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Table of Contents

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

Safety Section

Safety Messages............................................... 6

General Hazard Information.............................. 9

Burn Prevention............................................... 13

Fire Prevention and Explosion Prevention...... 14

Crushing Prevention and Cutting Prevention.. 16

Mounting and Dismounting ............................. 16

High Pressure Fuel Lines ................................ 16

Before Starting Engine .................................... 18

Engine Starting................................................ 18

Engine Stopping .............................................. 18

Electrical System............................................. 19

Engine Electronics........................................... 20

Product Information Section

General Information ........................................ 22

Product Identification Information ................... 28

Operation Section

Lifting and Storage .......................................... 30

Features and Controls..................................... 32

Engine Diagnostics ......................................... 39

Engine Starting................................................ 41

Engine Operation ............................................ 43

Cold Weather Operation ................................. 44

Engine Stopping .............................................. 48

Maintenance Section

Refill Capacities............................................... 50

Maintenance Recommendations .................... 66

Maintenance Interval Schedule....................... 69

Warranty Section

Warranty Information....................................... 99

Reference Information Section

Reference Materials ...................................... 100

Index Section

Index.............................................................. 103

M0090743

Table of Contents

Содержание 1206A-E70TTA

Страница 1: ...Operation and Maintenance Manual 1206A E70TTA and 1206D E70TTA Industrial Engines BP1 Engine BQ1 Engine M0090743 en us September 2018...

Страница 2: ...rmation 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...

Страница 3: ...19 Engine Electronics 20 Product Information Section General Information 22 Product Identification Information 28 Operation Section Lifting and Storage 30 Features and Controls 32 Engine Diagnostics 3...

Страница 4: ...s manual Whenever a question arises regarding your engine or this manual please consult with your Perkins dealer or your Perkins distributor for the latest available information Safety This safety sec...

Страница 5: ...ar the engine as a convenient reminder Perkins also recommends that a maintenance record be maintained as part of the permanent record of the engine Your authorized Perkins dealer or your Perkins dist...

Страница 6: ...rsh chemicals could loosen the adhesive that 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 si...

Страница 7: ...he engine On the valve mechanism cover and on the intake manifold refer to illustration 2 Ether Warning 2 Do not use aerosol types of starting aids such as ether Such use could result in an explosion...

Страница 8: ...sure 3 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 in struc...

Страница 9: ...he engine exhaust to the outside when the engine is operated in an enclosed area If the engine is not running do not release the secondary brake or the parking brake systems unless the vehicle is bloc...

Страница 10: ...of combustion which may be harmful to your health Always start the engine and operate the engine in a well ventilated area If the engine is in an enclosed area vent the engine exhaust to the outside C...

Страница 11: ...cause severe injury If fluid is injected into your skin you must get treatment immediately Seek treatment from a doctor that is familiar with this type of injury Containing Fluid Spillage Care must be...

Страница 12: ...rake bands lining material clutch plates and some gaskets The asbestos that is used in these components is usually bound in a resin or sealed in some way Normal handling is not hazardous unless airbor...

Страница 13: ...he sulfuric acid may spill from the cooler during service of the en gine The sulfuric acid will burn the eyes skin and clothing on contact Always wear the appro priate personal protective equipment PP...

Страница 14: ...ne 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...

Страница 15: ...as Never check the battery charge by placing a metal object across the terminal posts Use a voltmeter or a hydrometer Incorrect jumper cable connections can cause an explosion that can result in injur...

Страница 16: ...ort the component correctly 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 rota...

Страница 17: ...y service or repair is performed on the engine fuel lines The 10 minute wait will also allow static charge to dissipate from the low pressure fuel system Do not loosen the high pressure fuel lines in...

Страница 18: ...l protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures To help prevent an accident that is caused by parts in rotation wor...

Страница 19: ...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 p...

Страница 20: ...e battery i07291428 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 dama...

Страница 21: ...ilar for all engines Note Many of the engine control systems and display modules that are available for Perkins engines will work in unison with the Engine Monitoring System Together the two controls...

Страница 22: ...engine Due to individual applications your engine may appear different from the illustrations Note There will be no visual difference between the 1206A E70TTA and the 1206D E70TTA engines Full Engine...

Страница 23: ...re cap Coolant top up cap Engine Only Illustration 19 g06276515 Typical example 1 Secondary fuel filter 2 On engine primary fuel filter 3 Breather outlet hose 4 Electronic Control Module ECM 5 Electri...

Страница 24: ...l filler cap 11 Air intake and throttle valve 12 Coolant pump 13 Idler roller for belt 14 Crankshaft damper 15 Auto belt tensioner 16 Alternator 17 Drive belt 18 NOx reduction valve 24 M0090743 Produc...

