Operation and

Maintenance

Manual

1206E-E66TA Industrial Engine

BK (Engine)

This document is printed from SPI². Not for RESALE

 

Important Safety Information

Most  accidents    tha t involve  produc  t  op eration,  ma intena nc e and   repair   are  caus  ed  by  failure  to

ob serve  basic   safety   rules  or  precautions  .  An accident    can   often  be  avoided   by  recog nizing  pote ntially

ha za rdous  situations   before   an  accident    oc curs . A person    mus t be  alert   to pote ntial  ha za rds.  This

person   should   also  ha ve  the  ne cessary   training,  skills  and   tools  to perform   the se  func tions properly.

Improper operation, lubrication, maintenance or repair  of this product can be dangerous and

could result in injury  or death.

Do not operate or perform any lubrication, maintenance or repair on this  product, until you have

read and understood the operation, lubrication, maintenance and repair information.

Sa fety precautions     and  warning s  are   provided   in this  ma nua l and   on  the  produc t.  If the se  ha za rd

warning s  are  not  he eded,   bod ily injury  or death   could   oc cur to  you  or to  othe r persons  .

The  ha za rds are   identified   by  the  “Safety  Alert  Symb ol”  and  followed  by  a  “Signa l  Word” suc h  as

“DANGER”, “WARNING”  or “CAUTION”.  The Sa fety  Alert  “WARNING” label  is  shown   below.

The  me aning  of  this safety   alert   symb ol is  as  follows:

Attention! Become Alert! Your Safety is  Involved.

The  me ssage   tha t appears     und er the   warning  explains    the  ha za rd and   can  be   either  written  or

pictorially   presente  d.

Op erations  tha t  ma y caus e  produc  t dama  ge  are  identified   by  “NOTICE” labels   on  the  produc  t and   in

this  pub lication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The

warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,

work method or operating technique that is not specifically recommended by Perkins is used,

you must satisfy yourself that it is safe  for you and for others. You should also ensure that the

product will not be damaged or be  made unsafe by the operation, lubrication, maintenance or

repair procedures that you choose.

The  informa tion, specifications   ,  and  illustrations   in  this  pub lication  are   on the  basis    of informa tion tha t

was  available    at  the  time  tha t the  pub lication   was  written.   The  specifications   , torque  s,  pressure  s,

me asure me nts , adjustme  nts , illustrations ,  and  othe r  items  can  cha  ng e at  any  time.  These  cha ng es  can

affect   the  service   tha t is given   to the  produc  t.  Ob tain the  comp  lete  and  mos t current   informa tion before

you  start any   job. Pe  rkins  dealers   or   Pe rkins  distributors     ha ve  the  mos t current   informa tion  available.

When  replacement  parts  are  required  for  this

product Perkins recommends using Perkins

 replacement  parts.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

This document is printed from SPI². Not for RESALE

 

SEBU8603-01

3

Table of Contents

Table of Contents

Maintenance Interval Schedule ............................  78

Warranty Section

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

Warranty Information ........................................... 110

Safety Section

Reference Information Section

Safety Messages ....................................................  5

General Hazard Information ...................................  8

Burn Prevention ..................................................... 11

Fire Prevention and Explosion Prevention ............ 12

Crushing Prevention and Cutting Prevention ........ 14

Mounting and Dismounting ................................... 14

High Pressure Fuel Lines .....................................  14

Before Starting Engine .......................................... 16

Engine Starting .....................................................  16

Engine Stopping ...................................................  16

Electrical System ..................................................  17

Engine Electronics ................................................ 18

Reference Materials ............................................. 114

Index Section

Index .................................................................... 115

Product Information Section

Model Views .........................................................  20

Product Identification Information  ........................  27

Operation Section

Lifting and Storage ................................................ 29

Gauges and Indicators .......................................... 32

Features and Controls ..........................................  34

Engine Diagnostics ............................................... 45

Engine Starting .....................................................  51

Engine Operation .................................................. 54

Engine Stopping ...................................................  56

Cold Weather Operation ....................................... 58

Maintenance Section

Refill Capacities ....................................................  62

Maintenance Recommendations ..........................  76

This document is printed from SPI². Not for RESALE

 

4

SEBU8603-01

Foreword

Foreword

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 than is

specified in the Maintenance Interval Schedule may

be necessary.

Literature Information

This manual contains safety, operation instructions,

lubrication and maintenance information.  This

manual should be stored in or near the engine area

in a literature holder or literature storage area. Read,

study and keep it with  the literature and engine

information.

The maintenance schedule items are organized for

a preventive maintenance management program. If

the preventive maintenance program is followed, a

periodic tune-up is not required. The implementation

of a preventive maintenance management program

should minimize operating  costs through cost

avoidances resulting from reductions in unscheduled

downtime and failures.

English is the primary  language for all Perkins

publications. The English used facilitates translation

and consistency.

Some photographs or illustrations in this  manual

show details or attachments that may be different

from your engine. Guards and  covers may have

been removed for illustrative purposes. Continuing

improvement and advancement of product design

may have caused changes to your engine which are

not included in this 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.

