Operation and Maintenance Manual: 1206E-E66TA Industrial Engine

SEBU8603-04 (en-us)
March 2021
Operation and
Maintenance
Manual
1206E-E66TA Industrial Engine
BK (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions correctly.
Incorrect 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.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins 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. You must not use
this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of
the product in the location of use, including site-specific rules and precautions applicable to the
worksite. 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 you are authorized to perform this work, and that the product will not
be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information 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.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU8603-04 3
Table of Contents
Table of Contents Cold Weather Operation ................................. 59
Foreword ........................................................... 4 Maintenance Section
Refill Capacities............................................... 63
Safety Section
Maintenance Recommendations .................... 79
Safety Messages............................................... 6
Maintenance Interval Schedule....................... 81
General Hazard Information.............................. 9
Burn Prevention............................................... 12 Warranty Section
Fire Prevention and Explosion Prevention...... 13 Warranty Information......................................114
Crushing Prevention and Cutting Prevention.. 15 Reference Information Section
Mounting and Dismounting ............................. 16 Reference Materials .......................................118
High Pressure Fuel Lines ................................ 16 Index Section
Before Starting Engine .................................... 17 Index...............................................................119
Engine Starting................................................ 18
Engine Stopping .............................................. 18
Electrical System............................................. 18
Engine Electronics........................................... 20
Product Information Section
Model Views .................................................... 21
Product Identification Information ................... 28
Operation Section
Lifting and Storage .......................................... 30
Gauges and Indicators .................................... 33
Features and Controls..................................... 35
Engine Diagnostics ......................................... 45
Engine Starting................................................ 51
Engine Operation ............................................ 55
Engine Stopping .............................................. 57

4 SEBU8603-04
Foreword
Foreword Some photographs or illustrations in this manual

show details or attachments that may be different
from your engine. Guards and covers may have been
California Proposition 65 Warning removed for illustrative purposes. Continuing
improvement and advancement of product design
Diesel engine exhaust and some of its may have caused changes to your engine which are
not included in this manual. Whenever a question
constituents are known to the State of arises regarding your engine, or this manual, please
California to cause cancer, birth defects, consult with your Perkins dealer or your Perkins
and other reproductive harm. distributor for the latest available information.
WARNING – This product can Safety

expose you to chemicals
including ethylene glycol, which This safety section lists basic safety precautions. In
is known to the State of California to addition, this section identifies hazardous, warning
cause birth defects or other reproductive situations. Read and understand the basic
precautions listed in the safety section before
harm. For more information go to: operating or performing lubrication, maintenance,
and repair on this product.
www.P65Warnings.ca.gov
Do not ingest this chemical. Wash hands Operation
after handling to avoid incidental Operating techniques outlined in this manual are
ingestion. basic. The operating techniques assist with
developing the skills and techniques required to
WARNING – This product can operate the engine more efficiently and economically.
expose you to chemicals Skill and techniques develop as the operator gains
including lead and lead knowledge of the engine and the capabilities of the
compounds, which are known to the engine.
State of California to cause cancer, birth The operation section is a reference for operators.
defects, or other reproductive harm. For Photographs and illustrations guide the operator
more information go to: through procedures of inspecting, starting, operating,
and stopping the engine. This section also includes a
www.P65Warnings.ca.gov discussion of electronic diagnostic information.
Wash hands after handling components Maintenance

that may contain lead.
The maintenance section is a guide to engine care.
Literature Information The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
This manual contains safety, operation instructions, intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
lubrication, and maintenance information. This
manual should be stored in or near the engine area in Recommended service should be performed at the
a literature holder or literature storage area. Read, appropriate intervals as indicated in the Maintenance
study, and keep the manual with the literature and Interval Schedule. The actual operating environment
engine information. of the engine also governs the Maintenance Interval
Schedule. Therefore, under severe, dusty, wet, or
English is the primary language for all Perkins freezing cold operating conditions, more frequent
publications. The English used facilitates translation lubrication, and maintenance than is specified in the
and consistency. Maintenance Interval Schedule may be necessary.
SEBU8603-04 5
Foreword
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.
Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation, and application. Perkins recommends that
the maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
Perkins also recommends that a maintenance record
be maintained as part of the permanent record of the
engine.
Your authorized Perkins dealer or your Perkins
distributor can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.
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 are best left to trained personnel or an
authorized Perkins distributor or dealer. Your Perkins
dealer or your Perkins distributor offers various
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.
6 SEBU8603-04
Safety Section
Safety Messages
Safety Section
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.
Illustration 1 g01154807
Typical example
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).
SEBU8603-04 7
Safety Section
Safety Messages
Typical example
(1) Universal warning
(2) Hand (High Pressure)
Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
8 SEBU8603-04
Safety Section
Safety Messages
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.
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.
SEBU8603-04 9
Safety Section
General Hazard Information
• 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 to help
prevent damage to hearing.
• Do not wear loose clothing or jewelry that can
snag on controls or on other parts of the engine.
• Ensure that all protective guards and all covers

are secured in place on the engine.
Typical example
• Never put maintenance fluids into glass
An ether warning label will be installed on the air containers. Glass containers can break.
cleaner or close to the air cleaner. The location will
depend on the application. • Use all cleaning solutions with care.
i08315538 • Report all necessary repairs.

Unless other instructions are provided, perform the
General Hazard Information maintenance under the following conditions:
• The engine is stopped. Ensure that the engine
cannot 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.
• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads to help prevent sparks.
• Disconnect the connector for the unit injector that
Illustration 6 g00104545 is on the valve cover base. This action will help
prevent personal injury from the high voltage to
Attach a “Do Not Operate” warning tag or a similar the unit injectors. Do not come in contact with the
warning tag to the start switch or to the controls unit injector terminals while the engine is
before the engine is serviced or before the engine is operating.
repaired. Attach the warning tags to the engine and
to each operator control station. When appropriate, • Do not attempt any repairs or any adjustments to
disconnect the starting controls. the engine while the engine is operating.
Do not allow unauthorized personnel on the engine, • Do not attempt any repairs that are not
or around the engine when the engine is being understood. Use the proper tools. Replace any
serviced. equipment that is damaged or repair the
• Tampering with the engine installation or equipment.
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.
10 SEBU8603-04
Safety Section
• For initial start-up of a new engine or for starting • Do not wear loose clothing or jewelry that can
an engine that has been serviced, make snag on controls or on other parts of the engine.
provisions to stop the engine if an overspeed
occurs. This action may be accomplished by • Ensure that all protective guards and all covers
shutting off the fuel supply and/or the air supply to are secured in place on the engine.
the engine.
• Never put maintenance fluids into glass
• Start the engine from the operators station (cab). containers. Glass containers can break.
Never short across the starting motor terminals or
the batteries. This action could bypass the engine • Use all cleaning solutions with care.
neutral start system and/or the electrical system
• Report all necessary repairs.
could be damaged.
Unless other instructions are provided, perform
Engine exhaust contains products of combustion the maintenance under the following conditions:
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated • The engine is stopped. Ensure that the engine
area. If the engine is in an enclosed area, vent the cannot be started.
engine exhaust to the outside.
• Disconnect the batteries when maintenance is
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids, performed or when the electrical system is
hold a rag over the part that is being removed. serviced. Disconnect the battery ground leads.
Tape the leads to help prevent sparks.
• Filler caps
• Do not attempt any repairs that are not
• Grease fittings understood. Use the proper tools. Replace any
equipment that is damaged or repair the
• Pressure taps equipment.
• Breathers Pressurized Air and Water

• Drain plugs Pressurized air and/or water can cause debris and/or
hot water to be blown out and could result in personal
Use caution when cover plates are removed. injury.
Gradually loosen, but do not remove the last two
bolts or nuts that are at opposite ends of the cover When pressurized air and/or pressurized water is
plate or the device. Before removing the last two used for cleaning, wear protective clothing, protective
bolts or nuts, pry the cover loose to relieve any spring shoes, and eye protection. Eye protection includes
pressure or other pressure. 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
• Wear a hard hat, protective glasses, and other or personal injury may occur. Refer to the OEM
protective equipment, as required. information for any procedures that are required to
relieve the hydraulic pressure.
• When work is performed around an engine that is
operating, wear protective devices for ears to help
prevent damage to hearing.
SEBU8603-04 11
Safety Section
Avoid static electricity risk when fueling. Ultra-

low sulfur diesel fuel (ULSD fuel) poses a greater
static ignition hazard than earlier diesel formula-
tions with a higher sulfur contents. Avoid death
or serious injury from fire or explosion. Consult
with your fuel or fuel system supplier to ensure
the delivery system is in compliance with fueling
standards for proper grounding and bonding
practices.
Inhalation
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.
Containing Fluid Spillage

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. Illustration 9 g00702022
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids. Exhaust
Dispose of all fluids according to local regulations Use caution. Exhaust fumes can be hazardous to
and mandates. health. If you operate the equipment in an enclosed
area, adequate ventilation is necessary.
Static Electricity Hazard when Hexavalent Chromium

Fueling with Ultra-low Sulfur Diesel Perkins equipment and replacement parts comply
with applicable regulations and requirements where
Fuel originally sold. Perkins recommends the use of only
genuine Perkins replacement parts.
The removal of sulfur and other compounds in ultra-
low sulfur diesel fuel (ULSD fuel) decreases the Hexavalent chromium has occasionally been
conductivity of ULSD and increases the ability of detected on exhaust and heat shield systems on
ULSD to store static charge. Refineries may have Perkins engines. Although laboratory testing is the
treated the fuel with a static dissipating additive. only accurate way to know if hexavalent chromium is,
Many factors can reduce the effectiveness of the in fact, present, the presence of a yellow deposit in
additive over time. Static charges can build up in areas of high heat (for example, exhaust system
ULSD fuel while the fuel is flowing through fuel components or exhaust insulation) may be an
delivery systems. Static electricity discharge when indication of the presence of hexavalent chromium.
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to Use caution if you suspect the presence of
refuel your machine (fuel supply tank, transfer pump, hexavalent chromium. Avoid skin contact when
transfer hose, nozzle, and others) is properly handling items that you suspect may contain
grounded and bonded. Consult with your fuel or fuel hexavalent chromium, and avoid inhalation of any
system supplier to ensure that the delivery system dust in the suspect area. Inhalation of, or skin contact
complies with fueling standards for proper grounding with, hexavalent chromium dust may be hazardous to
and bonding. your health.
12 SEBU8603-04
Safety Section
Burn Prevention
If such yellow deposits are found on the engine, • Use exhaust ventilation on permanent machining
engine component parts, or associated equipment or jobs.
packages, Perkins recommends following local
health and safety regulations and guidelines, utilizing • Wear an approved respirator if there is no other
good hygiene, and adhering to safe work practices way to control the dust.
when handling the equipment or parts. Perkins also
recommends the following: • Comply with applicable rules and regulations for
the work place. In the United States, use
• Wear appropriate Personal Protective Equipment Occupational Safety and Health Administration
(PPE) (OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Wash your hands and face with soap and water
prior to eating, drinking, or smoking, and also • Obey environmental regulations for the disposal of
during rest room breaks, to prevent ingestion of asbestos.
any yellow powder
• Stay away from areas that might have asbestos
• Never use compressed air for cleaning areas particles in the air.
suspected of containing hexavalent chromium
• Avoid brushing, grinding, or cutting materials Dispose of Waste Properly

suspected of containing hexavalent chromium
• Obey environmental regulations for the disposal of

all materials that may contain or have come into
contact with hexavalent chromium
• Stay away from areas that might have hexavalent

chromium particles in the air.
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 Illustration 10 g00706404
debris.
Use caution. Avoid inhaling dust that might be Improperly disposing of waste can threaten the
generated when you handle components that contain environment. Potentially harmful fluids should be
asbestos fibers. Inhaling this dust can be hazardous disposed of according to local regulations.
to your health. The components that may contain Always use leakproof containers when you drain
asbestos fibers are brake pads, brake bands, lining fluids. Do not pour waste onto the ground, down a
material, clutch plates, and some gaskets. The
drain, or into any source of water.
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 i04224009
contains asbestos is generated.
Burn Prevention
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning. Do not touch any part of an operating engine system.
The engine, the exhaust, and the engine
• Avoid brushing materials that contain asbestos. aftertreatment system surface temperatures can
reach temperatures of approximately 600° C
• Avoid grinding materials that contain asbestos. (1112 ° F) under normal operating conditions.
• Use a wet method to clean up asbestos materials. Allow the engine system to cool before any
maintenance is performed.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
SEBU8603-04 13
Safety Section
Fire Prevention and Explosion Prevention
Relieve all pressure in the following systems, Cooling system conditioner contains alkali. Alkali can
hydraulic system, lubrication system, fuel system, cause personal injury. Do not allow alkali to contact
and the coolant system before the related items are the skin, the eyes, or the mouth.
disconnected.
Oils
Hot oil and hot lubricating components can cause
Contact with high pressure fuel may cause fluid personal injury. Do not allow hot oil to contact the
penetration and burn hazards. High pressure fuel skin. Also, do not allow hot components to contact
spray may cause a fire hazard. Failure to follow the skin.
structions may cause personal injury or death. Batteries
Electrolyte is an acid. Electrolyte can cause personal
After the engine has stopped, you must wait for 10 injury. Do not allow electrolyte to contact the skin or
minutes in order to allow the fuel pressure to be the eyes. Always wear protective glasses for
purged from the high-pressure fuel lines before any servicing batteries. Wash hands after touching the
service or repair is performed on the engine fuel batteries and connectors. Use of gloves is
lines. recommended.
Allow the pressure to be purged in the air system, in
the hydraulic system, in the lubrication system, or in i07817010
the cooling system before any lines, fittings, or
related items are disconnected. Fire Prevention and Explosion
Induction System Prevention
Sulfuric Acid Burn Hazard may cause serious

personal 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 en-
gine. 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.
All fuels, most lubricants, and some coolant mixtures

Coolant are flammable.
When the engine is at operating temperature, the Flammable fluids that are leaking or spilled onto hot
engine coolant is hot. The coolant is also under surfaces or onto electrical components can cause a
pressure. The radiator and all lines to the heaters or fire. Fire may cause personal injury and property
to the engine contain hot coolant. damage.
Any contact with hot coolant or with steam can cause After the emergency stop button is operated, ensure
severe burns. Allow cooling system components to that you allow 15 minutes, before the engine covers
cool before the cooling system is drained. are removed.
Check that the coolant level after the engine has Determine whether the engine will be operated in an
stopped and the engine has been allowed to cool. environment that allows combustible gases to be
drawn into the air inlet system. These gases could
Ensure that the filler cap is cool before removing the cause the engine to overspeed. Personal injury,
filler cap. The filler cap must be cool enough to touch property damage, or engine damage could result.
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
14 SEBU8603-04
Safety Section
Fire Prevention and Explosion Prevention
If the application involves the presence of Ensure that the engine is stopped. Inspect all lines
combustible gases, consult your Perkins dealer and/ and hoses for wear or for deterioration. Ensure that
or your Perkins distributor for additional information the hoses are correctly routed. The lines and hoses
about suitable protection devices. must have adequate support and secure clamps. If
any fuel lines or fuel hoses become kinked, the fuel
Remove all flammable combustible materials or line or fuel hose must be replaced. Refer to the
conductive materials such as fuel, oil, and debris Disassembly and Assembly manual for more
from the engine. Do not allow any flammable information.
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
Store fuels and lubricants in correctly marked torque. Refer to the Disassembly and Assembly
containers away from unauthorized persons. Store manual for more information.
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray if there was a line,
a tube, or a seal failure. Exhaust shields must be
installed correctly.
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. 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 Use caution when you are refueling an engine. Do
bypass any fuses and/or circuit breakers. not smoke while you are refueling an engine. Do not
Arcing or sparking could cause a fire. Secure refuel an engine near open flames or sparks. Always
connections, recommended wiring, and correctly stop the engine before refueling.
maintained battery cables will help to prevent arcing
Avoid static electricity risk when fueling. Ultra-low
or sparking.
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
Contact with high pressure fuel may cause fluid system supplier to ensure that the delivery system is
penetration and burn hazards. High pressure fuel in compliance with fueling standards for proper
spray may cause a fire hazard. Failure to follow grounding and bonding practices.
After the engine has stopped, you must wait for 10

minutes 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. The 10
minute wait will also allow static charge to dissipate
from the low-pressure fuel system.
SEBU8603-04 15
Safety Section
Crushing Prevention and Cutting Prevention
Do not smoke while you are replacing an ether

cylinder.
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.
Lines, Tubes, and Hoses

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.
Illustration 13 g00704135 • End fittings are damaged or leaking.
Gases from a battery can explode. Keep any open • Outer coverings are chafed or cut.
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas. • Wires are exposed.
Never check the battery charge by placing a metal • Outer coverings are ballooning.
object across the terminal posts. Use a voltmeter or a
hydrometer. • Flexible parts of the hoses are kinked.
Incorrect jumper cable connections can cause an • Outer covers have embedded armoring.
explosion that can result in injury. Refer to the
Operation Section of this manual for specific • End fittings are displaced.
instructions.
Make sure that all clamps, guards, and heat shields
Do not charge a frozen battery. A frozen battery may are installed correctly. During engine operation,
cause an explosion. correct installation will help to prevent vibration,
rubbing against other parts, and excessive heat.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box i02143194
covers when the engine is operated.
Crushing Prevention and
Fire Extinguisher Cutting Prevention
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher. Support the component correctly when work beneath
Inspect the fire extinguisher and service the fire the component is performed.
extinguisher regularly. Obey the recommendations
on the instruction plate. Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
Ether 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,
Do not use aerosol types of starting aids such as reinstall the guards.
ether. Such use could result in an explosion and
personal injury. Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
Ether is flammable and poisonous.
16 SEBU8603-04
Safety Section
Mounting and Dismounting
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.
i05768982
Mounting and Dismounting
Do not climb on the engine or the engine

aftertreatment system. The engine and
aftertreatment system 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.
i07671624
High Pressure Fuel Lines
Contact with high pressure fuel may cause fluid

spray may cause a fire hazard. Failure to follow
(1) High-pressure line (4) High-pressure line (7) High-pressure fuel manifold (rail)
(2) High-pressure line (5) High-pressure line (8) High-pressure line
(3) High-pressure line (6) High-pressure line (9) Fuel transfer line that is high pressure
SEBU8603-04 17
Safety Section
Before Starting Engine
The high-pressure fuel lines are the fuel lines that are • Do not attach any other item to the high-pressure
between the high-pressure fuel pump and the high- fuel lines.
pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These • Loosened high-pressure fuel lines must be
fuel lines are different from fuel lines on other fuel replaced. High-pressure fuel lines that have been
systems. removed must be replaced. Refer to Disassembly
and assembly manual, “Fuel Injection Lines -
The differences are as follows:
Install”.
• The high-pressure fuel lines are constantly
charged with high pressure while the engine is in i05874054
operation and up to 10 minutes after the engine
has stopped. Before Starting Engine
• The internal pressures of the high-pressure fuel
lines are higher than other types of fuel system.
NOTICE
• The high-pressure fuel lines are formed to shape For initial start-up of a new or rebuilt engine, and for
and then strengthened by a special process. start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
Do not step on the high-pressure fuel lines. Do not occur. This may be accomplished by shutting off the
deform the high-pressure fuel lines. Do not bend or air and/or fuel supply to the engine.
strike the high-pressure fuel lines. Deformation or
damage of the high-pressure fuel lines may cause a
point of weakness and potential failure.
Do not check the high-pressure fuel lines with the
engine or the starting motor in operation. After the Engine exhaust contains products of combustion
engine has stopped, you must wait for 10 minutes to which may be harmful to your health. Always
allow the fuel pressure to be purged from the high- start and operate the engine in a well ventilated
pressure fuel lines before any service or repair is area and, if in an enclosed area, vent the exhaust
performed on the engine fuel lines. The 10 minute to the outside.
wait will also allow static charge to dissipate from the Inspect the engine for potential hazards.
low-pressure fuel system.
Do not start the engine or move any of the controls if
Do not loosen the high-pressure fuel lines to remove there is a “DO NOT OPERATE” warning tag or similar
air from the fuel system. This procedure is not warning tag attached to the start switch or to the
required. controls.
Visually inspect the high-pressure fuel lines before Before starting the engine, ensure that no one is on,
the engine is started. This inspection should be underneath, or close to the engine. Ensure that the
performed each day. area is free of personnel.
If the engine is inspected whilst in operation, always If equipped, ensure that the lighting system for the
use the correct inspection procedure to avoid a fluid engine is suitable for the conditions. Ensure that all
penetration hazard. Refer to Operation and lights work properly, if equipped.
Maintenance Manual, “General hazard Information”.
All protective guards and all protective covers must
• Inspect the high-pressure fuel lines for damage, be installed if the engine must be started in order to
deformation, a nick, a cut, a crease, or a dent. perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
• Do not operate the engine with a fuel leak. If there around the parts carefully.
is a leak, do not tighten the connection, to stop the
leak. The connection must only be tightened to the Do not bypass the automatic shutoff circuits. Do not
recommended torque. Refer to Disassembly and disable the automatic shutoff circuits. The circuits are
Assembly, “Fuel injection lines - Remove and Fuel provided in order to help prevent personal injury. The
injection lines - Install”. circuits are also provided in order to help prevent
engine damage.
• If the high-pressure fuel lines are torqued correctly
and the high-pressure fuel lines are leaking, the See the Service Manual for repairs and for
adjustments.
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.
18 SEBU8603-04
Safety Section
Engine Starting
i08185623 i02234873
Engine Starting Engine Stopping
Stop the engine according to the procedure in the

Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
Do not use aerosol types of starting aids such as overheating of the engine and accelerated wear of
ether. Such use could result in an explosion and the engine components.
personal injury.
Use the Emergency Stop Button (if equipped) ONLY
If a warning tag is attached to the engine start switch, in an emergency situation. Do not use the
or to the controls DO NOT start the engine or move Emergency Stop Button for normal engine stopping.
the controls. Consult with the person that attached After an emergency stop, DO NOT start the engine
the warning tag before the engine is started. until the problem that caused the emergency stop
has been corrected.
All protective guards and all protective covers must
be installed if the engine must be started to perform Stop the engine if an overspeed condition occurs
service procedures. To help prevent an accident that during the initial start-up of a new engine or an
is caused by parts in rotation, work around the parts engine that has been overhauled.
carefully.
To stop an electronically controlled engine, cut the
Start the engine from the operator's compartment or power to the engine and/or shutting off the air supply
from the engine start switch. to the engine.
Always start the engine according to the procedure
i04193189
described in the Operation and Maintenance Manual,
“Engine Starting” topic in the Operation Section.
Knowing the correct procedure will help to prevent Electrical System
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
To ensure that the jacket water heater (if equipped)
is operating. A spark can cause the combustible
and/or the lube oil heater (if equipped) is working
gases that are produced by some batteries to ignite.
correctly, check the water temperature gauge. Also,
check the oil temperature gauge during the heater To help prevent sparks from igniting combustible
operation. gases that are produced by some batteries, the
Engine exhaust contains products of combustion negative “−” cable should be connected last from the
external power source to the primary position for
which can be harmful to health. Always start the
engine and operate the engine in a well ventilated grounding.
area. If the engine is started in an enclosed area, Check the electrical wires daily for wires that are
vent the engine exhaust to the outside. loose or frayed. Tighten all loose electrical
connections before the engine is started. Repair all
Note: The engine is equipped with a device for cold frayed electrical wires before the engine is started.
starting. If the engine will be operated in very cold See the Operation and Maintenance Manual for
conditions, an extra cold starting aid may be specific starting instructions.
required. Normally, the engine will be equipped with
the correct type of starting aid for the region of
operation.
These engines are equipped with a glow plug starting
aid in each cylinder which heats the intake air to
improve starting. Some Perkins engines may have a
cold starting system that is controlled by the ECM
which 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.
SEBU8603-04 19
Safety Section
Electrical System
Grounding Practices
Typical example
Illustration 15 g02383098 (5) Ground to the battery
Typical example (6) Ground to the cylinder block
(1) Ground to the battery
(2) Primary position for grounding Correct grounding for the engine electrical system is
(3) Ground to the starting motor necessary for optimum engine performance and
(4) Ground to the engine block reliability. Incorrect grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to the crankshaft bearing journal surfaces
and to aluminum components.
Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
discharge.
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.
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.
20 SEBU8603-04
Safety Section
Engine Electronics
The power supply connections and the ground • Engine Aftertreatment System
connections for the engine electronics should always
be from the isolator to the battery. The Engine Monitoring package can vary for different
engine models and different engine applications.
i03642610
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Engine Electronics 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
Tampering with the electronic system installation information on the Engine Monitoring System.
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.
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.
The following actions are available for engine
monitoring control:
• Warning
• Derate
• Shutdown
The following monitored engine operating conditions
have the ability to limit engine speed and/or the
engine power:
• Engine Coolant Temperature

• Engine Oil Pressure
• Engine Speed
• Intake Manifold Air Temperature

• Engine Intake Throttle Valve Fault
• Wastegate Regulator
• Supply Voltage to Sensors
• Fuel Pressure in Manifold (Rail)

• NOx Reduction System
SEBU8603-04 21
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
Typical example
(1) Secondary fuel filter (5) Fuel strainer (9) Primary fuel filter
(2) Crankcase breather (6) Oil filter (10) High-pressure fuel pump
(3) Electronic control module (ECM) (7) Fuel priming pump
(4) Oil sampling valve (8) Oil gauge (Dipstick)
22 SEBU8603-04
The location of the in-line strainer (5) and the priming

pump (7) will depend on the application.
Typical example
(11) Rear lifting eye (15) Back pressure valve (19) Flywheel housing
(12) NOx reduction system (NRS) (16) Engine oil pan (Sump) (20) Flywheel
(13) Front lifting eye (17) Starting motor (21) Exhaust outlet
(14) Turbocharger (18) Engine oil drain plug (22) Exhaust gas cooler
SEBU8603-04 23
Typical example
(23) Belt (26) Water temperature regulator housing (29) Inlet connection for the Coolant
(24) Connection for air inlet (Thermostat housing) (30) Vibration damper
(25) Outlet connection for the coolant (27) Water pump (31) Belt tensioner
(28) Oil filler (32) Alternator
24 SEBU8603-04
Typical example
(33) Coolant drain plug for cylinder block (34) Coolant drain plug for exhaust gas
cooler
SEBU8603-04 25
Engine Description
Engine Aftertreatment System
Typical example
(1) Clean emissions module (CEM) (3) Outlet connection (5) Flexible exhaust pipe from engine to
(2) Inlet connection (4) Mounting cradle CEM
i04340730
Engine Description
The Perkins 1206-E66 Industrial Engine has the

following characteristics.
• In-line Six cylinder
• Four stroke cycle
• Turbocharged charge cooled
Engine Specifications
Note: The front end of the engine is opposite the Cylinder and valve location
flywheel end of the engine. The left and the right (A) Exhaust valves
sides of the engine are determined from the flywheel (B) Inlet valves
end. The number 1 cylinder is the front cylinder.
26 SEBU8603-04
Engine Description
Table 1
Engine Specifications There are three types of diagnostic codes: active,
Operating Range (rpm) 900 to 2800(1)
logged and event.
Number of Cylinders 6 In-Line Most of the diagnostic codes are logged and stored in
the ECM. For additional information, refer to the
Bore 105 mm (4.13 inch) Operation and Maintenance Manual, “Engine
Diagnostics” topic (Operation Section).
Stroke 127 mm (5 inch)
The ECM provides an electronic governor that
Power 129.4 kW (173.52 hp)
controls the injector output in order to maintain the
Aspiration Turbocharged charge cooled desired engine rpm.
Compression Ratio 16.5:1

Engine Cooling and Lubrication
Displacement 6.6 L (402.7 cubic inch)
The cooling system and lubrication system consists
Firing Order 1-5-3-6-2-4 of the following components:
Rotation (flywheel end) Counterclockwise
• Gear-driven centrifugal water pump
(1) The operating rpm is dependent on the engine rating, the appli-
cation, and the configuration of the throttle. • Water temperature regulator which regulates the
engine coolant temperature
Electronic Engine Features • Gear-driven rotor type oil pump
The engine operating conditions are monitored. The • Oil cooler
Electronic Control Module (ECM) controls the
response of the engine to these conditions and to the The engine lubricating oil is supplied by a rotor type
demands of the operator. These conditions and oil pump. The engine lubricating oil is cooled and the
operator demands determine the precise control of engine lubricating oil is filtered. The bypass valve can
fuel injection by the ECM. The electronic engine provide unrestricted flow of lubrication oil to the
control system provides the following features: engine if the oil filter element should become
plugged.
• Engine monitoring
Engine efficiency, efficiency of emission controls, and
• Engine speed governing engine performance depend on adherence to proper
operation and maintenance recommendations.
• Control of the injection pressure Engine performance and efficiency also depend on
the use of recommended fuels, lubrication oils, and
• Cold start strategy coolants. Refer to this Operation and Maintenance
Manual, “Maintenance Interval Schedule” for more
• Automatic air/fuel ratio control information on maintenance items.
• Torque rise shaping Aftertreatment System

• Injection timing control
The aftertreatment system is approved for use by
• System diagnostics Perkins. In order to be emission-compliant only the
approved Perkins aftertreatment system must be
• Low temperature regeneration used on a Perkins engine.
For more information on electronic engine features, Clean Emission Module (CEM)
refer to the Operation and Maintenance Manual,
“Features and Controls” topic (Operation Section). The CEM comprises of two main components in a
single unit, the Diesel Oxidation Catalyst DOC and
Engine Diagnostics 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
The engine has built-in diagnostics in order to ensure operation.
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.
SEBU8603-04 27
Engine Description
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.
28 SEBU8603-04
Product Identification Information
Product Identification
Information
i03865704
Plate Locations and Film

Locations
(Engine Aftertreatment System)
Typical example
The module arrangement exhaust plate is installed Record the information that is on the plate. This
on the mounting plate (1). The location of the information identifies the engine aftertreatment
arrangement plate mounting plate can alter system. This information will be required by your
depending on the application. 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

Illustration 24 g02109493 Engine Model
Module Arrangement Exhaust Plate
Engine Serial number
Engine Low Idle rpm
SEBU8603-04 29
Emissions Certification Film
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
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.
Typical example
30 SEBU8603-04
Operation Section
Lifting and Storage
Operation Section NOTICE

Always inspect lifting eyebolts and all other lifting
equipment for damage before performing any lifting.
Lifting and Storage Never Bend the eyebolts and the brackets. Never
perform product lifting if the components are
damaged.
i07434782
Use a hoist to remove heavy components. Use an
adjustable lifting beam to lift the engine. All
Product Lifting supporting members (chains and cables) should be
(Engine) parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
Some removals require lifting the fixtures in order to
obtain correct balance and safety.
To remove the engine ONLY, use the lifting eyes that
are on the engine.
Lifting eyes are designed and installed for specific
engine arrangements. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure that
correct lifting devices are provided. Consult your
Perkins dealer or your Perkins distributor for
information regarding fixtures for correct engine
lifting.
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Re-
member that the capacity of an eyebolt is less as the
angle between the supporting members and the ob-
ject becomes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
SEBU8603-04 31
Operation Section
Product Lifting
i07442887 i04084189
Product Lifting Product Storage

(Clean Emission Module) (Engine and Aftertreatment)
Perkins are not responsible for damage which may

occur when an engine is in storage after a period in
service.
Your Perkins dealer or your Perkins distributor can
assist in preparing the engine for extended storage
periods.
Condition for Storage

The engine must be stored in a water proof building.
The building must be kept at a constant temperature.
Engines that are filled with Perkins ELC will have
coolant protection to an ambient temperature of
−36° C (−32.8° F). The engine must not be subjected
to extreme variations in temperature and humidity.
Storage Period
An engine can be stored for up to 6 months provided
all the recommendation are adhered to.
Illustration 27 g02385036 Storage Procedure

Keep a record of the procedure that has been
NOTICE completed on the engine.
Always inspect lifting eyebolts and all other lifting
equipment for damage before performing any lifting. Note: Do not store an engine that has biodiesel in the
Never bend the eyebolts and the brackets. Never fuel system.
perform product lifting if components are damaged.
Only load the eyebolts and the brackets under ten- 1. Ensure that the engine is clean and dry.
sion. Remember that the capacity of an eyebolt is
less as the angle between the supporting members a. If the engine has been operated using
and the object becomes less than 90 degrees. biodiesel, the system must be drained and new
filters installed. The fuel tank will require
Ensure that the correct clothing is worn, refer to this
Operation and Maintenance Manual, “General flushing.
Hazard Information”. b. Fill the fuel system with an ultra low sulfur fuel.
The weight of the clean emission module (CEM) For more information on acceptable fuels refer
when laden is approximately 50 kg (110 lb). Two to this Operation and Maintenance Manual,
suitable double looped slings are required to lift the “Fluid recommendations”. Operate the engine
CEM. Also a suitable hoist will be required to remove for 15 minutes in order to remove all biodiesel
and install the assembly. from the system.
The slings must be attached to the CEM in the 2. Drain any water from the primary filter water
positions as shown in illustration 27 . separator. Ensure that the fuel tank is full.
Ensure that the slings only contact the body of the 3. The engine oil will not need to be drained in order
CEM. A test lift may be required to achieve the to store the engine. Provided the correct
correct balance of the assembly.
specification of engine oil is used the engine can
Some applications may require a frame or jig to lift be stored for up to 6 months. For the correct
the CEM. A frame or jig must only be connected to specification of engine oil refer to this Operation
the cradle of the CEM. Refer to the OEM for more and Maintenance Manual, “Fluid
information.
recommendations”.
32 SEBU8603-04
Operation Section
Engine and Aftertreatment
4. Remove the drive belt from the engine.

Sealed Coolant System
Ensure that the cooling system is filled with Perkins

ELC, or an antifreeze that meets “ASTM D6210”
specification.
Open Cooling System
Ensure that all cooling drain plugs have been

opened. Allow the coolant to drain. Install the drain
plugs. Place a vapor phase inhibitor into the system.
The coolant system must be sealed once the vapor
phase inhibitor has been introduced. The effect of the
vapor phase inhibitor will be lost if the cooling system
is open to the atmosphere.
For maintenance procedures ref to this Operation
and Maintenance Manual.
Aftertreatment
No special procedures are required. The exhaust
outlet of the aftertreatment should be capped. Before
storing, the engine and the aftertreatment must be
enclosed in a cover.
Monthly Checks
The crankshaft must be rotated in order to change
the spring loading on the valve train. Rotate the
crankshaft more than 180 degrees. Visibly check for
damage or corrosion to the engine and
aftertreatment.
Ensure that the engine and aftertreatment are
covered completely before storage. Log the
procedure in the record for the engine.
SEBU8603-04 33
Operation Section
Gauges and Indicators
Gauges and Indicators 3. Check and maintain the oil level.

Jacket Water Coolant Temperature –
i04220531 Typical temperature range is 82° to 94°C
(179.6° to 201.2°F). This temperature
Gauges and Indicators range will vary according to engine load and the
ambient temperature.
A 100 kPa (14.5 psi) radiator cap must be installed
Your engine may not have the same gauges or all of on the cooling system. The maximum temperature for
the gauges that are described. For more information the cooling system is 108° C (226.4° F). This
about the gauge package, see the OEM information. temperature is measured at the outlet for the water
temperature regulator. The engine coolant
Gauges provide indications of engine performance. temperature is regulated by the engine sensors and
Ensure that the gauges are in good working order. the engine ECM. This programming cannot be
Determine the normal operating range by observing altered. An engine derate can occur if the maximum
the gauges over a period of time. engine coolant temperature is exceeded.
Noticeable changes in gauge readings indicate If the engine is operating above the normal range,
potential gauge or engine problems. Problems may
reduce the engine load. If high coolant temperatures
also be indicated by gauge readings that change
are a frequent event, perform the following
even if the readings are within specifications. procedures:
Determine and correct the cause of any significant
change in the readings. Consult your Perkins 1. Reduce the load and the engine rpm.
distributor for assistance.
2. Determine if the engine must be shut down
Some engine applications are equipped with immediately or if the engine can be cooled by
Indicator Lamps. Indicator lamps can be used as a
diagnostic aid. There are two lamps. One lamp has reducing the load.
an orange lens and the other lamp has a red lens. 3. Inspect the cooling system for leaks. If necessary,
These indicator lamps can be used in two ways: consult your Perkins distributor for assistance.
• The indicator lamps can be used to identify the Tachometer – This gauge indicates
current operational status of the engine. The engine speed (rpm). When the throttle
indicator lamps can also indicate that the engine control lever is moved to the full throttle
has a fault. This system is automatically operated position without load, the engine is running at
via the ignition switch. high idle. The engine is running at the full load
rpm when the throttle control lever is at the full
• The indicator lamps can be used to identify active throttle position with maximum rated load.
diagnostic codes. This system is activated by
pressing the Flash Code button. NOTICE
Operation at speeds exceeding high idle rpm should
Refer to the Troubleshooting Guide, “Indicator be kept to a minimum. Overspeeding can result in
Lamps” for further information. serious damage to the engine.
NOTICE
If no oil pressure is indicated, STOP the engine. If Ammeter – This gauge indicates the
maximum coolant temperature is exceeded, STOP amount of charge or discharge in the
the engine. Engine damage can result. battery charging circuit. Operation of
the indicator should be to the “ +”” side of “ 0””
(zero).
Engine Oil Pressure – The oil pressure
should be greatest after a cold engine is Fuel Level – This gauge indicates the
started. The typical engine oil pressure fuel level in the fuel tank. The fuel level
with SAE10W40 is 350 to 450 kPa ( 50 to 65 psi) gauge operates when the “ START/STOP””
at rated rpm. switch is in the “ on”” position.
A lower oil pressure is normal at low idle. If the load is Service Hour Meter – The gauge
stable and the gauge reading changes, perform the indicates total operating hours of the
following procedure: engine.
1. Remove the load.
2. Stop the engine.
34 SEBU8603-04
Operation Section
Gauges and Indicators
Indicator Lamps
There is four indicator lamps that are available.
• Shutdown Lamp
• Warning Lamp
• Wait to Start Lamp

• Low Oil Pressure Lamp
For information, refer to this manual, “Monitoring
System (Table for the Indicator Lamps)” for the
sequence of operation of the shutdown lamp and the
warning lamp.
The function of the wait to start lamp is automatically
controlled at engine start-up.
The function of the low oil pressure lamp is controlled
by the engine ECM. If low oil pressure is detected,
the lamp will be illuminated. The reason for the
illumination of the low-pressure lamp should be
investigated immediately.
All lamps will illuminate for 2 seconds in order to
check that the lamps are functioning when the
keyswitch is turned to the ON position. If any of the
lamps stay illuminated, the reason for illumination
should be investigated immediately.
Instrument panels and Displays

In order to monitor the engine a wide verity of
instrument panels are available. These instrument
panels can contain the indicator lamps and the
gauges for the application.
Also available are mini power displays and
performance monitors. These displays and monitors
can show the operator the following engine
information.
• The system configuration parameters
• The customer specified parameters

• Diagnostic codes
• Event codes
• Coolant temperature
• Oil temperature
• Oil pressure
• Intake temperature
• Intake pressure
• Atmospheric pressure
• Fuel temperature
SEBU8603-04 35
Operation Section
Features and Controls
Features and Controls

i04201172
Monitoring System
(Table for the Indicator lamps)
Note: When in operation the amber warning lamp

has three states, solid, flashing, and fast flashing.
The sequence is to give a visual indication of the
importance of the warning. Some application can
have an audible warning installed.
Ensure that the engine maintenance is carried out at
the correct intervals. A lack of maintenance can
result in illumination of the warning lamp. For the
correct intervals of maintenance, refer to the
Operation and Maintenance Manual, “Maintenance
Interval Schedule”.
Table 2
Warning Shutdown
Lamp Lamp Lamp State Description of the Indication Engine Status
On On Lamp Check When the keyswitch is moved to the ON po- The keyswitch is in the ON position but the en-
sition, the lamps come on for 2 seconds and gine has not yet been cranked.
the lamps will then go off.
Off Off No Faults With the engine in operation, there are no The engine is operating with no detected
active warnings, diagnostic codes, or event faults.
codes.
On Solid Off Warning Level 1 warning The engine is operating normally but there is
one or more faults with the electronic manage-
ment system for the engine.
Flashing Off Warning Level 2 warning The engine continues to be operated, but the
level of importance of the warning has
increased.
Depending on the particular fault and the se-
verity the engine may be de-rated.
The engine could be damaged if continued to
be operated.
Flashing On Engine Shutdown Level 3 warning The engine is either shutdown or an engine
If both the warning lamp and the shutdown shutdown is imminent. One or more monitored
lamp are in operation, this issue indicates engine parameters have exceeded the limit for
one of the following conditions. an engine shutdown. This pattern of lamps can
be caused by the detection of a serious active
1. One or more of the shutdown values for diagnostic code.
the engine protection strategy has been
exceeded.
2. A serious active diagnostic code has

been detected.
After a short time period, the engine may

shut down.
36 SEBU8603-04
Operation Section
Monitoring System
i04340829 The engine can be programmed to the following

modes:
Monitoring System
“ Warning””
The orange “Warning” lamp will turn “ON” and the
warning signal is activated continuously in order to
alert the operator that one or more of the engine
If the Shutdown mode has been selected and the parameters is not within normal operating range.
warning indicator activates, engine shutdown
may take as little as 20 seconds from the time the “ Derate””
warning indicator is activated. Depending on the
application, special precautions should be taken The orange warning lamp will be flashing. After the
to avoid personal injury. The engine can be re- warning, the engine power will be derated.
started following shutdown for emergency ma-
neuvers, if necessary. The engine will be derated if the engine exceeds
preset operational limits. The engine derate is
achieved by restricting the amount of fuel that is
NOTICE available for each injection. The amount of this
The Engine Monitoring System is not a guarantee reduction of fuel is dependent on the severity of the
against catastrophic failures. Programmed delays fault that has caused the engine derate, typically up
and derate schedules are designed to minimize false to a limit of 50%. This reduction in fuel results in a
alarms and provide time for the operator to stop the predetermined reduction in engine power.
engine.
“ Shutdown””
The following parameters are monitored:
The orange warning lamp will be flashing and the red
• Coolant temperature shutdown lamp will be on solid. After the warning, the
engine power will be derated. The engine will
• Intake manifold air temperature continue at the rpm of the set derate until a shutdown
of the engine occurs. The engine can be restarted
• Intake manifold air pressure after a shutdown for use in an emergency.
• Oil pressure A shutdown of the engine may occur in as little as 20
seconds. The engine can be restarted after a
• Pressure in the fuel rail shutdown for use in an emergency. However, the
cause of the initial shutdown may still exist. The
• Engine speed/timing engine may shut down again in as little as 20
seconds.
• Fuel temperature
If there is a signal for high coolant temperature, there
• Atmospheric pressure (Barometric pressure) will be a 2 second delay in order to verify the
condition.
• The Inlet pressure and outlet pressure of the NOx
reduction system If there is a signal for low oil pressure, there will be a
2 second delay in order to verify the condition.
• Temperature of the NOx reduction system
For information on the operation of the warning
• Water in fuel switch lamps and the shutdown lamp, refer to this Operation
and Maintenance Manual, “ Monitoring System
• The amount of soot in the Diesel particulate filter (Table for Indicator Lamps)”. For each of the
programmed modes, refer to Troubleshooting Guide,
“Indicator Lamps” for more information on Indicator
Programmable Options and Lamps.
Systems Operation
If the Warning/Derate/Shutdown mode has been

selected and the warning indicator activates,
bring the engine to a stop whenever possible. De-
pending on the application, special precautions
should be taken to avoid personal injury.
SEBU8603-04 37
Operation Section
Sensors and Electrical Components
For more information or assistance for repairs,

consult your Perkins distributor or your Perkins
dealer.
i04215952
Sensors and Electrical

Components
(Aftertreatment)
The illustration within the section shows the typical

locations of the sensors and other electrical
components on the industrial engine. Specific engine
aftertreatment systems may appear different due to
the application.
(1) Temperature Sensor (3) Soot Sensor Connection (5) Soot Sensor Connection
(2) Connector for Temperature Sensor (4) Aftertreatment Identification Module (6) Soot Sensor
Note: The location of the soot sensor will depend on i04220589

the application.
Sensors and Electrical
Components
The Illustration within the section shows the typical

locations of the sensors for a 1206E-66 Industrial
Engine. Specific engines may appear different from
the illustration due to differences in applications.
38 SEBU8603-04
Operation Section
Typical example
(1) Coolant Temperature Sensor (6) Intake Manifold Pressure Sensor (11) Oil Pressure Sensor
(2) Wastegate Regulator (7) Diagnostic Connector (12) Fuel Priming Pump
(3) Throttle valve (8) Electronic Control Module (ECM) (13) Water in Fuel Switch
(4) Fuel Pressure Sensor (Fuel Rail (9) Atmospheric Pressure Sensor (14) Fuel Temperature Sensor
Pressure Sensor) (Barometric Pressure Sensor) (15) Solenoid for the High Pressure Fuel
(5) Intake Manifold Air Temperature Sensor (10) Primary Speed/Timing Sensor Pump
Note: The location of the secondary fuel filter, the

primary fuel filter, and the fuel priming pump will
depend on the application. These locations will affect
items (12, and 13).
SEBU8603-04 39
Operation Section
Typical example
(16) Inlet Pressure Sensor for the NOx (18) Control Valve for the NRS (21) Back Pressure Valve
Reduction System (NRS) (19) Temperature Sensor for the NRS (22) Secondary Speed/Timing Sensor
(17) Outlet Pressure sensor for the NRS (20) Alternator (23) Starter Motor
40 SEBU8603-04
Operation Section
Typical example
(1) Coolant Temperature Sensor (2) Wastegate Regulator (3) Throttle valve
Typical example
(4) Fuel Pressure Sensor (Fuel Rail (7) Diagnostic Connector (10) Primary Speed/Timing Sensor
Pressure Sensor) (8) Electronic Control Module (ECM) (11) Oil Pressure Sensor
(5) Intake Manifold Air Temperature Sensor (9) Atmospheric Pressure Sensor (12) Fuel Priming Pump
(6) Intake Manifold Pressure Sensor (Barometric Pressure Sensor)
SEBU8603-04 41
Operation Section
Typical example
(13) Water in Fuel Switch
(14) Fuel Temperature Sensor
(15) Solenoid for the High Pressure Fuel Pump
42 SEBU8603-04
Operation Section
Typical example
(16) Inlet Pressure Sensor for the NOx (17) Outlet Pressure sensor for the NRS (19) Temperature Sensor for the NRS
Reduction System (NRS) (18) Control Valve for the NRS
SEBU8603-04 43
Operation Section
Engine Shutoffs and Engine Alarms
Typical example
(20) Alternator (22) Secondary Speed/Timing Sensor
(21) Back Pressure Valve (23) Starter Motor
i04372685
NOTICE
Always determine the cause of the engine shutdown.
Engine Shutoffs and Engine Make necessary repairs before attempting to restart
Alarms the engine.
Be familiar with the following items:

Shutoffs • Types and locations of the shutoff
The shutoffs are electrically operated or mechanically • Conditions which cause each shutoff to function
operated. The electrically operated shutoffs are
controlled by the ECM. • The resetting procedure that is required to restart
the engine
Shutoffs are set at critical levels for the following
items:
Alarms
• Operating temperature
The alarms are electrically operated. The operation
• Operating pressure of the alarms is controlled by the ECM.
• Operating level The alarm is operated by a sensor or by a switch.

