Operation and

Maintenance

Manual

2206D-E13TA Industrial Engine

Table of Contents

Refill Capacities....................... ....................... 39

Maintenance Recommendations.......... .......... 54

Maintenance Interval Schedule........... ........... 57

Warranty Section

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

Safety Section

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

General Hazard Information............... .............. 6

Burn Prevention....................... ....................... 10

Fire Prevention and Explosion Prevention ... .. 10

Crushing Prevention and Cutting Prevention .  12

Mounting and Dismounting............... .............. 12

Before Starting Engine ................. .................. 12

Engine Starting........................ ....................... 13

Engine Stopping....................... ...................... 13

Electrical System...................... ...................... 13

Engine Electronics..................... ..................... 14

Product Information Section

Warranty Information................... ................... 82

Reference Information Section

Reference Materials ........................................ 83

Index Section

Index................................ ............................... 86

General Information.................... .................... 15

Product Identification Information.......... ......... 18

Operation Section

Lifting and Storage..................... ..................... 20

Features and Controls.................. .................. 23

Engine Diagnostics..................... .................... 28

Engine Starting........................ ....................... 30

Engine Operation...................... ...................... 34

Cold Weather Operation................. ................ 36

Engine Stopping....................... ...................... 38

Maintenance Section

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4

SEBU9072

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.

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SEBU9072

5

Safety Section

Safety Messages

Safety Section

i06218430

Safety Messages

There may be several specific safety messages on

your engine. The exact location and a description of

the safety messages are reviewed in this section.

Become familiar with all safety messages.

Ensure that all of the safety messages are legible.

Clean the safety messages or replace the safety

messages if the words cannot be read or if the

illustrations are not visible. Use a cloth, water, and

soap to clean the safety messages. Do not use

solvents, gasoline, or other harsh chemicals.

Solvents, gasoline, or harsh chemicals could loosen

the adhesive that secures the safety messages. The

safety messages that are loosened could drop off the

engine.

Replace any safety message that is damaged or

missing. If a safety message is attached to a part of

the engine that is replaced, install a new safety

message on the replacement part. Your Perkins

distributor can provide new safety messages.

Illustration 1

g03859164

Typical example

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SEBU9072

Safety Section

General Hazard Information

Universal Warning (1)

Do not allow unauthorized personnel on the engine,

or around the engine when the engine is being

serviced.

•   Tampering with the engine installation or tampering

with the OEM supplied wiring can be dangerous.

Personal injury, death and/or engine damage

could result.

•   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.

Illustration 2

g01370904

One safety message is located on the left side of the

engine. One safety message is located on the right

side of the engine.

•   When work is performed around an engine that is

operating, 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.

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.

•   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 solutions with care.

•   Report all necessary repairs.

i06106934

General Hazard Information

Unless other instructions are provided, perform the

maintenance under the following conditions:

Illustration 3

g00104545

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 appropriate,

disconnect the starting controls.

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SEBU9072

7

Safety Section

General Hazard Information

•   The engine is stopped. Ensure that the engine

cannot be started.

•   Filler caps

•   Grease fittings

•   Pressure taps

•   Breathers

•   The protective locks or the controls are in the

applied position.

•   Engage the secondary brakes or parking brakes.

•   Drain plugs

•   Block the vehicle or restrain the vehicle before

maintenance or repairs are performed.

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.

•   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. If

equipped, allow the diesel exhaust fluid to be

purged before disconnecting the battery.

•   If equipped, disconnect the connectors for the unit

injectors that are located on the valve cover base.

This action 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 attempt any repairs or any adjustments to

the engine while the engine is operating.

•   Do not attempt any repairs that are not

understood. Use the proper tools. Replace any

equipment that is damaged or repair the

equipment.

Illustration 4

g00702020

•   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. The

stopping of the engine may be accomplished by

shutting off the fuel supply and/or the air supply to

the engine. Ensure that only the fuel supply line is

shut off. Ensure that the fuel return line is open.

•   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.

•   Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

•   Start the engine from the operators station (cab).

Never short across the starting motor terminals or

the batteries. This action could bypass the engine

neutral start system and/or the electrical system

could be damaged.

•   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.

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.

•   Use all cleaning solutions with care.

•   Report all necessary repairs.

Unless other instructions are provided, perform

the maintenance under the following conditions:

Cautiously remove the following parts. To help

prevent spraying or splashing of pressurized fluids,

hold a rag over the part that is being removed.

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8

SEBU9072

Safety Section

General Hazard Information

•   The engine is stopped. Ensure that the engine

cannot be started.

•   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.

•   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

Pressurized air and/or water can cause debris and/or

hot water to be blown out. This action could result in

personal injury.

Illustration 5

g00687600

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.

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).

Containing Fluid Spillage

Care must be taken to ensure that fluids are

contained during performance of inspection,

maintenance, testing, adjusting, and repair of the

product. Be prepared to collect the fluid with suitable

containers before opening any compartment or

disassembling any component containing fluids.

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.

Dispose of all fluids according to local regulations and

mandates.

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.

Static Electricity Hazard when

Fueling with Ultra-low Sulfur Diesel

Fuel

The removal of sulfur and other compounds in ultra-

low sulfur diesel fuel (ULSD fuel) decreases the

conductivity of ULSD and increases the ability of

ULSD to store static charge. Refineries may have

treated the fuel with a static dissipating additive.

Many factors can reduce the effectiveness of the

additive over time. Static charges can build up in

ULSD fuel while the fuel is flowing through fuel

delivery systems. Static electricity discharge when

combustible vapors are present could result in a fire

or explosion. Ensure that the entire system used to

refuel your machine (fuel supply tank, transfer pump,

transfer hose, nozzle, and others) is properly

grounded and bonded. Consult with your fuel or fuel

system supplier to ensure that the delivery system

complies with fueling standards for proper grounding

and bonding.

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SEBU9072

9

Safety Section

General Hazard Information

•   Never use compressed air for cleaning.

•   Avoid brushing materials that contain asbestos.

•   Avoid grinding materials that contain asbestos.

Avoid static electricity risk when fueling. Ultra-low

sulfur diesel fuel (ULSD fuel) poses a greater stat-

ic ignition hazard than earlier diesel formulations

with a higher sulfur contents. Avoid death or seri-

ous  injury from  fire  or  explosion. Consult  with

your fuel or fuel system supplier to ensure the de-

livery system is in compliance with fueling stand-

ards for proper grounding and bonding practices.

•   Use a wet method in order to clean up asbestos

materials.

•   A vacuum cleaner that is equipped with a high

efficiency particulate air filter (HEPA) can also be

used.