Страница 25: ...A E70TTA with a prefix of BP The 1206A E70TTA with a prefix of BQ The engines have the same characteristics In line six cylinder Four stroke cycle Four valves per cylinder Series turbocharged Air char...

Страница 26: ...refer to the Operation and Maintenance Manual Features and Controls topic Operation Section Engine Diagnostics The engine has built in diagnostics to ensure that the engine systems are functioning co...

Страница 27: ...on fuel consumption of the engine over time Reduced hours of operation at full throttle and or operating at reduced throttle settings result in a lower average power demand Reduced hours of operation...

Страница 28: ...l Serial Number Plate 1 The engine serial number plate is on the left side of the cylinder block to the rear of the front engine mounting Illustration 24 g01094203 Serial number plate i07297203 Emissi...

Страница 29: ...lement Lubrication Oil Filter Element Auxiliary Oil Filter Element Total Lubrication System Capacity Total Cooling System Capacity Air Cleaner Element Drive Belt M0090743 29 Product Information Sectio...

Страница 30: ...ead all the information within product lifting before any lifting is attempted Ensure that the correct set of lifting eyes for the assembly to be lifted have been selected Use a hoist to remove heavy...

Страница 31: ...nual Fluid recommendations Operate the engine for 15 minutes in order to remove all biodiesel from the system 2 Drain any water from the primary filter water separator Ensure that the fuel tank is ful...

Страница 32: ...h pressure or low pressure in the fuel rail The ECM will Check the pressure Engine oil pressure The engine oil pressure sensor indicates when oil pressure drops below rated system pressure at a set en...

Страница 33: ...hanges perform the following procedure 1 Remove the load 2 Stop the engine 3 Check and maintain the oil level Jacket Water Coolant Temperature Typical temperature range is 82 to 94 C 179 6 to 169 2 F...

Страница 34: ...he duration will depend on ambient temperature and engine temperature The lamps will illuminate for 2 seconds to check that the lamps are functioning when the keyswitch is turned to the ON position If...

Страница 35: ...ult should be investigated Flashing Off Warning Level 2 warning The engine continues to be operated but the level of importance of the warning has increased Depending on the particular fault and the s...

Страница 36: ...mation refer to this Operation and Maintenance Manual Diagnostic Lamp i07306134 Sensors and Electrical Components The illustrations within the following sections are typical location of the sensors or...

Страница 37: ...pressure sensor 9 Water in fuel switch 10 Fuel suction control valve 11 Fuel temperature sensor Illustration 28 g06277422 Typical example 12 NOx Reduction System NRS mixer differential pressure sensor...

Страница 38: ...Secondary speed timing sensor 19 Starting motor 20 Barometric pressure sensor A turbocharge outlet temperature sensor not shown will be installed within the exhaust outlet system 38 M0090743 Operatio...

Страница 39: ...ning lamp will flash once 3 A flashing YELLOW lamp indicates a 3 digit diagnostic code for the engine The sequence of flashes represents the system diagnostic message Count the first sequence of flash...

Страница 40: ...tween these active diagnostic codes and engine performance i01797063 Engine Operation with Intermittent Diagnostic Codes If a diagnostic lamp illuminates during normal engine operation and the diagnos...

Страница 41: ...bles Do Not Use This Procedure in Hazardous Locations that have Explosive Atmospheres The connection of battery cables to a battery and the disconnection of battery cables from a battery may cause an...

Страница 42: ...ation between 1 and 25 seconds to allow engine systems to stabilize The duration will depend on ambient temperature time since last run and other factors Note In ambient temperatures from 0 C to 60 C...

Страница 43: ...rmal operating developments Significant changes in the readings should be investigated i04018232 Fuel Conservation Practices The efficiency of the engine can affect the fuel economy Perkins design and...

Страница 44: ...s from sticking The cooling system and the lubrication system for the engine do not lose heat immediately upon shutdown An engine can be shut down for a period and the engine can still have the abilit...

Страница 45: ...operate at low idle for 3 minutes before used at operational speed If the low idle option is not available then operate the engine at operational speed with no load for 2 minutes Recommendations for...

Страница 46: ...ir flow over components will also affect under hood temperatures Reducing air flow can increase surface temperatures and could affect component reliability If an airflow restriction device must be use...

Страница 47: ...from the bottom of the tanks 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 fr...

Страница 48: ...the engine oil to return to the oil pan 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 inspectio...

Страница 49: ...wly in order to relieve the pressure Allow the engine to cool Check the coolant level Check the coolant for correct antifreeze protection and the correct corrosion protection Add the correct coolant w...

