B ” will

midity for two year. Level “B” is for the

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.

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 ﬁ xtures in order to obtain proper balance and safety.

ToremovetheengineONLY,usetheliftingeyesthat are on the engine.

Lifting eyes are designed and installed for speciﬁc engine arrangements. 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 dealer for information regarding ﬁxtures for proper engine lifting.

Level “C ”

In order to p Perkins Engines Company Limited Stafford.

rotect the product to Level “C”, contact

22 SEBU8337 Operation Section Gauges and Indicators

Gauges and Indicators

i02773410

Gauges and Indicators

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

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

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

If no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded, STOP the engine

ay not have the same gauges or all of

e normal operating range by observing

hanges in gauge readings indicate

eadings are within speciﬁcations.

or for assistance.

NOTICE

. Engine damage can result.

Engine Oil Pressure – The range for the engine oil

pressure is 420 kPa (61 psi).

Jacket Wat

Typical water temperature into the engine

is 88 °C (190 °F). Higher temperatures may occur u temperature reading may vary according to load. The reading should never exceed 107 °C (224 °F).

1. Ahighwate

cooling system.

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

nder certain conditions. The water

Tachomete

speed (rpm).

Ammeter – This gauge indicates the

amount of charge or discharge in the

battery charging circuit. Operation of the

Service Hour M eter – The gauge indicates

operating hours of the engine.

er Coolant Temperature –

r temperature switch is installed in the

r–This gauge indicates engine

SEBU8337 23

Operation Section

Features and Controls

i02780670

Monitoring System

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 of time that is longer than the delay period, the ECM logs an event code and the indicator switches ON.

The following parameters are monitored for event codes:

Lubricating Oil Pressure

•

Coolant Temperature

•

Overspeed

•

Intake Manifold Temperature

•

Intake Manifold Pressure

•

Fuel Temperature

•

The temperature protection is disabled for a period of time when the engine is cranking in order to compensate for heat soak solutions.

Warning Alarm

The Warning ala is approaching a critical condition.

If the engine is event will be logged in the memory of the ECM. A event code will be transmitted over the Perkins Data link and energized. If the engine is in the Warning condition, the event code and output will remain while the condition ex remove the event code from the memory of the ECM. ThetrippointfortheWarningalarmwillbesettoa factory def toolmaybeusedtoalterthetrippointforaWarning within predeﬁned limits.

rm informs the user that the engine

in the Warning condition, then the

the hard wired Warning output will be

ists. The electronic service tool is used to

ault in production. The electronic service

Action Alert

The Action Alert informs the OEM that the engine is approaching a critical condition. The engine should be stopped the engine may result in an immediate shutdown.

If the engi will be logged in the memory of the ECM. A event code will be transmitted over the Perkins Data link and the har the engine is in the Action Alert condition the event code and output will remain while the condition exists. The event of the ECM without using a factory password.

in a controlled manner. Further running of

ne is in the Action Alert condition, the event

d wired Action Alert will be energized. If

code can not be cleared from the memory

Shutdown

If the eng the following events has occurred: low lubricating oil pressure, high coolant temperature or overspeed. The even The engine will be shut down. A event code will be transmitted over the Perkins Data link and the hard wir Shutdown condition will latch until the ECM is reset. The event code for the shutdown can not be cleared from th password.

ine reaches the Shutdown condition,one of

t will be logged in the memory of the ECM.

ed Shutdown output will be energized. The

e memory of the ECM without using a factory

Critical Protection Override

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.

If the e safety, the protection system can be overridden in order to ensure the continuation of the power supply durin

ngine is in an application that is critical for

g engine fault conditions.

24 SEBU8337 Operation Section Features and Controls

Critical Prote input from the OEM. For example, this may be a switch to battery + in order to disable a critical override. Cri 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 con shutdown. If the shutdown is overridden a event code is generated. The ECM will log the event code. The ECM will ene Alert, Shutdown, oil pressure, coolant temperature, and overspeed outputs as normal. The warranty of theenginew in the following conditions: active event code and Critical Protection Override mode.

ctionOverridewillbesetbyaswitch

tical Protection Override input can be

ditions with the exception of Overspeed

rgize the following: Warning, Action

ill be invalidated if the engine is operated

Standard Warning Outputs

The ECM provides individual outputs in order to drive warning lamps or relays to indicate each of the following

Diagnostic Fault

•

Oil Pressure

•

Coolant Te

•

Overspeed

•

Action Alert

•

Warning

•

Shutdown

•

If the ECM detects a warning for the coolant temperature , the output on the coolant temperature will be en energized. If the ECM detects a warning for the low oil pressure, the output on the oil pressure will be energize

If the Action Alert alarms are enabled and the ECM detects a 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 outp engine shuts down on coolant temperature or the engine shuts down on overspeed the dedicated output

fault conditions:

mperature

ergized and the warning output will be

d and the warning output will be energized.

coolant temperature condition, the output

ut on the shutdown will be energized. If the

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: It is not possible to reset the ECM by using the Reset input until the engine has come to rest.

Altitude derate

At high altitudes or high ambient temperatures, the engine will be derated. The engine derate information can be obtained from the Applications Department at Perkins Engines Company Limited Stafford.

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

•

SEBU8337 25

Operation Section

Features and Controls

The Diagnostic Shutdown outputs. The Warning and Shutdown outputs refer to the operation of the engine. The Diagnostic ou electronic system and software system.