When the sensor or the switch is activated, a signal is
• Operating rpm sent to the ECM. An event code is created by the
ECM. The ECM will send a signal in order to
The particular shutoff may need to be reset before illuminate the lamp.
the engine will start.
Your engine may be equipped with the following
sensors or switches:
44 SEBU8603-04
Operation Section
Overspeed
Coolant level – The low coolant level switch Refer to Troubleshooting, KENR9116 for more
indicates when the coolant level is low. information.
Coolant temperature – The coolant temperature
i03554501
sensor indicates high jacket water coolant
temperature.
Overspeed
Intake manifold air temperature – The intake
manifold air temperature sensor indicates high intake
air temperature.
• ECM Electronic Control Module
Intake manifold pressure – The intake manifold
pressure sensor checks the rated pressure in the • RPM Revolutions Per Minute
engine manifold.
An overspeed is detected by the speed/timing
Fuel rail pressure – The fuel rail pressure sensor sensors.
checks for high pressure or low pressure in the fuel
rail. The default setting for an overspeed is 3000 rpm.
The ECM will cut the power to the electronic unit
Engine oil pressure – The engine oil pressure injectors, until the rpm drops below 200 rpm of the
sensor indicates when oil pressure drops below rated overspeed setting. A diagnostic fault code will be
system pressure, at a set engine speed. logged into the ECM memory and a warning lamp will
indicate a diagnostic fault code.
Engine overspeed – If the engine rpm exceeds the
overspeed setting, the alarm will be activated. An overspeed can be set from 2600 rpm to 3000 rpm.
This setting depends on the application.
Air filter restriction – The switch checks the air filter
when the engine is operating.
User-Defined switch – This switch can shut down
the engine remotely.
Water in fuel switch – This switch checks for water
in the primary fuel filter when the engine is operating.
Fuel temperature – The fuel temperature sensor
monitors the pressurized fuel in the high-pressure
fuel pump.
Note: The sensing element of the coolant

temperature switch must be submerged in coolant in
order to operate.
Engines may be equipped with alarms in order to
alert the operator when undesirable operating
conditions occur.
NOTICE
When an alarm is activated, corrective measures
must be taken before the situation becomes an emer-
gency in order to avoid possible engine damage.
If corrective measures are not taken within a

reasonable time, engine damage could result. The
alarm will continue until the condition is corrected.
The alarm may need to be reset.
Testing
Turning the keyswitch to the ON position will check
the indicator lights on the control panel. All the
indicator lights will be illuminated for 2 seconds after
the keyswitch is operated. Replace suspect bulbs
immediately.
SEBU8603-04 45
Operation Section
Engine Diagnostics
Engine Diagnostics i04215570
i02651093
Diagnostic Flash Code
Retrieval
Self-Diagnostics
Use the “DIAGNOSTIC” lamp or an electronic service
tool to determine the diagnostic flash code.
Perkins electronic engines have the capability to
perform a self-diagnostics test. When the system Use the following procedure to retrieve the flash
detects an active problem, a diagnostic lamp is codes if the engine is equipped with a
activated. Diagnostic codes will be stored in
permanent memory in the Electronic Control Module “DIAGNOSTIC” lamp:
(ECM). The diagnostic codes can be retrieved by 1. Move the keyswitch from the on/off two times
using the electronic service tool. Refer to within 3 seconds.
Troubleshooting , “Electronic Service Tools” for
further information. A flashing YELLOW lamp indicates a 3-digit code for
the engine. The sequence of flashes represents the
Some installations have electronic displays that system diagnostic message. Count the first
provide direct readouts of the engine diagnostic sequence of flashes in order to determine the first
codes. Refer to the manual that is provided by the digit of the flash code. After a two second pause, the
OEM for more information on retrieving engine second sequence of flashes will identify the second
diagnostic codes. Alternatively refer to digit of the flash code. After the second pause, the
Troubleshooting , “Indicator Lamps” for further third sequence of flashes will identify the flash code.
information.
Table 3
Active codes represent problems that currently exist. Flash Code Table
These problems should be investigated first.
Description Flash Code
Logged codes represent the following items:
Injector fault 111
• Intermittent problems
Injector number 2 current out of range 112
• Recorded events Injector number 3 current out of range 113
• Performance history Injector number 4 current out of range 114
The problems may have been repaired since the Injector number 5 current out of range (6 115
logging of the code. These codes do not indicate that cylinder only)
a repair is needed. The codes are guides or signals
Injector number 6 current out of range (6 116
when a situation exists. Codes may be helpful to
cylinder only)
troubleshoot problems.
Intake manifold air temperature sensor out 133
When the problems have been corrected, the of range
corresponding logged fault codes should be cleared.
Engine speed sensor out of range 141
i02651107
Engine timing offset fault 143
Diagnostic Lamp Engine operation mode selector switch er- 144

ratic, intermittent, or incorrect
High air filter restriction - Warning 151

A diagnostic lamp is used to indicate the existence of
an active fault. Refer to Troubleshooting , “Indicator Atmospheric pressure sensor out of range 152
Lamps” for more information. A fault diagnostic code Throttle position sensor out of range 154
will remain active until the problem is repaired. The
diagnostic code may be retrieved by using the Secondary throttle position sensor out of 155
electronic service tool. Refer to Troubleshooting , range
“Electronic Service Tools” for more information.
Oil pressure sensor out of range 157
Fuel rail pressure sensor out of range 159
(continued)
46 SEBU8603-04
Operation Section
Fault Logging
(Table 3, contd)
Fuel temperature sensor out of range 165 (Table 3, contd)
Engine coolant temperature sensor out of 168 Programmed parameter fault erratic, inter- 527
range mittent, or incorrect
Low Engine Coolant Level - Shutdown 169 5 Volt Sensor DC Power Supply #2 out of 528
range
Turbo wastegate drive out of range 177
No diagnostic code detected 551
Intake manifold pressure sensor out of 197
range
Refer to Troubleshooting, “Diagnostic Flash Code
Glow plug start aid relay current above 199 Cross Reference” for more information.
normal
Diesel Particulate Filter DPF Intake temper- 224 i01902949
ature sensor out of range
DPF Soot sensors out of range 226

Fault Logging
Exhaust gas recirculation temperature/pres- 227
sure out of range The system provides the capability of Fault Logging.
When the Electronic Control Module (ECM)
Exhaust gas recirculation valve control cur- 228
generates an active diagnostic code, the code will be
rent out of range
logged in the memory of the ECM. The codes that
Exhaust gas recirculation valve control volt- 229 have been logged by the ECM can be identified by
age out of range the electronic service tool. The active codes that
have been logged will be cleared when the fault has
Exhaust gas recirculation pressure sensor 231 been rectified or the fault is no longer active. The
out of range following logged faults can not be cleared from the
memory of the ECM without using a factory
Air inlet temperature sensor voltage out of 232 password: Overspeed, low engine oil pressure and
range high engine coolant temperature.
Ether injection control solenoid out of range 233
i03554534
Idle validation switch #1 erratic, intermittent, 245
or incorrect
Engine Operation with Active
Idle validation switch #2 erratic, intermittent, 246
or incorrect Diagnostic Codes
Exhaust Gas Recirculation Outlet Pressure 247
Sensor out of range
If a diagnostic lamp illuminates during normal engine
Exhaust back pressure regulator position 249 operation, the system has identified a situation that is
voltage out of range not within the specification. Use electronic service
tools to check the active diagnostic codes.
Engine Fuel Supply Lift Pump Relay out of 253
range Note: If the customer has selected “DERATE” and if
there is a low oil pressure condition, the Electronic
Personality module erratic, intermittent, or 415
incorrect
Control Module (ECM) will limit the engine power
until the problem is corrected. If the oil pressure is
Machine security system module abnormal 426 within the normal range, the engine may be operated
update rate at the rated speed and load. However, maintenance
Ignition key switch loss of signal 429 should be performed as soon as possible.
Electrical System Voltage fault 511 The active diagnostic code should be investigated.
The cause of the problem should be corrected as
SAE J1939 Data Link abnormal update rate 514 soon as possible. If the cause of the active diagnostic
code is repaired and there is only one active
5 Volt sensor DC power supply voltage out 516
diagnostic code, the diagnostic lamp will turn off.
of range
8 V DC Supply voltage out of range 517
(continued)
SEBU8603-04 47
Operation Section
Engine Operation with Intermittent Diagnostic Codes
Operation of the engine and performance of the System Configuration Parameters

engine can be limited as a result of the active
diagnostic code that is generated. Acceleration rates System configuration parameters affect the
may be significantly slower. Refer to the emissions of the engine or the power of the engine.
Troubleshooting Guide for more information on the System configuration parameters are programmed at
relationship between these active diagnostic codes the factory. Normally, system configuration
and engine performance. parameters would never require changing through
the life of the engine. System configuration
i01902995 parameters must be reprogrammed if an ECM is
replaced. System configuration parameters do not
Engine Operation with require reprogrammed if the ECM software is
changed. Factory passwords are required to change
Intermittent Diagnostic Codes these parameters.
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.
i04217251
Configuration Parameters
The engine electronic control module (ECM) has two

types of configuration parameters. The system
configuration parameters and the customer specified
parameters.
The electronic service tool is required in order to alter
the configuration parameters.
Table 4
System Configuration Parameters
Configuration Parameters Record
Full Load Setting
(continued)
48 SEBU8603-04
Operation Section
(Table 4, contd)
Full Torque Setting
Rating
Engine Serial Number
Factory Installed Aftertreatment Identification Number
DPF Soot Loading Sensing System Configuration Code
Limp Home Engine Speed Ramp Rate
ECM Software Release Date
Customer Specified Parameters

Customer specified parameters allow the engine to
be configured to the exact needs of the application.
The electronic service tool is required in order to alter
the customer configuration parameters.
Customer parameters may be changed repeatedly as
operational requirements change.
Table 5
Customer Specified Parameters
Specified Parameters Record
Low Idle Parameters

ECM Identification Parameter
Ether Solenoid Configuration
PTO and Throttle Lock Parameters

Throttle Lock Feature Installation Status
PTO Mode
Throttle Lock Engine Set Speed 1
Throttle Lock Engine Set Speed 2
Throttle Lock Increment Speed Ramp Rate
Throttle Lock Decrement Speed Ramp Rate
Throttle Lock Engine Set Speed Increment
Throttle Lock Engine Set Speed Decrement
Monitoring Mode Shutdowns
Monitoring Mode Derates
Limp Home Desired Engine Speed
Engine Acceleration Rate
Engine Speed Decelerating Ramp Rate
Coolant Level Switch

Air Filter Restriction Switch Installation Status
Air Filter Restriction Switch Configuration
(continued)
SEBU8603-04 49
Operation Section
(Table 5, contd)
System Operating Voltage Configuration
Minimum Ambient Air Temperature
Maximum Ambient Air Temperature
Shutdown Enable Status

Shutdown Delay Time
Ambient Temperature Override Enable Status
Air Shutoff
Intermediate Engine Speed
Engine Fan Control
Engine Fan Type Configuration
Pulley Ratio
Temperature Error Increasing Hysteresis
Temperature Error Decreasing Hysteresis
Current Ramp Rate
Fan Speed
Top Fan Speed
Minimum Desired Fan Speed
Solenoid Minimum Current

Solenoid Maximum Current
Solenoid Dither Frequency
Solenoid Dither Amplitude
Charge Air Cooler Outlet Temperature Input Enable
Maximum Air Flow Charge Air Cooler Outlet Temperature
Minimum Air Flow Charge Air Cooler Outlet Temperature
Coolant Temperature Input Enable Status
Maximum Air Flow Coolant Temperature
Minimum Air Flow Coolant Temperature
Transmission Oil Temperature Input Enable Status
Maximum Air Flow Transmission Oil Temperature
Minimum Air Flow Transmission Oil Temperature
Hydraulic Oil Temperature Input Enable Status
Maximum Air Flow Hydraulic Oil Temperature
Minimum Air Flow Hydraulic Oil Temperature
Auxiliary #1 Temperature Input Enable Status
Maximum Air Flow Auxiliary #1 Temperature
Minimum Air Flow Auxiliary #1 Temperature
(continued)
50 SEBU8603-04
Operation Section
(Table 5, contd)
Auxiliary #2 Temperature Input Enable Status
Maximum Air Flow Auxiliary #2 Temperature
Minimum Air Flow Auxiliary #2 Temperature
Reversing Feature
Reverse Operation Early Termination Enable Status
Manual Purge
Suspend Purge
Purge Cycle Interval
Purge Cycle Duration
Coolant Level Switch

Air Filter Restriction Switch Installation Status
Air Filter Restriction Switch Configuration
Water in Fuel Switch Installation Status

User Defined Switch Installation Status
Auxiliary Temperature Sensor Installation Status
Auxiliary Pressure Sensor Installation Status
Diesel Particulate Filter Regeneration Force/Inhibit Switch Installation
Remote Torque Speed Control Enable Status
System Operating Voltage Configuration
Customer Password 1
Customer Password 2
CAN Communication Protocol Write Security
CAN Communication Protocol Read Security

SEBU8603-04 51
Operation Section
Engine Starting
Engine Starting i08165241
i03648917
Starting the Engine
Before Starting Engine Note: Do not adjust the engine speed control during
start-up. The electronic control module (ECM) will
control the engine speed during start-up.
Perform the required daily maintenance and other
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can Starting the Engine
help prevent major repairs at a later date. Refer to
the Operation and Maintenance Manual, 1. Disengage any equipment that is driven by the
“Maintenance Interval Schedule” for more engine.
information.
2. Turn the keyswitch to the RUN position. Leave the
• Ensure that the engine has an adequate fuel keyswitch in the RUN position until the warning
supply. light for the glow plugs is extinguished.
• Open the fuel supply valve (if equipped). Note: If the keyswitch has been left in the RUN
position for a long period of time without engaging the
NOTICE electric starting motor, turn the keyswitch from the
All valves in the fuel return line must be open and fuel RUN position to the OFF position and then back to
supply lines must be open. Damage to the fuel sys- the RUN position to reactivate the glow plug preheat
tem can occure if fuel lines are closed with the engine stage.
in operation.
Note: During the key on, the indicator lamps will be
illuminated for 2 seconds to check lamp operation. If
If the engine has not been started for several weeks,
fuel may have drained from the fuel system. Air may any of the lamps do not illuminate, check the bulb. If
have entered the filter housing. Also, when fuel filters any indicator lamps stay illuminated or flash, refer to
have been changed, some air pockets will be trapped Troubleshooting, “Indicator Lamp Circuit - Test”.
in the engine. In these instances, prime the fuel
system. Refer to the Operation and Maintenance 3. When the warning light for the glow plugs is
Manual, “Fuel System - Prime” for more information extinguished, turn the keyswitch to the START
on priming the fuel system. Also, check that the fuel position to engage the electric starting motor and
specification is correct and that the fuel condition is crank the engine.
correct. Refer to the Operation and Maintenance
Manual, “Fuel Recommendations”. Note: The operating period of the warning light for
the glow plugs will change due to the temperature of
the engine.
Engine exhaust contains products of combustion NOTICE

which may be harmful to your health. Always Do not engage the starting motor when flywheel is
start and operate the engine in a well ventilated turning. Do not start the engine under load.
area and, if in an enclosed area, vent the exhaust
to the outside. If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
• Do not start the engine or move any of the controls start the engine again.
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
to the controls. 4. Allow the keyswitch to return to the RUN position
after the engine starts.
• Reset all of the shutoffs or alarm components.
5. Repeat step 2 through step 4 if the engine fails to
• Ensure that any driven equipment has been start.
disengaged. Minimize electrical loads or remove
any electrical loads.
52 SEBU8603-04
Operation Section
Cold Weather Starting
6. After starting, the engine may be held at low speed

NOTICE
for a duration between 1 and 60 seconds to allow Do not engage the starting motor when flywheel is
engine systems to stabilize. The duration will turning. Do not start the engine under load.
depend on ambient temperature, time since last
run and other factors. The glow plug warning light If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
will flash to indicate that the engine is being held at allow the starting motor to cool before attempting to
low speed in some applications. start the engine again.
i07677844
4. Allow the keyswitch to return to the RUN position
Cold Weather Starting after the engine starts.
5. Repeat step 2 through step 4 if the engine fails to
start.
Note: After starting, the engine may be held at low
speed for a duration of between 1 and 25 seconds to
Do not use aerosol types of starting aids such as allow engine systems to stabilize. The duration will
ether. Such use could result in an explosion and depend on ambient temperature, time since last run
personal injury. and other factors. The glow plug warning lamp will
The ability to start the engine will be improved at flash to indicate that the engine is being held at low
temperatures below −18 °C (0 °F) by the use of a speed.
jacket water heater or a battery with extra capacity.
6. The engine should not be raced to speed up the
The following items provide a means of minimizing engine warming up process. Allow the engine to
starting problems and fuel problems in cold weather: idle for 3 to 5 minutes, or allow the engine to idle
Engine oil pan heaters, jacket water heaters, fuel until the water temperature indicator begins to rise.
heaters, and fuel line insulation. When idling after the engine has started in cold
Use the procedure that follows for cold weather weather, increase the engine rpm from 1000 to
starting. 1200 rpm. This operation will warm up the engine
more quickly.
Note: Do not adjust the engine speed control during
start-up. The electronic control module (ECM) will 7. Operate the engine at low load until all systems
control the engine speed during start-up. reach operating temperature. Check the gauges
during the engine warming up period.
1. Disengage any driven equipment.
Following a cold start white smoke can be seen from
Note: During key-ON, the indicator lamps will be the tailpipe. This smoke is normal and caused by
illuminated for 2 seconds to check the lamp condensation leaving the exhaust system after
operation. If any of the indicator lamps do not warming up. The white smoke should clear following
illuminate check the bulb. If any indicator lamps stay working of the engine.
illuminated or flash, refer to Troubleshooting,
“Indicator Lamp Circuit - Test”.
2. Turn the keyswitch to the RUN position. Leave the

keyswitch in the RUN position until the warning
light for the glow plugs is extinguished.
3. When the warning light for the glow plugs is
extinguished cycle the keyswitch. Turn the
keyswitch to the OFF position and then to the
START position to engage the electric starting
motor and crank the engine.
Note: The operating period of the warning light for