Maintenance Intervals

Perform maintenance on items  at multiples of

the original requirement. We recommend that the

maintenance schedules be reproduced and displayed

near the engine as a convenient reminder. We also

recommend that a maintenance record be maintained

as part of the engine's permanent record.

Safety

Your authorized Perkins dealer  or your Perkins

distributor can assist  you in adjusting  your

maintenance schedule to meet the needs of  your

operating environment.

This safety section lists basic safety  precautions.

In addition, this  section identifies hazardous,

warning situations. Read and understand the basic

precautions listed in  the safety section before

operating or performing lubrication, maintenance and

repair on this product.

Overhaul

Major engine overhaul details are not  covered in

the Operation and Maintenance Manual  except

for the interval and the maintenance items  in that

interval. Major repairs should only be carried out by

Perkins authorized personnel. Your Perkins dealer

or your Perkins distributor offers a variety of options

regarding overhaul programs. If you  experience

a major engine failure, there  are also numerous

after failure overhaul options available. Consult with

your Perkins dealer or your Perkins distributor for

information regarding these options.

Operation

Operating techniques outlined in this manual  are

basic. They assist with developing  the skills and

techniques required to operate the  engine more

efficiently and economically. Skill and techniques

develop as the operator gains  knowledge of the

engine and its capabilities.

The operation section is a reference for operators.

Photographs and illustrations guide the  operator

through procedures of inspecting, starting, operating

and stopping the engine. This section also includes a

discussion of electronic diagnostic information.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents

are known to the State of California to cause cancer,

birth defects, and other reproductive harm. Battery

posts, terminals and related accessories contain lead

and lead compounds. Wash hands after handling.

Maintenance

The maintenance section is a guide to engine care.

The illustrated, step-by-step instructions are grouped

by service hours and/or calendar time maintenance

intervals. Items in the maintenance schedule  are

referenced to detailed instructions that follow.

This document is printed from SPI². Not for RESALE

 

SEBU8603-01

5

Safety Section

Safety Messages

Safety Section

The Universal Warning label (1) is  located in two

positions. The warning labels are located on the font

right side of the valve mechanism cover and located

on the side of the NOx reduction system (NRS).

i04220089

Safety Messages

There may be several specific warning signs on your

engine. The exact location and a description of the

warning signs are reviewed in this section. Please

become familiar with all warning signs.

Ensure that all of the warning signs are legible. Clean

the warning signs or replace the  warning signs if

the words cannot be read or if the illustrations are

not visible. Use a cloth, water, and  soap to clean

the warning signs. Do not use solvents, gasoline, or

other harsh chemicals. Solvents, gasoline, or harsh

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 sign is attached to a part of the

engine that is replaced, install a new warning sign on

the replacement part. Your Perkins distributor can

provide new warning signs.

(1) Universal Warning

Do not operate or work on this equipment unless

you  have read  and understand  the  instructions

and warnings  in the Operation  and Maintenance

Manuals.  Failure  to   follow  the  instructions  or

heed the  warnings could result  in serious injury

or death.

g01154807

Illustration 1

Typical example

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6

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 fluid

penetration and  burn hazards. High pressure  fu-

el spray  may cause  a fire  hazard. Failure to  fol-

low these inspection, maintenance and service in-

structions may cause personal injury or death.

This document is printed from SPI². Not for RESALE

 

SEBU8603-01

7

Safety Section

Safety Messages

g02382677

Illustration 3

Typical example

The 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 starting aids such as

ether. Such use could  result in an explosion and

personal injury.

This document is printed from SPI². Not for RESALE

 

8

SEBU8603-01

Safety Section

General Hazard Information

•  Vent the 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 blocked or unless the vehicle

is restrained.

•  Wear a hard hat, protective glasses,  and other

protective equipment, as required.

•  When work is performed around an engine that is

operating, wear protective devices for ears in order

to help prevent damage to hearing.

g01154809

Illustration 5

•

•

Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

Typical example

An ether warning label will be installed  on the air

cleaner or close to the air cleaner. The location will

depend on the application.

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.

i03566024

General Hazard Information

•  Use all cleaning solutions with care.

•  Report all necessary repairs.

  

Unless other instructions are provided, perform the

maintenance under the following conditions:

•  The engine is stopped. Ensure that the engine can

not be started.

•  The protective locks or the  controls are in the

applied position.

•  Engage the secondary brakes or parking brakes.

•  Block the vehicle or restrain the  vehicle before

maintenance or repairs are performed.

g00104545

•  Disconnect the batteries when  maintenance

is performed or when the  electrical system is

serviced. Disconnect the battery ground leads.

Tape the leads in order to help prevent sparks.

Illustration 6

Attach a “Do Not Operate” warning tag or a similar

warning tag to the start  switch or to the controls

before the engine is serviced or before the engine is

repaired. Attach the warning tags to the engine and to

each operator control station. When it is appropriate,

disconnect the starting controls.