Inhalation

•   Use exhaust ventilation on permanent machining

jobs.

•   Wear an approved respirator if there is no other

way to control the dust.

•   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.

Dispose of Waste Properly

Illustration 6

g00702022

Exhaust

Use caution. Exhaust fumes can be hazardous to

health. If you operate the equipment in an enclosed

area, adequate ventilation is necessary.

Asbestos Information

Perkins equipment and replacement parts that are

shipped from Perkins engine company limited 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.

Illustration 7

g00706404

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.

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.

If dust that may contain asbestos is present, there are

several guidelines that should be followed:

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10

SEBU9072

Safety Section

Burn Prevention

i06106969

i05945996

Fire Prevention and Explosion

Prevention

Burn Prevention

Coolant

When the engine is at operating temperature, the

engine coolant is hot. The coolant is also under

pressure. The radiator and all lines to the heaters or

to the engine contain hot coolant. Any contact with

hot coolant or with steam can cause severe burns.

Allow cooling system components to cool before the

cooling system is drained.

Check that the coolant level after the engine has

stopped and the engine has been allowed to cool.

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.

Cooling system conditioner contains alkali. Alkali can

cause personal injury. Do not allow alkali to contact

the skin, the eyes, or the mouth.

Illustration 8

g00704000

All fuels, most lubricants, and some coolant mixtures

are flammable.

Oils

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.

Skin may be irritated following repeated or prolonged

exposure to mineral and synthetic base oils. Refer to

your suppliers Material Safety Data Sheets for

detailed information. Hot oil and lubricating

components can cause personal injury. Do not allow

hot oil to contact the skin. Appropriate personal

protective equipment should be used.

After the emergency stop button is operated, ensure

that you allow 15 minutes, before the engine covers

are removed.

Diesel Fuel

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.

Diesel may be irritating to the eyes, respiratory

system, and skin. Prolonged exposure to diesel may

cause various skin conditions. Appropriate personal

protective equipment should be used. Refer to

supplier Material safety Data sheets for detailed

information.

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.

Batteries

The liquid in a battery is an electrolyte. Electrolyte is

an acid that can cause personal injury. Do not allow

electrolyte to contact the skin or the eyes.

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.

Do not smoke while checking the battery electrolyte

levels. Batteries give off flammable fumes which can

explode.

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.

Always wear protective glasses when you work with

batteries. Wash hands after touching batteries. The

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.

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SEBU9072

11

Safety Section

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.

Avoid static electricity risk when fueling. Ultra-low

Sulfur Diesel fuel (ULSD fuel) poses a greater static

ignition hazard than earlier diesel formulations with a

higher sulfur content. Avoid death or serious injury

from fire or explosion. Consult your fuel or fuel system

supplier to ensure that the delivery system is in

compliance with fueling standards for proper

grounding and bonding practices.

Wiring must be kept in good condition. Ensure that all

electrical wires are correctly installed 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.

Arcing or sparking could cause a fire. Secure

connections, recommended wiring, and correctly

maintained battery cables will help to prevent arcing

or sparking.

Ensure that the engine is stopped. Inspect all lines

and hoses for wear or for deterioration. Ensure that

the hoses are correctly routed. The lines and hoses

must have adequate support and secure clamps.

Oil filters and fuel filters must be installed correctly.

The filter housings must be tightened to the correct

torque. Refer to the Disassembly and Assembly

manual for more information.

Illustration 10

g00704135

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.

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. A frozen battery 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

Illustration 9

g00704059

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.

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.

Ether

Ether is flammable and poisonous.

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12

SEBU9072

Safety Section

Crushing Prevention and Cutting Prevention

Do not smoke while you are replacing an ether

cylinder or while you are using an ether spray.

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.

Do not store ether cylinders in living areas or in the

engine compartment. Do not store ether cylinders in

direct sunlight or in temperatures above 49° C

(120° F). Keep ether cylinders away from open

flames or sparks.

i05875651

Mounting and Dismounting

Lines, Tubes, and Hoses

Do not climb on the engine. The engine has not been

designed with mounting or dismounting locations.

Do not bend high-pressure lines. Do not strike high-

pressure lines. Do not install any lines that are

damaged.

Refer to the OEM for the location of foot and hand

holds for your specific application.

Leaks can cause fires. Consult your Perkins dealer or

your Perkins distributor for replacement parts.

i04257031

Replace the parts if any of the following conditions

are present:

Before Starting Engine

•   End fittings are damaged or leaking.

•   Outer coverings are chafed or cut.

•   Wires are exposed.

NOTICE

For initial start-up of a  new or rebuilt engine, and for

start-up of  an engine that  has been serviced,  make

provision to shut the engine off should  an overspeed

occur. This may  be accomplished by shutting off the

air and/or fuel supply to the engine.

•   Outer coverings are ballooning.

•   Flexible parts of the hoses are kinked.

•   Outer covers have embedded armoring.

•   End fittings are displaced.

Make sure that all clamps, guards, and heat shields

are installed correctly. During engine operation,

correct installation will help to prevent vibration,

rubbing against other parts, and excessive heat.

Engine exhaust contains products of combustion

which may be harmful to your health. Always start

and operate  the engine  in a well  ventilated area

and, if in an enclosed area, vent the exhaust to the

outside.

i02143194

Crushing Prevention and

Cutting Prevention

Inspect the engine for potential hazards.

Do not start the engine or move any of the controls if

there is a “DO NOT OPERATE” warning tag or

similar warning tag attached to the start switch or to

the controls.

Support the component correctly when work beneath

the component is performed.

Before starting the engine, ensure that no one is on,

underneath, or close to the engine. Ensure that the

area is free of personnel.

Unless other maintenance instructions are provided,

never attempt adjustments while the engine is

running.

If equipped, ensure that the lighting system for the

engine is suitable for the conditions. Ensure that all

lights work properly, if equipped.

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.

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.

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.

Do not start an engine when the governor linkage is

disconnected.

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SEBU9072

13

Safety Section

Engine Starting

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.

i01462046

Engine Stopping

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.

i02583384

Engine Starting

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 NOTstart the engine until the

problem that caused the emergency stop has been

corrected.

Do not use aerosol types of starting aids such as

ether. Such use  could result in an explosion and

personal injury.

Stop the engine if an overspeed condition occurs

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

that has been overhauled. This may be accomplished

by shutting off the fuel supply to the engine and/or

shutting off the air supply to the engine.

If a warning tag is attached to the engine start switch

or to the controls DO NOTstart the engine or move

the controls. Consult with the person that attached

the warning tag before the engine is started.