the glow plugs will vary according to the ambient air
temperature.
SEBU8603-04 53
Operation Section
Starting with Jump Start Cables
i08134367
NOTICE
Using a battery source with the same voltage as the
Starting with Jump Start electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
Cables the electrical system.
(Do Not Use This Procedure in Do not reverse the battery cables. The alternator can
Hazardous Locations that have be damaged. Attach ground cable last and remove
first.
Explosive Atmospheres)
Turn all electrical accessories OFF before attaching
the jump start cables.
Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en-
The connection of battery cables to a battery and gine being started.
the disconnection of battery cables from a battery
may cause an explosion which may result in in- 1. Turn the start switch on the stalled engine to the
jury or death. The connection and the disconnec-
OFF position. Turn off all the engines accessories.
tion of other electrical equipment may also cause
an explosion which may result in injury or death. 2. Connect one positive end of the jump-start cable to
The procedures for the connection and the dis- the positive cable terminal of the discharged
connection of battery cables and other electrical
equipment should only be performed in a nonex- battery. Connect the other positive end of the
plosive atmosphere. jump-start cable to the positive cable terminal of
the electrical source.
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
Improper jump start cable connections can cause
an explosion resulting in personal injury. jump-start cable to the engine block or to the
chassis ground. This procedure helps to prevent
Prevent sparks near the batteries. Sparks could potential sparks from igniting the combustible
cause vapors to explode. Do not allow jump start gases that are produced by some batteries.
cable ends to contact each other or the engine.
Note: The engine ECM must be powered before the
starting motor is operated or damage can occur.
Note: If possible, first diagnose the reason for the
starting failure. Refer to Troubleshooting, “Engine 4. Start the engine in the normal operating
Will Not Crank and Engine Cranks But Will Not Start” procedure. Refer to this Operation and
for further information. Make any necessary repairs. Maintenance Manual, “Starting the Engine”.
If the engine will not start only due to the condition of
the battery, either charge the battery, or start the 5. Immediately after the engine is started, disconnect
engine by using another battery with jump-start the jump-start cables in reverse order.
cables. The condition of the battery can be
rechecked after the engine has been switched OFF. 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
NOTICE proper voltage with a battery charger after the engine
Never attempt to start an engine from an external
power source such as electric welding equipment, is stopped. Many batteries which are considered
which has a voltage that is unsuitable for engine unusable are still rechargeable. Refer to Operation
starting and will damage the electrical system. and Maintenance Manual, “Battery - Replace” and
Testing and Adjusting Manual, “Battery - Test”.
For 904D-E28T industrial engines, use a 12 VDC bat-
tery source to start the engine.
For 904D-E36TA industrial engines, ensure that a 12
VDC or 24 VDC battery source is used to start the
engine.
54 SEBU8603-04
Operation Section
After Starting Engine
i02330138 Do not check the high-pressure fuel lines with the

engine or the starting motor in operation. If you
After Starting Engine inspect the engine in operation, always use the
correct inspection procedure to avoid a fluid
penetration hazard. Refer to Operation and
Note: In ambient temperatures from 0 to 60°C
(32 to 140°F), the warm-up time is approximately • Check for any fluid or for any air leaks at idle rpm
three minutes. In temperatures below 0°C (32°F), and at one-half full rpm (no load on the engine)
additional warm-up time may be required. before operating the engine under load. This
check may not be possible in some applications.
When the engine idles during warm-up, observe the
following conditions: • Allow the engine to idle for 3 to 5 minutes, or allow
the engine to idle until the water temperature
Do not check the high pressure fuel lines with the indicator begins to rise. Check all gauges during
engine or the starting motor in operation. If you the warm-up period.
inspect the engine in operation, always use the
proper inspection procedure in order to avoid a fluid Constant speed engines should be allowed to
penetration hazard. Refer to Operation and operate at low idle for 3 minutes before used at
Maintenance Manual, “General hazard Information”. operational speed. If the low idle option is not
available, then operate the engine at operational
• Check for any fluid or for any air leaks at idle rpm speed with no load for 2 minutes.
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is not Note: Gauge readings should be observed and the
possible in some applications. data should be recorded frequently while the engine
is operating. Comparing the data over time will help
• Allow the engine to idle for three to five minutes, or to determine normal readings for each gauge.
allow the engine to idle until the water temperature Comparing data over time will also help detect
indicator begins to rise. Check all gauges during abnormal operating developments. Significant
the warm-up period. changes in the readings should be investigated.
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.
i07671688
After Starting Engine
After starting, the engine may be held at low speed

for a duration between 1 and 25 seconds to allow
engine systems to stabilize. Holding the engine
speed low is controlled by the Electronic Control
Module (ECM). The duration will depend on ambient
temperature, time since last run and other factors.
Note: In ambient temperatures from 0°C to 60°C
(32°F 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.
When the engine idles during warm-up, observe the
following conditions:
SEBU8603-04 55
Operation Section
Engine Operation
Engine Operation During normal engine operation, the operator of the

engine may notice the lack of black smoke from the
exhaust system. In some application the operator
i05643897 may notice an increase in engine idle speed during
the regeneration process.
Engine Operation
i07677865
Proper operation and maintenance are key factors in Fuel Conservation Practices
obtaining the maximum life and economy of the
engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be The efficiency of the engine can affect the fuel
minimized and engine service life can be maximized. economy. Perkins design and technology in
The time that is needed for the engine to reach manufacturing provides maximum fuel efficiency in
normal operating temperature can be less than the all applications. Follow the recommended procedures
time taken for a walk-around inspection. to attain optimum performance for the life of the
engine.
The engine can be operated at the rated rpm after
the engine is started and after the engine reaches • Avoid spilling fuel.
operating temperature. The engine will reach normal Fuel expands when it is warmed up. The fuel may
operating temperature sooner during a low engine
overflow from the fuel tank. Inspect fuel lines for
speed (rpm) and during a low-power demand. This leaks. Repair the fuel lines, as needed.
procedure is more effective than idling the engine at
no load. The engine should reach operating • Be aware of the properties of different fuels. Use
temperature in a few minutes. only the recommended fuels. Refer to the
Avoid excess idling. Excessive idling causes carbon Operations and Maintenance Manual, “Fuel
buildup, engine slobber and soot loading of the Recommendations” for further information.
Diesel Particulate Filter (DPF). These issues are
harmful to the engine. • Avoid unnecessary idling.
Gauge readings should be observed and the data Shut off the engine rather than allowing the engine to
should be recorded frequently while the engine is idle for long periods of time.
operating. Comparing the data over time will help to
determine normal readings for each gauge. • Observe the service indicator frequently. Keep the
Comparing data over time will also help detect air cleaner elements clean.
abnormal operating developments. Significant
changes in the readings should be investigated. • Ensure that the turbocharger is operating
correctly. For more information refer to this
Operation and Maintenance Manual,
Reduction of Particulate Emissions “Turbocharger - Inspect”
The Diesel Particulate Filter (DPF) will reduce • Maintain a good electrical system.
particulate emissions. The DPF collects the soot and
any ash that is produced by the combustion in the One faulty battery cell will overwork the alternator.
engine. During regeneration, the soot is converted This fault will consume excess power and excess
into a gas which is released into the atmosphere. The fuel.
Ash remains in the DPF.
• The belt should be in good condition. Refer to the
The temperature of the DPF must be above a
particular value in order for regeneration to occur. Systems Operation, Testing and Adjusting, “V-Belt
The exhaust gas provides heat for the regeneration Test” for further information.
process.
• Ensure that all the connections of the hoses are
tight. The connections should not leak.
Engine Operation and the DPF
• Ensure that the driven equipment is in good
Regeneration is the process that is used by the DPF working order.
in order to remove soot from the DPF.
The process of regeneration is fully automatic. The
engine electronic control module will decide when to
start and when to stop the process. The operation
requires no intervention from the operator.
56 SEBU8603-04
Operation Section
Fuel Conservation Practices
• Cold engines consume excess fuel. Utilize heat

from the jacket water system and the exhaust
system, when possible. Keep cooling system
components clean and keep cooling system
components in good repair. Never operate the
engine without water temperature regulators. All
these items will help maintain operating
temperatures.
SEBU8603-04 57
Operation Section
Engine Stopping
Engine Stopping i05784249
i06832774
After Stopping Engine
Stopping the Engine Note: Before you check the engine oil, do not
operate the engine for at least 10 minutes. This
period will allow the engine oil to return to the oil pan.
NOTICE
Stopping the engine immediately after it has been
working under load, can result in overheating and ac-
celerated wear of the engine components. Contact with high pressure fuel may cause fluid
Avoid accelerating the engine prior to shutting it spray may cause a fire hazard. Failure to follow
down. these inspection, maintenance and service in-
Avoiding hot engine shutdowns will maximize turbo- structions may cause personal injury or death.
charger shaft and bearing life.
• After the engine has stopped, you must wait for 10
Note: Individual applications will have different minutes in order to allow the fuel pressure to be
control systems. Ensure that the shutoff procedures purged from the high-pressure fuel lines before
are understood. Use the following general guidelines any service or repair is performed on the engine
to stop the engine. fuel lines. The 10 minute wait will also allow static
charge to dissipate from the low-pressure fuel
1. Remove the load from the engine. Reduce the system. If necessary, perform minor adjustments.
engine speed (rpm) to low idle. Allow the engine to Repair any leaks from the low-pressure fuel
idle for 5 minutes to cool the engine. system and from the cooling, lubrication, or air
systems. Replace any high-pressure fuel line that
2. Stop the engine after the cool down period has leaked. Refer to Disassembly and assembly
according to the shutoff system on the engine. Manual, “Fuel Injection Lines - Install”.
Turn the ignition key switch to the OFF position. If
necessary, refer to the instructions that are • Check the crankcase oil level. Maintain the oil
level between the “MIN” mark and the “MAX” mark
provided by the OEM.
on the engine oil level gauge.
NOTICE • If the engine is equipped with a service hour
Before any service or repairs are performed, ensure meter, note the reading. Perform the maintenance
that the power supply to the engine is disconnected. that is in the Operation and Maintenance Manual,
“Maintenance Interval Schedule”.
i07764840 • Fill the fuel tank, in order to help prevent
accumulation of moisture in the fuel. Do not overfill
Emergency Stopping the fuel tank.
NOTICE
Only use antifreeze/coolant mixtures recommended
NOTICE in this Operation and Maintenance Manual, “Refill
Emergency shutoff controls are for EMERGENCY Capacities and Recommendations” topic or in this
use ONLY. DO NOT use emergency shutoff devices Operation and Maintenance Manual, “Fluid Recom-
or controls for normal stopping procedure. mendations” topic. Failure to do so can cause engine
damage.
The Original Equipment Manufacturer (OEM) may
have equipped the application with an emergency
stop button. For more information about the
emergency stop button, refer to the OEM information.
Ensure that any components for the external system
that support the engine operation are secured after
the engine is stopped.
58 SEBU8603-04
Operation Section
After Stopping Engine
Pressurized System: Hot coolant can cause seri-

ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the
pressure.
• Allow the engine to cool. Check the coolant level.
• Check the coolant for correct antifreeze protection

and the correct corrosion protection. Add the
correct coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in
the instructions from the OEM.
SEBU8603-04 59
Operation Section
Cold Weather Operation
Cold Weather Operation • Achieving operating temperature will help prevent

the intake valves and exhaust valves from
sticking.
i07671718
• The cooling system and the lubrication system for
Cold Weather Operation the engine do not lose heat immediately upon
shutdown. This means that an engine can be shut
down for aperiodof timeand the retained heat
Perkins Diesel Engines can operate effectively in within the engine will allow the engine readily start.
cold weather. During cold weather, the starting and
the operation of the diesel engine depends on the • Install the correct specification of engine lubricant
following items: before the beginning of cold weather. Refer to this
Operation and Maintenance Manual, “Fluid
• The type of fuel that is used Recommendations” for the recommended
viscosity of oil.
• The viscosity of the engine oil
• Check all rubber parts (hoses, fan drive belts)
• The operation of the glow plugs weekly.
• Optional Cold starting aid • Check all electrical wiring and connections for any
fraying or damaged insulation.
• Battery condition
• Keep all batteries fully charged and warm by
• Ambient air temperature and altitude ensuring that the engine is allowed to operate at
normal operating temperature.
• Parasitic load of the application
• Fill the fuel tank at the end of each shift.
• Application hydraulic and transmission oil
viscosities • Check the air cleaners and the air intake daily.
This section will cover the following information: Check the air intake more often when you operate
in snow.
• Potential problems that are caused by cold-
weather operation • Ensure that the glow plugs are in working order.
Refer to Troubleshooting, “Glow Plug Starting Aid-
• Suggest steps which can be taken to minimize Test”.
starting problems and operating problems when
the ambient air temperature is between
0° to−40 °C (32° to 40 °F).
Personal injury or property damage can result
The operation and maintenance of an engine in from alcohol or starting fluids.
freezing temperatures is complex . This complexity is
because of the following conditions: Alcohol or starting fluids are highly flammable
and toxic and if improperly stored could result in
• Weather conditions injury or property damage.
• Engine applications
Recommendations from your Perkins dealer or your
Perkins distributor are based on past proven
practices. The information that is contained in this Do not use aerosol types of starting aids such as
section provides guidelines for cold-weather ether. Such use could result in an explosion and
operation. personal injury.
Hints for Cold-Weather Operation

• After starting the engine, the engine speed will be
governed for up to a maximum of 25 seconds.
After this period, the engine should be operated at
low loads until a minimum operating temperature
of 80° C (176° F) is achieved.
60 SEBU8603-04
Operation Section
Cold Weather Operation
• For jump starting with cables in cold weather, refer While the engine is idling, the application of a light
to the Operation and Maintenance Manual, load (parasitic load) will assist in achieving the
“Starting with Jump-Start Cables.” for instructions. minimum operating temperature. The minimum
operating temperature is 80° C (176° F).
Viscosity of the Engine Lubrication
Oil Recommendations for Coolant
Warm Up
Correct engine oil viscosity is essential. Oil viscosity
affects lubrication properties and wear protection that Warm up an engine that has cooled below normal
the oil provides for the engine. Refer to this Operation operating temperatures due to inactivity. This warm
and Maintenance Manual, “Fluid Recommendations” -up should be performed before the engine is
for the recommended viscosity of oil. returned to full operation. During operation in very
cold temperature conditions, damage to engine valve
At temperatures below −10° C (14° F) damage to mechanisms can result from engine operation for
engine components can occur if the engine is short intervals. This damage can happen if the
allowed to operate at high load and speed engine is started and the engine is stopped many
immediately after starting. times without being operated to warm up completely.
Recommendations for the Coolant When the engine is operated below normal operating
temperatures, fuel and oil are not burned completely
Provide cooling system protection for the lowest in the combustion chamber. This fuel and oil causes
expected outside temperature. Refer to this soft carbon deposits to form on the valve stems.
Operation and Maintenance Manual, “Fluid Generally, the deposits do not cause problems and
Recommendations” for the recommended coolant the deposits are burned off during operation at
mixture. normal engine operating temperatures.
In cold weather, check the coolant often for the When starting and stopping an engine many times
correct glycol concentration to ensure adequate without being operated to warm up completely, the
freeze protection. carbon deposits become thicker. This starting and
stopping can cause the following problems:
Engine Block Heaters
• Free operation of the valves is prevented.
Engine block heaters (if equipped) heat the engine
jacket water that surrounds the combustion • Valves become stuck.
chambers. This heat provides the following functions:
• Pushrods may become bent.
• Startability is improved.
• Other damage to valve train components can
• Warm up time is reduced. result.
An electric block heater can be activated once the For these reasons, when the engine is started, the
engine is stopped. A block heater can be 110 V dc or engine must be operated until the coolant
240 V dc. The output can be 750/1000W. Consult temperature is 80° C (176° F) minimum. Carbon
your Perkins dealer or your Perkins distributor for deposits on the valve stems will be kept at a
more information. minimum. The free operation of the valves and the
valve components will be maintained.
Idling the Engine The engine must be warmed thoroughly to keep
other engine parts in better condition. The service life
After starting the engine, the engine speed will be of the engine will be generally extended. Lubrication
governed for a maximum period of 25 seconds. will be improved. There will be less acid and less
When idling after the engine is started in cold sludge in the oil. This condition will provide longer
weather, increase the engine rpm from 1000 to 1200 service life for the engine bearings, the piston rings,
rpm. This idling will warm up the engine more quickly. and other parts. However, limit unnecessary idle time
Maintaining an elevated low idle speed for extended to 10 minutes to reduce wear and unnecessary fuel
periods will be easier with the installation of a hand consumption.
throttle. The engine should not be “raced” to speed
up the warm-up process.
SEBU8603-04 61
Operation Section
Fuel and the Effect from Cold Weather
The Water Temperature Regulator and Consult with your Perkins dealer or your Perkins
Insulated Heater Lines distributor for the recommended breather
components for operation from −25° to -40°C
The engine is equipped with a water temperature (−13° to -72.°F).
regulator. When the engine coolant is below the
correct operating temperature, jacket water circulates i07818744
through the engine cylinder block and into the engine
cylinder head. The coolant then returns to the Fuel and the Effect from Cold
cylinder block via an internal passage that bypasses
the valve of the coolant temperature regulator. This Weather
return ensures that coolant flows around the engine
under cold operating conditions. The water
temperature regulator begins to open when the
Note: Only use grades of fuel that are recommended
engine jacket water has reached the correct
minimum operating temperature. As the jacket water by Perkins. Refer to this Operation and Maintenance
coolant temperature rises above the minimum Manual, “Fluid Recommendations”.
operating temperature, the water temperature Properties of the diesel fuel can have a significant
regulator opens further allowing more coolant effect on the engine cold start capability. It is critical
through the radiator to dissipate excess heat. that the low temperature properties of diesel fuel are
The progressive opening of the water temperature acceptable for the minimum ambient temperature the
regulator operates the progressive closing of the engine is expected to see in operation.
bypass passage between the cylinder block and Following properties are used to define fuels low
head. This action ensures maximum coolant flow to temperature capability:
the radiator to achieve maximum heat dissipation.
Note: Do not restrict the air flow. Restriction of the air • Cloud point
flow can damage the fuel system. Perkins • Pour point
discourages the use of all air flow restriction devices
such as radiator shutters. Restriction of the air flow • Cold Filter Plugging Point (CFPP)
can result in the following: high exhaust
temperatures, power loss, excessive fan usage, and The cloud point of the fuel is the temperature at
reduction in fuel economy. which waxes naturally found in the diesel fuel begin
to form crystals. The cloud point of the fuel must be
A cab heater is beneficial in very cold weather. The below lowest ambient temperature to prevent filters
feed from the engine and the return lines from the from plugging.
cab should be insulated to reduce heat loss to the
outside air. Pour point is the last temperature before the fuel flow
stops and waxing of the fuel will start.
Recommendation for Crankcase
Cold Filter Plugging Point (CFPP) is a temperature at
Breather Protection which a particular fuel will pass through a
standardized filtration device. This CFPP gives an
Crankcase ventilation gases contain a large quantity estimate of the lower operability temperature of fuel
of water vapor. This water vapor can freeze in cold
ambient conditions and can plug or damage the Be aware of these properties when diesel fuel is
crankcase ventilation system. If the engine is purchased. Consider the average ambient air
operated in temperatures below −25° C (−13° F), temperature for the engines application. Engines that
measures must be taken to prevent freezing and are fueled in one climate may not operate well if the
plugging of the breather system. Insulated hoses and engines are shipped to colder climate. Problems can
a heated canister assembly should be installed. result due to changes in temperature.
Before troubleshooting for low power or for poor
performance in the winter, check the fuel for waxing
The following components can provide a means of
minimizing fuel waxing problems in cold weather:
• Fuel heaters, which may be an OEM option

• Fuel line insulation, which may be an OEM option
62 SEBU8603-04
Operation Section
Fuel Related Components in Cold Weather
Winter and arctic grades of diesel fuel are available in For more information about fuel heaters (if equipped),
the countries and territories with severe winters. For refer to the OEM information.
more information refer to the Operation and
Maintenance Manual, “Fuel For Cold-Weather
Operation”
Another important fuel property which can affect cold
start and operation of diesel engine is Cetane
number. Detail and requirements of this property are
given in this Operation and Maintenance Manual,
“Fluid Recommendations”.
i05359588
Fuel Related Components in

Cold Weather
Fuel Tanks
Condensation can form in partially filled fuel tanks.
Top off the fuel tanks after you operate the engine.
Fuel tanks should contain some provision for draining
water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe.
Some fuel tanks use supply lines that take fuel
directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.
Drain the water and sediment from any fuel storage
tank at the following intervals: weekly, service
intervals and refueling of the fuel tank. Draining will
help prevent water and/or sediment from being
pumped from the fuel storage tank and into the
engine fuel tank.
Fuel Filters
After you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
system. Refer to the Operation and Maintenance
Manual in the Maintenance Section for more
information on priming the fuel system.
The micron rating and the location of a primary fuel
filter is important in cold-weather operation. The In-
line filter, primary fuel filter, and the fuel supply line
are the most common components that are affected
by cold fuel.
Fuel Heaters
Note: The OEM may equip the application with fuel
heaters. If so, the temperature of the fuel must not
exceed 73 °C (163 °F) at the fuel transfer pump. The
fuel heater should be installed before the electric lift
pump.
SEBU8603-04 63
Maintenance Section
Refill Capacities
Maintenance Section (Table 7, contd)

(1) The External System includes a radiator or an expansion tank
with the following components: heat exchanger and piping. Re-
fer to the OEM specifications. Enter the value for the capacity
Refill Capacities of the External System in this row.
i07074302
i03995972
Refill Capacities Fluid Recommendations

(General Fuel Information)
Lubrication System • Glossary

The refill capacities for the engine crankcase reflect • ISO International Standards Organization
the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems will • ASTM American Society for Testing and
require additional oil. Refer to the OEM specifications Materials
for the capacity of the auxiliary oil filter. Refer to the
Operation and Maintenance Manual, “Maintenance • HFRR High Frequency Reciprocating Rig
Section” for more information on Lubricant for Lubricity testing of diesel fuels
Specifications.
Table 6 • FAME Fatty Acid Methyl Esters
Engine
Refill Capacities
• CFR Co-ordinating Fuel Research
Compartment or System Minimum Maximum • ULSD Ultra Low Sulfur Diesel
13.5 L 16.5 L • RME Rape Methyl Ester

Crankcase Oil Sump(1)
(3.56 US gal) (4.36 US gal)
(1)
• SME Soy Methyl Ester
These values are the approximate capacities for the crankcase
oil sump (aluminum) which includes the standard factory in-
stalled oil filters. Engines with auxiliary oil filters will require ad- • EPA Environmental Protection Agency of
ditional oil. Refer to the OEM specifications for the capacity of the United States
the auxiliary oil filter. The design of the oil pan can change the
oil capacity of the oil pan. • PPM Parts Per Million
• DPF Diesel Particulate Filter
Cooling System
• v/v (volume of solute)/(volume of solution)
Refer to the OEM specifications for the External
System capacity. This capacity information will be • CFPP Cold Filter Plugging Point
needed in order to determine the amount of coolant/
antifreeze that is required for the Total Cooling • BTL Biomass to liquid
System.
Table 7 • GTL Gas to liquid
Engine • CTL Coal to liquid
Refill Capacities
• HVO Hydrotreated Vegetable Oil
Compartment or System Liters
Engine Only
15 L General Information
(3.96 US gal)
External System Per OEM(1) NOTICE