•  Disconnect the connector for the unit injector that

is located on the valve cover base. This will help

prevent personal injury from the high voltage to the

unit injectors. Do not come in contact with the unit

injector terminals while the engine is operating.

Do not allow unauthorized personnel on the engine,

or around the engine  when the engine is being

serviced.

•  Do not attempt any repairs or any adjustments to

the engine while the engine is operating.

•  Tampering with the engine installation or tampering

with the OEM supplied wiring can be dangerous.

Personal injury, death and/or engine damage could

result.

•  Do not attempt any repairs that are not understood.

Use the proper tools. Replace any equipment that

is damaged or repair the equipment.

This document is printed from SPI². Not for RESALE

 

SEBU8603-01

9

Safety Section

General Hazard Information

•  For initial start-up of a new engine or for starting an

engine that has been serviced, make provisions to

stop the engine if an overspeed occurs. This may

be accomplished by shutting off the fuel supply

and/or the air supply to the engine.

•  Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

•  Ensure that all protective guards and all covers are

secured in place on the engine.

•  Start the engine from the operator's station (cab).

Never short across the starting motor terminals or

the batteries. This could bypass the engine neutral

start system and/or the electrical system could be

damaged.

•  Never put maintenance fluids into glass containers.

Glass containers can break.

•  Use all cleaning solutions with care.

•  Report all necessary repairs.

Engine exhaust contains products 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.

Unless other instructions are provided, perform

the maintenance under the following conditions:

•  The engine is stopped. Ensure that the  engine

cannot be started.

Cautiously remove the following  parts. To help

prevent spraying or splashing of pressurized fluids,

hold a rag over the part that is being removed.

•  Disconnect the batteries when  maintenance

is performed or when the  electrical system is

serviced. Disconnect the battery ground leads.

Tape the leads in order to help prevent sparks.

•  Filler caps

•  Grease fittings

•  Pressure taps

•  Breathers

•  Do not attempt any repairs that are not understood.

Use the proper tools. Replace any equipment that

is damaged or repair the equipment.

Pressurized Air and Water

•  Drain plugs

Pressurized air and/or water  can cause debris

and/or hot water to be blown out. This could result in

personal injury.

Use caution when  cover plates are removed.

Gradually loosen, but do not remove  the last two

bolts or nuts that are located  at opposite ends of

the cover plate or the device. Before removing the

last two bolts or nuts, pry the cover loose in order to

relieve any spring pressure or other pressure.

When pressurized air and/or pressurized water is

used for cleaning, wear protective clothing, protective

shoes, and eye protection. Eye protection includes

goggles or a protective face shield.

The maximum air pressure for cleaning purposes

must be below 205 kPa  (30 psi). The maximum

water pressure for cleaning purposes must be below

275 kPa (40 psi).

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long

after the engine has been stopped. The pressure can

cause hydraulic fluid or items such as pipe plugs to

escape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or parts

until pressure has been relieved or personal injury

may occur. Do not  disassemble any hydraulic

components or parts until pressure has been relieved

or personal injury may occur.  Refer to the OEM

information for any procedures that are required to

relieve the hydraulic pressure.

g00702020

Illustration 7

•  Wear a hard hat, protective glasses,  and other

protective equipment, as required.

•  When work is performed around an engine that is

operating, wear protective devices for ears in order

to help prevent damage to hearing.

This document is printed from SPI². Not for RESALE

 

10

SEBU8603-01

Safety Section

General Hazard Information

Perkins replacement parts that are shipped  from

Perkins are asbestos free. Perkins recommends

the use of only genuine Perkins replacement parts.

Use the following guidelines when you handle any

replacement parts that contain asbestos or when you

handle asbestos 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 contain

asbestos fibers are brake pads, brake 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 airborne dust that

contains asbestos is generated.

g00687600

Illustration 8

Always use a board or cardboard when you check

for a leak. Leaking fluid that is under pressure can

penetrate body tissue. Fluid penetration can cause

serious injury and possible death. A pin hole leak can

cause severe injury. If fluid is injected into your skin,

you must get treatment immediately. Seek treatment

from a doctor that is familiar with this type of injury.

If dust that may contain asbestos is present, there

are several guidelines that should be followed:

•  Never use compressed air for cleaning.

•  Avoid brushing materials that contain asbestos.

•  Avoid grinding materials that contain asbestos.

Containing Fluid Spillage

•  Use a wet method in order to clean up asbestos

materials.

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before  open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

•  A vacuum cleaner that is equipped  with a high

efficiency particulate air filter (HEPA) can also be

used.

•  Use exhaust ventilation on permanent machining

jobs.

Dispose of all fluids according to local regulations and

mandates.

•  Wear an approved respirator if there is no other

way to control the dust.

Asbestos Information

•  Comply with applicable rules and  regulations

for the work place.  In the United States, use

Occupational Safety and Health Administration

(OSHA) requirements. These OSHA requirements

can be found in “29 CFR 1910.1001”.

•  Obey environmental regulations for the disposal

of asbestos.

