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SEBU8731

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Summary of Contents for 1106C-70TA

Page 1: ...Operation and Maintenance Manual 1106C 70TA and 1106D 70TA Industrial Engines PV Engine PW Engine SEBU8731 April 2013...

Page 2: ...ing 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 canno...

Page 3: ...14 Engine Electronics 15 Product Information Section General Information 16 Product Identification Information 21 Operation Section Lifting and Storage 23 Features and Controls 25 Engine Diagnostics 3...

Page 4: ...ced 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...

Page 5: ...uld loosen the adhesive that secures the warning signs Replace any warning sign that is damaged or missing If a warning sign is attached to a part of the engine that is replaced install a new warning...

Page 6: ...y cause a fire hazard Failure to follow these inspection maintenance and service in structions may cause personal injury or death Illustration 3 g01154858 Typical example Illustration 4 g03342264 2 Ha...

Page 7: ...s 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 a...

Page 8: ...liquids i05302522 Burn Prevention Do not touch any part of an operating engine Allow the engine to cool before any maintenance is performed on the engine Contact with high pressure fuel may cause flu...

Page 9: ...ials Do not expose the engine to any flame Exhaust shields if equipped protect hot exhaust components from oil or fuel spray in a line a tube or a seal failure Exhaust shields must be installed correc...

Page 10: ...e operation of the fire extinguisher Inspect the fire extinguisher and service the fire extinguisher regularly Obey the recommendations on the instruction plate Lines Tubes and Hoses Do not bend high...

Page 11: ...ure that no one will be injured by flying debris i04016709 Mounting and Dismounting Do not climb on the engine or the engine aftertreatment The engine and aftertreatment have not been designed with mo...

Page 12: ...to be purged before any service or repair is performed on the engine fuel lines Do not loosen the high pressure fuel lines in order to remove air from the fuel system This procedure is not required V...

Page 13: ...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...

Page 14: ...starting motor 3 Starting motor to engine block Illustration 14 g03342706 4 Battery to ground 5 Ground to engine block 6 Primary position for grounding Correct grounding for the engine electrical syst...

Page 15: ...initiate an immediate action The following actions are available for engine monitoring control Warning Derate Shutdown The following monitored engine operating conditions have the ability to limit eng...

Page 16: ...ns your engine may appear different from the illustrations Illustration 15 g03343017 1 Secondary fuel filters 2 Crankcase breather hose 3 Oil sample valve 4 Electronic control module 5 Oil filter 6 Oi...

Page 17: ...Illustration 16 g03343019 9 Coolant outlet 10 Water pump 11 Coolant intake 12 Vibration damper 13 Belt tensioner 14 Belt 15 Belt idler pulley SEBU8731 17 General Information Model View Illustrations...

Page 18: ...ifold 17 Font lifting eye 18 Alternator 19 Refrigerant compressor 20 Turbocharger 21 Starting motor 22 Solenoid for starting motor 23 Flywheel 24 Flywheel housing 25 Rear lifting eye 18 SEBU8731 Gener...

Page 19: ...aftercooled Engine Specifications Note The front end of the engine is opposite the flywheel end of the engine The left and the right sides of the engine are determined from the flywheel end The numbe...

Page 20: ...tain conditions the engine horsepower and the vehicle speed may be limited The electronic service tool may be used to display the diagnostic codes There are three types of diagnostic codes active logg...

Page 21: ...Year of Manufacture Perkins dealers or Perkins distributors need all of these numbers in order to determine the components that were included with the engine This information permits accurate identif...

Page 22: ...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 Low Idle rpm Engine Full Load rpm Primary Fuel Filt...

Page 23: ...or your Perkins distributor can assist in preparing the engine for extended storage periods Condition for Storage The engine must be stored in a water proof building The building must be kept at a con...

Page 24: ...inhibitor has been introduced The effect of the vapor phase inhibitor will be lost if the cooling system is open to the atmosphere For maintenance procedures refer to this Operation and Maintenance Ma...

Page 25: ...d pressure The intake manifold pressure sensor checks the rated pressure in the engine manifold Fuel rail pressure The fuel rail pressure sensor checks for high pressure or low pressure in the fuel ra...

Page 26: ...e the load 2 Stop the engine 3 Check and maintain the oil level Jacket Water Coolant Temperature Typical temperature range is 83 to 95 C 181 4 to 171 F The maximum allowable temperature at sea level w...