To stop an electronically controlled engine, cut the

power to the engine.

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.

i06088340

Electrical System

Start the engine from the operator's 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 the correct procedure will help to

prevent major damage to the engine components.

Knowing the procedure will also help to prevent

personal injury.

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  “−” jump-start cable should be connected

last from the external power source to the negative

“−”  terminal of the starting motor. If the starting motor

is not equipped with a negative “−” terminal, connect

the jump-start cable to the engine block.

To ensure that the jacket water heater (if equipped) is

working correctly, check the water temperature gauge

and/or the oil temperature gauge during the heater

operation.

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.

Check the electrical wires daily for wires that are

loose or frayed. Tighten all loose electrical wires

before the engine is started. Repair all frayed

electrical wires before the engine is started. Refer to

the “Engine Starting” section of this Operation and

Maintenance Manual for specific starting instructions.

Note: The engine may be 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.

Grounding Practices

Proper grounding for the engine electrical system is

necessary for optimum engine performance and

reliability. Improper grounding will result in

uncontrolled electrical circuit paths and in unreliable

electrical circuit paths.

Uncontrolled electrical circuit paths can result in

damage to main bearings, to crankshaft bearing

journal surfaces, and to aluminum components.

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14

SEBU9072

Safety Section

Engine Electronics

Engines that are installed without engine-to-frame

ground straps can be damaged by electrical

discharge.

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.

To ensure that the engine and the engine electrical

systems function properly, 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 starting motor

ground, a starting motor ground to the frame, or a

direct engine ground to the frame.

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 the Troubleshooting

Manual for more information.

All grounds should be tight and free of corrosion. The

engine alternator must be grounded to the negative

“-” battery terminal with a wire that is adequate to

handle the full charging current of the alternator.

i06091234

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.

This engine has a comprehensive, programmable

Engine Monitoring System. The Engine Control

Module (ECM) will monitor the engine operating

conditions. If any of the engine parameters extend

outside an allowable range, the ECM will initiate an

immediate action.

The following actions are available for engine

monitoring control: WARNING, DERATE and

SHUTDOWN. These engine monitoring modes can

limit engine speed and/or the engine power.

Many of the parameters that are monitored by the

ECM can be programmed for the engine monitoring

functions. The following parameters can be monitored

as a part of the Engine Monitoring System:

•   Operating Altitude

•   Engine Coolant Level

•   Engine Coolant Temperature

•   Engine Oil Pressure

•   Engine Speed

•   Fuel Temperature

•   Intake Manifold Air Temperature

•   System Voltage

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SEBU9072

15

Product Information Section

Model View Illustrations

Product Information

Section

General Information

i06107001

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.

Illustration 11

g03812155

(1) Refrigerant compressor

(2) Alternator

(3) Belt tensioner

(5) Crankshaft damper

(6) Coolant intake

(7) Oil cooler

(9) Engine oil filter

(10) Turbocharger

(4) Fuel transfer pump

(8) Secondary fuel filter

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16

SEBU9072

General Information

Product Description

Illustration 12

g03812156

(11) Engine front lifting eye

(12) Coolant outlet

(16) Flywheel housing

(17) Flywheel

(21) Oil gauge (dipstick)

(22) Air compressor

(13) Water temperatureregulator housing

(14) Engine rear lifting eye

(15) Electronic control module

(18) Starting motor

(19) Air intake

(20) Oil drain valve

(23) Location for oil filler

(24) Engine crankcase breather

i06109638

Engine Specifications

Product Description

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.

The Perkins 2206D-E13TA Industrial Engine have

the following characteristics:

•   Four-stroke cycle

•   Mechanically actuated, electronically controlled

fuel injection system

•   Turbocharged

•   Air to air charged cooled

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SEBU9072

17

General Information

Product Description

Additional Features

The following additional features provide increased

engine fuel economy and serviceability:

•   Cold starting capability

•   Tampering detection

•   Diagnostics

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.

Illustration 13

g01387009

Cylinder and valve location

(A) Exhaust valve

(B) Inlet valv, e

Expected engine life is predicted by the average

power that is demanded. The average power that is

demanded is based on fuel consumption of the

engine over a 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.

Table 1

Engine Specifications

Engine

Arrangement and Cylinders

Bore

2206D

In-Line 6 cylinder

130 mm (5.1 inch)

Stroke

157 mm (6.2 inch)

ATAAC(1)

Aspiration

Aftermarket Products and Perkins

Engines

Displacement

12.5 L (763 cubic inch)

1-5-3-6-2-4

Perkins does not warrant the quality or performance

of non-Perkins  fluids and filters.

Firing Order

Rotation (flywheel end)

Counterclockwise

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.

(1)

Air-to-air aftercooled

Electronic Engine Features

However, failures that result from the installation

or use of other manufacturers devices,

accessories, or consumables are NOT Perkins

defects. Therefore, the defects are NOTcovered

under the Perkins warranty.

The engine is designed for electronic controls. The

integral on board computer controls the operation of

the engine. Current 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:

•   Engine speed governor

•   Automatic air/fuel ratio control

•   Torque rise shaping

•   Injection timing control

•   System diagnostics

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18

SEBU9072

Product Identification Information

Plate Locations and Film Locations

Product Identification

Information

i06109784

Plate Locations and Film

Locations

Illustration 15

g01403841

Serial number plate

The following information is stamped on the serial

number plate: engine serial number, engine model

and arrangement number.

The engine information plate is located on top of the

valve cover near the middle of the engine.

The following information is on the information plate:

engine serial number, engine model, engine

arrangement number, maximum altitude of the engine

that is necessary to achieve the rated power,

horsepower, high idle, full load rpm, fuel settings and

other information

i05951816

Emissions CertificationFilm

Illustration 14

g03812733

Typical example

(1) Information plate

(2) Serial number plate

Note: This information is pertinent in the United

States, in Canada and in Europe.

The engine serial number plate is located on the left

side of the engine block.

The emissions label is located on the top of the valve

mechanism cover.

i06109817

Reference Information

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.

This document has been printed from SPI2. NOT FOR RESALE

 

SEBU9072

19

Product Identification Information

Reference Information

Record for Reference

Engine Model

Engine Serial number

Engine Low Idle rpm

Engine Full Load rpm

Primary Fuel Filter Element

Secondary Fuel Filters

Lubrication Oil Filter

Breather Fume Filter Element

Auxiliary Oil Filter

Total Lubrication System Capacity

Total Cooling System Capacity

Air Cleaner Element

Drive Belt

This document has been printed from SPI2. NOT FOR RESALE

 

20

SEBU9072

Operation Section

Product Lifting

Operation Section

Lifting and Storage

i06109969

Product Storage

Your Perkins distributor can assist in preparing the

engine for extended storage periods.

i06109876

Product Lifting

An engine can be stored for up to 6 months provided

all the recommendation are adhered to.