Every attempt is made to provide accurate, up-to-
date information. By use of this document you agree
(continued) that Perkins Engines Company Limited is not respon-
sible for errors or omissions.
64 SEBU8603-04
Maintenance Section
General Fuel Information
NOTICE
These recommendations are subject to change with-
out notice. Contact your local Perkins distributor for
the most up-to-date recommendations.
Diesel Fuel Requirements

Perkins is not in a position to continuously evaluate
and monitor all worldwide distillate diesel fuel
specifications that are published by governments and
technological societies.
The "Perkins Specification for Distillate Diesel Fuel"
provides a known reliable baseline to judge the
expected performance of distillate diesel fuels that
are derived from conventional sources.
Satisfactory engine performance depends on the use
of a good quality fuel. The use of a good quality fuel
will give the following results: long engine life and
acceptable exhaust emissions levels. The fuel must
meet the minimum requirements that are stated in
the table 8 .
NOTICE
The footnotes are key part of the Perkins "Specifica-
tion for Distillate Diesel Fuel" Table. Read ALL of the
footnotes.
Table 8
"Perkins Specification for Distillate Diesel Fuel"
Property UNITS Requirements “ASTM”Test “ISO/Other”Test
Aromatics %Volume 35% maximum “D1319” “ISO 3837”

Ash %Weight 0.01% maximum “D482” “ISO 6245”
Carbon Residue on 10% %Weight 0.35% maximum “D524” “ISO 4262”

Bottoms
Cetane Number(1) - 40 minimum “D613 or D6890” “ISO 5165”
Cloud Point °C The cloud point must not “D2500” “ISO 3015”
exceed the lowest expected
ambient temperature.
Copper Strip Corrosion - No. 3 maximum “D130” “ISO 2160”
Distillation °C 10% at 238° C (460.4° F) “D86” “ISO 3405”

maximum
90% at 350° C (662° F)
maximum
Density at 15 °C (59 °F) (2) kg/M3 800 minimum and 860 No equivalent test “ISO 3675”“ISO 12185”
maximum
Flash Point °C legal limit “D93” “ISO 2719”
Thermal Stability - Minimum of 80% reflec- “D6468” No equivalent test

tance after aging for 180 mi-
nutes at 150 °C (302 °F)
(continued)
SEBU8603-04 65
Maintenance Section
(Table 8, contd)
Pour Point °C 6 °C (42.8 °F) minimum be- “D97” “ISO 3016”
low ambient temperature
Sulfur(3) %mass 0.0015 % maximum “D5453” “ISO 20846”
Kinematic Viscosity (4) MM2/S (cSt) The viscosity of the fuel that “D445” “ISO 3405”
is delivered to the fuel injec-
tion pump. 1.4 minimum
and 4.5 maximum
Water and sediment % weight 0.05% maximum “D1796” “ISO 3734”
Water % weight 0.05% maximum “D1744” No equivalent test
Sediment % weight 0.05% maximum “D473” “ISO 3735”
Gums and Resins (5) mg/100mL 10 mg per 100 mL “D381” “ISO 6246”
maximum
Lubricity correctedwear mm 0.52 maximum “D6079” “ISO 12156-1”
scar diameter at 60 °C
(140 °F). (6)
Fuel Cleanliness (7) - “ISO 18/16/13” “D7619” “ISO 4406”
Trace Metals (8) mg/mg Max 1 or non-detectable “D7111”
Oxidation Stability g/m^3 Max 25 “D2274” “ISO 12205”
Hours(9) Min 20 “EN 15751”

(1) To insure minimum cetane number of 40 a distillate diesel fuel should have minimum cetane index of 44 when“ASTM D4737” test method is
used. A fuel with a higher cetane number is recommended to operate at a higher altitude or in cold weather
(2) Density range allowed includes summer and winter diesel fuel grades.
(3) Ultra Low Sulfur Diesel Fuel with sulphur content less than 0.0015 percent 15 PPM (mg/kg) must be used. Use of diesel fuel with higher than
15 PPM sulphur limit in these engines will harm or permanently damage emissions control systems. Also, use of diesel fuel with higher than
15 PPM sulphur limit can shorten service interval.
(4) The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscos-
ity requirement and the fuel should meet the maximum viscosity requirements at 40 °C (104 °F) of either the “ASTM D445” test method or
the “ISO 3104” test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain “1.4 cSt”or greater viscosity
at the fuel injection pump. Fuels with a high viscosity might require fuel heaters to lower the viscosity to “1.4 cSt” at the fuel injection pump.
(5) Follow the test conditions and procedures for gasoline (motor).
(6) The lubricity of a fuel is a concern with low sulfer and ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1 or ASTM
D6079 High Frequency Reciprocating Rig (HFRR)” test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel
supplier. Do not treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in
the fuel system.
(7) Recommended cleanliness level for fuel as dispensed into machine or engine fuel tank is“ISO 18/16/13”or cleaner as per “ISO 4406”. Refer
to the “Contamination Control Recommendations for Fuels.
(8) Examples of trace metals include but not limited to Cu, Fe, Mn, Na, P, Pb, Si, and Zn. Use of metal-based additives is not allowed.
(9) Additional limit for fuel containing FAME. Fuel containing more than 2% v/v FAME must meet both tests.
Engines that are manufactured by Perkins are

certified with the fuel that is prescribed by the United NOTICE
Operating with fuels that do not meet the Perkins rec-
States Environmental Protection Agency. Engines ommendations can cause the following effects: Start-
that are manufactured by Perkins are certified with ing difficulty, reduced fuel filter service life, poor
the fuel that is prescribed by the European combustion, deposits in the fuel injectors, signifi-
Certification. Perkins does not certify diesel engines cantly reduce service life of the fuel system. Also, the
on any other fuel. creation of deposits in the combustion chamber and
reduced service life of the engine.
Note: The owner and the operator of the engine has
the responsibility of using the fuel that is prescribed
by the EPA and other appropriate regulatory
agencies. NOTICE
The Perkins 1200 series of diesel engine must be op-
erated using Ultra Low Sulfur Diesel. The sulphur
content of this fuel must be lower than 15 PPM. This
fuel complies with the emissions regulations that are
prescribed by the Environmental Protection Agency
of the United States.
66 SEBU8603-04
Maintenance Section
Illustration 36 is a representation of the label that will

be installed next to the fuel filler cap on the fuel tank
of the application.
The fuel specifications that are listed in the table 9
are released as acceptable to use on all 1200 series
of engine.
Table 9
Acceptable Fuel Specification for the 1200 Series of Engines(1)
Fuel Specification Comments
EN590 European Automotive Diesel Fuel (DERV)
“ASTM D975 GRADE 1D S15” “North American Light Distillate Diesel fuel with less than 15 PPM sul-
fur level”
“ASTM D975 GRADE 2D S15” “North American Middle Distillate general-purpose Diesel fuel with less
than 15 PPM sulfur level”
“JIS K2204” “Japanese Diesel Fuel” Must meet the requirements that are stated in
the section “Lubricity”.
“BS 2869: 2010 CLASS A2 or EU equivalent” “EU Off-Road Diesel fuel. Acceptable from 2011 MUST have less than
10 PPM sulfur level”
(1) All the fuels must comply with the specification in the table for the Perkins Specification Distillate Diesel Fuel.
Diesel Fuel Characteristics Fuel with a low cetane number can be the root cause
of problems during a cold start.
Cetane Number
Viscosity
Fuel that has a high cetane number will give a shorter
ignition delay. A high cetane number will produce a
Viscosity is the property of a liquid of offering
better ignition quality. Cetane numbers are derived
resistance to shear or flow. Viscosity decreases with
for fuels against proportions of cetane and
increasing temperature. This decrease in viscosity
heptamethylnonane in the standard CFR engine.
follows a logarithmic relationship for normal fossil
Refer to “ISO 5165” for the test method.
fuel. The common reference is to kinematic viscosity.
Cetane numbers more than 45 are normally expected Kinematic viscosity is the quotient of the dynamic
from current diesel fuel. However, a cetane number viscosity that is divided by the density. The
of 40 may be experienced in some territories. The determination of kinematic viscosity is normally by
United States of America is one of the territories that readings from gravity flow viscometers at standard
can have a low cetane value. A minimum cetane temperatures. Refer to “ISO 3104” for the test
value of 40 is required during average starting method.
conditions. A fuel with higher cetane number is
recommended for operations at high altitudes or in
cold-weather operations.
SEBU8603-04 67
Maintenance Section
The viscosity of the fuel is significant because fuel Lubricity

serves as a lubricant for the fuel system components.
Fuel must have sufficient viscosity to lubricate the Lubricity is the capability of the fuel to prevent pump
fuel system in both extremely cold temperatures and wear. The fluids lubricity describes the ability of the
extremely hot temperatures. If the kinematic viscosity fluid to reduce the friction between surfaces that are
of the fuel is lower than “1.4 cSt” at the fuel injection under load. This ability reduces the damage that is
pump, damage to the fuel injection pump can occur. caused by friction. Fuel injection systems rely on the
This damage can be excessive scuffing and seizure. lubricating properties of the fuel. Until fuel sulfur limits
Low viscosity may lead to difficult hot restarting, were mandated, the fuels lubricity was generally
stalling, and loss of performance. High viscosity may believed to be a function of fuel viscosity.
result in seizure of the pump.
The lubricity has particular significance to the current
Perkins recommends kinematic viscosities of 1.4 and ultra low sulfur fuel, and low aromatic fossil fuels.
4.5 mm2/sec that is delivered to the fuel injection These fuels are made to meet stringent exhaust
pump. If a fuel with a low viscosity is used, cooling of emissions.
the fuel may be required to maintain 1.4 cSt or
greater viscosity at the fuel injection pump. Fuels with The lubricity of these fuels must not exceed wear
a high viscosity might require fuel heaters to lower scar diameter of 0.52 mm (0.0205 inch). The fuel
the viscosity to 4.5 cSt at the fuel injection pump. lubricity test must be performed on an HFRR,
operated at 60 °C (140 °F). Refer to “ISO 12156-1”.
Density
NOTICE
The fuels system has been qualified with fuel having
Density is the mass of the fuel per unit volume at a lubricity up to 0.52 mm (0.0205 inch) wear scar diam-
specific temperature. This parameter has a direct eter as tested by “ISO 12156-1”. Fuel with higher
influence on engine performance and a direct wear scar diameter than 0.52 mm (0.0205 inch) will
influence on emissions. This influence determines lead to reduced service life and premature failure of
from a heat output given injected volume of fuel. This
parameter is quoted in the following kg/m3 at 15 °C the fuel system.
(59 °F).
Perkins recommends a density of 841 kg/m 3 to Fuel additives can enhance the lubricity of a fuel.
obtain the correct power output. Lighter fuels are Contact your fuel supplier for those circumstances
acceptable but these fuels will not produce the rated when fuel additives are required. Your fuel supplier
power. can make recommendations for additives to use, and
for the proper level of treatment.
Sulfur Distillation
The level of sulfur is governed by emissions
legislations. Regional regulation, national Distillation is an indication of the mixture of different
hydrocarbons in the fuel. A high ratio of lightweight
regulations, or international regulations can require a hydrocarbons can affect the characteristics of
fuel with a specific sulfur limit. The sulfur content of combustion.
the fuel and the fuel quality must comply with all
existing local regulations for emissions.
Recommendation for Biodiesel and
Perkins 1200 series diesel engines have been Using B20
designed to operate only with ULSD. By using the
test methods “ASTM D5453, or ISO 20846”, the Biodiesel is a fuel that can be defined as mono-alkyl
content of sulfur in ULSD fuel must be below 15 PPM esters of fatty acids. Biodiesel is a fuel that can be
(mg/kg) or 0.0015% mass. made from various feedstocks. The most commonly
available biodiesel in Europe is Rape Methyl Ester
NOTICE (RME). This biodiesel is derived from rapeseed oil.
Use of diesel fuel with higher than 15 PPM sulphur Soy Methyl Ester (SME) is the most common
limit in these engines will harm or permanently dam- biodiesel in the United States. This biodiesel is
age emissions control systems and/or shorten serv- derived from soybean oil. Soybean oil or rapeseed oil
ice interval. are the primary feedstocks. These fuels are together
known as Fatty Acid Methyl Esters (FAME).
68 SEBU8603-04
Maintenance Section
Raw pressed vegetable oils are NOT acceptable for Engine Service Requirements
use as a fuel in any concentration in compression
engines. Without esterification, these oils solidify in Aggressive properties of biodiesel fuel may cause
the crankcase and the fuel tank. These fuels may not debris in the fuel tank and fuel lines. The aggressive
be compatible with many of the elastomers that are properties of biodiesel will clean the fuel tank and fuel
used in engines that are manufactured today. In lines. This cleaning of the fuel system can
original forms, these oils are not suitable for use as a prematurely block of the fuel filters. Perkins
fuel in compression engines. Alternate base stocks recommend that after the initial usage of B20
for biodiesel may include animal tallow, waste biodiesel blended fuel the fuel filters must be
cooking oils, or various other feedstocks. To use any replaced at 50 hours.
of the products that are listed as fuel, the oil must be
esterified. Glycerides present in biodiesel fuel will also cause
fuel filters to become blocked more quickly. Therefore
Fuel made of 100 percent FAME is generally referred the regular service interval should be reduced to 250
to as B100 biodiesel or neat biodiesel. hours.
Biodiesel can be blended with distillate diesel fuel. When biodiesel fuel is used, crank case oil and
The blends can be used as fuel. The most commonly aftertreatment systems may be influenced. This
available biodiesel blends are B5, which is 5 percent influence is due to the chemical composition and
biodiesel and 95 percent distillate diesel fuel. B20, characteristics of biodiesel fuel, such as density and
which is 20 percent biodiesel and 80 percent distillate volatility, and to chemical contaminants that can be
diesel fuel. present in this fuel, such as alkali and alkaline metals
(sodium, potassium, calcium, and magnesium).
Note: The percentages given are volume-based.
• Crankcase oil fuel dilution can be higher when
The U.S. distillate diesel fuel specification “ASTM biodiesel or biodiesel blends are used. This
D975-09a” includes up to B5 (5 percent) biodiesel. increased level of fuel dilution when using
biodiesel or biodiesel blends is related to the
European distillate diesel fuel specification EN590:
2010 includes up B7 (7 percent) biodiesel. typically lower volatility of biodiesel. In-cylinder
emissions control strategies utilized in many of the
Note: Engines that are manufactured by Perkins are industrial latest engine designs may lead to a
certified by use of the prescribed Environmental higher level of biodiesel concentration in the
Protection Agency (EPA) and European Certification sump. The long-term effect of biodiesel
fuels. Perkins does not certify engines on any other concentration in crankcase oil is unknown
fuel. The user of the engine has the responsibility of currently.
using the correct fuel that is recommended by the
manufacturer and allowed by the EPA and other • Perkins recommend the use of oil analysis to
appropriate regulatory agencies. check the quality of the engine oil if biodiesel fuel
is used. Ensure that the level of biodiesel in the
Specification Requirements fuel is noted when the oil sample is taken.
The neat biodiesel must conform to the latest Performance Related Issues
“EN14214 or ASTM D6751” (in the USA). The
biodiesel can only be blended in mixture of up to 20% Due to the lower energy content than the standard
by volume in acceptable mineral diesel fuel meeting distillate fuel B20 will cause a power loss in order of 2
latest edition of “EN590 or ASTM D975 S15” to 4 percent. In addition, over time the power may
designation. deteriorate further due to deposits in the fuel
injectors.
In United States Biodiesel blends of B6 to B20 must
meet the requirements listed in the latest edition of Biodiesel and biodiesel blends are known to cause
“ASTM D7467” (B6 to B20) and must be of an API an increase in fuel system deposits, most significant
gravity of 30-45. of which are deposits within the fuel injector. These
deposits can cause a loss in power due to restricted
In North America biodiesel and biodiesel blends must or modified fuel injection or cause other functional
be purchased from the BQ-9000 accredited issues associated with these deposits.
producers and BQ-9000 certified distributors.
Note: Perkins T40-0012 Fuel Cleaner is most
In other areas of the world, the use of biodiesel that is effective in cleaning and preventing the formation of
BQ-9000 accredited and certified, or that is deposits. Perkins Diesel Fuel Conditioner helps to
accredited and certified by a comparable biodiesel
quality body to meet similar biodiesel quality limit deposit issues by improving the stability of
standards is required. biodiesel and biodiesel blends. For more information
refer to “Perkins Diesel Fuel System Cleaner, and
Perkins”.
SEBU8603-04 69
Maintenance Section
Biodiesel fuel contains metal contaminants (sodium, Renewable and Alternative Fuels
potassium, calcium, and/or magnesium) that form
ash products upon combustion in the diesel engine. Perkins supports development and use of renewable
The ash can have an impact on the life and fuels through sustainability initiatives. In recent years
performance of aftertreatment emissions control various forms of renewable and alternative
devices and can accumulate in DPF. The ash (synthetic) diesel fuels have started to emerge.
accumulation may cause the need for more frequent
ash service intervals and cause loss of performance Synthetic diesel fuels are produced by gasification of
various feedstock and then synthesis to liquid to
General Requirements obtain paraffinic diesel fuel. Based on the feedstock
used these fuels are commonly referred to as
Biodiesel has poor oxidation stability, which can Biomass to liquid (BTL), Gas to liquid (GTL) and Coal
result in long-term problems in the storage of to liquid (CTL). Hydrotreating of vegetable oils and
biodiesel. Biodiesel fuel should be used within 6 animal fats is another emerging process for
months of manufacture. Equipment should not be production of bio based diesel fuel called
stored with the B20 biodiesel blends in the fuel Hydrotreated Vegetable Oil (HVO).
system for longer than 3 months.
BTL and HVO fuels are considered to be low carbon
Due to poor oxidation stability and other potential fuels as they reduce carbon foot print compared to
issues, it is strongly recommended that engines with fossil fuels and are commonly referred to as
limited operational time either not use B20 biodiesel renewable fuels. These fuels must not be confused
blends or, whilst accepting some risk, limit biodiesel with biodiesel FAME which is fundamentally different
blend to a maximum of B5. Examples of applications fuel and is discussed in a separate section in this
that should limit the use of biodiesel are the following: manual.
Standby Generator sets and certain emergency
vehicles. These paraffinic fuels have virtually no sulphur or
aromatics and have very high cetane numbers which
For standby generator sets and emergency vehicles enable very clean burning and efficient engine
that cannot avoid use of biodiesel blends fuel quality operation. Chemically these fuels are similar to diesel
in the engine fuel tank must be sampled and checked fuel derived form petroleum and are therefore
monthly. Test should include acid number suitable to use in diesel engines as a replacement or
(EN14104), oxidation stability (EN 15751 commonly blend stock with conventional diesel fuel. To be
know as the Rancimant test), and sediment acceptable renewable and alternative fuels must
(ISO12937). For standby generator sets oxidation meet latest edition of the paraffinic diesel fuel
stability of biodiesel blend must be 20 hours or more specification “CENTS 15940”. The fuel should also
as per EN 15751. If the test shows that the fuel has meet requirements described in table , Perkins
degraded, fuel tank must be drained and engine Specification for Distillate Diesel Fuel, EN590, or
flashed by running with the fresh high-quality diesel latest ASTM D975 specification.
fuel.
Ensure that the fuel has got appropriate cold flow
Perkins strongly recommended that seasonally properties (cloud point and CFPP) for the minimum
operated engines have the fuel systems, including statistical ambient temperature the engine is
fuel tanks, flashed with conventional diesel fuel expected to see in the operation. The Fuel must also
before prolonged shutdown periods. An example of meet lubricity requirements as specified in the
an application that should seasonally flush the fuel lubricity section of this “Operation and Maintenance
system is a combine harvester. Manual” Fluid Recommendations
Microbial contamination and growth can cause Fuel for Cold-Weather Operation
corrosion in the fuel system and premature plugging
of the fuel filter. Consult your supplier of fuel for The European standard “EN590” contains climate
assistance in selecting appropriate anti-microbial dependant requirements and a range of options. The
additive. options can be applied differently in each country.
Water accelerates microbial contamination and There are five classes that are given to arctic
growth. When biodiesel is compared to distillate climates and severe winter climates. 0, 1, 2, 3 and 4.
fuels, water is naturally more likely to exist in the
Fuel that complies with “EN590” CLASS 4 can be
biodiesel. Therefore check frequently and if
used at temperatures as low as −44 °C (−47.2 °F).
necessary, drain the water separator.
Refer to “EN590” fora detailed discretion of the
physical properties of the fuel.
Materials such as brass, bronze, copper, lead, tin,
and zinc accelerate the oxidation process of the The diesel fuel “ASTM D975 1-D” used in the United
biodiesel fuel. The oxidation process can cause States of America may be used in very cold
deposits formation therefore these materials must not temperatures that are below −18 °C (−0.4 °F).
be used for fuel tanks and fuel lines.
70 SEBU8603-04
Maintenance Section
Aftermarket Fuel Additives Details instruction on the rate of which the fuel
cleaner must be use are on the container.
NOTICE Note: Perkins fuel cleaner is compatible with existing
Perkins does not warrant the quality or performance and U.S. EPA Tier 4 nonroad certified diesel engine
of non-Perkins fluids and filters. emission control catalysts and particulate filters.
When auxiliary devices, accessories, or consum- Perkins fuel system cleaner contains less than 15
ables (filters, additives) which are made by other ppm of sulfur and is acceptable for use with ULSD
manufacturers are used on Perkins products, the fuel.
Perkins warranty is not affected simply because of
such use. Contamination Control
However, failures that result from the installation Recommendations for Fuels
or use of other manufacturers devices, accesso-
ries, or consumables are NOT Perkins defects. Fuels of “ISO 18/16/13” cleanliness level or cleaner
Therefore, the defects are NOT covered under the as dispensed into the engine or application fuel tank
Perkins warranty. should be used. This will reduce risk of power loss,
fuel system failures, and related down time of
Supplemental diesel fuel additives are not generally engines. This cleanliness level is important for new
recommended. This recommendation is due to fuel system designs such as common rail injection
potential damage to the fuel system or the engine.
Your fuel supplier or the fuel manufacturer will add systems and unit injectors. These fuels systems
the appropriate supplemental diesel fuel additives. utilize higher fuel injection pressures and have tight
clearances between moving parts to meet required
Perkins recognizes the fact that additives may be stringent emissions regulations. Peak injection
required in some special circumstances. pressures in current fuel injection systems may
exceed 2000 bar (29000 psi). Clearances in these
Note: Some anti-corrosion additives can lead to systems are less than 5 µm. As a result, particle
injector fouling, this fouling can cause the injector to contaminants as small as 4 µm can cause scoring
operate incorrectly. and scratching of internal pump and injector surfaces
and of injector nozzles.
Contact your fuel supplier for those circumstances
when fuel additives are required. Your fuel supplier Water in the fuel causes cavitation, corrosion of fuel
system parts, and provides an environment where
can recommend the appropriate fuel additive and the
correct level of treatment. microbial growth in the fuel can flourish. Other
sources of fuel contamination are soaps, gels, or
Note: For the best results, your fuel supplier should other compounds that may result from undesirable
treat the fuel when additives are required. The chemical interactions in the fuels, particularly in
ULSD. Gels and other compounds can also form in
treated fuel must meet the requirements that are biodiesel fuel at low temperatures or if biodiesel is
stated in table 8 . stored for extended periods. The best indication of
microbial contamination, fuel additives, or cold
Perkins Diesel Fuel System Cleaner temperature gel is rapid filter plugging of bulk fuel
filters or application fuel filters.
Perkins T40-0012 Fuel Cleaner is the only fuel
cleaner that is recommended by Perkins. To reduce downtime due to contamination, follow
these fuel maintenance guidelines.
If biodiesel or biodiesel blends of fuel are to be used,
Perkins require the use of Perkins fuel cleaner. The • Use high-quality fuels per recommended and
use of the fuel is to remove deposits within the fuel required specifications
system that is created with the use of biodiesel. For
more information on the use of biodiesel and • Fill fuel tanks with fuels of “ISO 18/16/13”
biodiesel blends refer to “Recommendation for cleanliness level or cleaner, in particular for
Biodiesel and Using B20”.
engines with common rail and unit injection
Perkins fuel cleaner will remove deposits that can systems. When you refuel the tank, filter the fuel
form in the fuel system with the use of biodiesel and through a 4 µm absolute filter (Beta 4 = 75 up to
biodiesel blends. These deposits can create a loss of 200) to reach the recommended cleanliness level.
power and engine performance. This filtration should be installed at the device that
dispenses the fuel to the fuel tank. In addition,
Once the fuel cleaner has been added to the fuel, the filtration at the dispensing point should remove
deposits within the fuel system are removed after 30 water to ensure that fuel is dispensed at 500 ppm
hours of engine operation. For maximum results,
water or less.
continue to use the fuel cleaner for up to 80 hours.
Perkins fuel cleaner can be used on an on-going
basis with no adverse impact on engine or fuel
system durability.
SEBU8603-04 71
Maintenance Section
Fluid Recommendations
• Perkins recommends the use of bulk fuel filter / Consult your local Perkins distributor for additional
coalescer units which clean the fuel of both information on Perkins designed and produced
particulate contamination and water in a single filtration products.
pass.
i07675883
• Ensure that you use Perkins Advanced Efficiency
Fuel Filters. Change your fuel filters per
recommended service requirements or as needed.
• Drain your water separators daily.
• Drain your fuel tanks of sediment and water per General Coolant Information
the Operation and Maintenance Manual
instructions. NOTICE
Never add coolant to an overheated engine. Engine
• Install and maintain a properly designed bulk filter damage could result. Allow the engine to cool first.
/ coalescer filtration system. Continuous bulk
filtration systems may be required to ensure that
dispensed fuel meets the cleanliness target. NOTICE
Consult your Perkins distributor for availability of If the engine is to be stored in, or shipped to an area
bulk filtration products. with below freezing temperatures, the cooling system
must be either protected to the lowest outside tem-
• Centrifugal filters may need to be used as a pre- perature or drained completely to prevent damage.
filter with fuel that is severely contaminated with
gross amounts of water and/or large particulate
contaminants. Centrifugal filters can effectively NOTICE
remove large contaminants. Centrifugal filters may Frequently check the specific gravity of the coolant
not be able to remove the small abrasive particles for proper freeze protection or for anti-boil protection.
required to achieve the recommended “ISO”
cleanliness level. Bulk filter / coalescers are Clean the cooling system for the following reasons:
necessary as a final filter to achieve the
• Contamination of the cooling system
recommended cleanliness level.
• Overheating of the engine
• Install desiccant type breathers of 4 µm or less
absolute efficiency with the ability to remove water • Foaming of the coolant
on bulk storage tanks.
• Follow proper practices of fuel transportation. NOTICE
Filtration from the storage tank to the application Never operate an engine without water temperature
promotes the delivery of clean fuel. Fuel filtration regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
can be installed at each transport stage to keep
proper operating temperature. Cooling system prob-
the fuel clean. lems can develop without water temperature
regulators.
• Cover, protect, and ensure cleanliness of all
connection hoses, fittings, and dispensing
nozzles. Many engine failures are related to the cooling
system. The following problems are related to cooling
system failures: Overheating, leakage of the water
pump and plugged radiators or heat exchangers.
These failures can be avoided with correct cooling
system maintenance. Cooling system maintenance is
as important as maintenance of the fuel system and
the lubrication system. Quality of the coolant is as
important as the quality of the fuel and the lubricating
oil.
Coolant is normally composed of three elements:
Water, additives, and glycol.
Water
Water is used in the cooling system to transfer heat.
72 SEBU8603-04
Maintenance Section
Note: The water must be used with an inhibitor to • Plugging of radiators, coolers, and small passages
protect the engine.
Glycol
Distilled water or deionized water is
recommended for use in engine cooling systems.
Glycol in the coolant helps to provide protection
DO NOT use the following types of water in cooling against the following conditions:
systems: Hard water, softened water that has been
conditioned with salt and sea water. • Boiling
If distilled water or deionized water is not available, • Freezing