•  Stay away from areas that might have asbestos

particles in the air.

g00702022

Illustration 9

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SEBU8603-01

11

Safety Section

Burn Prevention

Dispose of Waste Properly

Allow the pressure to be purged in the air system, in

the hydraulic system, in the lubrication system, or

in the cooling system before any lines,  fittings, or

related items are disconnected.

Induction System

Sulfuric Acid Burn Hazard may cause serious per-

sonal injury or death.

The  exhaust  gas   cooler  may  contain  a  small

amount of sulfuric acid.  The use of fuel with sul-

fur levels  greater than 15  ppm may increase  the

amount of sulfuric acid formed. The  sulfuric acid

may  spill from  the cooler  during  service of  the

engine. The sulfuric acid  will burn the eyes, skin

and clothing on  contact. Always wear the appro-

priate personal  protective  equipment (PPE)  that

is noted  on a material  safety data  sheet (MSDS)

for sulfuric acid. Always follow  the directions for

first aid  that are noted  on a material  safety data

sheet (MSDS) for sulfuric acid.

g00706404

Illustration 10

Improperly disposing of waste  can threaten the

environment. Potentially harmful fluids should be

disposed of according to local regulations.

Always use leakproof containers when you  drain

fluids. Do not pour waste onto the ground, down a

drain, or into any source of water.

i04224009

Coolant

Burn Prevention

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.

Do not touch any  part of an operating  engine

system. The engine, the exhaust, and the  engine

aftertreatment system surface temperatures can

reach temperatures of  approximately 600° C

(1112 ° F) under normal operating conditions.

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 that the coolant level after  the engine has

stopped and the engine has been allowed to cool.

Allow the engine  system to cool  before any

maintenance is performed.

Ensure that the filler cap is cool before removing the

filler cap. The filler cap must be cool enough to touch

with a bare hand. Remove the filler  cap slowly in

order to relieve pressure.

Relieve all pressure  in the following systems,

hydraulic system, lubrication system, fuel system,

and the coolant system before the related items are

disconnected.

Cooling system conditioner contains alkali. Alkali can

cause personal injury. Do not allow alkali to contact

the skin, the eyes, or the mouth.

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 service in-

structions may cause personal injury or death.

Oils

Hot oil and hot lubricating components can cause

personal injury. Do not allow hot oil to contact  the

skin. Also, do not allow hot components to contact

the skin.

After the engine has stopped, you must wait for 10

minutes 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.

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12

SEBU8603-01

Safety Section

Fire Prevention and Explosion Prevention

Batteries

Store fuels and lubricants  in correctly marked

containers away from unauthorized persons. Store

oily rags and any flammable materials in protective

containers. Do not smoke in areas that are used for

storing flammable materials.

Electrolyte is an acid. Electrolyte can cause personal

injury. Do not allow electrolyte to contact the skin or

the eyes. Always wear protective glasses for servicing

batteries. Wash hands after touching the batteries

and connectors. Use of gloves is recommended.

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.

i03652933

Fire Prevention and Explosion

Prevention

Do not weld on lines or tanks that contain flammable

fluids. Do not flame cut lines or tanks  that contain

flammable fluid. Clean any  such lines or tanks

thoroughly with a nonflammable solvent  prior to

welding or flame cutting.

  

Wiring must be kept in good condition. All electrical

wires must be correctly routed and securely attached.

Check all electrical wires daily. Repair  any wires

that are loose or frayed  before you operate the

engine. Clean all electrical connections and tighten

all electrical connections.

Eliminate all wiring that is unattached or unnecessary.

Do not use any wires or cables that are smaller than

the recommended gauge. Do not bypass any fuses

and/or circuit breakers.

g00704000

Illustration 11

Arcing or sparking  could cause a fire. Secure

connections, recommended wiring, and correctly

maintained battery cables will help to prevent arcing

or sparking.

All fuels, most lubricants, and some coolant mixtures

are flammable.

Flammable fluids that are leaking or spilled onto hot

surfaces or onto electrical components can cause

a fire. Fire may cause personal injury and property

damage.

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 service in-

structions may cause personal injury or death.

After the emergency stop button is operated ensure

that you allow 15 minutes, before the engine covers

are removed.

Determine whether the engine will be operated in an

environment that allows combustible gases to be

drawn into the air inlet system. These gases could

cause the engine to overspeed.  Personal injury,

property damage, or engine damage could result.

After the engine has stopped, you must wait for 10

minutes 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.

If the application involves the presence of combustible

gases, consult your Perkins  dealer and/or your

Perkins distributor for additional information about

suitable protection devices.

Ensure that the engine is stopped. Inspect all lines

and hoses for wear or for deterioration. The hoses

must be correctly routed. The lines and hoses must

have adequate support and secure clamps.

Remove all flammable combustible materials  or

conductive materials such as fuel, oil, and debris from

the engine. Do not allow any flammable combustible

materials or conductive materials to accumulate on

the engine.

Oil filters and fuel filters must be correctly installed.

The filter housings must be tightened to the correct

torque. Refer to the Disassembly  and Assembly

manual for more information.

