Perkins 2206-E13, Operation And Maintenance Manual

Page 1: ...May 2008 Operation and Maintenance Manual 2206 E13 Industrial Engine TGB Engine TGD Engine TGF Engine SEBU8337 00 ...

Page 2: ...ning 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 o...

Page 3: ...Engine Stopping 11 Electrical System 11 Engine Electronics 12 Product Information Section General Information 13 Model Views 14 Product Identification Information 17 Operation Section Lifting and Storage 21 Gauges and Indicators 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...

Page 4: ... schedule are referenced to detailed instructions that follow Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule The actual operating environment of the engine also governs the Maintenance Interval Schedule Therefore under extremely severe dusty wet or freezing cold operating conditions more frequent lubrication and maintenance th...

Page 5: ... 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 ...

Page 6: ...t 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 information for the procedure for placing the equipment in the servicing position Pressure Air and Water Pressurized air and or water can cause debris and or hot water to be blown out This could result in per...

Page 7: ...ted 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 engi...

Page 8: ...rs Do not smoke in areas that are used for storing flammable materials Do not expose the engine to any flame Exhaust shields if equipped protect hot exhaust components from oil or fuel spray in case of a line a tube or a seal failure Exhaust shields must be installed correctly Do not weld on lines or tanks that contain flammable fluids Do not flame cut lines or tanks that contain flammable fluid C...

Page 9: ...rike high pressure lines Do not install any lines that are bent or damaged Do not clip any other items to the high pressure lines Repair any lines that are loose or damaged Leaks can cause fires Consult your Perkins dealer or your Perkins distributor for repair or for replacement parts Check lines tubes and hoses carefully Do not use your bare hand to check for leaks Use a board or cardboard to ch...

Page 10: ...e that no one is on underneath or close to the engine Ensure that the area is free of personnel If equipped ensure that the lighting system for the engine is suitable for the conditions Ensure that all lights work correctly if equipped All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures To help prevent an accident t...

Page 11: ...ark 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 Chec...

Page 12: ...meters 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 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 Intak...

Page 13: ...y If a battery disconnect switch is provided open the switch 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 g00765012 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 compon...

Page 14: ...770579 Model View Illustrations g01385634 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 Primary fuel filter 6 Fuel pump 7 Crankshaft damper 8 Oil filler ...

Page 15: ...mm 6 2 inch Displacement 12 5 L 763 in3 Firing Order 1 5 3 6 2 4 Rotation flywheel end Counterclockwise 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 g...

Page 16: ... system component deviation from the programmed limits the operator will be alerted to the condition by a DIAGNOSTIC lamp that is mounted on the control panel An electronic service tool that is provided by Perkins may be used to read the diagnostic codes These codes are logged and stored in the ECM Refer to Operation and Maintenance Manual Engine Diagnostics for additional information The cooling ...

Page 17: ...lm Locations g01385686 Illustration 13 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 ...

Page 18: ...te 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 _________ __...

Page 19: ...___ Second Password _________ _____________________________ Rating Selection L N _________ _________________________ Equipment ID _________ _____________________________________ 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...

Page 20: ...04 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 Engine Overspeed 1 Warn Operator 1 On 2000 RPM 1 second 2 Action Alert 2 Always On 2050 RPM 0 second 3 Engine Shutdown 3 Always On 2140 RPM 0 second E363 High Fuel Supply Temperature 1 Warn Operator 1 On 60 C 140 F 60 seconds 2 Action Alert 2 Always On 68 C 154 F 60 se...

Page 21: ...ne 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 i02848873 Product Storage Refer to Perkins Engine Company...

Page 22: ... change in the readings Consult your Perkins distributor for assistance NOTICE If no oil pressure is indicated STOP the engine If maximum coolant temperature is exceeded STOP the engine Engine damage can result Engine Oil Pressure The range for the engine oil pressure is 420 kPa 61 psi Jacket Water Coolant Temperature Typical water temperature into the engine is 88 C 190 F Higher temperatures may ...