Engine

NOTICE

1. Clean the engine of any dirt, rust, grease, and oil.

Inspect the exterior. Paint areas that contain paint

damage with a good quality paint.

Never bend the eyebolts and the brackets. Only load

the eyebolts and the brackets under tension. Remem-

ber that the capacity of an eyebolt is less as the angle

between the supporting members and the  object be-

comes less than 90 degrees.

2. Remove dirt from the air cleaners. Check all seals,

gaskets, and the filter element for damage.

When it  is necessary to  remove a component at  an

angle, only use a link bracket that is properly rated for

the weight.

3. Apply lubricant to all points in this Operation and

Maintenance Manual, “Maintenance Interval

Schedule”.

Read all the information within produce lifting before

any lifting is attempted. Ensure that the correct set of

lifting eyes for the assembly to be lifted have been

selected.

4. Drain the crankcase oil. Replace the crankcase oil

and change the oil filters. For the proper

procedure, refer to this Operation and

Maintenance Manual.

Use a hoist to remove heavy components. Use an

adjustable lifting beam to lift the assembly. 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 is being

lifted.

5. Add VCI oil to the crankcase oil. The volume of VCI

oil in the crankcase oil should be 3 to 4 percent.

Note: If the engine crankcase is full, drain enough

engine oil so the mixture can be added.

6. Remove the air filter elements. Turn the engine at

cranking speed with the throttle control in FUEL

OFF position. Use a sprayer to add a mixture of 50

percent VCI oil and 50 percent engine oil into the

air inlet or turbocharger inlet.

Note: The mixture of VCI oil can be added to the inlet

by removing the plug for checking turbocharger boost

pressure. The minimum application rate for the VCI

oil mixture is 5.5 mL per L  (3 oz per 1000 cu in) of

engine displacement.

7. Use a sprayer to apply a mixture of 50 percent VCI

oil and 50 percent crankcase oil into the exhaust

openings. The minimum application rate for the oil

mixture is 5.5 mL per L (3 oz per 1000 cu in) of

engine displacement. Seal the exhaust pipe and

seal any drain holes in the muffler.

8. Remove the fuel from the secondary fuel filter

housing. Alternately, empty and reinstall the spin-

on fuel filter element in order to remove any dirt

and water. Drain any sleeve metering fuel pump.

Illustration 16

g03812766

(1) Engine lifting eyes

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SEBU9072

21

Lifting and Storage

Product Storage

Clean the primary fuel filter. Fill with calibration

fluid or kerosene. Install the primary fuel filter and

operate the priming pump. This procedure will

send clean oil to the secondary filter and the

engine.

13. Remove the drive belts from the engine

14. Place a waterproof cover over the engine. Ensure

that the engine cover is secure. The cover should

be loose enough to allow air to circulate around the

engine in order to prevent damage from

condensation.

Open the fuel tank drain valve in order to drain any

water and dirt from the fuel tank. Apply a spray of

calibration fluid or kerosene at the rate of

30 mL per 30 L (1 oz per 7.50 gal US) of fuel tank

capacity in order to prevent rust in the fuel tank.

Add 0.15 mL per L (.02 oz per 1 gal US) of

15. Attach a tag with the storage date to the engine.

16. Remove the waterproof cover at 2 month or 3

month intervals in order to check the engine for

corrosion. If the engine has signs of corrosion,

repeat the protection procedure.

commercial biocide such as Biobor JF to the fuel.

Apply a small amount of oil to the threads on the

fuel tank filler neck and install the cap. Seal all

openings to the tank in order to prevent

evaporation of the fuel and as a preservative.

Coolant System

9. Remove the fuel injectors. Apply 30 mL  (1 oz) of

the mixture of oils (50 percent VCI oil and 50

percent engine oil) into each cylinder.

Completely fill the cooling system before storage.

Refer to this Operation and Maintenance Manual,

“Fluid Recommendations” for more information about

coolants.

Use a bar or a turning tool in order to turn over the

engine slowly. This procedure puts the oil on the

cylinder walls. Install all fuel injectors and tighten to

the correct torque. Refer to Disassembly and

Assembly Manual for more information.

Remove Engine from Storage

1. Remove all outside protective covers.

2. Change the oil and filters.

10. Spray a thin amount of a mixture of 50 percent

VCI oil and 50 percent engine oil onto the following

components: flywheel, ring gear teeth and starter

pinion. Install the covers in order to prevent

evaporation of the vapors from the VCI oil.

3. Check the condition of the fan and alternator belts.

Replace the belts, if necessary. Refer to this

Operation and Maintenance Manual, “Belts -

Inspect/Adjust/Replace” for the correct procedure.

11. Apply a heavy amount of Multipurpose Grease to

all outside parts that move, such as rod threads,

ball joints, linkage.

4. Replace the fuel filter elements.

5. Remove the plastic covers from the air cleaner

elements.

Note: Install all covers. Ensure that tape has been

installed over all openings, air inlets, exhaust

openings, the flywheel housing, the crankcase

breathers, the dipstick tubes.

6. Use a bar or a turning tool in order to turn the

engine in the normal direction of rotation. The

procedure ensures that no hydraulic locks or

resistance exist.

Ensure that all covers are airtight and

weatherproof. Use a waterproof weather resistant

tape such as Kendall No. 231  or an equivalent.

Do not use duct tape. Duct tape will only seal for a

short time.

7. Before starting the engine, remove the valve cover

or covers. Put a large amount of engine oil on the

camshaft, cam followers, and valve mechanism in

order to prevent damage to the mechanism.

12. Under most conditions, removing the batteries is

the best procedure. As an alternative, place the

batteries in storage. As needed, periodically

charge the batteries while the batteries are in

storage.

If the batteries are not removed, wash the tops of

the batteries until the tops are clean. Apply an

electrical charge to the batteries in order to obtain

a specific gravity of 1.225.

Disconnect the battery terminals. Place a plastic

cover over the batteries.

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22

SEBU9072

Lifting and Storage

Product Storage

10. Before start-up, test the cooling system for a 3

percent to a 6 percent concentration of coolant

conditioner. Add liquid coolant conditioner or a

coolant conditioner element, if equipped.

Test the coolant mixture for proper nitrite level. If

necessary, adjust the coolant mixture.

Prime the engine with clean diesel fuel before

starting.

11. Ensure that the cooling system is clean. Ensure

that the system is full. Ensure that the system has

the correct amount of supplemental cooling system

conditioner.

