Perkins Engine 2506-15 Service Manual
Operation and
Maintenance
Manual
SEBU8313
July 2006
2506-15 Industrial Engine
(Engine)
MGA
MGB (Engine)
MGD (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.
SEBU8313 3
Table of Contents
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 ........ 10
Mounting and Dismounting ................................... 10
Before Starting Engine ........................................... 11
Engine Starting ...................................................... 11
Engine Stopping .................................................... 11
Electrical System .................................................. 12
Warranty Secti
Warranty Information ............................................ 75
on
Index Section
Index ..................................................................... 76
Engine Electronics ................................................ 13
Product Information Section
General Information .............................................. 14
Model Views ......................................................... 15
Product Identification Information ........................ 18
Operation Section
Lifting and Storage ................................................ 23
Gauges and Indicators .......................................... 24
Features and Controls .......................................... 25
Engine Diagnostics ............................................... 30
Engine Starting ..................................................... 32
Engine Operation .................................................. 34
Engine Stopping ................................................... 35
Cold Weather Operation ....................................... 36
Maintenance Section
Refill Capacities .................................................... 39
Maintenance Interval Schedule ............................ 51
4 SEBU8313
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.
n
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.
SEBU8313 5
Safety Section
Safety Messages
Safety Section
i02581679
Safety Messages
There may be s
engine. The exact location and a description of the
warning signs are reviewed in this section. Please
become famil
Ensure that all of the warning signs are legible. Clean
the warning s
the words cannot be read or if the illustrations are
not visible. Use a cloth, water, and soap to clean
the warning
other harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
warning si
could drop off of the engine.
Replace an
missing.Ifawarningsignisattachedtoapartofthe
engine that is replaced, install a new warning sign on
the replac
distributor can provide new warning signs.
everal specific warning signs on your
iar with all warning signs.
igns or replace the warning signs if
signs. Do not use solvents, gasoline, or
gns. The warning signs that are loosened
y warning sign that is damaged or
ement part. Your Perkins dealer or your
(1) Universal Warning
Do not operate or work on this equipment unless
you have r
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
heed the
or death.
ead and understand the instructions
warnings could result in serious injury
Illustration 1
lexample
Typica
The Universal Warning label (1) is located on both
sides o
f the engine. Refer to illustration 2.
g01154807
6 SEBU8313
Safety Section
General Hazard Information
Illustration 2
ation 3
ample
i02328435
azard Information
g00104545
Typical ex
General H
Illustr
Attach a “Do Not Operate” warning tag or a similar
g tag to the start switch or to the controls
warnin
before you service the equipment or before you
repair the equipment.
g01294688
Illustration 4
g00702020
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.
Keep the engine free from foreign material. Remove
debris, oil, tools, and other items from the deck, from
walkways, and from steps.
SEBU8313 7
Safety Section
Burn Prevention
Never put maint
Drain all liquids into a suitable container.
Obey all local
Use all cleaning solutions with care.
Report all necessary repairs.
Do not allow un
equipment.
Ensure that th
you work on the bus bar or the glow plugs.
Perform maint
equipment in the servicing position. Refer to the
OEM information for the procedure for placing the
equipment in
Pressure Air
Pressurized air and/or water can cause debris
and/or hot wa
personal injury.
The direct a
pressurized water to the body could result in personal
injury.
When pressurized air and/or water is used for
cleaning, wear protective clothing, protective shoes,
and eye prot
oraprotectivefaceshield.
The maximu
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40
Fluid Pene
Pressure can be trapped in the hydraulic circuit long
after the e
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur
components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
informa
relieve the hydraulic pressure.
tion for any procedures that are required to
enance fluids into glass containers.
regulations for the disposal of liquids.
authorized personnel on the
e power supply is disconnected before
enance on the engine with the
the servicing position.
and Water
tertobeblownout.Thiscouldresultin
pplication of pressurized air or
ection. Eye protection includes goggles
m air pressure for cleaning purposes
psi).
tration
ngine has been stopped. The pressure can
. Do not disassemble any hydraulic
Illustration 5
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
g00687600
Containing Fluid Spillage
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 fluid with a
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.
i02334785
Burn Pre
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance is
perform
ed on the engine.
vention
8 SEBU8313
Safety Section
Fire Prevention and Explosion Prevention
i02320721
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
After the engine has stopped, you must wait for 60
seconds in order to allow the fuel pressure to be
purged from the high pressure fuel lines before any
service or repair is performed on the engine fuel lines.