Page 23: ...dition exists The electronic service tool is used to remove the event code from the memory of the ECM The trip point for the Warning alarm will be set to a factory default in production The electronic service tool may be used to alter the trip point for a Warning within predefined limits Action Alert The Action Alert informs the OEM that the engine is approaching a critical condition The engine sh...

Page 24: ...uts down on low oil pressure the output on the low oil pressure will be energized and the output on the shutdown will be energized If the engine shuts down on coolant temperature or the engine shuts down on overspeed the dedicated output and the shutdown output will be energized Shutdown Reset The cause of an engine shutdown must be investigated Corrective action must be taken before the system is...

Page 25: ...erature sensors For example if a Shutdown protection sensor has a fault this will result in an engine shutdown unless the system is in critical protection override If a diagnostic fault occurs with one of the engine speed sensors while the engine is running The engine continues to run by using the other timing sensor for reference i02772006 Sensors and Electrical Components Sensor Locations Illust...

Page 26: ... open Sensor output is shorted to battery or battery Measured reading of the sensor is out of the specification 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...

Page 27: ...he main oil gallery The engine oil pressure sensor detects engine oil pressure for diagnostic purposes The engine oil pressure sensor sends a signal to the ECM Low Oil Pressure Warning The setpoint for the low pressure warning is dependent upon the engine speed The fault will be active and logged only if the engine has been running for more than 8 seconds Low Oil Pressure The very low oil pressure...

Page 28: ...erating parameters through the software within the ECM and the inputs from the various sensors The software within the ECM can be changed by installing a new flash file The flash file defines the following characteristics of the engine Engine power Torque curves Engine speed rpm Engine Noise Smoke and Emissions ...

Page 29: ...engine operation the system has identified a situation that is not within the specification Use the electronic service tool to check the active diagnostic codes The active diagnostic code should be investigated The cause of the problem should be corrected as soon as possible If the cause of the active diagnostic code is repaired and there is only one active diagnostic code the diagnostic lamp will...

Page 30: ...the engine Minimize electrical loads or remove any electrical loads Ensure that the coolant level is correct Ensure that the engine oil level is correct i02583442 Starting the Engine Note Do not adjust the engine speed control during start up The electronic control module ECM will control the engine speed during start up New engines Prime the turbocharger This can be achieved by cranking the engin...

Page 31: ...the START position in order to engage the electric starting motor and crank the engine 2 Repeat step 1 three times if the engine fails to start 3 If the engine fails to start investigate the problem Use the Perkins electronic service tool A system fault may be indicated after the engine is started If this occurs the ECM has detected a problem with the system Investigate the cause of the problem Us...

Page 32: ... Check for any fluid or for any air leaks at idle rpm and at one half full rpm no load on the engine before operating the engine under load This is not possible in some applications Operate the engine at low idle until all systems achieve operating temperatures Check all gauges during the warm up period Note Gauge readings should be observed and the data should be recorded frequently while the eng...

Page 33: ...rformance for the life of the engine Avoid spilling fuel Fuel expands when the fuel is warmed up The fuel may overflow from the fuel tank Inspect fuel lines for leaks Repair the fuel lines as needed Be aware of the properties of the different fuels Use only the recommended fuels Avoid unnecessary operation at no load Shut off the engine instead of operating the engine at no load for long periods o...

Page 34: ...e operation are secured after the engine is stopped i02583411 After Stopping Engine Note Before you check the engine oil do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan Check the crankcase oil level Maintain the oil level between the LOW mark and the HIGH mark on the oil level gauge Note Only use oil that is recommended in this Operation ...

Page 35: ... rubber parts hoses fan drive belts etc weekly Check all electrical wiring and connections for any fraying or damaged insulation Keep all batteries fully charged and warm Check the air cleaners and the air intake daily Personal injury or property damage can result from alcohol or starting fluids Alcohol or starting fluids are highly flammable and toxic and if improperly stored could result in inju...