Page 27: ...m configuration parameters The customer specified parameters Diagnostic codes Event codes Coolant temperature Oil temperature Oil pressure Intake temperature Intake pressure Fuel temperature i05245144...

Page 28: ...in a predetermined reduction in engine power Warning Derate Shutdown The Diagnostic lamp turns ON and the warning signal red lamp is activated After the warning the engine power will be derated The en...

Page 29: ...lly FLASHING FLASHING Derate and warning One or more of the engine protection values has been exceeded The engine is running but the engine has been derated ON ON Engine shutdown One or more of the en...

Page 30: ...rature sensor 4 Connector for glow plugs 5 Wastegate regulator 6 Fuel rail pressure sensor 7 Electronic control module 8 Primary speed timing sensor 9 Oil pressure sensor 10 Solenoid for the high pres...

Page 31: ...on 25 g03344462 12 Secondary speed timing sensor 13 Alternator 14 Refrigerant compressor 15 Starting motor and solenoid 16 Priming pump relay SEBU8731 31 Features and Controls Sensors and Electrical C...

Page 32: ...Illustration 26 g03344866 1 Connections for injectors 2 Intake manifold pressure sensor 3 Intake manifold temperature sensor 32 SEBU8731 Features and Controls Sensors and Electrical Components...

Page 33: ...plugs 5 Wastegate regulator 6 Fuel rail pressure sensor 7 Electronic control module 8 Oil pressure sensor 9 Primary speed timing sensor 10 Solenoid for the high pressure fuel pump SEBU8731 33 Features...

Page 34: ...mpressor is an option only Item 15 starting motor can be 12 V or 24 V The starting motor can be mounted on the left side or the right side of the engine Item 16 the relay for the electric priming pump...

Page 35: ...ing Electronic Service Tools for more information i05253179 Diagnostic Flash Code Retrieval Diagnostic Lamp Use the DIAGNOSTIC lamp or an electronic service tool to determine the diagnostic flash code...

Page 36: ...Speed Timing Sensor Fault X 143 Engine Timing Calibration Fault X X 144 Engine Operation Mode Se lector Switch Fault X X 151 High Air Filter Restriction X X 154 Throttle Position Sensor Fault X X 155...

Page 37: ...code will be logged in the memory of the ECM The codes that have been logged by the ECM can be identified by the electronic service tool The active codes that have been logged will be cleared when th...

Page 38: ...d for future reference For more information on diagnostic codes refer to the Troubleshooting Guide for this engine i05299648 Configuration Parameters The engine electronic control module ECM has two t...

Page 39: ...rements change Table 5 Customer Specified Parameters Specified Parameters Record ECM Identification Parameters ECM Serial Number Software Group Part Number Software Group Release Date Software Group D...

Page 40: ...iguration Pulley Ratio Temperature Error Increasing Hysteresis Temperature Error Decreasing Hysteresis Current Ramp Rate Fan Speed Proportional Gain Percentage Fan Speed Integral Stability Percentage...

Page 41: ...itch Installation Status Auxiliary Temperature Sensor Installation Status Auxiliary Pressure Sensor Installation Status Engine Charge Air Cooler 1 Outlet Temperature Sensor Installation Status Engine...

Page 42: ...i05298520 Cold Weather Starting Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury Startability will be improved at temperatures below 1...

Page 43: ...al low the starting motor to cool before attempting to start the engine again 4 Allow the keyswitch to return to the RUN position after the engine starts 5 Repeat step 2 through step 4 if the engine f...

Page 44: ...n ambient temperatures from 0 to 60 C 32 to 140 F the warm up time is approximately three minutes In temperatures below 0 C 32 F additional warm up time may be required When the engine idles during wa...

Page 45: ...ow the recommended procedures in order to attain optimum performance 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 Ins...

Page 46: ...cking The cooling system and the lubrication system for the engine do not lose heat immediately upon shutdown This means that an engine can be shut down for a period and the engine can still have the...

Page 47: ...ion chamber This fuel and oil causes soft carbon deposits to form on the valve stems Generally the deposits do not cause problems and the deposits are burned off during operation at normal engine oper...

Page 48: ...facts when diesel fuel is purchased Consider the average ambient air temperature for the engine s application Engines that are fueled in one climate may not operate well if the engines are moved to an...