12. On the first day of operation, check the entire

engine several times for leaks and correct

operation.

Illustration 17

g03862125

Typical example

(1) plug

8. If an engine is stored for more than 1 year, Perkins

recommends Pre lubrication of the engine in order

to avoid dry starting. Use a suitable pump in order

to put engine oil into the engine oil system.

The pump will need to create a minimum pressure

within the engine of 0.25 bar (3.6 psi). This

pressure is needed for 15 seconds in order to

lubricate the internal surfaces.

Remove of the plug shown in illustration 17  in

order to connect to the engine oil system. The

connection required is 9/16" x 18 tpi. Ensure that

the correct oil specification is used, refer to this

Operation and Maintenance Manual, “Fluid

Recommendations” for more information. After the

engine internal surfaces have been lubricated,

remove connector and install plug (1). Tighten plug

to a torque of 30 N·m (265 lb in). Perkins

recommends that the procedure must be

performed in a minimum ambient temperature of

10° C (50° F).

9. Check the condition of all rubber hoses. Replace

any worn hoses. Replace any damaged hoses.

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SEBU9072

23

Features and Controls

Battery Disconnect Switch

Features and Controls

The battery disconnect switch and the engine start

switch perform different functions. The entire

electrical system is disabled when you turn the

battery disconnect switch to the OFF position. The

battery remains connected to the electrical system

when you turn the engine start switch to the OFF

position.

i05422613

Battery Disconnect Switch

(If Equipped)

Turn the battery disconnect switch to the OFF

position and remove the key when you service the

electrical system or any other engine components.

Turn the battery disconnect switch to the OFF

position and remove the disconnect switch key after

you operate the engine. This will prevent the battery

from being discharged. The following problems can

cause battery discharge:

•   short circuits

•   current draw via some components

•   vandalism

i06119742

MonitoringSystem

Illustration 18

g03422039

NOTICE

The monitoring system is designed to alert the

operator to an immediate problem.

Do not turn off the battery disconnect switch until the

indicator lamp has turned off. If the switch is turned off

when the indicator lamp is illuminated the  Diesel Ex-

haust Fluid  (DEF) system will  not purge the  DEF. If

the DEF does not purge, DEF could freeze and dam-

age the pump and lines.

The engine has protection in three stages:

•   Warning

•   Action Alert

•   Shutdown

NOTICE

Never move the battery disconnect switch to the OFF

position while the  engine is operating. Serious  dam-

age to the electrical system could result.

The engine protection may be overridden by the

critical condition mode.

The Electronic Control Module (ECM) monitors the

following parameters:

Battery Disconnect Switch – The battery

disconnect switch can be used in order

to disconnect the battery from the

engines electrical system. The key must be

inserted into the battery disconnect switch before

the battery disconnect switch can be turned.

•   Engine Temperatures

•   Engine Pressures

•   Engine Speed

If the parameters exceed a trip point for a period that

is longer than the delay period, the ECM logs an

event code. The indicator switches to the ON

position.

ON – To activate the electrical system,

insert the disconnect switch key and

turn the battery disconnect switch

clockwise. The battery disconnect switch must be

turned to the ON position before you start the

engine.

The following parameters are monitored for event

codes:

OFF – To deactivate the electrical

system, turn the battery disconnect

switch counterclockwise to the OFF

position.

This document has been printed from SPI2. NOT FOR RESALE

 

24

SEBU9072

Features and Controls

Monitoring System

•   Lubricating Oil Pressure

•   Coolant Temperature

•   Overspeed

Shutdown

If the engine reaches the Shutdown condition, one of

the following events has occurred: low lubricating oil

pressure, high coolant temperature, or overspeed.

The event will be logged in the memory of the ECM.

The engine will be shut down. An event code will be

transmitted over the Perkins  Data link and the hard

wired Shutdown output will be energized. The

Shutdown condition will latch until the ECM is reset.

The event code for the shutdown cannot be cleared

from the memory of the ECM without using a factory

password.

•   Intake Manifold Temperature

•   Intake Manifold Pressure

•   Fuel Temperature

The temperature protection is disabled for a period

when the engine is cranking in order to compensate

for heat soak solutions.

Critical Protection Override

The ECM has dedicated alarm outputs for each of the

three stages of protection. There are also dedicated

alarm outputs for oil pressure, coolant temperature,

and overspeed events which are energized at any

stage of protection.

If the engine is in an application that is critical for

safety, the protection system can be overridden in

order to ensure the continuation of the power supply

during engine fault conditions.

Critical Protection Override will be set by a switch

input from the OEM. For example, switch to battery +

in order to disable a critical override. Critical

Protection Override input can be enabled in the

electronic service tool by use of a factory password.

Warning Alarm

The Warning alarm informs the user that the engine is

approaching a critical condition.

When the Critical Protection Override feature is

active, the ECM will continue to run the engine in all

shutdown conditions except for Overspeed shutdown.

If the shutdown is overridden, an event code is

generated. The ECM will log the event code. The

ECM will energize the following: Warning, Action

Alert, Shutdown, oil pressure, coolant temperature

and overspeed outputs as normal. The warranty of

the engine will be invalidated if the engine is operated

in the following conditions: active event code and

Critical Protection Override mode.

If the engine is in the Warning condition, then the

event will be logged in the memory of the ECM. An

event code will be transmitted over the Perkins Data

link and the hard wired Warning output will be

energized. If the engine is in the Warning condition,

the event code and output will remain while the

condition exists. The electronic service tool is used to

remove the event code from the memory of the ECM.

The trip point for the Warning alarm will be set to a

factory default in production. The electronic service

tool may be used to alter the trip point for a Warning

within predefined limits.

Standard Warning Outputs

Action Alert

The ECM provides individual outputs in order to drive

warning lamps or relays to indicate each of the

following fault conditions:

The Action Alert informs the OEM that the engine is

approaching a critical condition. The engine should

be stopped in a controlled manner. Further running of

the engine may result in an immediate shutdown.

•   Diagnostic Fault

•   Oil Pressure

•   Coolant Temperature

•   Overspeed

If the engine is in the Action Alert condition, the event

will be logged in the memory of the ECM. An event

code will be transmitted over the Perkins Data link

and the hard wired Action Alert will be energized. If

the engine is in the Action Alert condition, the event

code and output will remain while the condition exists.

The event code cannot be cleared from the memory

of the ECM without using a factory password.

•   Action Alert

•   Warning

•   Shutdown

If the ECM detects a warning for the coolant

temperature , the output on the coolant temperature

will be energized and the warning output will be

energized. If the ECM detects a warning for the low

oil pressure, the output on the oil pressure will be

energized and the warning output will be energized.