Page 36: ...are three major differences between Group 1 fuels and Group 2 fuels Group 1 fuels have the following different characteristics to Group 2 fuels A lower cloud point A lower pour point A lower energy per unit volume of fuel Note Group 3 fuels reduce the life of the engine The use of Group 3 fuels is not covered by the Perkins warranty Group 3 fuels include Low Temperature Fuels and Aviation Kerosene...

Page 37: ... is important Drain the water and sediment from any fuel storage tank at the following intervals weekly oil changes and refueling of the fuel tank This will help prevent water and or sediment from being pumped from the fuel storage tank and into the engine fuel tank Fuel Filters A primary fuel filter is installed between the fuel tank and the engine fuel inlet After you change the fuel filter alwa...

Page 38: ...Refer to the OEM specifications Enter the value for the capacity of the External System in this row i03040206 Fluid Recommendations Cooling System Specifications General Coolant Information NOTICE Never add coolant to an overheated engine Engine damage could result Allow the engine to cool first NOTICE If the engine is to be stored in or shipped to an area with below freezing temperatures the cool...

Page 39: ...rs to drop out of solution The deposits can enable the following problems to occur Formation of gel compounds Reduction of heat transfer Leakage of the water pump seal Plugging of radiators coolers and small passages Glycol Glycol in the coolant helps to provide protection against the following conditions Boiling Freezing Cavitation of the water pump For optimum performance Perkins recommends a 1 ...

Page 40: ...rs Perkins POWERPART SCA 3000 Service Hours or Two Years Commercial SCA and Water 3000 Service Hours or Two Years Extended Life Coolant ELC Perkins provides Extended Life Coolant ELC for use in the following applications Heavy duty spark ignited gas engines Heavy duty diesel engines Automotive applications The anti corrosion package for ELC is different from the anti corrosion package for other co...

Page 41: ... container Flush the cooling system with clean water 6 Fill the cooling system with clean water and operate the engine until the engine is warmed to 49 to 66 C 120 to 150 F NOTICE Incorrect or incomplete flushing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear water Co...

Page 42: ...s SCA that is required when the cooling system is initially filled Table 10 Equation For Adding The SCA To The Heavy Duty Coolant At The Initial Fill V 0 045 X V is the total volume of the cooling system X is the amount of SCA that is required Table 11 is an example for using the equation that is in Table 10 Table 11 Example Of The Equation For Adding The SCA To The Heavy Duty Coolant At The Initi...

Page 43: ...l Esters CFR Co ordinating Fuel Research LSD Low Sulfur Diesel ULSD Ultra Low Sulfur Diesel RME Rape Methyl Ester SME Soy Methyl Ester EPA Environmental Protection Agency of the United States General Information NOTICE Every attempt is made to provide accurate up to date information By use of this document you agree that Perkins Engines Company Limited is not responsible for errors or omissions NO...

Page 44: ...3 801 minimum and 876 maximum No equivalent test ISO 3675 ISO 12185 Distillation C 10 at 282 C 539 6 F maximum 90 at 360 C 680 F maximum D86 ISO 3405 Flash Point C legal limit D93 ISO 2719 Thermal Stability Minimum of 80 reflectance after aging for 180 minutes at 150 C 302 F D6468 No equivalent test Pour Point C 6 C 42 8 F minimum below ambient temperature D97 ISO 3016 Sulfur 1 4 mass 1 maximum D5...

Page 45: ...a fuel does not meet the minimum requirements consult your fuel supplier Do not treat the fuel without consulting the fuel supplier Some additives are not compatible These additives can cause problems in the fuel system NOTICE Operating with fuels that do not meet the Perkins rec ommendations can cause the following effects Start ing difficulty poor combustion deposits in the fuel in jectors reduc...

Page 46: ...ulfur fuel can be used in countries that do not regulate emissions When only high sulfur fuels are available it will be necessary that high alkaline lubricating oil is used in the engine or that the lubricating oil change interval is reduced Refer to this Operation and Maintenance Manual Fliud Recommendations Genernal Lubrication Information for information on sulfur in fuel Lubricity This is the ...