Page 49: ...eaters If this is the case the temperature of the fuel must not exceed 73 C 163 F at the fuel transfer pump For more information about fuel heaters if equipped refer to the OEM information SEBU8731 49...

Page 50: ...NLY DO NOT use emergency shutoff devices or controls for normal stopping procedure Ensure that any components for the external system that support the engine operation are secured after the engine is...

Page 51: ...l tank in order to help prevent accumulation of moisture in the fuel Do not overfill the fuel tank NOTICE Only use antifreeze coolant mixtures recommended in this Operation and Maintenance Manual Refi...

Page 52: ...NOTICE Frequently check the specific gravity of the coolant for proper freeze protection or for anti boil protection Clean the cooling system for the following reasons Contamination of the cooling sy...

Page 53: ...Perkins recommends a 1 1 mixture of a water glycol solution Note Use a mixture that will provide protection against the lowest ambient temperature Note 100 percent pure glycol will freeze at a tempera...

Page 54: ...correct amount of these additives in order to provide superior corrosion protection for all metals in engine cooling systems ELC is available in a premixed cooling solution with distilled water ELC is...

Page 55: ...e system until all the signs of the cleaning agent are gone 7 Drain the cooling system into a suitable container and flush the cooling system with clean water Note The cooling system cleaner must be t...

Page 56: ...ty antifreeze of all types REQUIRE periodic additions of an SCA Test the antifreeze periodically for the concentration of SCA For the interval refer to the Operation and Maintenance Manual Maintenance...

Page 57: ...at will be of assistance in purchasing lubricants Recommended oil viscosities can be found in this publication Fluid Recommendations Engine Oil Specification topic Maintenance Section Engine Oil Comme...

Page 58: ...e Fully formulated finished oils consist of base oils and of commercial additive packages These additive packages are blended into the base oils at precise percentages in order to help provide finishe...

Page 59: ...ethyl Ester EPA Environmental Protection Agency of the United States PPM Parts Per Million General Information NOTICE Every attempt is made to provide accurate up to date information By use of this do...

Page 60: ...ulations or international regulations can require a fuel with a specific sulfur limit Consult all applicable regu lations before selecting a fuel for a given engine application Perkins fuel systems an...

Page 61: ...the fuel is significant because fuel serves as a lubricant for the fuel system components Fuel must have sufficient viscosity in order to lubricate the fuel system in both extremely cold temperatures...

Page 62: ...is Rape Methyl Ester RME This biodiesel is derived from rapeseed oil Soy Methyl Ester SME is the most common biodiesel in the United States This biodiesel is derived from soybean oil Soybean oil or ra...

Page 63: ...ncrease in fuel system deposits most significant of which are deposits within the fuel injector These deposits can cause a loss in power due to restricted or modified fuel injection or cause other fun...

Page 64: ...e only fuel cleaner that is recommended by Perkins If biodiesel or biodiesel blends of fuel are to be used Perkins require the use of Perkins fuel cleaner The use of the fuel is in order to remove dep...

Page 65: ...e to the weld This will help reduce the pos sibility of damage Note Perform the welding in areas that are free from explosive hazards 1 Stop the engine Turn the switched power to the OFF position 2 En...

Page 66: ...m reliability and retention of full service life Due to individual applications it is not possible to identify all of the factors which can contribute to severe service operation Consult your Perkins...

Page 67: ...gine Air Cleaner Element Dual Element Canister Type Clean Replace 77 Engine Air Cleaner Element Single Element Inspect Replace 79 Engine Crankcase Breather Element Replace 81 Engine Oil and Filter Cha...

Page 68: ...ter Thoroughly rinse the core with clean water After cleaning start the engine and accelerate the engine to high idle rpm This will help in the removal of debris and drying of the core Stop the engine...

Page 69: ...battery terminal 10 Turn the battery disconnect switch to the ON position i02724529 Battery Electrolyte Level Check When the engine is not run for long periods of time or when the engine is run for s...

Page 70: ...e removal of material can cause the clamps to not fit correctly Coat the clamps and the terminals with a suitable silicone lubricant or petroleum jelly 6 Tape the cable connections in order to help pr...

Page 71: ...fluid with suitable containers before opening any compartment or disassembling any component containing fluids Dispose of all fluids according to Local regulations and mandates NOTICE Keep all parts...

Page 72: ...ap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain cock or remove the drain plug on the engine Open the drain cock or remove the drain plug on the radiator...

Page 73: ...ned component life Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist The engine overheats frequently Foaming of the co...