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SEBU8603-01

13

Safety Section

Fire Prevention and Explosion Prevention

Incorrect jumper cable connections  can cause

an explosion that  can result in injury. Refer  to

the Operation Section of this  manual for specific

instructions.

Do not charge a frozen battery. This may cause an

explosion.

The batteries must be  kept clean. The covers

(if equipped) must be kept  on the cells. Use the

recommended 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.

Inspect the fire extinguisher and  service the fire

extinguisher regularly. Obey the recommendations

on the instruction plate.

g00704059

Illustration 12

Lines, Tubes and Hoses

Use caution when you are refueling an engine. Do

not smoke while you are refueling an engine. Do not

refuel an engine near open flames or sparks. Always

stop the engine before refueling.

Do not bend high pressure lines. Do not strike high

pressure lines. Do not  install any lines that are

damaged.

Leaks can cause fires. Consult your Perkins dealer

or your Perkins distributor for replacement parts.

Replace the parts if any of the following conditions

are present:

•  High pressure fuel line or lines are removed.

•  End fittings are damaged or leaking.

•  Outer coverings are chafed or cut.

•  Wires are exposed.

•  Outer coverings are ballooning.

•  Flexible part of the hoses are kinked.

•  Outer covers have embedded armoring.

•  End fittings are displaced.

g00704135

Illustration 13

Make sure that all clamps, guards, and heat shields

are installed correctly. During engine operation, this

will help to prevent vibration, rubbing against other

parts, and excessive heat.

Gases from a battery can explode. Keep any open

flames or sparks away from the top of a battery. Do

not smoke in battery charging areas.

Never check the battery charge by placing a metal

object across the terminal posts. Use a voltmeter or

a hydrometer.

This document is printed from SPI². Not for RESALE

 

14

SEBU8603-01

Safety Section

Crushing Prevention and Cutting Prevention

i02143194

Crushing Prevention  and

Cutting Prevention

Support 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 rotating  parts and of all moving

parts. Leave the guards in place until maintenance

is performed. After the maintenance is performed,

reinstall the guards.

Keep objects away from moving fan blades. The fan

blades will throw objects or cut objects.

When objects are struck, wear protective glasses in

order to avoid injury to the eyes.

Chips or other debris may fly off objects when objects

are struck. Before objects are struck, ensure that no

one will be 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 mounting or dismounting

locations.

Refer to the OEM for the location of foot and hand

holds for your specific application.

i03550790

High Pressure Fuel Lines

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 service in-

structions may cause personal injury or death.

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SEBU8603-01

15

Safety Section

High Pressure Fuel Lines

g01877473

Illustration 14

(1) High pressure line

(2) High pressure line

(3) High pressure line

(4) High pressure line

(5) High pressure line

(6) High pressure line

(7) High pressure fuel manifold (rail)

(8) High pressure line

(9) Fuel transfer line that is high pressure

The high pressure fuel lines are the fuel lines  that

are between the high pressure fuel pump and  the

high pressure fuel manifold and the fuel lines that are

between the fuel manifold and cylinder head. These

fuel lines are different from fuel lines on other  fuel

systems.

Visually inspect the high pressure fuel lines before

the engine is started. This inspection should be each

day.

If you inspect the engine in operation, always use

the proper inspection procedure in order to  avoid

a fluid penetration hazard. Refer to Operation and

Maintenance Manual, “General hazard Information”.

This is because of the following items:

•  The high pressure fuel lines are constantly charged

with high pressure.

•  Inspect the high pressure fuel lines for damage,

deformation, a nick, a cut, a crease, or a dent.

•  The internal pressures of the high pressure fuel

lines are higher than other types of fuel system.

•  Do not operate the engine with a fuel leak. If there

is a leak do not tighten the  connection in order

to stop the leak. The  connection must only be

tightened to the recommended torque. Refer to

Disassembly and Assembly, “Fuel injection lines -

Remove and Fuel injection lines - Install”.

•  The high pressure fuel lines are formed to shape

and then strengthened by a special process.

Do not step on the high pressure fuel lines. Do not

deflect the high pressure fuel lines. Do not bend or

strike the high pressure fuel lines. Deformation or

damage of the high pressure fuel lines may cause a

point of weakness and potential failure.

•  If the high pressure fuel lines are torqued correctly

and the high pressure fuel lines are leaking the

high pressure fuel lines must be replaced.

•  Ensure that all clips on the high pressure fuel lines

are in place. Do not operate the engine with clips

that are damaged, missing or loose.

Do not check the high pressure fuel lines with  the

engine or the starting motor in operation. After the

engine has stopped, you must wait for 10 minutes 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 attach any other item to the high pressure

fuel lines.

•  Loosened high pressure  fuel lines must be

replaced. Also removed high pressure fuel lines

must be replaced. Refer  to Disassembly and

assembly manual, “ Fuel Injection Lines - Install”.

Do not loosen the high pressure fuel lines in order

to remove air from the fuel system. This procedure

is not required.

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16

SEBU8603-01

Safety Section

Before Starting Engine

i02813489

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 that is caused by parts  in rotation, work

around the parts carefully.