Page 47: ...ptable provided that these fuels are used with an appropriate fuel additive These fuels must meet the requirements that are stated in table 14 Fuel samples should be analyzed for the compliance These fuels MUST NOT exceed lubricity wear scar diameter of 0 52 mm 0 0205 inch The fuel lubricity test must be performed on a HFRR operated at 60 C 140 F Refer to ISO 12156 1 Fuels must have minimum viscos...

Page 48: ... engine is converted back to 100 percent distillate diesel fuel The compatibility of the elastomers with biodiesel is being monitored The condition of seals and hoses should be monitored regularly Biodiesel may pose low ambient temperature problems for both storage and operation At low ambient temperatures fuel may need to be stored in a heated building or a heated storage tank The fuel system may...

Page 49: ...addressed in table 14 To ensure optimum engine performance a complete fuel analysis should be obtained before engine operation The fuel analysis should include all of the properties that are stated in the table 14 Fuel Additive Supplemental diesel fuel additives are not generally recommended This is due to potential damage to the fuel system or the engine Your fuel supplier or the fuel manufacture...

Page 50: ...o provide superior performance in comparison to API CG 4 and API CF 4 DHD 1 oils will meet the needs of high performance Perkins diesel engines that are operating in many applications The tests and the test limits that are used to define DHD 1 are similar to the new API CH 4 classification Therefore these oils will also meet the requirements for diesel engines that require low emissions DHD 1 oils...

Page 51: ...hese oil recommendations can cause shortened engine service life due to deposits and or excessive wear Total Base Number TBN and Fuel Sulfur Levels for Direct Injection DI Diesel Engines The Total Base Number TBN for an oil depends on the fuel sulfur level For direct injection engines that use distillate fuel the minimum TBN of the new oil must be 10 times the fuel sulfur level The TBN is defined ...

Page 52: ... oils can be used exclusively in finished oil or in a combination with new base stock oils The US military specifications and the specifications of other heavy equipment manufacturers also allow the use of re refined base stock oils that meet the same criteria The process that is used to make re refined base stock oil should adequately remove all wear metals that are in the used oil and all the ad...

Page 53: ...il viscosity grade for your engine At the specified interval service the engine Use new oil and install a new oil filter Perform maintenance at the intervals that are specified in the Operation and Maintenance Manual Maintenance Interval Schedule Oil analysis Some engines may be equipped with an oil sampling valve If oil analysis is required the oil sampling valve is used to obtain samples of the ...

Page 54: ...Hours or 1 Year Aftercooler Core Clean Test 55 Engine Air Cleaner Element Single Element Inspect Replace 62 Engine Crankcase Breather Replace 64 Engine Mounts Inspect 66 Engine Oil and Filter Change 68 Fan Drive Bearing Lubricate 71 Fuel System Primary Filter Water Separator Element Replace 73 Fuel System Secondary Filter Replace 74 Hoses and Clamps Inspect Replace 76 Radiator Clean 78 Every 1000 ...

Page 55: ... fins may be opened with a comb Inspect these items for good condition welds mounting brackets air lines connections clamps and seals Make repairs if necessary i02322311 Alternator Inspect Perkins recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and correct battery charging Check the ammeter if equipped during engine operation in order to ensure corr...

Page 56: ... addition of water is necessary use distilled water If distilled water is not available use clean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with a suitable battery tester 3 Install the caps 4 Keep the batteries clean Clean the battery case with one of the following cleaning solutions A mixture of 0 1 kg 0 2 lb of washing soda or b...

Page 57: ...applications that require multiple drive belts replace the drive belts in matched sets Replacing one drive belt of a matched set will cause the new drive belt to carry more load because the older drive belts are stretched The additional load on the new drive belt could cause the new drive belt to fail Alternator Belt Adjustment g01391209 Illustration 20 1 Remove the belt guard 2 Loosen alternator ...

Page 58: ...n ing any compartment or disassembling any compo nent containing fluids Dispose of all fluids according to Local regulations and mandates NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist The engine overheats ...