This document has been printed from SPI2. NOT FOR RESALE

 

SEBU9072

25

Features and Controls

Sensors and Electrical Components

If the Action Alert alarms are enabled and the ECM

detects a coolant temperature condition, the output

on the coolant Temperature will be energized and the

output on the Action Alert will be energized.

The Diagnostic output differs from the Warning and

Shutdown outputs. The Warning and Shutdown

outputs refer to the operation of the engine. The

Diagnostic output refers to the condition of the

electronic system and software system.

If the engine shuts down on low oil pressure the

output on the low oil pressure will be energized and

the output on the shutdown will be energized. If the

engine shuts down on coolant temperature, or the

engine shuts down on overspeed the dedicated

output and the shutdown output will be energized.

A diagnostic fault may develop on the lubricating oil

pressure or coolant temperature sensors. For

example, if a Shutdown protection sensor has a fault,

this will result in an engine shutdown, unless the

system is in critical protection override. If a diagnostic

fault occurs, with one of the engine speed sensors

while the engine is running. The engine continues to

run by using the other timing sensor for reference.

Shutdown Reset

The cause of an engine shutdown must be

investigated. Corrective action must be taken before

the system is reset in order to operate the engine.

i06137289

Sensors and Electrical

Components

After an engine shutdown, operate the reset input of

the ECM or power down the controller.

Powering down the electronic control module can be

achieved by the operation of the keyswitch into sleep

mode. The electronic control module can be powered

down by isolating the power supply to the electronic

control module.

The illustrations within the following sections are

typical location of the sensors or electrical

components for an industrial engine. Specific engines

may appear different due to differences in

applications.

Note: The ECM cannot be reset by using the Reset

input until the engine has stopped.

Diagnostic

If there is a fault with an engine protection sensor on

the engine, the engine activates a diagnostic code.

The engine communicates the diagnostic code to the

operator via the Diagnostic output. The diagnostic

code provides an indication to the operator of a fault

with the engine protection system. Running of the

engine for a prolonged period in this condition may

result in engine failure. The output is generally used

to drive lamps or relays.

The following sensors are monitored in order to

determine if the sensors are out of the normal range,

an open circuit, or a short circuit:

•   Atmosphere Pressure

•   Lubricating Oil Pressure

•   Inlet Manifold Pressure

•   Inlet Manifold Temperature

•   Fuel Temperature

•   Coolant Temperature

•   Engine Speed

•   Desired Speed Input

This document has been printed from SPI2. NOT FOR RESALE

 

26

SEBU9072

Features and Controls

Sensors and Electrical Components

Illustration 19

g03822008

(1) Coolant temperature sensor

(2) Inlet manifold pressure sensor

(3) Inlet air temperature sensor

(4) Electronic control module

(5) Starting motor

(6) Oil pressure sensor

(7) Camshaft speed timing sensor

(8) Barometric pressure sensor

This document has been printed from SPI2. NOT FOR RESALE

 

SEBU9072

27

Features and Controls

Sensors and Electrical Components

Illustration 20

g03822009

(9) Alternator

(10) Crankshaft speed timing sensor

(11) Fuel temperature sensor

(12) Fuel pressure sensor

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28

SEBU9072

Engine Diagnostics

Self-Diagnostics

Engine Diagnostics

i01902949

Fault Logging

i05194988

Self-Diagnostics

The system provides the capability of Fault Logging.

When the Electronic Control Module (ECM)

generates an active diagnostic code, the code will be

logged in the memory of the ECM. The codes that

have been logged by the ECM can be identified by

the electronic service tool. The active codes that have

been logged will be cleared when the fault has been

rectified or the fault is no longer active. The following

logged faults can not be cleared from the memory of

the ECM without using a factory password:

Perkins Electronic Engines have the capability to

perform a self-diagnostics test. When the system

detects an active problem, a diagnostic lamp is

activated. Diagnostic codes will be stored in

permanent memory in the Electronic Control Module

(ECM). The diagnostic codes can be retrieved by

using Perkins electronic service tools.

Overspeed, low engine oil pressure and high engine

coolant temperature.

Some installations have electronic displays that

provide direct readouts of the engine diagnostic

codes. Refer to the manual that is provided by the

OEM for more information on retrieving engine

diagnostic codes.

i03554534

Engine Operation with Active

Diagnostic Codes

Active codes represent problems that currently exist.

These problems should be investigated first.

Logged codes represent the following items:

•   Intermittent problems

If a diagnostic lamp illuminates during normal engine

operation, the system has identified a situation that is

not within the specification. Use electronic service

tools to check the active diagnostic codes.

•   Recorded events

•   Performance history

Note: If the customer has selected  “DERATE”  and if

there is a low oil pressure condition, the Electronic

Control Module (ECM) will limit the engine power until

the problem is corrected. If the oil pressure is within

the normal range, the engine may be operated at the

rated speed and load. However, maintenance should

be performed as soon as possible.

The problems may have been repaired since the

logging of the code. These codes do not indicate that

a repair is needed. The codes are guides or signals

when a situation exists. Codes may be helpful to

troubleshoot problems.

When the problems have been corrected, the

corresponding logged fault codes should be cleared.

The active diagnostic code should be investigated.

The cause of the problem should be corrected as

soon as possible. If the cause of the active diagnostic

code is repaired and there is only one active

i03554520

diagnostic code, the diagnostic lamp will turn off.

Diagnostic Lamp

Operation of the engine and performance of the

engine can be limited as a result of the active

diagnostic code that is generated. Acceleration rates

may be significantly slower. Refer to the

Troubleshooting Guide for more information on the

relationship between these active diagnostic codes

and engine performance.

A diagnostic lamp is used to indicate the existence of

an active fault. A fault diagnostic code will remain

active until the problem is repaired. The diagnostic

code may be retrieved by using the electronic service

tool.

i06225055

Configuration Parameters

The engine electronic control module (ECM) has two

types of configuration parameters. The system

configuration parameters and the customer specified

parameters.

This document has been printed from SPI2. NOT FOR RESALE

 

SEBU9072

29

Engine Diagnostics

Engine Operation with Intermittent Diagnostic Codes

The electronic service tool is required in order to alter

the configuration parameters.

System ConfigurationParameters

System configuration parameters affect the emissions

of the engine or the power of the engine. System

configuration parameters are programmed at the

factory. Normally, system configuration parameters

would never require changing through the life of the

engine. System configuration parameters must be

reprogrammed if an ECM is replaced. System

configuration parameters do not require

reprogrammed if the ECM software is changed.

