Perkins 1206E-E66TA Operation And Maintenance Manual Download Page 6

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SEBU8603-01

Safety Section

Safety Messages

g02382617

Illustration 2

Typical example
(1) Universal warning

(2) Hand (High Pressure)

Contact with high pressure fuel may cause

uid

penetration and burn hazards. High pressure fu-

el spray may cause a

re hazard. Failure to fol-

low these inspection, maintenance and service in-

structions may cause personal injury or death.

Summary of Contents for 1206E-E66TA

Page 1: ...SEBU8603 01 May 2011 Operation and Maintenance Manual 1206E E66TA Industrial Engine BK Engine...

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: ...16 Electrical System 17 Engine Electronics 18 Product Information Section Model Views 20 Product Identification Information 27 Operation Section Lifting and Storage 29 Gauges and Indicators 32 Feature...

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 operatin...

Page 5: ...at secures the warning signs The warning signs that are loosened could drop off the engine Replace any warning sign that is damaged or missing If a warning sign is attached to a part of the engine tha...

Page 6: ...mple 1 Universal warning 2 Hand High Pressure Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these in...

Page 7: ...he warning label for the Hand High Pressure 3 is a wrap around label that is installed on the high pressure fuel line g02382618 Illustration 4 Typical example Ether Warning Do not use aerosol types of...

Page 8: ...ating wear protective devices for ears in order to help prevent damage to hearing Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine Ensure that all protec...

Page 9: ...of the engine Ensure that all protective guards and all covers are secured in place on the engine Never put maintenance fluids into glass containers Glass containers can break Use all cleaning solutio...

Page 10: ...tos debris Use caution Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers Inhaling this dust can be hazardous to your health The components that may co...

Page 11: ...any lines fittings or related items are disconnected Induction System Sulfuric Acid Burn Hazard may cause serious per sonal injury or death The exhaust gas cooler may contain a small amount of sulfuri...

Page 12: ...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 li...

Page 13: ...mmended cables connections and battery box covers when the engine is operated Fire Extinguisher Make sure that a fire extinguisher is available Be familiar with the operation of the fire extinguisher...

Page 14: ...hen 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...

Page 15: ...utes 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 Do not loosen the high pressure fuel lines in...

Page 16: ...vers must be installed if the engine must be started in order to perform service procedures To help prevent an accident that is caused by parts in rotation work around the parts carefully Start the en...

Page 17: ...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...

Page 18: ...he power supply connections and the ground connections for the engine electronics should always be from the isolator to the battery i03642610 Engine Electronics Tampering with the electronic system in...

Page 19: ...pplications However the monitoring system and the engine monitoring control will be similar for all engines Note Many of the engine control systems and display modules that are available for Perkins E...

Page 20: ...es of the engine Due to individual applications your engine may appear different from the illustrations Engine views g02361696 Illustration 17 Typical example 1 Secondary fuel filter 2 Crankcase breat...

Page 21: ...ill depend on the application g02361697 Illustration 18 Typical example 11 Rear lifting eye 12 NOx reduction system NRS 13 Front lifting eye 14 Turbocharger 15 Back pressure valve 16 Engine oil pan Su...

Page 22: ...ation 19 Typical example 23 Belt 24 Connection for air inlet 25 Outlet connection for the coolant 26 Water temperature regulator housing Thermostat housing 27 Water pump 28 Oil filler 29 Inlet connect...

Page 23: ...SEBU8603 01 23 Product Information Section Model Views g02381218 Illustration 20 Typical example 33 Coolant drain plug for cylinder block 34 Coolant drain plug for exhaust gas cooler...

Page 24: ...Engine Description The Perkins 1206 E66 Industrial Engine has the following characteristics In line Six cylinder Four stroke cycle Turbocharged charge cooled Engine Specifications Note The front end o...

Page 25: ...er certain 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 activ...

Page 26: ...tion use recommended fuels coolants and lubricants Use the Operation and Maintenance Manual as a guide for required engine maintenance Expected engine life is generally predicted by the average power...

Page 27: ...ion 24 Module Arrangement Exhaust Plate Record the information that is on the plate This information identifies the engine aftertreatment system This information will be required by your Perkins distr...

Page 28: ...___ ______________________ Total Lubrication System Capacity _________ ____________ Total Cooling System Capacity _________ ________________ Air Cleaner Element _________ _____________________________...

Page 29: ...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...

Page 30: ...rage The engine must be stored in a water proof building The building must be kept at a constant temperature Engines that are filled with Perkins ELC will have coolant protection to an ambient tempera...

Page 31: ...of the vapor phase inhibitor will be lost if the cooling system is open to the atmosphere For maintenance procedures ref to this Operation and Maintenance Manual Aftertreatment No special procedures a...