Page 59: ...ure Remove the cooling system filler cap Open the drain cock or remove the drain plug on the radiator Allow the water to drain Flush the cooling system with clean water Fill 1 Close the drain cock or install the drain plug on the radiator NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 2 Fill the co...

Page 60: ... Replace Replace the water temperature regulator before the water temperature regulator fails This is a recommended preventive maintenance practice Replacing the water temperature regulator reduces the chances for unscheduled downtime A water temperature regulator that fails in a partially opened position can cause overheating or overcooling of the engine A water temperature regulator that fails i...

Page 61: ...erature of the damper fluid is too high Refer to the Service Manual or consult your Perkins distributor for information about damper replacement i02151646 Driven Equipment Check Refer to the OEM specifications for more information on the following maintenance recommendations for the driven equipment Inspection Adjustment Lubrication Other maintenance recommendations Perform any maintenance for the...

Page 62: ...er service the air cleaner element with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Element Note The air filter system may not have been provided by Perkins The procedure that follows is for a typical air filter system Refer to the OEM information for the correct procedure If the air cleaner element becomes plugged the air can split the material of t...

Page 63: ... procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than three times Use filtered dry air with a maximum pressure of 207 kPa 30 psi Pressurized air will not remove deposits o...

Page 64: ...t air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises If your engine is equipped with a different type of service indicator follow the OEM recommendations in order to service the air cleaner service indicator The s...

Page 65: ...ve the filter bowl and remove the filter element 5 Remove the O ring seal 4 with the filter element 4 Remove the main O ring seal 3 Clean the filter bowl 5 Install a new O ring seal 3 Install the new O ring seal 4 on the new filter element 5 Install the filter element into the filter bowl 6 6 Align the filter element and the filter bowl Install the filter bowl to the top of the breather Connect th...

Page 66: ...rect bolt torque Engine vibration can be caused by the following conditions Incorrect mounting of the engine Deterioration of the engine mounts Loose engine mounts Any engine mount that shows deterioration should be replaced Refer to the OEM information for the recommended torques i02790188 Engine Oil Level Check Hot oil and hot components can cause personal injury Do not allow hot oil or hot comp...

Page 67: ...il sampling valve if equipped is included in order to regularly sample the engine lubricating oil g01393937 Illustration 34 Typical example Perkins recommends using a sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when a sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during ...

Page 68: ...is recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil Drain the Engine Oil After the engine has been run at the normal operating temperature stop the engine Use one of the following methods to drain the engine crankcase oil If the engine is equipped with a drain valve turn the drain valve knob counterclockwise in order to ...

Page 69: ...th engine oil Refer to the Operation and Maintenance Manual Refill Capacities and Operation and Maintenance Manual Fluid recommendations for more information NOTICE If equipped with an auxiliary oil filter system or a re mote oil filter system follow the OEM or filter manu facturer s recommendations Under filling or overfilling the crankcase with oil can cause engine damage NOTICE To prevent crank...

Page 70: ...s are in good working order during normal operation Malfunctions must be simulated in order to test the engine protective devices To prevent damage to the engine only authorized service personnel or your Perkins distributor should perform the tests Consult your Perkins distributor or refer to the Service Manual for more information i02790456 Engine Speed Timing Sensors Check Clean Calibrate g01394...

Page 71: ...ore mea suring adjusting valve lash clearance Ensure that the engine is stopped before measuring the valve lash To obtain an accurate measurement allow the valves to cool before this maintenance is performed The following components should be inspected and adjusted when the valves are inspected and adjusted Valve actuators Injectors Refer to Systems Operation Testing and Adjusting Engine Valve Las...

Page 72: ... to cool for 30 seconds Repeat steps 3 to 6 in order to eliminate air from the fuel system 9 Continue to eliminate air from the fuel system if these events occur The engine starts but the engine does not run evenly The engine starts but the engine continues to misfire or smoke 10 Run the engine with no load until the engine runs smoothly i02792791 Fuel System Primary Filter Water Separator Drain F...

Page 73: ...cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component g01394516 Illustration 42 Typical example 1 T...