Страница 50: ...Engine and radiator 22 L 5 8 US gal i07306220 Fluid Recommendations General Coolant Information NOTICE Never add coolant to an overheated engine Engine damage could result Allow the engine to cool fi...

Страница 51: ...s 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...

Страница 52: ...wever ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite Perkins ELC has been formulated with the correct amount of these additives to provide superior corrosion...

Страница 53: ...tem Contamination NOTICE Mixing ELC with other products reduces the effective ness of the ELC and shortens the ELC service life Use only Perkins Products for premixed or concen trate coolants Failure...

Страница 54: ...hat is required if necessary Table 11 Equation For Adding The SCA To The Heavy Duty Coolant For Maintenance V 0 023 X V is the total volume of the cooling system X is the amount of SCA that is require...

Страница 55: ...n topic Maintenance Section Engine Oil Perkins Diesel Engine Oil Perkins DEO CI 4 multi grade oil has been developed and tested to provide full performance and service life that has been designed and...

Страница 56: ...re are no industry standard tests that evaluate the performance or the compatibility of aftermarket additives in finished oil Aftermarket additives may not be compatible with the finished oils additiv...

Страница 57: ...rate up to date information By use of this document you agree that Perkins Engines Company Limited is not respon sible for errors or omissions NOTICE These recommendations are subject to change with o...

Страница 58: ...osity of the fuel that is delivered to the fuel injec tion pump 1 4 minimum and 4 5 maximum D445 ISO 3405 Water and sediment weight 0 05 maximum D1796 ISO 3734 Water weight 0 02 maximum D1744 No equiv...

Страница 59: ...oes not certify diesel engines on any other fuel Note The owner and the operator of the engine has the responsibility of using the fuel that is prescribed by the Environmental Protection Agency EPA an...

Страница 60: ...nificance to the current low viscosity fuel low sulfur fuel and low aromatic fossil fuel These fuels are made to meet stringent exhaust emissions The lubricity of these fuels must not exceed wear scar...

Страница 61: ...y gel in the crankcase and the fuel tank These fuels may not be compatible with many of the elastomers that are used in engines that are manufactured today In original forms these oils are not suitabl...

Страница 62: ...tor Perkins Diesel Fuel Cleaner T400012 is most effective in cleaning and preventing the formation of deposits Refer to section Perkins Diesel Fuel System Cleaner for more information Perkins Diesel F...

Страница 63: ...e aviation kerosene fuels that are specified in Group 2 These fuels are intended to be used in temperatures that can be as low as 54 C 65 2 F Refer to Group 2 for detail and conditions of use of the a...

Страница 64: ...t rate during the early weeks of fuel storage Contamination Control Recommendations for Fuels Fuels of ISO 18 16 13 cleanliness level or cleaner as dispensed into the engine or application fuel tank s...

Страница 65: ...y initiatives In recent years various forms of renewable and alternative synthetic diesel fuels have started to emerge Synthetic diesel fuels are produced by gasification of various feedstock and then...

Страница 66: ...Do not loosen the high pressure fuel lines in order to remove air from the fuel system Engine Oil To relieve pressure from the lubricating system turn off the engine i07307205 Welding on Engines with...

Страница 67: ...Electronic component 8 Minimum 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...

Страница 68: ...ment incorrect operating procedures and incorrect maintenance procedures can be factors which contribute to a severe service application Environmental Factors Ambient temperatures The engine may be ex...

Страница 69: ...Hours or 1 Year Battery Electrolyte Level Check 71 Crankshaft Vibration Damper Inspect 79 Engine Air Cleaner Element Replace 80 Fuel System Primary Filter Water Separator Element Replace 87 Fuel Syst...

Страница 70: ...e 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 amme...

Страница 71: ...d be very near zero when the engine is in operation All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on...

Страница 72: ...he belt is worn or damaged 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 pres...

Страница 73: ...he cooling system pressure cap slowly in order to relieve the pressure DEAC Diesel Engine Antifreeze Coolant Clean the cooling system and flush the cooling system before the recommended maintenance in...

Страница 74: ...ller cap 1 Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage Illustration 37 g06280061 Typical example 4 Cylinder block drain plug...

Страница 75: ...ystem drain plugs Allow the water to drain Flush the cooling system with clean water Install the system drain plugs Fill NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to...

Страница 76: ...perature regulator after the cooling system has been drained Replace the water pump the water temperature regulator and the hoses if necessary NOTICE Service or repair of the engine cooling system mus...

Страница 77: ...sal of the material Alternative Drain Plug If necessary remove drain plug 3 to drain coolant from system If necessary replace O ring seal on plug and install drain plug 3 Tighten to 35 N m 25 lb ft Fl...

Страница 78: ...ling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on...