Before Starting Engine

Before the initial start-up of an engine that is new,

serviced or repaired, make provision  to shut the

engine off, in order to stop an overspeed. This may

be accomplished by shutting off the air and/or fuel

supply to the engine.

Start the engine from the operators compartment or

from the engine start switch.

Always start the engine according to the procedure

that is described in the Operation and Maintenance

Manual, “Engine Starting” topic in  the Operation

Section. Knowing that the correct procedure will help

to prevent major damage to the engine components.

Knowing that the procedure will also help to prevent

personal injury.

Overspeed shutdown should occur automatically for

engines that are controlled electronically. If automatic

shutdown does not occur, press the emerg, ency stop

button in order to cut the fuel and/or air to the engine.

Inspect the engine for potential hazards.

To ensure that the jacket water heater (if equipped)

and/or the lube oil heater (if equipped) is  working

correctly, check the water temperature gauge. Also,

check the oil temperature gauge during the heater

operation.

Before starting the engine, ensure 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.

Engine exhaust contains products of combustion

which can be harmful to your health. Always start the

engine and operate the engine in a well ventilated

area. If the engine is started in an  enclosed area,

vent the engine exhaust to the outside.

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 that is caused by parts in  rotation, work

around the parts carefully.

Note: The engine is equipped with a device for cold

starting. If the engine will be operated in very cold

conditions, then an extra cold starting aid may be

required. Normally, the engine will be equipped with

the correct type of starting  aid for your region of

operation.

Do not bypass the automatic shutoff circuits. Do not

disable the automatic shutoff circuits. The circuits are

provided in order to help prevent personal injury. The

circuits are also provided in order to  help prevent

engine damage.

These engines are equipped with a glow plug starting

aid in each individual cylinder that heats the intake air

in order to improve starting. Some Perkins engines

may have a cold starting system that is controlled by

the ECM that allows a controlled flow of ether into

the engine. The ECM will disconnect the glow plugs

before the ether is introduced. This system would

be installed at the factory.

See the  Service Manual for repairs  and for

adjustments.

i03996487

Engine Starting

i02234873

Engine Stopping

Do not use aerosol types of starting aids such as

ether. Such use could  result in an explosion and

personal injury.

Stop the engine according  to the procedure in

the Operation and Maintenance Manual, “Engine

Stopping (Operation Section)” in  order to avoid

overheating of the engine and accelerated wear of

the engine components.

If a warning tag is attached to the engine start switch,

or to the controls DO NOT start the engine or move

the controls. Consult with the person that attached

the warning tag before the engine is started.

This document is printed from SPI². Not for RESALE

 

SEBU8603-01

17

Safety Section

Electrical System

Grounding Practices

Use the Emergency Stop Button (if equipped) ONLY

in an emergency situation. Do not use the Emergency

Stop Button for normal engine stopping.  After an

emergency stop, DO NOT start the engine until the

problem that caused the emergency stop has been

corrected.

Stop the engine if an overspeed condition  occurs

during the initial start-up of a new engine or an engine

that has been overhauled.

To stop an electronically controlled engine, cut the

power to the engine and/or shutting off the air supply

to the engine.

i04193189

Electrical System

Never disconnect any charging unit circuit or battery

circuit cable from the battery when the charging unit

is operating. A spark can cause  the combustible

gases that are produced by some batteries to ignite.

To help prevent sparks from igniting  combustible

gases that are produced by  some batteries, the

negative “−” cable should be connected last  from

the external power source to the primary position for

grounding.

g02383098

Illustration 15

Typical example

(1) Ground to the battery

Check the electrical  wires daily for wires that

are loose or frayed.  Tighten all loose electrical

connections before the engine is started. Repair all

frayed electrical wires before the engine is started.

See the Operation and Maintenance  Manual for

specific starting instructions.

(2) Primary position for grounding

(3) Ground to the starting motor

(4) Ground to the engine block

This document is printed from SPI². Not for RESALE

 

18

SEBU8603-01

Safety Section

Engine Electronics

The 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 installation

or the OEM  wiring installation can be dangerous

and could result in personal injury or death and/or

engine damage.

Electrical Shock Hazard. The electronic unit injec-

tors use DC voltage. The ECM sends this  voltage

to the  electronic  unit injectors.  Do not  come in

contact with  the harness connector for  the elec-

tronic unit injectors while the engine is operating.

Failure to  follow  this instruction  could result  in

personal injury or death.

g02383099

Illustration 16

Typical example

This engine has a comprehensive, programmable

Engine Monitoring System. The Electronic Control

Module (ECM) has the ability to monitor the engine

operating conditions. If any of the engine parameters

extend outside an allowable range, the  ECM will

initiate an immediate action.

(5) Ground to the battery

(6) Ground to the cylinder block

Correct grounding for the engine electrical system

is necessary for optimum  engine performance

and reliability. Incorrect grounding  will result in

uncontrolled electrical circuit paths and in unreliable

electrical circuit paths.