Allow the pressure to be purged in the air system, in
the hydraulic system, in the lubrication system, or in
the cooling system before any lines, fittings or related
items are disconnected.
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
withabarehand.Removethefillercapslowlyin
order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.
Batteries
Fire Prevention and Explosion
Prevention
on 6
Illustrati
All fuels, most lubricants, and some coolant mixtures
are flammab
Flammable fluids that are leaking or spilled onto hot
surfaces or
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 remove
Determinewhethertheenginewillbeoperatedinan
environme
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property
If the application involves the presence of combustible
gases, co
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
materials or conductive materials to accumulate on
the engine.
le.
onto electrical components can cause
d.
nt that allows combustible gases to be
damage, or engine damage could result.
nsult your Perkins dealer and/or your
ne. Do not allow any flammable combustible
g00704000
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.
Store fuels and lubricants in correctly marked
containers away from unauthorized persons. Store
oily rag
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.
s and any flammable materials in protective
SEBU8313 9
Safety Section
Fire Prevention and Explosion Prevention
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 no
t flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or fl
ame 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.
Illustration 7
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.
Contact w
ith high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these
inspection, maintenance and service in-
structions may cause personal injury or death.
After the
engine has stopped, you must wait for 60
seconds in order to allow the fuel pressure to be
purged from the high pressure fuel lines before any
service
or repair is performed on the engine fuel lines.
Ensure that the engine is stopped. Inspect all lines
and hose
s for wear or for deterioration. The hoses
must be correctly routed. The lines and hoses must
have adequate support and secure clamps.
Oil filters and fuel filters must be correctly installed.
The filter housings must be tightened to the correct
. Refer to the Disassembly and Assembly
torque
manual for more information.
Illustration 8
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
ahydrometer.
10 SEBU8313
Safety Section
Crushing Prevention and Cutting Prevention
Incorrect jump
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions
Do not charge a frozen battery. This may cause an
explosion.
The batteries must be kept clean. The covers
(if equipped
recommended cables, connections, and battery box
covers when the engine is operated.
er cable connections can cause
.
) must be kept on the cells. Use the
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the f
extinguisher regularly. Obey the recommendations
on the instruction plate.
ire extinguisher and service the fire
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are
damaged.
Leaks can cause fires. Consult your Perkins dealer
or your Per
Replace the parts if any of the following conditions
are presen
kins distributor for replacement parts.
t:
i01359666
Crushing Preventio n and
Cutting Preve
Support the component properly 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
is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be i
the guards in place until maintenance
njured by flying debris.
ntion
i01372247
Mounting and Dismounting
High pressure fuel line or lines are removed.
•
End fittings are damaged or leaking.
•
Outer cove
•
Wires are exposed.
•
Outer coverings are ballooning.
•
Flexible p
•
Outer covers have embedded armoring.
•
End fittings are displaced.
•
Make sure t
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
parts, an
rings are chafed or cut.
art of the hoses are kinked.
hat all clamps, guards, and heat shields
d excessive heat.
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.
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.
SEBU8313 11
Safety Section
Before Starting Engine
i02322199
Before Starting Engine
The initial sta
or repaired make provision to shut the engine
off, in order to stop an overspeed. This may be
accomplished
supply to the engine.
Overspeed shu
engines that are controlled electronically. If automatic
shutdown does not occur, press the emergency stop
buttoninord
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
If equipped, ensure that the lighting system for the
engine is su
lights work correctly, if equipped.
All protect
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident t
around the parts carefully.