Page 32: ...A lower oil pressure is normal at low idle If the load is stable and the gauge reading changes perform the following procedure 1 Remove the load 2 Stop the engine 3 Check and maintain the oil level Ja...

Page 33: ...on of the low pressure lamp should be investigated immediately All lamps will illuminate for 2 seconds in order to check that the lamps are functioning when the keyswitch is turned to the ON position...

Page 34: ...personal injury The engine can be programmed to the following modes Warning The orange Warning lamp will turn ON and the warning signal is activated continuously in order to alert the operator that o...

Page 35: ...own lamp refer to this Operation and Maintenance Manual Monitoring System Table for Indicator Lamps For each of the programmed modes refer to Troubleshooting Guide Indicator Lamps for more information...

Page 36: ...operation there are no active warnings diagnostic codes or event codes The engine is operating with no detected faults On Solid Off Warning Level 1 warning The engine is operating normally but there i...

Page 37: ...he application g02395776 Illustration 28 1 Temperature Sensor 2 Connector for Temperature Sensor 3 Soot Sensor Connection 4 Aftertreatment Identification Module 5 Soot Sensor Connection 6 Soot Sensor...

Page 38: ...d Pressure Sensor 7 Diagnostic Connector 8 Electronic Control Module ECM 9 Atmospheric Pressure Sensor Barometric Pressure Sensor 10 Primary Speed Timing Sensor 11 Oil Pressure Sensor 12 Fuel Priming...

Page 39: ...ration 30 Typical example 16 Inlet Pressure Sensor for the NOx Reduction System NRS 17 Outlet Pressure sensor for the NRS 18 Control Valve for the NRS 19 Temperature Sensor for the NRS 20 Alternator 2...

Page 40: ...valve g02394157 Illustration 32 Typical example 4 Fuel Pressure Sensor Fuel Rail Pressure Sensor 5 Intake Manifold Air Temperature Sensor 6 Intake Manifold Pressure Sensor 7 Diagnostic Connector 8 Ele...

Page 41: ...SEBU8603 01 41 Operation Section Features and Controls g02395396 Illustration 33 Typical example 13 Water in Fuel Switch 14 Fuel Temperature Sensor 15 Solenoid for the High Pressure Fuel Pump...

Page 42: ...tion Features and Controls g02395399 Illustration 34 Typical example 16 Inlet Pressure Sensor for the NOx Reduction System NRS 17 Outlet Pressure sensor for the NRS 18 Control Valve for the NRS 19 Tem...

Page 43: ...ritical levels for the following items Operating temperature Operating pressure Operating level Operating rpm The particular shutoff may need to be reset before the engine will start NOTICE Always det...

Page 44: ...he engine is operating Fuel temperature The fuel temperature sensor monitors the pressurized fuel in the high pressure fuel pump Note The sensing element of the coolant temperature switch must be subm...

Page 45: ...iagnostic code will remain active until the problem is repaired The diagnostic code may be retrieved by using the electronic service tool Refer to Troubleshooting Electronic Service Tools for more inf...

Page 46: ...tor position voltage out of range 249 Engine Fuel Supply Lift Pump Relay out of range 253 Personality module erratic intermittent or incorrect 415 Machine security system module abnormal update rate 4...

Page 47: ...stic lamp shuts off an intermittent fault may have occurred If a fault has occurred the fault will be logged into the memory of the Electronic Control Module ECM In most cases it is not necessary to s...

Page 48: ...he customer configuration parameters Customer parameters may be changed repeatedly as operational requirements change Table 5 Customer Specified Parameters Specified Parameters Record Low Idle Paramet...

Page 49: ...m Current Solenoid Maximum Current Solenoid Dither Frequency Solenoid Dither Amplitude Charge Air Cooler Outlet Temperature Input Enable Maximum Air Flow Charge Air Cooler Outlet Temperature Minimum A...

Page 50: ...on Switch Installation Status Air Filter Restriction Switch Configuration Water in Fuel Switch Installation Status User Defined Switch Installation Status Auxiliary Temperature Sensor Installation Sta...

Page 51: ...s a DO NOT OPERATE warning tag or similar warning tag attached to the start switch or to the controls Reset all of the shutoffs or alarm components Ensure that any driven equipment has been disengaged...

Page 52: ...se the engine rpm from 1000 to 1200 rpm This will warm up the engine more quickly Maintaining an elevated low idle speed for extended periods will be easier with the installation of a hand throttle Al...

Page 53: ...attery Test i02330138 After Starting Engine Note In 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 ti...

Page 54: ...ngs should be observed and the data should be recorded frequently while the engine is operating Comparing the data over time will help to determine normal readings for each gauge Comparing data over t...

Page 55: ...f time Observe the service indicator frequently Keep the air cleaner elements clean Ensure that the turbocharger is operating correctly For more information refer to this Operation and Maintenance Man...