Page 74: ...d dispose of the fuel safely Turn the fuel supply valve if equipped to the ON position 9 Prime the fuel system Refer to the Operation and Maintenance Manual Fuel System Prime for more information 10 Operate the engine and check for fuel leaks i02793014 Fuel System Secondary Filter Replace Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible ...

Page 75: ...e that the correct elements are installed into the fuel system 4 Ensure that the insert 4 is the same shape as the tab 3 5 Align the insert to the tab and install the element into the filter bowl g01394685 Illustration 47 6 Install a new O ring seal 5 Lubricate the threads on the bowl assembly with CV60889 Special Lubricant 7 Install the bowl assembly Tighten the bowl assembly to a torque of 80 N ...

Page 76: ... operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equi...

Page 77: ...order to relieve any pressure Remove the cooling system filler cap Note Drain the coolant into a suitable clean container The coolant can be reused 3 Drain the coolant from the cooling system to a level that is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose 6 Replace the old hose with a new hose 7 Install the hose clamps 8 Refill the cooling system 9 Clean...

Page 78: ... water If the radiator is blocked internally refer to the OEM for information regarding flushing the cooling system After cleaning the radiator start the engine This will help in the removal of debris and the drying of the core Run the engine for two minutes and then stop the engine Inspect the core for cleanliness Repeat the cleaning if necessary i02578376 Severe Service Application Check Severe ...

Page 79: ...ect Periodic inspection and cleaning is recommended for the turbocharger compressor housing inlet side Any fumes from the crankcase are filtered through the air inlet system Therefore by products from oil and from combustion can collect in the turbocharger compressor housing Over time this buildup can contribute to loss of engine power increased black smoke and overall loss of engine efficiency If...

Page 80: ...ean the turbocharger housing with standard shop solvents and a soft bristle brush 7 Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing i02568213 Walk Around Inspection Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avo...

Page 81: ...for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Inspect the ECM to the cylinder head ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a m...

Page 82: ...with exhaust emission standards and gaseous emission standards that are prescribed by the law at the time of manufacture and this engine may be covered by an Emissions Warranty Consult your authorized Perkins dealer or your authorized Perkins distributor in order to determine if your engine is emissions certified and if your engine is subject to an Emissions Warranty ...

Page 83: ... Engine Air Cleaner Element Single Element Inspect Replace 62 Cleaning the Air Cleaner Element 62 Servicing the Air Cleaner Element 62 Engine Air Cleaner Service Indicator Inspect If Equipped 64 Engine Crankcase Breather Replace 64 Crankcase Breather 64 Open Breather 66 Engine Description 15 Aftermarket Products and Perkins Engines 16 Engine Diagnostics 29 Engine Electronics 12 Engine Mounts Inspe...

Page 84: ...he Clamps 77 I Important Safety Information 2 J Jacket Water Heater Check 77 L Lifting and Storage 21 M Maintenance Interval Schedule 54 Maintenance Section 38 Manual Stop Procedure 34 Emergency Stopping 34 Stopping the Engine 34 Model View Illustrations 14 Model Views 14 Monitoring System 23 Action Alert 23 Altitude derate 24 Critical Protection Override 23 Diagnostic 24 Shutdown 23 Shutdown Rese...

Page 85: ...condary Speed Timing Sensor 5 27 Sensor Locations 25 Severe Service Application Check 78 Environmental Factors 79 Incorrect Maintenance Procedures 79 Incorrect Operating Procedures 79 Starting Motor Inspect 79 Starting the Engine 30 New engines 30 Starting the Engine 30 Starting with Jump Start Cables 31 T Table of Contents 3 Turbocharger Inspect 79 Cleaning and Inspecting 80 Removal and Installat...

Page 86: ...86 SEBU8337 Index Section ...

Page 87: ...Maintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Information Customer Equipment Number Dealer Equipment Number Dealer Information Name Branch Address Dealer Contact Phone Number Hours Sales Parts Service ...

Page 88: ...Copyright 2008 Perkins Engines Company Limited All Rights Reserved Printed in U K ...