A diagnostic oil pressure or coolant temperature sensors. For example, if a Shutdown protection sensor has a fault, this will res system is in critical protection override. If a diagnostic fault occurs with one of the engine speed sensors while the en run by using the other timing sensor for reference.

output differs from the Warning and

tput refers to the condition of the

fault may develop on the lubricating

ult in an engine shutdown, unless the

gine is running. The engine continues to

i02772006

Sensors and Electrical Components

Sensor Locations

Illustration 17 shows the typical locations of the sensors on the engine. Speciﬁc engines may appear different from the illustration due to differences in applications.

26 SEBU8337 Operation Section Features and Controls

Illustration 1 7

(1) Engine coolant temperature sensor (2) Intake m anifold pressure sensor (3) Intake manifold air temperature sensor

(4) Atmospheric pressure sensor (5) Secondary position sensor (Camshaft) (6) Engine o il pressure sensor

Failure of Sensors

All Sensors

A failure of any of the sensors may be caused by one of the following malfunctions:

Sensor output is open.

•

Sensor output is shorted to “- battery” or “+ battery”.

•

Measured reading of the sensor is out of the

•

speciﬁcation.

g01386180

(7) Fuel temper ature sensor (8) Primary position sensor (Crankshaft) (9) Electronic control module (ECM)

Programmable Monitoring System (PMS)

The Programmable Monitoring System determines the level of action that is taken by the Engine Control Module (ECM) in response to a condition that can damage the engine. These conditions are identiﬁed by the ECM from the signals that are produced from the following sensors.

Engine Coolant Temperature Sensor 1

The coolant temperature sensor monitors engine coolant temperature. The output of the ECM can indicate a high coolant temperature through a relay or a lamp. The coolant temperature sensor is used by the ECM to determine initiation of the Cold Start Condition.

SEBU8337 27

Operation Section

Features and Controls

Failure of the C

oolant Temperature

Sensor

The ECM will de temperature sensor. The diagnostic lamp will warn the operator about the status of the coolant temperature temperature sensor will cause a shutdown of the engine. The faulty sensor should be replaced. Refer to Disassemb Temperature Sensor - Remove and Install”.

tect a failure of the coolant

sensor. A failure of the coolant

ly and Assembly Manual, “Coolant

Intake Manifold Pressure Sensor 2

The intake ma pressure in the intake manifold. A signal is sent to the ECM. A failure of the inlet manifold pressure sensor will limit t

Intake Mani

nifold pressure sensor measures boost

he power of the engine.

fold Air Temperature

Sensor 3

The Intake manifold air temperature sensor measures the intake air temperature. A signal is sent to the ECM. The in also used by the ECM to determine initiation of the Cold Start Strategy.

take manifold air temperature sensor is

Low Oil Pressur

The setpoint for the low pressure warning is dependent upo active and logged only if the engine has been running for more than 8 seconds.

e Warning

n the engine speed. The fault will be

Low Oil Pressure

The very low oi the engine speed. If very low oil pressure is detected, the ECM will stop the engine immediately unless Critical Eve

l pressure setpoint is dependent upon

nts Override is active.

Failure of the Engine Oil Pressure Sensor

The ECM will detect failure of the engine oil pressure sensor. The diagnostic lamp warns the user about the status of the oil pressure related strategies will be disabled in the event of a failure of the engine oil pressure sensor. Afailureof a shutdown of the engine. The faulty sensor should be replaced. Refer to Disassembly and assembly Manual, “E Install”.

engine oil pressure sensor. The engine

the engine oil pressure sensor will cause

ngine Oil Pressure Sensor - Remove and

Fuel Temperature Sensor 7

Atmospheric Pressure Sensor 4

All the output signals from the pressure sensors are matched to the output signal of the atmospheric pressure the atmospheric pressure sensor is used by the ECM in order to determine the operating altitude of the engine. I

Secondar

The signal from the secondary speed/timing sensor is used b determine the stroke that the pistons are on. The secondary speed/timing sensor may be used by the ECM in or speed/timing sensor is faulty.

In order refer to Troubleshooting, “Engine speed/Timing sensor-Test”.

sensor during calibration. The signal from

f necessary, the ECM can derate the engine.

y Speed/Timing Sensor 5

y the ECM on engine start-up in order to

der to operate the engine if the primary

to check the correct operation of the sensor,

Engine Oil Pressure Sensor 6

The engine oil pressure sensor is an absolute pressure sensor that measures the engine oil

re in the main oil gallery. The engine oil

pressu pressure sensor detects engine oil pressure for diagnostic purposes. The engine oil pressure sensor

a signal to the ECM .

sends

The fu el te temperature. The signal from the sensor allows the ECM to compensate for changes in the fuel temperatu power.

mperature sensor monitors the fuel

re by adjusting the fuel rate for constant

Primary Speed/Timing Sensor 8

If the ECM speed/timing sensor , the “DIAGNOSTIC” lamp will indicate a diagnostic fault code which will be logged in the ECM

If the ECM does not receive a signal from the primary speed/t from the secondary speed/timing sensor (2). The ECM continually checks in order to determine if there is fails, the faulty sensor should be replaced. Refer to Disassembly and Assembly Manual, “Crankshaft Positi Disassembly and Assembly Manual, “Camshaft Position Sensor - Remove and Install”.

Intermittent failure of the sensors will cause erratic engine control.

does not receive a signal from the primary

memory.

iming sensor (9), the ECM will read the signal

a signal from both sensors. If either sensor

on Sensor - Remove and Install” or refer to

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