Page 74: ...Flush the cooling system with clean water Fill 1 Close the drain cock or install the drain plug on the engine Close the drain cock or install the drain plug on the radiator NOTICE Do not fill the cool...

Page 75: ...er cap slowly in order to relieve pressure 2 Maintain the coolant level at the maximum mark that is correct for your application If the engine is equipped with a sight glass maintain the coolant level...

Page 76: ...drained fluids according to local regulations 2 If necessary drain some coolant from the cooling system into a suitable container in order to allow space for the extra SCA 3 Add the correct amount of...

Page 77: ...dirt and debris as needed Operating conditions dust dirt and debris may require more frequent service of the air cleaner element The air cleaner element may be cleaned up to six times if the element h...

Page 78: ...rs in the filter material The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Use clean primary air...

Page 79: ...ir cleaner element with damaged pleats gaskets or seals Discard damaged primary air cleaner elements Storing Primary Air Cleaner Elements If a primary air cleaner element that passes inspection will n...

Page 80: ...ith a different service indicator Some engines are equipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that...

Page 81: ...is stopped before any servic ing or repair is performed 1 Place a container under canister 2 2 Clean the outside of the canister Using a suitable tool remove the canister Illustration 47 g03348323 Ty...

Page 82: ...e Obtain The condition of the engine lubricating oil may be checked at regular intervals as part of a preventive maintenance program Perkins include an oil sampling valve as an option The oil sampling...

Page 83: ...s settle on the bottom of the oil pan The waste particles are not removed with draining cold oil Drain the oil pan with the engine stopped Drain the oil pan with the oil warm This draining method allo...

Page 84: ...ion 51 g03351031 3 Clean the sealing surface of the oil filter base 1 4 Apply clean engine oil to the O ring seal 2 on the new oil filter NOTICE Do not fill the oil filters with oil before installing...

Page 85: ...nance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before m...

Page 86: ...neral Hazard Information and High Pressure Fuel Lines before adjustments and repairs are performed Note Refer to Testing and Adjusting Manual Cleanliness of Fuel System Components for detailed informa...

Page 87: ...ill help ensure that the air has been removed from the fuel system 6 If the engine will not start repeat steps 2 to step 5 After the engine has stopped you must wait for 10 minutes in order to allow t...

Page 88: ...from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from...

Page 89: ...owl 7 Remove the old O ring seal 6 Clean connecting bowl 7 5 Use a suitable tool in order to remove the fuel filter 5 6 Lubricate the O ring seal 4 with clean engine oil on the new filter Install the...

Page 90: ...a 73 psi Use the same method when draining the primary fuel filter with a hand priming pump installed Illustration 59 g03352638 Typical example 1 Place a suitable container under the water separator i...

Page 91: ...an be 500 kPa 73 psi Note Both fuel filter elements must be replaced Remove the Element 1 Ensure that the fuel supply valve if equipped is in the OFF position Place a suitable container under the fuel...

Page 92: ...l Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system Water can be introduced into the fuel tank when t...

Page 93: ...overing that is ballooning locally Flexible part of the hose that is kinked or crushed Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard...

Page 94: ...Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both...

Page 95: ...ce of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the intake air clogged air filters which causes the tur...

Page 96: ...or loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current...

Page 97: ...ndards 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 i...

Page 98: ...ne performance 4 Highly trained technicians carry out all repairs 5 Transferable coverage should you sell your machine Flexible coverage provides the right level of protection for your Perkins Engine...

Page 99: ...5 Cooling System Supplemental Coolant Additive SCA Test Add 75 Add the SCA If Necessary 76 Test for SCA Concentration 75 Crushing Prevention and Cutting Prevention 10 D Diagnostic Flash Code Retrieval...

Page 100: ...Weather 48 Fuel Filters 48 Fuel Heaters 49 Fuel Tanks 48 Fuel System Prime 86 Electric Prime 87 Hand Fuel Priming Pump 87 Fuel System Primary Filter Water Separator Element Replace 88 Fuel System Prim...

Page 101: ...Information 22 Record for Reference 22 Reference Information Section 98 Reference Materials 98 Refill Capacities 52 Coolant 52 Fuel 52 Lubricating Oil 52 S Safety Messages 5 1 Universal Warning 5 2 Ha...

Page 102: ...102 SEBU8731 Index Section...

Page 103: ...aintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Inf...

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