Page 56: ...ast 10 minutes in order to allow the engine oil to return to the oil pan Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard...

Page 57: ...coolant for correct antifreeze protection and the correct corrosion protection Add the correct coolant water mixture if necessary Perform all required periodic maintenance on all driven equipment Thi...

Page 58: ...iately upon shutdown This means that an engine can be shut down for a period and the engine can still have the ability to start readily Install the correct specification of engine lubricant before the...

Page 59: ...ine operating temperatures When starting and stopping an engine many times without being operated in order to warm up completely the carbon deposits become thicker This starting and stopping can cause...

Page 60: ...eather Note Only use grades of fuel that are recommended by Perkins Refer to this Operation and Maintenance Manual Fluid Recommendations The following components provide a means of minimizing problems...

Page 61: ...als 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 install...

Page 62: ...heat exchanger and piping Refer to the OEM specifications Enter the value for the capacity of the External System in this row i04229329 Fluid Recommendations General Coolant Information NOTICE Never...

Page 63: ...o 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 a...

Page 64: ...owing 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 cool...

Page 65: ...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 co...

Page 66: ...in Table 12 Table 13 Example Of The Equation For Adding The SCA To The Heavy Duty Coolant At The Initial Fill Total Volume of the Cooling System V Multiplication Factor Amount of SCA that is Required...

Page 67: ...of your engine Failure to use the appropriate spec ification of engine oil will also reduce the life of your aftertreatment system Table 16 Classifications for the 1200 Series Industrial Engine Oil Sp...

Page 68: ...termarket additives may not be compatible with the finished oils additive package which could lower the performance of the finished oil The aftermarket additive could fail to mix with the finished oil...

Page 69: ...dations are subject to change with out notice Contact your local Perkins distributor for the most up to date recommendations Diesel Fuel Requirements Perkins is not in a position to continuously evalu...

Page 70: ...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 reflectan...

Page 71: ...R test If the lubricity of 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 a...

Page 72: ...he common reference is to kinematic viscosity Kinematic viscosity is the quotient of the dynamic viscosity that is divided by the density The determination of kinematic viscosity is normally by readin...

Page 73: ...acids Biodiesel is a fuel that can be made from various feedstock The most commonly available biodiesel in Europe is Rape Methyl Ester REM This biodiesel is derived from rapeseed oil Soy Methyl Ester...

Page 74: ...formance Related Issues Due to the lower energy content than the standard distillate fuel B20 will cause a power loss in order of 2 to 4 percent In addition over time the power may deteriorate further...

Page 75: ...ircumstances Contact your fuel supplier for those circumstances when fuel additives are required Your fuel supplier can recommend the appropriate fuel additive and the correct level of treatment Note...

Page 76: ...fuel system Before any service or repair is performed on the engine fuel lines perform the following tasks 1 Stop the engine 2 Wait for 10 minutes Do not loosen the high pressure fuel lines in order t...

Page 77: ...h in the OFF position 4 Battery disconnect switch in the open position 5 Disconnected battery cables 6 Battery 7 Electrical Electronic component 8 Minimum distance between the component that is being...

Page 78: ...il and Filter Change 96 Every 500 Service Hours or 1 Year Battery Electrolyte Level Check 80 Cooling System Supplemental Coolant Additive SCA Test Add 86 Engine Air Cleaner Element Dual Element Clean...

Page 79: ...mmended 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 insp...

Page 80: ...battery from freezing If batteries are correctly charged the ammeter reading should be very near zero when the engine is in operation All lead acid batteries contain sulfuric acid which can burn the s...

Page 81: ...maged Inspect the belt for cracks splits glazing grease displacement of the cord and evidence of fluid contamination The belt must be replaced if the following conditions are present The belt has a cr...

Page 82: ...s needed NOTICE When any servicing or repair of the engine cooling system is performed the procedure must be performed with the engine on level ground This will allow you to accurately check the coola...

Page 83: ...mendations topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 3 Start and run the engine at low idle Increase the engine rpm t...

Page 84: ...ystem components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in...

Page 85: ...k that is correct for your application g00103639 Illustration 45 Filler cap 5 Clean the cooling system filler cap and inspect the gasket If the gasket is damaged discard the old filler cap and install...

Page 86: ...wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly in order to relieve pre...

Page 87: ...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 SCA Refer to the Operation and Mai...

Page 88: ...Inspection Adjustment Lubrication Other maintenance recommendations Perform any maintenance for the driven equipment which is recommended by the OEM i03991933 Engine Clean Personal injury or death can...

Page 89: ...r elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the...

Page 90: ...Discard any damaged air cleaner element Two methods may be used in order to clean the primary air cleaner element pressurized air Vacuum cleaning Pressurized Air Personal injury can result from air p...