Do not bypa
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits
engine damage.
See the Se
adjustments.
rt-up of an engine that is new, serviced
by shutting off the air and/or fuel
tdown should occur automatically for
er to cut the fuel and/or air to the engine.
of personnel.
itable for the conditions. Ensure that all
ive guards and all protective covers must
hat is caused by parts in rotation, work
ss the automatic shutoff circuits. Do not
are also provided in order to help prevent
rvice Manual for repairs and for
All protective
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that
around the parts carefully.
Start the eng
from the engine start switch.
Always start
that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation
Section. Kno
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal in
To ensure that the jacket water heater (if equipped)
is working c
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
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
Note: Theenginemaybeequippedwithadevicefor
cold starting. If the engine will be operated in very
cold cond
be required. Normally, the engine will be equipped
with the correct type of starting aid for your region
of operat
guards and all protective covers must
is caused by parts in rotation, work
ine from the operator’s compartment or
theengineaccordingtotheprocedure
wing the correct procedure will help to
jury.
orrectly, check the water temperature
operate the engine in a well ventilated
itions, then an extra cold starting aid may
ion.
i014620
46
Engine Stopping
i02583384
Engine Starting
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
If a warning tag is attached to the engine start switch
or to the controls DO NOT start the engine or move
the controls. Consult with the person that attached
thewarningtagbeforetheengineisstarted.
Stop the
the Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overhea
the engine components.
Use the
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emerge
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 h
by shutting off the fuel supply to the engine and/or
shutting off the air supply to the engine.
engine according to the procedure in
ting of the engine and accelerated wear of
Emergency Stop Button (if equipped) ONLY
ncy stop, DO NOT start the engine until the
as been overhauled. This may be accomplished
12 SEBU8313
Safety Section
Electrical System
To stop an elect
ronically controlled engine, cut the
power to the engine.
i02469632
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 “í” jump start cable should be connected
last from the external power source to the negative
“í” terminal of the starting motor. If the starting motor
is not equipped with a negative “í” terminal, connect
thejumpstartcabletotheengineblock.
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
Illustration 9
Typical example
Grounding Stud To Battery Ground
g00771448
SEBU8313 13
Safety Section
Engine Electronics
i02583382
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) has the ability to monitor the engine
operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
initiate an immediate action.
The following actions are available for engine
monitoring control: WARNING, ACTION ALERT, and
SHUTDOWN.
Illustration 10
Typical ex
Alternate Grounding Stud To Battery Ground
Proper grounding for the engine electrical system
is necessary for optimum engine performance
and relia
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
Engines that are installed without engine-to-frame
ground s
discharge.
To e ns u r
systems function properly, an engine-to-frame ground
strap with a direct path to the battery must be used.
This pa
ground, a starting motor ground to the frame, or a
direct engine ground to the frame.
ample
bility. Improper grounding will result in
surfaces, and to aluminum components.
traps can be damaged by electrical
e that the engine and the engine electrical
th may be provided by way of a starting motor
g00771487
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:
Atmospheric Pressure
•
Inlet Manifold Pressure
•
Coolant Temperature
•
Engine Oil Pressure
•
Crankshaft Position
•
Camshaft Position
•
Fuel Temperature
•
Inlet Manifold T emperature
•
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.
All grounds should be tight and free of corrosion. The
engine alternator must be grounded to the negative
tery terminal with a wire that is adequate to
“-” bat
handle the full charging current of the alternator.
14 SEBU8313
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 11
Use the ex ample 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) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) D isconnected battery cables
(6) Battery
(7) Elec trical/Electronic component
(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
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 flow from the welder could
severely damage the component.
g00765012
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.