The following actions  are available for engine

monitoring control:

Uncontrolled electrical circuit paths can  result in

damage to the crankshaft bearing journal surfaces

and to aluminum components.

•  Warning

•  Derate

Engines that are installed without engine-to-frame

ground straps can  be damaged by electrical

discharge.

•  Shutdown

The following monitored engine operating conditions

have the ability to limit  engine speed and/or the

engine power:

To ensure that the engine and the engine electrical

systems function correctly, an  engine-to-frame

ground strap with a direct path to the battery must be

used. This path may be provided by way of a direct

engine ground to the frame.

•  Engine Coolant Temperature

•  Engine Oil Pressure

The connections for the grounds should be tight and

free of corrosion. The engine  alternator must be

grounded to the negative “-” battery terminal. The

grounding wire must be adequate to handle the full

charging current of the alternator.

•  Engine Speed

•  Intake Manifold Air Temperature

•  Engine Intake Throttle Valve Fault

•  Wastegate Regulator

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SEBU8603-01

19

Safety Section

Engine Electronics

•  Supply Voltage to Sensors

•  Fuel Pressure in Manifold (Rail)

•  NOx Reduction System

•  Engine Aftertreatment System

The Engine Monitoring package can vary for different

engine models and different engine applications.

However, the monitoring system and the  engine

monitoring control will be similar for all engines.

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 will provide the  engine

monitoring function for the specific engine application.

Refer to Troubleshooting for more information on the

Engine Monitoring System.

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20

SEBU8603-01

Product Information Section

Model Views

Product Information

Section

Model Views

i04171351

Model View Illustrations

The following model views show typical  features

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 breather

(5) Fuel strainer

(6) Oil filter

(9) Primary fuel filter

(10) High-pressure fuel pump

(3) Electronic control module (ECM)

(4) Oil sampling valve

(7) Fuel priming pump

(8) Oil gauge (Dipstick)

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SEBU8603-01

21

Product Information Section

Model Views

The location of the in-line strainer (5) and the priming

pump (7) will depend on the application.

g02361697

Illustration 18

Typical example

(11) Rear lifting eye

(15) Back pressure valve

(19) Flywheel housing

(12) NOx reduction system (NRS)

(13) Front lifting eye

(14) Turbocharger

(16) Engine oil pan (Sump)

(17) Starting motor

(18) Engine oil drain plug

(20) Flywheel

(21) Exhaust outlet

(22) Exhaust gas cooler

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22

SEBU8603-01

Product Information Section

Model Views

g02379457

Illustration 19

Typical example

(23) Belt

(27) Water pump

(32) Alternator

(24) Connection for air inlet

(25) Outlet connection for the coolant

(26) Water temperature regulator housing

(Thermostat housing)

(28) Oil filler

(29) Inlet connection for the Coolant

(30) Vibration damper

(31) Belt tensioner

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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

This document is printed from SPI². Not for RESALE

 

24

SEBU8603-01

Product Information Section

Model Views

Engine Aftertreatment System

g02384560

Illustration 21

Typical example

(1) Clean emissions module (CEM)

(2) Inlet connection

(3) Outlet connection

(4) Mounting cradle

(5) Flexible exhaust pipe  from engine to

CEM

i04340730

Engine Description

The Perkins 1206-E66 Industrial Engine has  the

following characteristics.

•  In-line Six cylinder

•  Four stroke cycle

•  Turbocharged charge cooled

g01127295

Engine Specifications

Illustration 22

Cylinder and valve location

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 number 1 cylinder is the front cylinder.

(A) Exhaust valves

(B) Inlet valves

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SEBU8603-01

25

Product Information Section

Model Views

Table 1

Engine Diagnostics

Engine Specifications

The engine has built-in diagnostics in order to ensure

that the engine systems are functioning correctly. The

operator will be alerted to the condition by a “Stop or

Warning” lamp. Under certain conditions, the engine

horsepower and the vehicle speed may be limited.

The electronic service tool may be used to display

the diagnostic codes.

Operating Range (rpm)

Number of Cylinders

Bore

900 to  2800

(1)

6 In-Line

105 mm (4.13 inch)

127 mm (5  inch)

Stroke

Power

129.4 kW (173.52 hp)

There are three types of diagnostic codes: active,

logged, and event.

Aspiration

Turbocharged charge

cooled

Compression Ratio

Displacement

16.5:1

Most of the diagnostic codes are logged and stored

in the ECM. For  additional information, refer to

the Operation and Maintenance Manual, “Engine

Diagnostics” topic (Operation Section).

6.6 L (402.7 cubic inch)

1-5-3-6-2-4

Firing Order

Rotation (flywheel end)

Counterclockwise

The ECM provides an  electronic governor that

controls the injector output in order to maintain the

desired engine rpm.

(1)  The operating rpm is dependent on the  engine rating, the

application, and the configuration of the throttle.

Electronic Engine Features

Engine Cooling and Lubrication

The engine operating conditions are  monitored.