use water with the properties that are listed in Table
10 . • Cavitation of the water pump
Table 10
For optimum performance, Perkins recommends a
Acceptable Water 1:1 mixture of a water/glycol solution.
Property Maximum Limit Note: Use a mixture that will provide protection
Chloride (Cl) 40 mg/L against the lowest ambient temperature.
Sulfate (SO4) 100 mg/L Note: 100 percent pure glycol will freeze at a
temperature of −13 °C (8.6 °F).
Total Hardness 170 mg/L
Most conventional antifreezes use ethylene glycol.
Total Solids 340 mg/L
Propylene glycol may also be used. In a 1:1 mixture
Acidity pH of 5.5 to 9.0 with water, ethylene and propylene glycol provide
similar protection against freezing and boiling. Refer
to Table 11 and refer to table 12 .
For a water analysis, consult one of the following Table 11
sources:
Ethylene Glycol
• Local water utility company
Concentration Freeze Protection
• Agricultural agent 50 Percent −36 °C (−33 °F)
• Independent laboratory 60 Percent −51 °C (−60 °F)
Additives
NOTICE
Additives help to protect the metal surfaces of the Do not use propylene glycol in concentrations that
cooling system. A lack of coolant additives or exceed 50 percent glycol because of the reduced
insufficient amounts of additives enable the following heat transfer capability of propylene glycol. Use ethyl-
conditions to occur: ene glycol in conditions that require additional protec-
tion against boiling or freezing.
• Corrosion
Table 12
• Formation of mineral deposits
Propylene Glycol
• Rust
Concentration Freeze Protection
• Scale −29 °C (−20 °F)
50 Percent
• Foaming of the coolant
To check the concentration of glycol in the coolant,
Many additives are depleted during engine operation. measure the specific gravity of the coolant.
These additives must be replaced periodically.
Additives must be added at the correct concentration.
Over concentration of additives can cause the
inhibitors to drop out-of-solution. The deposits can
enable the following problems to occur:
• Formation of gel compounds
• Reduction of heat transfer

• Leakage of the water pump seal
SEBU8603-04 73
Maintenance Section
Note: Some commercially available coolants are

NOTICE
based on alternative fluids, such as 1, 3-propanediol Do not use a commercial coolant/antifreeze that only
(beta-propylene glycol, PDO), glycerin (glycerol) or meets the ASTM D3306 specification. This type of
mixtures of these alternatives with ethylene/ coolant/antifreeze is made for light automotive
propylene glycols. At the time of publication of this applications.
document no industry standard exists for coolants
based on these chemicals. Until such standard/
specifications are published and evaluated by Perkins recommends a 50% mixture of water and
Perkins, use of PDO, glycerine or other alternative glycol. This mixture of water and glycol will provide
coolants is not recommended in Perkins diesel optimum heavy-duty performance as an antifreeze.
This ratio may be changed to 40% water to 60%
engines.
glycol if extra freezing protection is required.
Coolant Recommendations A mixture of SCA inhibitor and water is acceptable
but will not give the same level of corrosion, boiling
• ELC Extended Life Coolant and, freezing protection as ELC. Perkins
recommends a 6 percent to 8 percent concentration
• SCA Supplement Coolant Additive of SCA in those cooling systems. Distilled water or
deionized water is preferred.
• ASTM American Society for Testing and Table 13
Materials
Coolant Service Life
ELC - extended life coolant. A coolant that relies on
organic inhibitors for corrosion and cavitation Coolant Type Service Life (1)
protection. Also called OAT coolant (Organic Acid 6,000 Service Hours or Three
Technology). Perkins ELC
Years
SCA - supplemental coolant additive, concentrated Commercial Heavy-Duty Anti-
inorganic inhibitor package. freeze that meets “ASTM 3000 Service Hours or Two Year
D6210”
Extender - concentrated organic inhibitor package.
Commercial SCA inhibitor and
3000 Service Hours or One Year
Conventional Coolant - a coolant that relies on Water
inorganic inhibitors for corrosion and cavitation (1) Use the interval that occurs first. The cooling system must also
protection. be flushed out at this time.
Hybrid Coolant - a coolant in which the corrosion and

cavitation protection is based on a mixture of organic Perkins ELC
and inorganic inhibitors.
Perkins provides ELC for use in the following
The following coolants are recommended for used in applications:
Perkins diesel engines:
• Heavy-duty spark ignited gas engines
Preferred – Perkins ELC
• Heavy-duty diesel engines
Acceptable – A commercial heavy-duty antifreeze • Automotive applications
that meets “ASTM D6210” or “ASTM D4985”
specifications. The anti-corrosion package for ELC is different from
the anti-corrosion package for other coolants. ELC is
an ethylene glycol base coolant. However, ELC
NOTICE contains organic corrosion inhibitors and antifoam
The Perkins industrial engines with a NOx reduc- agents with low amounts of nitrite. Perkins ELC has
tion system must be operated with a minimum been formulated with the correct amount of these
30% volume glycol-water mixture, Perkins recom- additives to provide superior corrosion protection for
mends 50% volume glycol-water mixture of water all metals in engine cooling systems.
and glycol. The 50% concentration allows the
NOx reduction system to operate correctly at ELC is available in a premixed cooling solution with
high ambient temperatures. distilled water. ELC is a 1:1 mixture. The Premixed
ELC provides freeze protection to −36 °C (−33 °F).
The Premixed ELC is recommended for the initial fill
of the cooling system. The Premixed ELC is also
recommended for topping off the cooling system.
74 SEBU8603-04
Maintenance Section
Containers of several sizes are available. Consult

your Perkins distributor for the part numbers. NOTICE
Care must be taken to ensure that all fluids are con-
ELC Cooling System Maintenance nance, testing, adjusting and the repair of the
product. Be prepared to collect the fluid with suitable
Correct additions to the Extended Life containers before opening any compartment or disas-
sembling any component containing fluids.
Coolant
Dispose of all fluids according to local regulations
and mandates.
NOTICE
Use only Perkins products for pre-mixed coolants.
1. Drain the coolant into a suitable container.
Mixing Extended Life Coolant with other products re-
duces the Extended Life Coolant service life. Failure 2. Dispose of the coolant according to local
to follow the recommendations can reduce cooling
regulations.
system components life unless appropriate corrective
action is performed. 3. Fill the cooling system with a 33 percent solution of
Perkins ELC and operate the engine, ensure that
To maintain the correct balance between the
antifreeze and the additives, you must maintain the the thermostat opens. Stop the engine and allow
recommended concentration of ELC. Lowering the the engine to cool. Drain the coolant.
proportion of antifreeze lowers the proportion of
additive. Lowering the ability of the coolant to protect Note: Use distilled or deionized water in the solution.
the system will form pitting, from cavitation, from
erosion, and from deposits. 4. Again, fill the cooling system with a 33 percent
solution of Perkins ELC and operate the engine
NOTICE ensure that the thermostat opens. Stop the engine
Do not use a conventional coolant to top-off a cooling and allow to cool.
system that is filled with Extended Life Coolant
(ELC). 5. Drain the cooling system.
Do not use supplemental coolant additive (SCA). NOTICE
Incorrect or incomplete flushing of the cooling system
can result in damage to copper and other metal
ELC Cooling System Cleaning components.
Note: If the cooling system is already using ELC,

cleaning agents are not required to be used at the NOTICE
specified coolant change interval. Cleaning agents Most commercial cooling system cleaning agents are
are only required if the system has been corrosive and their use is not recommended by
contaminated by the addition of some other type of Perkins.
coolant or by cooling system damage.
Clean water is the only cleaning agent that is 6. Fill the cooling system with the Perkins Premixed
required when ELC is drained from the cooling ELC. Operate the engine. Ensure that all coolant
system. valves open then stop the engine. When cool
check the coolant level.
Before the cooling system is filled, the heater control
(if equipped) must be set to the HOT position. Refer ELC Cooling System Contamination
to the OEM to set the heater control. After the cooling
system is drained and the cooling system is refilled,
operate the engine until the coolant level reaches the NOTICE
normal operating temperature and until the coolant Mixing ELC with other products reduces the effective-
level stabilizes. As needed, add the coolant mixture ness of the ELC and shortens the ELC service life.
to fill the system to the specified level. Failure to follow these recommendations can result in
shortened cooling system component life.
Changing to Perkins ELC ELC cooling systems can withstand contamination to
a maximum of 10 percent of conventional heavy-duty
To change from heavy-duty antifreeze to the Perkins antifreeze or SCA. If the contamination exceeds 10
ELC, perform the following steps: percent of the total system capacity, perform ONE of
the following procedures:
SEBU8603-04 75
Maintenance Section
• Drain the cooling system into a suitable container. Table 14

Dispose of the coolant according to local Equation For Adding The SCA To The Heavy-Duty Coolant At
regulations. Flush the system with a 5 to 10 The Initial Fill
percent solution of Perkins ELC. Fill the system
with the Perkins ELC. V × 0.07 = X
V is the total volume of the cooling system.
• Maintain the system as a conventional Heavy-
Duty Coolant. Treat the system with an SCA. X is the amount of SCA that is required.
Change the coolant at the interval that is
recommended for the conventional Heavy-Duty Table 15 is an example for using the equation that is
Coolant. in Table 14 .
Table 15
Commercial Heavy-Duty Antifreeze and
Example Of The Equation For Adding The SCA To The Heavy-
SCA Duty Coolant At The Initial Fill
Total Volume of the Multiplication Amount of SCA

NOTICE Cooling System (V) Factor that is Required
Commercial Heavy-Duty Coolant which contains (X)
Amines as part of the corrosion protection system
must not be used. 15 L (4 US gal) × 0.07 1.05 L (35.5 oz)
NOTICE Adding The SCA to The Heavy-Duty

Never operate an engine without water temperature Coolant For Maintenance
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the Heavy-duty antifreeze of all types REQUIRE periodic
correct operating temperature. Cooling system prob- additions of an SCA.
lems can develop without water temperature
regulators. Test the antifreeze periodically for the concentration
of SCA. For the interval, refer to the Operation and
Check the glycol concentration to ensure adequate Maintenance Manual, “Maintenance Interval
protection against boiling or freezing. Perkins Schedule” (Maintenance Section). Cooling System
recommends the use of a refractometer for checking Supplemental Coolant Additive (SCA) Test/Add.
the glycol concentration. A hydrometer should not be
used. Additions of SCA are based on the results of the test.
The size of the cooling system determines the
Perkins engine cooling systems should be tested at amount of SCA that is needed.
500 hour intervals for the concentration of SCA.
Use the equation that is in Table 16 to determine the
Additions of SCA are based on the results of the test. amount of SCA that is required, if necessary:
An SCA that is liquid may be needed at 500 hour Table 16
intervals.
Equation For Adding The SCA To The Heavy-Duty Coolant
For Maintenance
NOTICE
Do not mix types and brands of coolant. V × 0.023 = X
Do not mix brands and types of SCAs. V is the total volume of the cooling system.
Do not mix SCAs and Extenders. X is the amount of SCA that is required.
Only use SCAs or Extender approved by coolant

Table 17 is an example for using the equation that is
manufacturer and compatible with coolant.
in Table 16 .
Table 17
Adding the SCA to Heavy-Duty Coolant Example Of The Equation For Adding The SCA To The Heavy-
Duty Coolant For Maintenance
at the Initial Fill
Total Volume of the Multiplication Amount of SCA
Coolants conforming to ASTM D4985 and not Cooling System (V) Factor that is Required
conforming D6210 require the addition of SCA at (X)
initial fill.
15 L (4 US gal) × 0.023 0.35 L (11.7 oz)
Use the equation that is in Table 14 to determine the
amount of SCA that is required when the cooling
system is initially filled.
76 SEBU8603-04
Maintenance Section
Cleaning the System of Heavy-Duty Licensing

Antifreeze
The Engine Oil Licensing and Certification System by
Note: Before corrosion inhibitors can be effective the the American Petroleum Institute (API) and the
cooling system must be free from rust, scale and Association des Constructers European Automobiles
(ACEA) is recognized by Perkins. For detailed
deposits.
information about this system, see the latest edition
• Drain the cooling system. of the “API publication No. 1509”. Engine oils that
bear the API symbol are authorized by API.
• Before filling the cooling system with acceptable
quality water, pre-dissolve the cleaning agent in
the water. Use a non-foaming detergent to clean
oil contamination, consult your Perkins dealer for
suitable product.
NOTICE
Most commercial cooling system cleaning agents are
corrosive and their use is not recommended by
Perkins.
The cooling system must be thoroughly flushed with
clean water after using cleaning agents.
Cleaning agents for marine or industrial cooling sys-
tem must not be used, these areveryaggressiveand Illustration 37 g06183768
can cause damage to cooling system components.
Typical API symbol
• Run the engine for approximately 30 minutes and Terminology

then leave the engine to cool down.
Certain abbreviations follow the nomenclature of
• Take a sample of the solution from the cooling “SAE J754”. Some classifications follow “SAE J183”
system, drain the system. abbreviations, and some classifications follow the
“EMA Recommended Guideline on Diesel Engine
• Allow the sample to sit for at least 30 minutes and Oil”. In addition to Perkins definitions, there are other
check for signs of oil and deposits. If oil and definitions that will be of assistance in purchasing
deposits are still present repeat the procedure. lubricants. Recommended oil viscosities can be
found in this publication, “Fluid Recommendations/
Engine Oil” topic (Maintenance Section).
• Flush the system with clean water.
• Fill the system with new coolant. Engine Oil

i07711004 Commercial Oils
Fluid Recommendations Perkins recommends use of Perkins Diesel Engine
Oil for all Perkins engines. Perkins unique oil
formulations have been developed to provide full
performance and maximum service life of your
General Lubricant Information engine, and in tests have been shown to provide
superior protection. Available in suitable API
Because of government regulations regarding the classifications to meet the emissions requirements
certification of exhaust emissions from the engine, and performance of your engine, Refer to 18 for the
the lubricant recommendations must be followed. correct oil specification for your engine. Consult your
Perkins distributor for more information on these
• API American Petroleum Institute multi-grade oils.
• SAE Society Of Automotive Engineers Inc. NOTICE

Perkins require the use of the following specifica-
• ACEA Association des Constructers tion of engine oil. Failure to use the appropriate
European Automobiles. specification of engine oil will reduce the life of
your engine. Failure to use the appropriate speci-
• ECF-3 Engine Crankcase Fluid fication of engine oil will also reduce the life of
your aftertreatment system.
SEBU8603-04 77
Maintenance Section
Table 18
Classifications for the 1200 Series Industrial Engine Refer to illustration 38 (minimum temperature) to
Oil Specification
determine the required oil viscosity for starting a cold
engine.
API CK-4
ACEA E9 Refer to illustration 38 (maximum temperature) to
ECF-3 select the oil viscosity for engine operation at the
highest ambient temperature that is anticipated.
API CK-4 and ACEA E9 oil categories have the Generally, use the highest oil viscosity that is
following chemical limits: available to meet the requirement for the temperature
at start-up.
• 0.1 percent maximum sulfated ash
• 0.12 percent maximum phosphorous
• 0. 4 percent maximum sulfur