Factory passwords are required to change these

parameters.

For more information on system configuration

parameters and customer specified parameters, refer

to Troubleshooting manual.

i01797063

Engine Operation with

Intermittent Diagnostic Codes

If a diagnostic lamp illuminates during normal engine

operation and the diagnostic 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 stop the engine

because of an intermittent code. However, the

operator should retrieve the logged fault codes and

the operator should reference the appropriate

information in order to identify the nature of the event.

The operator should log any observation that could

have caused the lamp to light.

•   Low power

•   Limits of the engine speed

•   Excessive smoke, etc

This information can be useful to help troubleshoot

the situation. The information can also be used for

future reference. For more information on diagnostic

codes, refer to the Troubleshooting Guide for this

engine.

This document has been printed from SPI2. NOT FOR RESALE

 

30

SEBU9072

Engine Starting

Before Starting Engine

Engine Starting

•   Do not start the engine or move any of the controls

if there is a “DO NOT OPERATE” warning tag or

similar warning tag attached to the start switch or

to the controls.

i02109067

Before Starting Engine

•   Ensure that the areas around the rotating parts are

clear.

•   All of the guards must be put in place. Check for

damaged guards or for missing guards. Repair any

damaged guards. Replace damaged guards and/

or missing guards.

Perform the required daily maintenance and other

periodic maintenance before the engine is started.

Inspect the engine compartment. This inspection can

help prevent major repairs at a later date. Refer to the

Operation and Maintenance Manual, “Maintenance

Interval Schedule” for more information.

•   Disconnect any battery chargers that are not

protected against the high current drain that is

created when the electric starting motor (if

equipped) is engaged. Check electrical cables and

check the battery for poor connections and for

corrosion.

•   For the maximum service life of the engine, make

a thorough inspection before the engine is started.

Look for the following items: oil leaks, coolant

leaks, loose bolts and trash buildup. Remove trash

buildup and arrange for repairs, as needed.

•   Reset all of the shutoffs or alarm components.

•   Inspect the aftercooler for loose connections and

for debris buildup.

•   Check the engine lubrication oil level. Maintain the

oil level between the “ADD”  mark and the “FULL”

mark on the oil level gauge.

•   Inspect the cooling system hoses for cracks and

for loose clamps.

•   Check the coolant level. Observe the coolant level

in the coolant recovery tank (if equipped). Maintain

the coolant level to the “FULL” mark on the

coolant recovery tank.

•   Inspect the alternator and accessory drive belts for

cracks, breaks, and other damage.

•   Inspect the wiring for loose connections and for

worn wires or frayed wires.

•   If the engine is not equipped with a coolant

recovery tank maintain the coolant level within

13 mm (0.5 inch) of the bottom of the filler pipe. If

the engine is equipped with a sight glass, maintain

the coolant level in the sight glass.

•   Check the fuel supply. Drain water from the water

separator (if equipped). Open the fuel supply

valve.

•   Observe the air cleaner service indicator (if

equipped). Service the air cleaner when the yellow

diaphragm enters the red zone, or when the red

piston locks in the visible position.

NOTICE

All valves in the fuel  return line must be open before

and during engine operation to help prevent high fuel

pressure. High fuel pressure may cause filter housing

failure or other damage.

•   Ensure that any driven equipment has been

disengaged. Minimize electrical loads or remove

any electrical loads.

If the engine has not been started for several weeks,

fuel may have drained from the fuel system. Air may

have entered the filter housing. Also, when fuel filters

have been changed, some air pockets will be trapped

in the engine. In these instances, prime the fuel

system. Refer to the Operation and Maintenance

Manual, “Fuel System - Prime” for more information

on priming the fuel system.

i04132731

Cold Weather Starting

Startability will be improved at temperatures below

10°C  (50°F) from the use of a cylinder block coolant

heater or from other means that are used to heat the

crankcase oil. Some engine applications use a jacket

water heater to improve startability. Use of a jacket

water heater will help reduce white smoke and misfire

during start-up in cold weather.

Engine exhaust contains products of combustion

which may be harmful to your health. Always start

and operate  the engine  in a well  ventilated area

and, if in an enclosed area, vent the exhaust to the

outside.

This document has been printed from SPI2. NOT FOR RESALE

 

SEBU9072

31

Engine Starting

Starting the Engine

Note: If the engine has not been run for several

weeks, fuel may have drained. Air may have moved

into the filter housing. Also, when fuel filters have

been changed, some air will be left in the filter

housing. Refer to the Operation and Maintenance

Manual, “Fuel System - Prime” (Maintenance

Section) for more information on priming the fuel

system.

During the key on, all warning lamps will illuminate

for a few seconds, in order to test the circuits. If

any lamps do not illuminate, check the bulbs and

replace as necessary.

NOTICE

Do not  engage the  starting motor  when flywheel  is

turning. Do not start the engine under load.

Ether Injection System (If

Equipped)

If the engine fails  to start within 30 seconds, release

the starter switch or button and wait two minutes to al-

low  the starting  motor to  cool  before attempting  to

start the engine again.

The ether injection system is controlled by the ECM.

The ECM monitors the coolant temperature, intake air

temperature, ambient air temperature, and barometric

pressure to determine when ether injection is needed.

At sea level, ether will be used if any of the

temperatures fails to exceed 0° C  (32° F). This

temperature is subject to an increase as barometric

pressure increases.

3. Push the start button or turn the ignition switch to

the START position in order to crank the engine.

Do not push down or hold the throttle down while

the engine is cranked. The system will

automatically provide the correct amount of fuel

that is needed to start the engine.

4. If the engine fails to start within 30 seconds,

release the start button, or the ignition switch. Wait

for 2 minutes in order to allow the starting motor to

cool before attempting to start the engine again.

Personal  injury  or property  damage  can  result

from alcohol or starting fluids.

Alcohol  or starting  fluids  are  highly  flammable

and toxic and if improperly stored could result in

injury or property damage.

NOTICE

Oil pressure should  rise within 15  seconds after the

engine starts. Do not increase engine rpm until the oil

pressure gauge indicates normal. If oil pressure is not

indicated on the  gauge within 15 seconds,  DO NOT

operate  the  engine. STOP  the  engine,  investigate

and correct the cause.

Follow the procedure in this Operation and

Maintenance Manual, “Starting the Engine”.

i06092648

Starting the Engine

5. Allow the engine to idle for approximately 3

minutes. Idle the engine until the water

temperature gauge has begun to rise. Check all

gauges during the warm-up period.