Страница 79: ...damper Ensure that the cooling fins 1 on the crankshaft damper are clean and free from dirt Illustration 41 g06279060 Typical example Inspect the damper and replace the damper for any of the followin...

Страница 80: ...er element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to pre vent air...

Страница 81: ...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...

Страница 82: ...laced Refer to the OEM information for the recommended torques i05300117 Engine Oil Level Check Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact t...

Страница 83: ...he sample can be checked for the following the quality of the oil the existence of any coolant in the oil the existence of any ferrous metal particles in the oil and the existence of any nonferrous me...

Страница 84: ...knob clockwise to close the drain valve If the engine is not equipped with a drain valve remove the oil drain plug 1 to allow the oil to drain If the engine is equipped with a shallow oil pan remove t...

Страница 85: ...illing the crankcase with oil can cause engine damage 2 Start the engine and run the engine at LOW IDLE on load for 2 minutes Perform this procedure to ensure that the lubrication system has oil and t...

Страница 86: ...for more information i05774864 Fuel System Prime Note Refer to Systems Operation Testing and Adjusting Cleanliness of Fuel System Components for detailed information on the standards of cleanliness t...

Страница 87: ...ry perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly...

Страница 88: ...ce Manual Fuel System Primary Filter Water Separator Drain for more information 4 Remove end cover 5 and remove O ring 4 Discard O ring 4 Ensure that the end cover 5 is clear and free from dirt 5 Remo...

Страница 89: ...the container If the fuel will not drain loosen the vent screw on the secondary fuel filter Note In some applications the vent screw on the secondary fuel filter will need to be open to drain the on...

Страница 90: ...condary filter element must be replaced at the same time as the primary fuel filters Refer to the Operation and Maintenance Manual Fuel System Filter Replace i07310613 Fuel System Primary Filter Water...

Страница 91: ...d 2 Ensure that the outer body of the filter assembly is clean and free from dirt Illustration 56 g03858194 Typical example 3 Install a suitable tube onto drain 3 Open the drain valve 2 Rotate the dra...

Страница 92: ...alve counterclockwise Two full turns are required Loosen vent screw 1 4 Allow the fuel to drain into the container and remove the tube 5 Tighten the vent screw 1 to a torque of 2 5 N m 22 lb in 6 Remo...

Страница 93: ...der to drain the water and the sediment Close the drain valve Check the fuel daily Allow five minutes after the fuel tank has been filled before draining water and sediment from the fuel tank Fill the...

Страница 94: ...without following prop er procedure When using pressure air wear a protective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purp...

Страница 95: ...or your Perkins distributor for assistance i07313514 Turbocharger Inspect Hot engine components can cause injury from burns Before performing maintenance on the en gine allow the engine and the compon...

Страница 96: ...at discoloration of the turbocharger Check for any loose bolts or any missing bolts Check for damage to the oil supply line and the oil drain line Check for cracks in the housing of the turbocharger E...

Страница 97: ...seal the rear crankshaft seal the oil pan the oil filters and the rocker cover Inspect the piping for the air intake system and the elbows for cracks and for loose clamps Ensure that hoses and tubes...

Страница 98: ...o the engine Illustration 63 g01904773 A Weep hole B Vent hole Note The water pump seals are lubricated by the coolant in the cooling system It is normal for a small amount of leakage to occur Refer t...

Страница 99: ...aseous emission standards that are prescribed by the law at the time of manufacture This engine may be covered by an Emissions Warranty Consult your authorized Perkins dealer or distributor to determi...

Страница 100: ...ating cost Records should be kept for the following items Fuel Consumption A record of fuel consumption is essential in order to determine when the load sensitive components should be inspected or rep...

Страница 101: ...aintenance Log Table 15 Engine Model Customer Identifier Serial Number Arrangement Number Service Hours Quantity Of Fuel Service Item Date Authorization M0090743 101 Reference Information Section Main...

Страница 102: ...rained 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 Coverage can be extended...

Страница 103: ...tic Flash Code Retrieval 39 Diagnostic Lamp 39 Driven Equipment Check 79 E Electrical System 19 Grounding Practices 19 Emergency Stopping 48 Emissions Certification Film 28 Emissions Warranty Informat...

Страница 104: ...nt 92 Fuel Tank Water and Sediment Drain 93 Drain the Water and the Sediment 93 Fuel Storage Tanks 93 Fuel Tank 93 G Gauges and Indicators 33 Indicator Lamps 34 General Hazard Information 9 Containing...

Страница 105: ...S Safety Messages 6 Ether Warning 2 7 Hand High Pressure 3 8 Universal Warning 1 6 Safety Section 6 Self Diagnostics 39 Sensors and Electrical Components 36 Severe Service Application 68 Environmenta...

Страница 106: ......

Страница 107: ...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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