SEBU8313 15
Product Information Section
Model Views
Model Views
i02572859
Model View Illustrations
The following model views show the 2506 Engine
features. Due
may appear different from the illustrations.
to individual applications, your engine
Illustration 12
Typical example
Left side view
(1) F ront timing gear housing
(2) Fuel priming pump
(3) Electronic Control Module (ECM)
(4) Flywheel housing
(5) Fuel filters
(6) Fuel transfer pump
g01289036
(7) Vibration Damper
16 SEBU8313
Product Information Section
Model Views
Illustration 13
Typical example
Right side view
(8) Exhaust manifo ld
(9) Turbocharger
(10) Temperature regulator housing
(11) Water pump
i02581540
Engine Description
Table 1
2506 Engine Specifications
Cylinders and Arrangement In-line six cylinder
Bore 137.2 mm (5.4 inch)
Stroke 171.5 mm (6.8 inch)
Displacement
Firing Order
Rotation (flywheel end) Counterclockwise
15.2 L (928 in3)
1-5-3-6-2-4
g01289038
(12) Oil cooler
(13) Oil filter
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.
SEBU8313 17
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 efficie
engine performance depend on adherence to proper
operation and maintenance recommendations. This
includes the u
and lubrication oils.
ncy, efficiency of emission controls, and
se of recommended fuels, coolants
Aftermarket Products and Perkins
Engines
When auxiliary devices, accessories, or consumables
(filters, ad
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
ditives, 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 numerical code of
the diag
diagnostic codes: ACTIVE, LOGGED, and EVENT.
These codes are logged and stored in the ECM.
Refer t
Diagnostics” for additional information.
The coo
a centrifugal pump that is driven by a gear, water
temperature regulator, an oil cooler, and a radiator
that i
The engine lubricating oil is supplied by a gear
type p
filtered. Bypass valves provide unrestricted flow
of lubrication oil to the engine parts when the oil
visco
filter elements (paper cartridge) become plugged.
ting properly. In the event of a system
TIC lamp that is mounted on the control
nostic flash code. There are three types of
o Operation and Maintenance Manual, “Engine
ling system consists of the following items:
ncorporates a shunt system.
ump. The engine lubricating oil is cooled and
sity is high or if either the oil cooler or the oil
18 SEBU8313
Product Information Section
Product Identification Information
Product Identification
Information
i02578572
Plate Locations and Film
Locations
Illustration 14
(1) Serial number plate
Perkins engines are identified by serial numbers.
These numbers are shown on the engine serial
number plate. Perkins distributors need these
numbers in order to determine the components that
were included with the engine. This permits accurate
identification of replacement part numbers.
Serial Number Plate (1)
Theengineserialnumberplateislocatedonthe
lower right side of the engine block.
g01291895
Engine serial number
Designation _________________________________________________
Engine Rating ______________________________________________
_____________________________________
SEBU8313 19
Product Information Section
Product Identification Information
i02563635
Reference Numbers
Information fo
r the following items may be needed to
order parts. Locate the information for your engine.
Record the information in the appropriate space.
Makeacopyoft
his list for a record. Keep the
information for future reference.
Record for Reference
Engine Model
Engine Serial number _____________________________________
Engine rpm __________________________________________________
Primary Fuel
Secondary Fuel Filter Element ___ _______________________
Lubrication Oil Filter Element ___________________________
Total Lubric
Total Cooling System Capacity _________________________
Air Cleaner Element _______________________________________
_______________________________________________
Filter
_________________________________________
ation System Capacity
_____________________
t
Fan Drive Bel
______________________________________________
Alternator Belt ______________________________________________
20 SEBU8313
Product Information Section
Product Identification Information
i02576079
Emissions Certification Film
Label for compliant engines
Illustration 15
Typical example of a label that is installed on engines that comply with emissions
g01290846
SEBU8313 21
Product Information Section
Product Identification Information
Illustration 16
Typical ex
Customer
ample o f a label that is installed on engines that comply with emissions
i02566844
Specified
Parameters
To record programmed specifications, use the
followin
Customer Passwords (If required).
•
•
Rating Selection (L-N) __________________________________
Equipment ID ______________________________________________
Programmable Monitoring System
(PMS)
gblanks.