The chemical limits were developed to maintain the
expected life of the engine aftertreatment system.
The performance of the engine aftertreatment system
can be adversely affected if oil that is not specified in
table 18 is used.
The life of your Aftertreatment system is defined by
the accumulation of ash on the surface of the filter.
Ash is the inert part of the particulate matter. The
system is designed to collect this particulate matter.
There is a very small percentage of particulate matter
that is left behind as the soot is burnt. This matter will
eventually block the filter, causing loss of
performance and increased fuel consumption. Most
of the ash comes from the engine oil which is
gradually consumed during normal operation. This
ash is passes through the exhaust. To meet the
designed life of the product, the use of the
appropriate engine oil is essential. The oil Illustration 38 g03329707
specification that is listed in table 18 has low ash Lubricant Viscosities
content.
Supplemental heat is recommended for cold soaked
Maintenance intervals for engines that use starts below the minimum ambient temperature.
biodiesel – The oil change interval can be adversely Supplemental heat may be required for cold soaked
affected by the use of biodiesel. Use oil analysis to starts that are above the minimum temperature that
monitor the condition of the engine oil. Use oil is stated, depending on the parasitic load and other
analysis also to determine the oil change interval that factors. Cold soaked starts occur when the engine
is optimum. has not been operated for aperiod of time. This
interval will allow the oil to become more viscous due
to cooler ambient temperatures.
Note: API FA-4 oil is designed for use in selected
on-highway applications and is NOT designed to Aftermarket Oil Additives
support off-road applications, including Perkins
Engines. DO NOT use API FA-4 oil for Perkins Perkins does not recommend the use of aftermarket
engines. These engine oils are not approved by additives in oil. The use of aftermarket additives is
Perkins and these engine oils must not be used: not necessary to achieve the engines maximum
CC, CD, CD-2, CF-4, CG-4, CH-4, and CI-4. service life or rated performance. Fully formulated,
finished oils consist of base oils and of commercial
additive packages. These additive packages are
Lubricant Viscosity Recommendations blended into the base oils at precise percentages to
for Direct Injection (DI) Diesel Engines help provide finished oils with performance
characteristics that meet industry standards.
The correct SAE viscosity grade of oil is determined
by the minimum ambient temperature during cold
engine start-up, and the maximum ambient
temperature during engine operation.
78 SEBU8603-04
Maintenance Section
There are no industry standard tests that evaluate

the performance or the compatibility of aftermarket
additives in finished oil. Aftermarket additives may
not be compatible with the finished oils additive
package, which could lower the performance of the
finished oil. The aftermarket additive could fail to mix
with the finished oil. This failure could produce sludge
in the crankcase. Perkins discourages the use of
aftermarket additives in finished oils.
To achieve the best performance from a Perkins
engine, conform to the following guidelines:
• See the appropriate “Lubricant Viscosities”. Refer
to the illustration 38 to find the correct oil viscosity
grade for your engine.
• At the specified interval, service the engine. Use

new oil and install a new oil filter.
• Perform maintenance at the intervals that are
specified in the Operation and Maintenance
Manual, “Maintenance Interval Schedule”.
Oil analysis
Some engines may be equipped with an oil sampling
valve. If oil analysis is required, the oil sampling valve
is used to obtain samples of the engine oil. The oil
analysis will complement the preventive maintenance
program.
The oil analysis is a diagnostic tool that is used to
determine oil performance and component wear
rates. Contamination can be identified and measured
by using oil analysis. The oil analysis includes the
following tests:
• The Wear Rate Analysis monitors the wear of the
engines metals. The amount of wear metal and
type of wear metal that is in the oil is analyzed.
The increase in the rate of engine wear metal in
the oil is as important as the quantity of engine
wear metal in the oil.
• Tests are conducted to detect contamination of the
oil by water, glycol, or fuel.
• The Oil Condition Analysis determines the loss of
the oils lubricating properties. An infrared analysis
is used to compare the properties of new oil to the
properties of the used oil sample. This analysis
allows technicians to determine the amount of
deterioration of the oil during use. This analysis
also allows technicians to verify the performance
of the oil according to the specification during the
entire oil change interval.
SEBU8603-04 79
Maintenance Section
Maintenance Recommendations
Maintenance • The high-pressure fuel lines are constantly

charged with high pressure.
Recommendations • The internal pressures of the high-pressure fuel
lines are higher than other types of fuel system.
i07819420
Before any service or repair is performed on the
System Pressure Release engine fuel lines, perform the following tasks:
1. Stop the engine.
2. Wait for 10 minutes.
Coolant System
Do not loosen the high-pressure fuel lines to remove
air from the fuel system.
Pressurized system: Hot coolant can cause seri- Engine Oil

ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve To relieve pressure from the lubricating system, turn
the pressure. off the engine.
i07915408
Welding on Engines with

When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid person- Electronic Controls
al injury, always remain clear of the the engine
when the engine is in the AUTOMATIC mode.
The engine can have the ability to auto start. Ensure NOTICE
that the power supply is isolated before any service Because the strength of the frame may decrease,
or repair is performed. some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
To relieve the pressure from the coolant system, turn ment or your Perkins dealer regarding welding on a
off the engine. Allow the cooling system pressure cap chassis frame or rail.
to cool. Remove the cooling system pressure cap
slowly to relieve pressure. Correct welding procedures are necessary to avoid
damage to the engines ECM, sensors, and
associated components. When possible, remove the
Fuel System component from the unit and then weld the
component. If removal of the component is not
To relieve the pressure from the fuel system, turn off possible, the following procedure must be followed
the engine. when you weld on a unit equipped with an Electronic
Engine. The following procedure is considered to be
High-Pressure Fuel Lines the safest procedure to weld on a component. This
procedure should provide a minimum risk of damage
to electronic components.
NOTICE
Contact with high pressure fuel may cause fluid Do not ground the welder to electrical components
penetration and burn hazards. High pressure fuel such as the ECM or sensors. Improper grounding
spray may cause a fire hazard. Failure to follow can cause damage to the drive train bearings, hy-
these inspection, maintenance and service in- draulic components, electrical components, and oth-
structions may cause personal injury or death. er components.
The high-pressure fuel lines are the fuel lines that are Clamp the ground cable from the welder to the com-
between the high-pressure fuel pump and the high- ponent that will be welded. Place the clamp as close
pressure fuel manifold and the fuel lines that are as possible to the weld. This will help reduce the pos-
between the fuel manifold and the fuel injectors. sibility of damage.
The high-pressure fuel lines are different from fuel
lines on other fuel systems, the differences are as Note: Perform the welding in areas that are free from
follows: explosive hazards.
80 SEBU8603-04
Maintenance Section
Welding on Engines with Electronic Controls
1. Stop the engine. Turn the switched power to the

OFF position.
2. Ensure that the fuel supply to the engine is turned
off.
3. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
open the switch.
4. Disconnect all electronic components from the
wiring harnesses. Include the following
components:
• Electronic components for the driven

equipment
• ECM
• Sensors
• Electric operated fuel pump

• Electronically controlled valves
Use the example above. The current flow from the
• Relays welder to the ground clamp of the welder will not
damage any associated components.
• Aftertreatment ID module (1) Engine
(2) Welding electrode
(3) Keyswitch in the OFF position
NOTICE (4) Battery disconnect switch in the open position
Do not use electrical components (ECM or ECM sen- (5) Disconnected battery cables
sors) or electronic component grounding points for (6) Battery
grounding the welder. (7) Electrical/Electronic component
(8) The component that is being welded
(9) Current path of the welder
(10) Ground clamp for the welder
5. Connect the welding ground cable directly to the

part that will be welded. Place the ground cable as
close as possible to the weld to reduce the
possibility of welding current damage to the
following components. Bearings, hydraulic
components, electrical components, and ground
straps.
Note: If electrical/electronic components are used as
a ground for the welder, or electrical/electronic
components are located between the welder ground
and the weld, current flow from the welder could
severely damage the component.
6. Protect the wiring harness from welding debris and

spatter.
7. Use standard welding practices to weld the
materials.
SEBU8603-04 81
Maintenance Section
Maintenance Interval Schedule
i08423550 “ Engine Oil and Filter - Change“. . . . . . . . . . . . . . 101
Maintenance Interval Schedule Every 500 Service Hours or 1 Year

“ Battery Electrolyte Level - Check“ . . . . . . . . . . . . 83
When Required “ Cooling System Supplemental Coolant Additive
(SCA) - Test/Add“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
“ Battery - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 82
“ Engine Air Cleaner Element (Dual Element) - Clean/
“ Battery or Battery Cable - Disconnect“ . . . . . . . . . 83 Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
“ Engine - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 “ Engine Air Cleaner Element (Single Element) -

Inspect/Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
“ Engine Air Cleaner Element (Dual Element) - Clean/
Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 “ Fuel System Primary Filter (Water Separator)
Element - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . 103
“ Engine Air Cleaner Element (Single Element) -
Inspect/Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 “ Fuel System Secondary Filter - Replace“. . . . . . 105
“ Engine Oil Sample - Obtain“ . . . . . . . . . . . . . . . . 100 “ Radiator - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . 109
“ Fuel System - Prime“ . . . . . . . . . . . . . . . . . . . . . . 102 Every 1000 Service Hours

“ Severe Service Application - Check“ . . . . . . . . . 109
“ Water Pump - Inspect“. . . . . . . . . . . . . . . . . . . . . 113
Daily
Every 1500 Service Hours
“ Cooling System Coolant Level - Check“. . . . . . . . 88
“ Engine Crankcase Breather Element -
“ Driven Equipment - Check“ . . . . . . . . . . . . . . . . . . 90 Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
“ Engine Air Cleaner Service Indicator - Inspect“ . . 94 “ Engine Crankcase Breather Element -
Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
“ Engine Air Precleaner - Check/Clean“ . . . . . . . . . 94
“ Engine Oil Level - Check“ . . . . . . . . . . . . . . . . . . 100 Every 2000 Service Hours
“ Fuel System Primary Filter/Water Separator - “ Aftercooler Core - Inspect“ . . . . . . . . . . . . . . . . . . 82
Drain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
“ Engine Mounts - Inspect“ . . . . . . . . . . . . . . . . . . . 99
“ Walk-Around Inspection“ . . . . . . . . . . . . . . . . . . . .111
“ Starting Motor - Inspect“ . . . . . . . . . . . . . . . . . . . 110
Every 12 000 Service Hours or 6 “ Turbocharger - Inspect“ . . . . . . . . . . . . . . . . . . . . 110
Years
“ Cooling System Coolant (ELC) - Change“ . . . . . . 86
“ Alternator - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . 82
Every Week
“ Alternator and Fan Belts - Replace“ . . . . . . . . . . . 82
“ Hoses and Clamps - Inspect/Replace“. . . . . . . . 108
“ Belt Tensioner - Inspect“ . . . . . . . . . . . . . . . . . . . . 84
Every 50 Service Hours or Weekly Every 3000 Service Hours or 2
“ Fuel Tank Water and Sediment - Drain“ . . . . . . . 107 Years
“ Cooling System Coolant (Commercial Heavy-Duty)
Every 500 Service Hours - Change“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
“ Belt - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
“ Aftercooler Core - Clean/Test“ . . . . . . . . . . . . . . . 82
82 SEBU8603-04
Maintenance Section
Aftercooler Core - Clean/Test
i01807350 i02322311
Aftercooler Core - Clean/Test Alternator - Inspect

(Air-To-Air Aftercooler)
Perkins recommends a scheduled inspection of the
alternator. Inspect the alternator for loose
The air-to-air aftercooler is OEM installed in many connections and correct battery charging. Check the
applications. Please refer to the OEM specifications ammeter (if equipped) during engine operation in
for information that is related to the aftercooler. order to ensure correct battery performance and/or
correct performance of the electrical system. Make
i02322295 repairs, as required.
Aftercooler Core - Inspect Check the alternator and the battery charger for
correct operation. If the batteries are correctly
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
Note: Adjust the frequency of cleaning according to batteries should be kept warm because temperature
the effects of the operating environment. affects the cranking power. If the battery is too cold,
the battery will not crank the engine. When the
Inspect the aftercooler for these items: damaged fins, engine is not run for long periods of time or if the
corrosion, dirt, grease, insects, leaves, oil and other engine is run for short periods, the batteries may not
debris. Clean the aftercooler, if necessary. fully charge. A battery with a low charge will freeze
more easily than a battery with a full charge.
For air-to-air aftercoolers, use the same methods that
are used for cleaning radiators.
i02680137
Alternator and Fan Belts -

Personal injury can result from air pressure. Replace
Personal injury can result without following prop-
er procedure. When using pressure air, wear a
Refer to Disassembly and Assembly Manual , “
protective face shield and protective clothing.
Alternator Belt - Remove and Install”.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes. i03559623
After cleaning, start the engine and accelerate the

Battery - Replace
engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine. Use
a light bulb behind the core in order to inspect the
core for cleanliness. Repeat the cleaning, if
necessary.
Batteries give off combustible gases which can
Inspect the fins for damage. Bent fins may be opened explode. A spark can cause the combustible
with a “comb”. gases to ignite. This can result in severe personal
injury or death.
Note: If parts of the aftercooler system are repaired
or replaced, a leak test is highly recommended. Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
Inspect these items for good condition: Welds, der to help prevent electrical arcs and/or sparks
mounting brackets, air lines, connections, clamps near batteries. Do not smoke when batteries are
serviced.
and seals. Make repairs, if necessary.
SEBU8603-04 83
Maintenance Section
Battery Electrolyte Level - Check
The battery cables or the batteries should not be All lead-acid batteries contain sulfuric acid which
removed with the battery cover in place. The bat- can burn the skin and clothing. Always wear a
tery cover should be removed before any servic- face shield and protective clothing when working
ing is attempted. on or near batteries.
Removing the battery cables or the batteries with

the cover in place may cause a battery explosion 1. Remove the filler caps. Maintain the electrolyte
resulting in personal injury. level to the “FULL” mark on the battery.
If the addition of water is necessary, use distilled
1. Switch the engine to the OFF position. Remove all water. If distilled water is not available use clean
electrical loads. water that is low in minerals. Do not use artificially
softened water.
2. Turn off any battery chargers. Disconnect any
battery chargers. 2. Check the condition of the electrolyte with a
3. Ensure that the battery disconnect switch is in the suitable battery tester.
OFF position. 3. Install the caps.
4. Disconnect the NEGATIVE “-” cable from the 4. Keep the batteries clean.
NEGATIVE “-” battery terminal.
Clean the battery case with one of the following
5. Disconnect the POSITIVE “+” cable from the cleaning solutions:
POSITIVE “+” battery terminal.
• Use a solution of 0.1 kg (0.2 lb) baking soda
Note: Always recycle a battery. Never discard a and 1 L (1 qt) of clean water.
battery. Dispose of used batteries to an appropriate
recycling facility. • Use a solution of ammonium hydroxide.
6. Remove the used battery. Thoroughly rinse the battery case with clean
water.
7. Install the new battery.
Note: Before the cables are connected, ensure that i07819485
the battery disconnect switch is in the OFF position.
Battery or Battery Cable -
8. Connect the POSITIVE “+” cable to the POSITIVE
“+” battery terminal.
Disconnect
9. Connect the NEGATIVE “-” cable to the
NEGATIVE “-” battery terminal.
10. Turn the battery disconnect switch to the ON
position. The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
i02747977
ing is attempted.
Battery Electrolyte Level - Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
Check resulting in personal injury.
When the engine is not run for long periods of time or 1. Turn the start switch to the OFF position. Turn the
when the engine is run for short periods, the batteries ignition switch (if equipped) to the OFF position
may not fully recharge. Ensure a full charge in order and remove the key and all electrical loads.
to help prevent the battery from freezing. If batteries
are correctly charged, the ammeter reading should 2. Disconnect the negative battery terminal. Ensure
be very near zero, when the engine is in operation. that the cable cannot contact the terminal. When
four 12 volt batteries are involved, two negative
connection must be disconnected.
3. Remove the positive connection.
84 SEBU8603-04
Maintenance Section
Belt - Inspect
4. Clean all disconnected connection and battery The belt must be replaced if the following conditions
terminals. are present.
5. Use a fine grade of sandpaper to clean the • The belt has a crack in more than one rib.
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT • More than one section of the belt is displaced in
remove material excessively. Excessive removal one rib of a maximum length of 50.8 mm (2 inch).
of material can cause the clamps to not fit To replace the belt, refer to Disassembly and
correctly. Coat the clamps and the terminals with a Assembly, “Alternator Belt - Remove and Install”. If
suitable silicone lubricant or petroleum jelly. necessary, replace the belt tensioner. Refer to
Disassembly and Assembly, “Alternator Belt -
6. Tape the cable connections to help prevent Remove and Install” for the correct procedure.
accidental starting.
i03868550
7. Proceed with necessary system repairs.
8. To connect the battery, connect the positive Belt Tensioner - Inspect
connection before the negative connection.
i03973719
Belt - Inspect
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
Typical example
Remove the belt. Refer to Disassembly and

Assembly, “Alternator Belt - Remove and Install”.
Ensure that the belt tensioner is securely installed.
Visually inspect the belt tensioner (2) for damage.
Check that the pulley on the tensioner rotates freely
and that the bearing is not loose. Some engines have
an idler pulley (1). Ensure that the idler pulley is
securely installed. Visually inspect the idler pulley for
Typical example damage. Ensure that the idler pulley can rotate freely
and that the bearing is not loose. If necessary,
To maximize the engine performance, inspect the replace damaged components.
belt (1) for wear and for cracking. Replace the belt if
the belt is worn or damaged. Install the belt. Refer to Disassembly and Assembly,
“Alternator Belt - Remove and Install”.
• Inspect the belt for cracks, splits, glazing, grease,
displacement of the cord and evidence of fluid
contamination.
SEBU8603-04 85
Maintenance Section
Cooling System Coolant (Commercial Heavy-Duty) - Change
i04007090 Drain
Cooling System Coolant
(Commercial Heavy-Duty - Pressurized System: Hot coolant can cause seri-
Change ous burns. To open the cooling system filler cap,
NOTICE pressure.
nance, testing, adjusting and repair of the product. 1. Stop the engine and allow the engine to cool.
Be prepared to collect the fluid with suitable contain- Loosen the cooling system filler cap slowly in
ers before opening any compartment or disassem- order to relieve any pressure. Remove the cooling
bling any component containing fluids. system filler cap.
Dispose of all fluids according to Local regulations
and mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.
• Foaming of the coolant is observed.

• The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the
Note: When the cooling system is cleaned, only
clean water is needed. Typical example
2. Open the drain cock or remove the drain plug (1)

NOTICE
When any servicing or repair of the engine cooling on the engine. Also, remove the drain plug (2).
system is performed the procedure must be per- Open the drain cock or remove the drain plug on
formed with the engine on level ground. This will al- the radiator.
low you to accurately check the coolant level. This
will also help in avoiding the risk of introducing an air Allow the coolant to drain.
lock into the coolant system.
NOTICE
Dispose of used engine coolant or recycle. Various
methods have been proposed to reclaim used cool-
ant for reuse in engine cooling systems. The full distil-
lation procedure is the only method acceptable by
Perkins to reclaim the coolant.
86 SEBU8603-04
Maintenance Section
Cooling System Coolant (ELC) - Change
For information regarding the disposal and the 3. Start and run the engine at low idle. Increase the
recycling of used coolant, consult your Perkins dealer engine rpm to high idle. Operate the engine in
or your Perkins distributor. order to open the engine thermostat. This
procedure will allow any air in the system to be
Flush purged. Decrease the engine speed to low idle.
Stop the engine.
1. Flush the cooling system with clean water in order
to remove any debris. 4. Maintain the coolant level at the maximum mark
that is correct for your application.
2. Close the drain cock or install the drain plug in the
engine. Close the drain cock or install the drain
plug on the radiator.
NOTICE
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute, in order to avoid air locks.
Cooling system air locks may result in engine
damage.
3. Fill the cooling system with clean water. Install the

cooling system filler cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
5. Stop the engine and allow the engine to cool. Filler cap
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling 5. Clean the cooling system filler cap and inspect the
system filler cap. Open the drain cock or remove gasket. If the gasket is damaged, discard the old
the drain plug on the engine. Open the drain cock filler cap and install a new filler cap. If the gasket is
or remove the drain plug on the radiator. Allow the not damaged, use a suitable pressurizing pump in
water to drain. Flush the cooling system with clean order to pressure test the filler cap. The correct
water. pressure is stamped on the face of the filler cap. If
the filler cap does not retain the correct pressure,
Fill install a new filler cap.
1. Close the drain cock or install the drain plug on the 6. Start the engine. Inspect the cooling system for
engine. Close the drain cock or install the drain leaks and for correct operating temperature.
plug on the radiator.
i04007109
NOTICE
Do not fill the cooling system faster than 5 L Cooling System Coolant (ELC
- Change
damage.
NOTICE
2. Fill the cooling system with Commercial Heavy- Care must be taken to ensure that fluids are con-
Duty Coolant. Add Supplemental Coolant Additive tained during performance of inspection, mainte-
to the coolant. For the correct amount, refer to the nance, testing, adjusting and repair of the product.
Operation and Maintenance Manual, “Fluid ers before opening any compartment or disassem-
Recommendations” topic (Maintenance Section) bling any component containing fluids.
for more information on cooling system
specifications. Do not install the cooling system Dispose of all fluids according to Local regulations
filler cap. and mandates.
SEBU8603-04 87
Maintenance Section
Cooling System Coolant (ELC) - Change
NOTICE
component life.
Clean the cooling system and flush the cooling

system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.
• Foaming of the coolant is observed.