Engine exhaust contains products of combustion

which may be harmful to your health. Always start

and operate  the engine  in a well  ventilated area

and, if in an enclosed area, vent the exhaust to the

outside.

Note: Oil pressures and fuel pressures should be in

the normal range on the instrument panel. Engines

that are equipped with “WARNING”  lamps do not

have an operating range. The “WARNING and

DIAGNOSTIC”  lamp (if equipped) will flash while the

engine is cranking. The lamp should turn off after

proper engine oil pressure or fuel pressure is

achieved. Do not apply a load to the engine or

increase engine rpm until the oil pressure gauge

indicates at least normal pressure. Inspect the engine

for leaks and/or unusual noises.

Starting the Engine

Refer to the Owners Manual of the OEM for your type

of controls. Use the following procedure to start the

engine.

1. Place the transmission in NEUTRAL. Disengage

the flywheel clutch in order to allow the engine to

start faster, and to reduce the draining of the

battery.

2. Turn the ignition switch to the ON position.

This document has been printed from SPI2. NOT FOR RESALE

 

32

SEBU9072

Engine Starting

Starting with Jump Start Cables

If the engine is operated with a low load, the engine

will reach normal operating temperature sooner than

idling the engine with no load. When the engine is

idled in cold weather, increase the engine rpm to

approximately 1000 to 1200 rpm in order to raise

engine temperature. Do not exceed the

recommended rpm in order to increase the speed of

the warm-up. Limit unnecessary idle time to 10

minutes.

2. If a wire is loose, push the wire back into the

connector. Pull the wire again in order to e, nsure

that the wire is secure.

3. Start the engine. If the engine does not start, check

for a diagnostic code and consult your Perkins

distributor.

i06092747

Starting Problems

Starting with Jump Start

Cables

An occasional starting problem may be caused by

one of the following items:

(Do Not Use This Procedure in

Hazardous Locations that have

Explosive Atmospheres)

•   Low battery charge

•   Lack of fuel

•   Problem with the wiring harness

If the engine fuel system has been run dry, fill the fuel

tank and prime the fuel system. Refer to the

Operation and Maintenance Manual, “Fuel System -

Prime” topic (Maintenance Section).

The connection of battery cables to a battery and

the disconnection of battery cables from a battery

may cause  an explosion which  may result in  in-

jury or death. The connection and the disconnec-

tion of other electrical equipment may also cause

an explosion which may result in injury or  death.

The procedures  for the  connection and  the dis-

connection of battery  cables and other electrical

equipment should only be performed in  a nonex-

plosive atmosphere.

If the other problems are suspected, perform the

appropriate procedure in order to start the engine.

Problems with the Wiring Harness

Improper jump start cable connections can cause

an explosion resulting in personal injury.

Prevent sparks  near the  batteries. Sparks  could

cause vapors to explode. Do not allow jump start

cable ends to contact each other or the engine.

Note: If possible, first diagnose the reason for the

starting failure. Refer to Troubleshooting, “Engine Will

Not Crank and Engine Cranks But Will Not Start” for

further information. Make any necessary repairs. If

the engine will not start only due to the condition of

the battery, either charge the battery, or start the

engine by using another battery with jump-start

cables.

Illustration 21

g01248812

ECM Connector J2/P2

The condition of the battery can be rechecked after

the engine has been switched OFF.

Locate the ECM. Check the connector in order to

ensure that the connector is secure. Lightly pull each

of the wires in the chassis harness.

1. Pull each wire with approximately 4.5 kg  (10 lb) of

force. The wire should remain in the connector.

This document has been printed from SPI2. NOT FOR RESALE

 

SEBU9072

33

Engine Starting

After Starting Engine

i05359363

NOTICE

Using a battery source with  the same voltage as the

electric starting  motor. Use  ONLY equal  voltage for

jump starting. The use of higher  voltage will damage

the electrical system.

After Starting Engine

Note: In temperatures from 0 to 60°C  (32 to 140°F),

the warm-up time is approximately 3 minutes. In

temperatures below 0°C (32°F), additional warm-up

time may be required.

Do not reverse the battery cables. The alternator can

be damaged.  Attach ground  cable last  and remove

first.

Turn all  electrical accessories OFF  before attaching

the jump start cables.

When the engine is idling during warm-up, observe

the following conditions:

Ensure that the main power switch is in the OFF posi-

tion before attaching the jump start cables  to the en-

gine being started.

•   Check for fluid or air leaks at idle rpm and at one-

half full rpm (no load on the engine) before

operating the engine under load. Operating the

engine at idle and at one-half full rpm with no load

is not possible in some applications.

1. Turn the start switch on the stalled engine to the

OFF position. Turn off all the engines accessories.

•   Operate the engine at low idle until all systems

achieve operating temperatures. Check all gauges

during the warm-up period.

2. Connect one positive end of the jump-start cable to

the positive cable terminal of the discharged

battery. Connect the other positive end of the jump-

start cable to the positive cable terminal of the

electrical source.

Note: Gauge readings 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 time will also help detect

abnormal operating developments. Significant

changes in the readings should be investigated.

3. Connect one negative end of the jump-start cable

to the negative cable terminal of the electrical

source. Connect the other negative end of the

jump-start cable to the engine block or to the

chassis ground. This procedure helps to prevent

potential sparks from igniting the combustible

gases that are produced by some batteries.

Extended Idle at Cold Ambient

Temperature

The engine may automatically change speeds when

the engine is idling in cold ambient temperatures

(typically less than 0° C (32° F) for extended periods.

The purpose of the automatic speed change is

threefold: to maintain the desired operation of the

NOx reduction system, to maintain the desired

operation of the regeneration system and to keep the

engine coolant warm. The engine speed may rise to

1600 rpm for as long as 20 minutes.

Note: The engine ECM must be powered before the

starting motor is operated or damage can occur.

4. Start the engine in the normal operating procedure.

Refer to this Operation and Maintenance Manual,

“Starting the Engine”.

5. Immediately after the engine is started, disconnect

the jump-start cables in reverse order.

The high exhaust system temperature lamp may

illuminate during extended idling conditions. This

illumination signals that a diesel particulate filter

(DPF) regeneration is in progress. Regenerations

during cold ambient extended idling may only last up

to 10 minutes.

After jump starting, the alternator may not be able to

recharge fully batteries that are severely discharged.

The batteries must be replaced or charged to the

proper voltage with a battery charger after the engine

is stopped. Many batteries which are considered

unusable are still rechargeable. Refer to Operation

and Maintenance Manual, “Battery - Replace” and

Testing and Adjusting Manual, “Battery - Test”.

This document has been printed from SPI2. NOT FOR RESALE