First Password ___________________________________________
Second Pa
ssword
____________________________ __________
Inlet Manifold T emperature Sensor
•
Coolant Temperature Sensor
•
Engine Oil Pressure Sensor
•
Engine Crankshaft/Camshaft Sensors
•
Inlet Manifold Pressure Sensor
•
Fuel Temperature Sensor
•
g01290859
The Programmable Monitoring System determines
the leve
response to a condition that can damage the engine.
These conditions are identified by the ECM from the
signals
lofactionthatistakenbytheECMin
that are produced from the following sensors.
22 SEBU8313
Product Information Section
Product Identification Information
Table 2
Event Code Parameter State Trip Point Delay Time
E162 High Boost Pressure
-1 Warn Operator (1) On 300 kPa (43.5 psi) 30 seconds
-2 Action Alert (2) Always On None 5 seconds
E360
-1
-2
-3
E361
-1
-2
-3
E362
-1 Warn Operator (1) On 2000 RPM 1 second
-2 Action Alert (2) Always On 2050 RPM 1 second
-3 Engine Shutdown (3) Always On 2140 RPM 0 second
E363
-1
-2
E368
-1
-2
Low Engine Oil Pressure
Warn Operator (1) On 300 kPa (43.5 psi)
Action Alert (2) Always On
Engine Shutdown (3) Always On
High Engine Coolant Temperature
Warn Operator (1) On 104°C(2190°F)
Action Alert (2) Always On 105 °C (221 °F)
Engine Shutdown (3) Always On 108 °C (226 °F)
Engine Ov
High Fuel Supply Temperature
Warn Operator (1) On 60 °C (140 °F)
Action Alert (2) Always On 68 °C (154 °F)
High Engine Intake Manifold Air Temperature
Warn Operator (1) On 75 °C (167 °F)
Action Alert (2) Always On 78 °C (172 °F)
erspeed
None 2 seconds
None 2 seconds
60 seconds
60 seconds
10 seconds
10 seconds
60 seconds
60 seconds
60 seconds
10 seconds
Refer to Troubleshooting , “System Configuration
Parameters” for additional information for the
Programmable Monitoring System.
SEBU8313 23
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage
Product Lifting
Illustration 17
i02513632
g00103219
i02427139
Product Storage
Refer to Perkin
for information on engine storage.
There is three
Level “A, B and C”.
Level “A ”
Level “A” will
engines and protection for one year for gas engines.
This is for engines that are transported by a container
or a truck.
Level “B ”
This level is additional to level “A”. Level “B ” will
give protect
í15° to +55°C (5.0000° to 99.0000°F) and “90%”
relative humidity for one year.
Level “C ”
s Engine Company limited, Stafford
different levels of engine storage.
give protection for six month for diesel
ion under normal storage condition from
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 fixtures 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.
This level is additional to level “B”. Level “C” will give
protection for five year in tropical temperatures or
arctic clim
level “J” for europe, when engines are stored in a
unheated building or in the open under waterproof
covers.
ates. Level “C” also meets MOD NES 724
24 SEBU8313
Operation Section
Gauges and Indicators
Gauges and Indicators
i02576034
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 dealer
or your Per
If no oil pressure is indicated, STOP the engine. If
maximum co
the engine. Engine damage can result.
ay not have the same gauges or all of
e normal operating range by observing
hanges in gauge readings indicate
eadings are within specifications.
kins distributor for assistance.
NOTICE
olant temperature is exceeded, STOP
Engine Oil
engine oil pressure is 420 kPa (61 psi).
Pressure – The range for the
Jacket Water Coolant Temperature –
Typical water temperature into the engine
is 88 °C (19
may occur under certain conditions. The water
temperature reading may vary according to load. The
reading s
1. A high water temperature switch is installed in the
indicator should be to the right side of “0” (zero).
hould never exceed 107 °C (224 °F).
cooling system.
Tachometer – This gauge indicates engine
speed (rpm).
Ammeter – This gauge indicates the
amount of charge or discharge in the
battery charging circuit. Operation of the
Service Hour Meter – The gauge indicates
operating hours of the engine.
0 °F). Higher temperatures
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