Page 91: ...with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NO...

Page 92: ...onal injury Do not allow hot oil or hot components to contact the skin NOTICE Ensure that the engine is stopped before any servicing or repair is performed NOTICE Care must be taken to ensure that flu...

Page 93: ...e the top cap 1 counterclockwise into the unlocked position Remove the top cap from the body of the breather 3 3 Note the orientation of the filter element 2 Remove the filter element g02346497 Illust...

Page 94: ...ion 57 Typical example A Alignment postion B Alignment postion 3 Note the orientation of the filter element Remove the filter element 4 from the bottom cap 2 Remove the seal 5 Note The bottom cap has...

Page 95: ...nents can cause personal injury Do not allow hot oil or hot components to contact the skin g02173847 Illustration 59 L Low H High NOTICE Perform this maintenance with the engine stopped Note Ensure th...

Page 96: ...ls and the supplies that are used for obtaining oil samples must be clean The sample can be checked for the following the quality of the oil the existence of any coolant in the oil the existence of an...

Page 97: ...O ring seal 3 for the new oil filter NOTICE Do not fill the oil filters with oil before installing them This oil would not be filtered and could be contaminat ed Contaminated oil can cause accelerated...

Page 98: ...5 minutes Ensure that the fuel system is free from leaks Note Operating the engine for this period will help ensure that the fuel system is free of air DO NOT loosen the high pressure fuel lines in o...

Page 99: ...are required Loosen vent screw 1 Note Two complete rotations of the valve will release the valve from the filter element 5 Allow the fuel to drain into the container Remove the tube and install the v...

Page 100: ...has an in line strainer installed before the electric priming pump Perkins recommended that the in line strainer be replaced when required The location of the in line strainer will depend on the appl...

Page 101: ...s of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system Remove the Element 1 Turn the fuel supply valve if equippe...

Page 102: ...ion and Maintenance Manual Fuel System Prime for more information i02348492 Fuel Tank Water and Sediment Drain NOTICE Care must be taken to ensure that fluids are contained during performance of inspe...

Page 103: ...mps Inspect Replace Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and s...

Page 104: ...ler will require cleaning Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the radiator for these items Damaged fins corrosion dirt grease insects le...

Page 105: ...s and incorrect maintenance procedures can be factors which contribute to a severe service application Environmental Factors Ambient temperatures The engine may be exposed to extended operation in ext...

Page 106: ...isual inspection of the turbocharger or turbochargers can minimize unscheduled downtime A visual inspection of the turbocharger or turbochargers can also reduce the chance for potential damage to othe...

Page 107: ...engine is a fire hazard Remove the accumulated grease and oil Re fer to this Operation and Maintenance Manual En gine Clean for more information Ensure that the cooling system hoses are correctly clam...

Page 108: ...leaks Look for loose fuel line clamps Drain the water and the sediment from the fuel tank on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wi...

Page 109: ...8603 01 109 Maintenance Section Water Pump Inspect The water pump is not a serviceable item In order to install a new water pump refer to the Disassembly and Assembly Manual Water Pump Remove and Inst...

Page 110: ...y limited parts Perkins Engine Company limited will reimburse the owner This reimbursement will include diagnostic charges for such an emergency repair These expenses shall not exceed the Perkins Engi...

Page 111: ...ere these regulations do not apply the warranty will be void Contact your Perkins dealer or your Perkins distributor for more information Maintenance Recommendations Perkins Engines Company Limited en...

Page 112: ...n and Maintenance Manual Maintenance Log Reference Materials Section The owner may perform routine maintenance repairs and other work that is outside of the warranty The work may be done at any repair...

Page 113: ...nts approved pursuant to CARB Regulations required to correct the defect Reasonable and customary labor during normal working hours that is required to make the warranty repair Included will be labor...

Page 114: ...rkins global network 3 Genuine Perkins parts ensure continued engine performance 4 Highly trained technicians carry out all repairs 5 Transferable coverage should you sell your machine Flexible covera...

Page 115: ...Regulator Replace 87 Crushing Prevention and Cutting Prevention 14 D Diagnostic Flash Code Retrieval 45 Diagnostic Lamp 45 Driven Equipment Check 88 E Electrical System 17 Grounding Practices 17 Emerg...

Page 116: ...rator Drain 100 Fuel System Secondary Filter Replace 101 Install the Element 102 Remove the Element 101 Fuel Tank Water and Sediment Drain 102 Drain the Water and the Sediment 102 Fuel Storage Tanks 1...

Page 117: ...tion Check 105 Environmental Factors 105 Incorrect Maintenance Procedures 105 Incorrect Operating Procedures 105 Starting Motor Inspect 105 Starting the Engine 51 Starting the Engine 51 Starting with...

Page 118: ...118 SEBU8603 01 Index Section...

Page 119: ...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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