The Electronic Control Module (ECM) controls the

response of the engine to these conditions and to

the demands of the operator. These conditions and

operator demands determine the precise control of

fuel injection by the ECM.  The electronic engine

control system provides the following features:

The cooling system and lubrication system consists

of the following components:

•  Gear-driven centrifugal water pump

•  Water temperature regulator which regulates the

engine coolant temperature

•  Engine monitoring

•  Gear-driven rotor type oil pump

•  Oil cooler

•  Engine speed governing

•  Control of the injection pressure

•  Cold start strategy

The engine lubricating oil is supplied by a rotor type

oil pump. The engine lubricating oil is cooled and the

engine lubricating oil is filtered. The bypass valve

can provide unrestricted flow of  lubrication oil to

the engine if the oil filter element  should become

plugged.

•  Automatic air/fuel ratio control

•  Torque rise shaping

Engine efficiency, efficiency of emission controls, and

engine performance depend on adherence to proper

operation and maintenance recommendations.

Engine performance and efficiency also depend on

the use of recommended fuels, lubrication oils, and

coolants. Refer to this Operation and Maintenance

Manual, “Maintenance Interval Schedule” for more

information on maintenance items.

•  Injection timing control

•  System diagnostics

•  Low temperature regeneration

For more information on electronic engine features,

refer to the Operation and Maintenance  Manual,

“Features and Controls” topic (Operation Section).

Aftertreatment System

The aftertreatment system is approved for use by

Perkins. In order to be emission-compliant only the

approved Perkins aftertreatment system must be

used on a Perkins engine.

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26

SEBU8603-01

Product Information Section

Model Views

Clean Emission Module (CEM)

The CEM comprises of two main components in a

single unit, the Diesel Oxidation Catalyst DOC and

the Diesel Particulate Filter DPF. The function of the

CEM is to ensure that the  engine exhaust meets

the required emissions regulation for the country of

operation.

The engine exhaust is connected by a flexible pipe to

the CEM. The exhaust gases pass through the DOC

in order to remove contaminants, carbon monoxide,

and hydrocarbons. The exhaust gases then enter the

DPF where any particulate matter soot and ash will

be trapped.

The CEM uses a passive regeneration process to

ensure that normal operation of the engine removes

the soot. The soot is removed at  an equal rate of

which the soot is captured. The ash remains in the

DPF and must be removed at an engine overhaul.

Engine Service Life

Engine efficiency and maximum utilization of engine

performance depend on the adherence to  proper

operation and maintenance recommendations. In

addition, 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 that is demanded. The average power

that is demanded is based on fuel consumption of

the engine over a period of 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 will increase

the length of  operating time before an engine

overhaul is required. For more information, refer to

the Operation and Maintenance Manual, “Overhaul

Considerations” topic (Maintenance Section).

Aftermarket Products and Perkins

Engines

Perkins does not warrant the quality or performance

of non-Perkins fluids and filters.

When auxiliary devices, accessories, or consumables

(filters, additives, catalysts,) which are made by other

manufacturers are used on Perkins products, the

Perkins warranty is not affected simply because of

such use.

However, failures that result from the installation

or use  of other manufacturers  devices,

accessories, or consumables are NOT Perkins

defects. Therefore, the defects are NOT covered

under the Perkins warranty.

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SEBU8603-01

27

Product Information Section

Product Identification Information

Product Identification

Information

i03865704

Plate Locations and  Film

Locations

(Engine Aftertreatment System

)

g02109488

Illustration 23

Typical example

The module arrangement exhaust plate is installed

on the mounting plate  (1). The location of  the

arrangement plate mounting  plate can alter

depending on the application.

Record the information that is  on the plate. This

information identifies the engine  aftertreatment

system. This information will be required  by your

Perkins distributor. The information is essential in

order to be emissions complaint.

i03867276

Reference Numbers

Information for the following items may be needed to

order parts. Locate the information for your engine.

Record the information in the appropriate space.

Make a copy of  this list for a record.  Keep the

information for future reference.

Record for Reference

g02109493

Illustration 24

Module Arrangement Exhaust Plate

Engine Model  _______________________________________________

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28

SEBU8603-01

Product Information Section

Product Identification Information

Engine Serial number  _____________________________________

Engine Low Idle rpm  ______________________________________

Engine Full Load rpm  _____________________________________

Primary Fuel Filter  _________________________________________

Water Separator Element  ________________________________

Secondary Fuel Filter Element  __________________________

Lubrication Oil Filter Element  ___________________________

Auxiliary Oil Filter Element  _______________________________

Total Lubrication System Capacity  _____________________

Total Cooling System Capacity  _________________________

Air Cleaner Element  _______________________________________

Drive Belt  ____________________________________________________

Engine Aftertreatment System

Part Number  ________________________________________________

Serial Number  ______________________________________________

i04274850

Emissions Certification Film

g02443596

Illustration 25

Typical example

An emission label is installed on the front gear cover.

Note: A second emission label will be supplied with

the engine. If necessary, the second emission label

will be installed on the application  by the original

equipment manufacturer.

This document is printed from SPI². Not for RESALE