• The oil has entered the cooling system and the
• The fuel has entered the cooling system and the
Note: When the cooling system is cleaned, only

clean water is needed when the ELC is drained and
replaced.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has 2. Open the drain cock or remove the drain plug (1)
been drained. This inspection is a good opportunity on the engine. Also remove the drain plug (2).
to replace the water pump, the water temperature Open the drain cock or remove the drain plug on
regulator, and the hoses, if necessary. the radiator.
NOTICE Note: There are two drain plugs on the cooler, only
When any servicing or repair of the engine cooling one is required for draining.
system is performed, the procedure must be per-
formed with the engine on level ground. This proce- Allow the coolant to drain.
dure will allow you to accurately check the coolant
level. This procedure will also help in avoiding the risk NOTICE
of introducing an air lock into the coolant system. Dispose of used engine coolant or recycle. Various
methods have been proposed to reclaim used cool-
ant for reuse in engine cooling systems. The full distil-
Drain lation procedure is the only method acceptable by
Perkins to reclaim the coolant.
For information regarding the disposal and the

Pressurized System: Hot coolant can cause seri- recycling of used coolant, consult your Perkins dealer
ous burns. To open the cooling system filler cap, or your Perkins distributor.
components are cool. Loosen the cooling system Flush
pressure.
1. Flush the cooling system with clean water in order
to remove any debris.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in 2. Close the drain cock or install the drain plugs.
order to relieve any pressure. Remove the cooling Close the drain cock or install the drain plug on the
system filler cap. radiator.
NOTICE
Do not fill the cooling system faster than 5 L
damage.
88 SEBU8603-04
Maintenance Section
Cooling System Coolant Level - Check
3. Fill the cooling system with clean water. Install the

cooling system filler cap.
4. Start and run the engine at low idle until the
temperature reaches 49 to 66 °C (120 to 150 °F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the drain cock or remove
the drain plug on the engine. Open the drain cock
or remove the drain plug on the radiator. Allow the
water to drain. Flush the cooling system with clean
water.
Fill Illustration 45 g00103639

Filler cap
1. Close the drain cock or install the drain plug on the
engine. Close the drain cock or install the drain 5. Clean the cooling system filler cap and inspect the
plug on the radiator. gasket. If the gasket is damaged, discard the old
filler cap and install a new filler cap. If the gasket is
NOTICE not damaged, use a suitable pressurizing pump in
Do not fill the cooling system faster than 5 L order to test the pressure of the filler cap. The
(1.3 US gal) per minute, in order to avoid air locks. correct pressure is stamped on the face of the filler
Cooling system air locks may result in engine cap. If the filler cap does not retain the correct
damage. pressure, install a new filler cap.
6. Start the engine. Inspect the cooling system for
2. Fill the cooling system with Extended Life Coolant leaks and for correct operating temperature.
(ELC). Refer to the Operation and Maintenance
Manual, “Fluid Recommendations” topic i04408743
(Maintenance Section) for more information on
cooling system specifications. Do not install the Cooling System Coolant Level
cooling system filler cap. - Check
3. Start and run the engine at low idle. Increase the
engine rpm to high idle. Operate the engine in
order to open the engine thermostat. Operate the Engines With a Coolant Recovery
engine will allow any air in the system to be
purged. Decrease the engine speed to low idle. Tank
Stop the engine.
Note: The cooling system may not have been
4. Maintain the coolant level at the maximum mark provided by Perkins. The procedure that follows is for
that is correct for your application. typical cooling systems. Refer to the OEM
information for the correct procedures.
Check the coolant level when the engine is stopped
and cool.
NOTICE
When any servicing or repair of the engine cooling
system is performed, the procedure must be per-
formed with the engine on level ground. This will al-
low you to accurately check the coolant level. This
will also help in avoiding the risk of introducing an air
lock into the coolant system.
1. Observe the coolant level in the coolant recovery

tank. Maintain the coolant level to “COLD FULL”
mark on the coolant recovery tank.
SEBU8603-04 89
Maintenance Section
Cooling System Coolant Level - Check

pressure.
2. Loosen filler cap slowly in order to relieve any

pressure. Remove the filler cap.
3. Pour the correct coolant mixture into the tank.
Refer to the Operation and Maintenance Manual,
“Refill Capacities and Recommendations” for
information on the correct mixture and type of Illustration 47 g00285520
coolant. Refer to the Operation and Maintenance Cooling system filler cap
Manual, “Refill Capacities and Recommendations”
for the cooling system capacity. Do not fill the
coolant recovery tank above “COLD FULL” mark.
pressure.
1. Remove the cooling system filler cap slowly in

order to relieve pressure.
2. Maintain the coolant level at the maximum mark
that is correct for your application. If the engine is
equipped with a sight glass, maintain the coolant
level to the correct level in the sight glass.
3. Clean the cooling system filler cap and inspect the
gasket. If the gasket is damaged, discard the old
not damaged, use a suitable pressurizing pump in
order to pressure test the filler cap. The correct
pressure is stamped on the face of the filler cap. If
the filler cap does not retain the correct pressure,
install a new filler cap.
Filler cap
4. Clean filler cap and the receptacle. Reinstall the

filler cap and inspect the cooling system for leaks.
Note: The coolant will expand as the coolant heats
up during normal engine operation. The additional
volume will be forced into the coolant recovery tank
during engine operation. When the engine is stopped
and cool, the coolant will return to the engine.
Engines Without a Coolant

Recovery Tank
Check the coolant level when the engine is stopped
and cool.
90 SEBU8603-04
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
4. Inspect the cooling system for leaks.

NOTICE
When any servicing or repair of the engine cooling
i03644948 system is performed the procedure must be per-
formed with the engine on level ground. This will al-
Cooling System Supplemental low you to accurately check the coolant level. This
will also help in avoiding the risk of introducing an air
Coolant Additive (SCA - Test/ lock into the coolant system.
Add
1. Slowly loosen the cooling system filler cap in order
to relieve the pressure. Remove the cooling
system filler cap.
Note: Always discard drained fluids according to
Cooling system coolant additive contains alkali. local regulations.
To help prevent personal injury, avoid contact
with the skin and the eyes. Do not drink cooling
2. If necessary, drain some coolant from the cooling
system coolant additive.
system into a suitable container in order to allow
space for the extra SCA.
Test for SCA Concentration 3. Add the correct amount of SCA. Refer to the
Operation and Maintenance Manual, “Refill
Heavy-Duty Coolant/Antifreeze and SCA Capacities and Recommendations” for more
information on SCA requirements.
NOTICE 4. Clean the cooling system filler cap and inspect the
Do not exceed the recommended six percent supple- gasket. If the gasket is damaged, discard the old
mental coolant additive concentration.
Use a Coolant Conditioner Test Kit in order to check not damaged, use a suitable pressurizing pump in
the concentration of the SCA. order to pressure test the filler cap. The correct
pressure is stamped on the face of the filler cap. If
Add the SCA, If Necessary the filler cap does not retain the correct pressure,
install a new filler cap.
NOTICE
Do not exceed the recommended amount of supple- i02151646
mental coolant additive concentration. Excessive
supplemental coolant additive concentration can form
deposits on the higher temperature surfaces of the
Driven Equipment - Check
cooling system, reducing the engine's heat transfer
characteristics. Reduced heat transfer could cause
cracking of the cylinder head and other high tempera- Refer to the OEM specifications for more information
ture components. Excessive supplemental coolant on the following maintenance recommendations for
additive concentration could also result in radiator the driven equipment:
tube blockage, overheating, and/or accelerated water
pump seal wear. Never use both liquid supplemental • Inspection
coolant additive and the spin-on element (if
equipped) at the same time. The use of those addi- • Adjustment
tives together could result in supplemental coolant
additive concentration exceeding the recommended • Lubrication
maximum.
• Other maintenance recommendations
Perform any maintenance for the driven equipment
which is recommended by the OEM.
pressure.
SEBU8603-04 91
Maintenance Section
Engine - Clean
i07819515 Aftertreatment
Engine - Clean During the engine cleaning process, ensure that
water or cleaning fluids cannot enter the
aftertreatment system. If cleaning fluids enters the
aftertreatment system, damage could occur.
i02334355
Personal injury or death can result from high
voltage. Engine Air Cleaner Element
Moisture can create paths of electrical (Dual Element) - Clean/Replace
conductivity.
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “ DO NOTICE
NOT OPERATE”” . Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements
NOTICE with damaged pleats, gaskets or seals. Dirt entering
Accumulated grease and oil on an engine is a fire the engine causes premature wear and damage to
hazard. Keep the engine clean. Remove debris and engine components. Air cleaner elements help to pre-
fluid spills whenever a significant quantity accumu- vent airborne debris from entering the air inlet.
lates on the engine.
Periodic cleaning of the engine is recommended. NOTICE
Steam cleaning the engine will remove accumulated Never service the air cleaner element with the engine
oil and grease. A clean engine provides the following running since this will allow dirt to enter the engine.
benefits:
• Easy detection of fluid leaks

Servicing the Air Cleaner Elements
• Maximum heat transfer characteristics
Note: The air filter system may not have been
• Ease of maintenance provided by Perkins. The procedure that follows is for
a typical air filter system. Refer to the OEM
Note: Caution must be used to prevent electrical information for the correct procedure.
components from being damaged by excessive water
when the engine is cleaned. Pressure washers and If the air cleaner element becomes plugged, the air
steam cleaners should not be directed at any can split the material of the air cleaner element.
electrical connectors or the junction of cables into the Unfiltered air will drastically accelerate internal
rear of the connectors. Avoid electrical components engine wear. Refer to the OEM information for the
such as the alternator, the starter, and the ECM. correct air cleaner elements for your application.
Protect the fuel injection pump from fluids to wash the
• Check the precleaner (if equipped) and the dust
engine.
bowl daily for accumulation of dirt and debris.
Ensure that care is taken that the safety labels, Remove any dirt and debris, as needed.
emission label, and all other information labels are
not removed during engine cleaning. • Operating in dirty conditions may require more
frequent service of the air cleaner element.
• The air cleaner element should be replaced at
least one time per year. This replacement should
be performed regardless of the number of
cleanings.
Replace the dirty air cleaner elements with clean air
cleaner elements. Before installation, the air cleaner
elements should be thoroughly checked for tears
and/or holes in the filter material. Inspect the gasket
or the seal of the air cleaner element for damage.
Maintain a supply of suitable air cleaner elements for
replacement purposes.
92 SEBU8603-04
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
Dual Element Air Cleaners 7. Reset the air cleaner service indicator.
The dual element air cleaner contains a primary air
cleaner element and a secondary air cleaner
Cleaning the Primary Air Cleaner
element. Elements
The primary air cleaner element can be used up to Refer to the OEM information in order to determine
six times if the element is properly cleaned and the number of times that the primary filter element
properly inspected. The primary air cleaner element can be cleaned. When the primary air cleaner
should be replaced at least one time per year. This element is cleaned, check for rips or tears in the filter
replacement should be performed regardless of the material. The primary air cleaner element should be
number of cleanings. replaced at least one time per year. This replacement
should be performed regardless of the number of
The secondary air cleaner element is not serviceable. cleanings.
Refer to the OEM information for instructions in order
to replace the secondary air cleaner element.
NOTICE
When the engine is operating in environments that Do not tap or strike the air cleaner element.
are dusty or dirty, air cleaner elements may require Do not wash the primary air cleaner element.
more frequent replacement.
Use low pressure (207 kPa; 30 psi maximum) pres-
surised air or vacuum cleaning to clean the primary
air cleaner element.
Take extreme care in order to avoid damage to the air
cleaner elements.
Do not use air cleaner elements that have damaged
pleats, gaskets or seals.
Refer to the OEM information in order to determine

the number of times that the primary air cleaner
element can be cleaned. Do not clean the primary air
filter element more than three times. The primary air
cleaner element must be replaced at least one time
per year.
(1) Cover Cleaning the air filter element will not extend the life
(2) Primary air cleaner element of the air filter element.
(3) Secondary air cleaner element
(4) Air inlet Visually inspect the primary air cleaner element
before cleaning. Inspect air cleaner elements for
1. Remove the cover. Remove the primary air cleaner damage to the pleats, the seals, the gaskets and the
element. outer cover. Discard any damaged air cleaner
element.
2. The secondary air cleaner element should be
Two methods may be used in order to clean the
removed and discarded for every three cleanings
primary air cleaner element:
of the primary air cleaner element.
• pressurized air
Note: Refer to “Cleaning the Primary Air Cleaner
Elements”. • Vacuum cleaning
3. Cover the air inlet with tape in order to keep dirt
out.
4. Clean the inside of the air cleaner cover and body
with a clean, dry cloth.
5. Remove the tapefrom the air inlet. Install the
secondary air cleaner element. Install a primary air
cleaner element that is new or cleaned.
6. Install the air cleaner cover.
SEBU8603-04 93
Maintenance Section
Engine Air Cleaner Element (Single Element) - Inspect/Replace
Pressurized Air Note: Refer to “Inspecting the Primary Air Cleaner

Elements”.
Inspecting the Primary Air Cleaner

Personal injury can result from air pressure. Elements
Personal injury can result without following prop-
protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Pressurized air can be used to clean primary air

cleaner elements that have not been cleaned more
than three times. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi). Pressurized air will not
remove deposits of carbon and oil.
Inspect the clean, dry primary air cleaner element.

Use a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears and/
or holes. Inspect the primary air cleaner element for
light that may show through the filter material. If it is
necessary in order to confirm the result, compare the
primary air cleaner element to a new primary air
cleaner element that has the same part number.
Do not use a primary air cleaner element that has
Note: When the primary air cleaner elements are any tears and/or holes in the filter material. Do not
cleaned, always begin with the clean side (inside) in use a primary air cleaner element with damaged
order to force dirt particles toward the dirty side pleats, gaskets or seals. Discard damaged primary
(outside). air cleaner elements.
Aim the air hose so that air flows along the length of i02152042
the filter. Follow the direction of the paper pleats in
order to prevent damage to the pleats. Do not aim the
air directly at the face of the paper pleats. Engine Air Cleaner Element
Note: Refer to “Inspecting the Primary Air Cleaner
(Single Element - Inspect/
Elements”. Replace
Vacuum Cleaning
Refer to Operation and Maintenance Manual,
Vacuum cleaning is a good method for removing “Engine Air Cleaner Service Indicator-Inspect”.
accumulated dirt from the dirty side (outside) of a
primary air cleaner element. Vacuum cleaning is NOTICE
especially useful for cleaning primary air cleaner Never run the engine without an air cleaner element
elements which require daily cleaning because of a installed. Never run the engine with a damaged air
dry, dusty environment. cleaner element. Do not use air cleaner elements
with damaged pleats, gaskets or seals. Dirt entering
Cleaning from the clean side (inside) with the engine causes premature wear and damage to
pressurized air is recommended prior to vacuum engine components. Air cleaner elements help to pre-
cleaning the dirty side (outside) of a primary air vent airborne debris from entering the air inlet.
cleaner element.
94 SEBU8603-04
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
• Check for ease of resetting. The service indicator

NOTICE
Never service the air cleaner element with the engine should reset in less than three pushes.
running since this will allow dirt to enter the engine.
• Check the movement of the yellow core when the
engine is accelerated to the engine rated speed.
A wide variety of air cleaners may be installed for use The yellow core should latch at the greatest
with this engine. Consult the OEM information for the vacuum that is attained.
correct procedure to replace the air cleaner.
If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
i02335405
the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
Engine Air Cleaner Service indicator may be restricted.
Indicator - Inspect The service indicator may need to be replaced
frequently in environments that are severely dusty.
Some engines may be equipped with a different i05967804

service indicator.
Some engines are equipped with a differential gauge Engine Air Precleaner - Check/
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
Clean
that is measured before the air cleaner element and (If Equipped)
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner element or in a remote location.
Typical example
(1) Wing nut
(2) Cover
(3) Body
Illustration 51 g00103777 Remove wing nut (1) and cover (2). Check for an
Typical service indicator accumulation of dirt and debris in body (3). Clean the
body, if necessary.
Observe the service indicator. The air cleaner
element should be cleaned or the air cleaner element After cleaning the precleaner, install cover (2) and
should be replaced when one of the following wing nut (1).
conditions occur:
Note: When the engine is operated in dusty
• The yellow diaphragm enters the red zone. applications, more frequent cleaning is required.
• The red piston locks in the visible position.
Test the Service Indicator

Service indicators are important instruments.
SEBU8603-04 95
Maintenance Section
Engine Crankcase Breather Element - Replace
i08410458 The breather element can be serviced from the top

position or the breather element can be serviced from
Engine Crankcase Breather the bottom position.
Element - Replace Top Service

(Type 1)
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
NOTICE
NOTICE
nance, testing, adjusting and repair of the product.
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to Local regulations
and mandates.
The crankcase breather is a very important
component to keep your engine emissions compliant.
• The filter element within the crankcase breather
must be serviced at the prescribed service
interval.
1. Ensure that dirt cannot enter the breather
• The correct filter element must be installed before assembly. Ensure that the outside body of the
the engine is operated. breather assembly is clean and free from damage.
Place a container under the breather assembly.
• The installation of the filter element is very
important. 2. Rotate the top cap (1) counterclockwise into the
unlocked position. Remove the top cap from the
• The quality of the filter element that is installed is body of the breather (3).
very important.
Note: The cap (1) is tightened or loosened by hand.
• The filter element protects the engine from If the cap (1) is difficult to remove, use a suitable tool
excessive quantities of oil from entering the to apply a suitable force to assist the removal of the
induction system. The filter element also protects cap (1). Care should be taken, as excessive force
the engine aftertreatment system. may cause damage to the cap (1).
Note: Excessive quantities of oil that enter the
3. Note the orientation of the filter element (2).
induction system of the engine can rapidly increase
the engine speed without control. Remove the filter element.
For information on aftermarket products, refer to

Description”. Within that section, refer to the title
“Aftermarket Products and Perkins Engines”.
96 SEBU8603-04
Maintenance Section
Type 1
5. Install a new filter element into the breather body

(3). Ensure the correct position of the element,
refer to illustration 55 . Align position (A) on the top
cap to position (B) on the filter element.
Typical example
4. Remove the old seal (4) and install a new seal.
Note: The cut away from section (5) in the top cap Illustration 56 g02346577
allows access to the seal. Typical example
6. Install the top cap (1). Rotate the top cap by hand
clockwise until the top cap locks into the locked
position (C) on the breather body.
7. Remove the container.
Bottom Service
Ensure that dirt cannot enter the breather assembly.
(A) Alignment position
(B) Alignment position
SEBU8603-04 97
Maintenance Section
Type 1
Typical example
(X) Alignment mark
(Y) Alignment mark
1. Ensure that the outside body of the breather

assembly is clean and free from damage. Place a Illustration 58 g03090968
container under the breather. Typical example
2. Remove the tube connection (1). Ensure that dirt (A) Alignment postion
(B) Alignment postion
cannot enter the tube connection. Note the
position of the alignment marks (X and Y). Rotate
3. Note the orientation of the filter element. Remove
the bottom cap (2) counterclockwise to release the
the filter element (4) from the bottom cap (2).
cap and the filter element (4) from the breather
Remove the seal (5).
body (3).
Note: The bottom cap has a section that allows
access to remove the seal.
4. Install a new seal (5). Install a new filter element

into the bottom cap (2).
5. Align position (A) on the top cap to position (B) on
the filter element. Refer to illustration 58 .
6. Install the assembly of the filter element and the
bottom cap (2). Rotate the bottom cap by hand
clockwise until the bottom cap locks into the
locked position on the breather body. Ensure that
the alignment marks (X and Y) are correctly
aligned. Refer to illustration 57 .
98 SEBU8603-04
Maintenance Section
Engine Crankcase Breather Element - Replace
7. Install tube connection (1). Ensure that the • The filter element within the crankcase breather
retaining clips on the tube connection are correctly must be serviced at the prescribed service
engaged. Remove the container. interval.
• The correct filter element must be installed before

Check the System the engine is operated.
• The installation of the filter element is very

important.
• The quality of the filter element that is installed is
very important.
• The filter element protects the engine from
excessive quantities of oil from entering the
induction system. The filter element also protects
the engine aftertreatment system.
Note: Excessive quantities of oil that enter the

induction system of the engine can rapidly increase
the engine speed without control.
For information on aftermarket products, refer to
Description”. Within that section, refer to the title
“Aftermarket Products and Perkins Engines”.
Typical example
Inspect the breather tube (1) for damage. Ensure that

the outlet (2) is clean and free from any obstructions.
Ice can cause obstructions in adverse weather
conditions.
i08421031
Engine Crankcase Breather

Element - Replace
(Type 2)
Hot oil and hot components can cause personal Illustration 60 g06623961
injury. Do not allow hot oil or hot components to Typical example
contact the skin.
1. Ensure that dirt cannot enter the breather
assembly. Ensure that the outside body of the
NOTICE
Ensure that the engine is stopped before any servic- breather assembly is clean and free from damage.
ing or repair is performed. Place a container under the breather assembly.
The crankcase breather is a very important 2. Rotate the cap (1) counterclockwise into the
component in order to keep your engine emissions unlocked position. Remove the cap from the body
compliant. of the breather (3).
SEBU8603-04 99
Maintenance Section
Engine Mounts - Inspect
Note: The cap (1) is tightened or loosened by hand. 6. Install the cap (1). Rotate the cap by hand
If the cap (1) is difficult to remove, use a suitable tool clockwise until the cap locks into the locked
to apply a suitable force to assist the removal of the position C on the breather body.
cap (1). Care should be taken, as excessive force
may cause damage to the cap (1). 7. Remove the container.
3. Note the orientation of the filter element (2). Check the System
Remove the filter element .
(B) Alignment position
Note: The cut away from section (5) in the cap allows
access to the seal.
4. Remove the old seal (4) and install a new seal. Illustration 63 g02416001
(1) Connection to breather cap for the engine
5. Install a new filter element into the breather body (2) Oil drain
(3) and orient the filter element so that position (A) (3) Tube assembly to atmosphere
(4) Outlet
is aligned. Refer to illustration 60 . Align position
(A) on the filter element to position (B) on the cap. Check the system for damage. Replace any
component that is damaged. Ensure that the outlet
(4) is clear and free from obstructions.
i07819538
Engine Mounts - Inspect
Note: The engine mounts may not have been

supplied by Perkins. Refer to the Original Equipment
Manufacturer (OEM) information for further details on
the engine mounts and the correct bolt torque.
Inspect the engine mounts for deterioration and for
correct bolt torque. Excessive engine vibration can
Illustration 62 g06623944 be caused by the following conditions:
Typical example • Incorrect mounting of the engine
100 SEBU8603-04
Maintenance Section
Engine Oil Level - Check
• Deterioration of the engine mounts

NOTICE
Operating your engine when the oil level is above the
• Loose engine mounts
“H” mark could cause your crankshaft to dip into the
Any engine mount that shows deterioration should be oil. The air bubbles created from the crankshaft dip-
replaced. Refer to the OEM information for the ping into the oil reduces the oils lubricating character-
recommended torques. istics and could result in the loss of power.
When the engine mounts are supplied by Perkins the

maintenance procedure will be supplied in the 2. Remove the oil filler cap and add oil, if necessary.
Disassembly and Assembly manual for your engine. Clean the oil filler cap. Install the oil filler cap.
If an increase in the oil level is noticed, refer to
i05300117 Troubleshooting, “Oil Contains Fuel”.
Engine Oil Level - Check i01907674
Engine Oil Sample - Obtain
Hot oil and hot components can cause personal The condition of the engine lubricating oil may be
injury. Do not allow hot oil or hot components to checked at regular intervals as part of a preventive
contact the skin. maintenance program. Perkins include an oil
sampling valve as an option. The oil sampling valve (if
equipped) is included in order to regularly sample the
engine lubricating oil. The oil sampling valve is
positioned on the oil filter head or the oil sampling
valve is positioned on the cylinder block.
Perkins recommends using a sampling valve in order
to obtain oil samples. The quality and the consistency
of the samples are better when a sampling valve is
used. The location of the sampling valve allows oil
that is flowing under pressure to be obtained during
normal engine operation.
Obtain the Sample and the

Analysis
“L” Low
“H” High Hot oil and hot components can cause personal
contact the skin.
NOTICE
Perform this maintenance with the engine stopped. In order to help obtain the most accurate analysis,
record the following information before an oil sample
is taken:
Note: Ensure that the engine is either level or that
the engine is in the normal operating position in order • The date of the sample
to obtain a true level indication.
• Engine model
Note: After the engine has been switched OFF, wait
for 10 minutes in order to allow the engine oil to drain • Engine number
to the oil pan before checking the oil level. • Service hours on the engine
1. Maintain the oil level between the mark (L) and the • The number of hours that have accumulated since
mark (H) on the engine oil dipstick. Do not fill the the last oil change
crankcase above the “H” .
• The amount of oil that has been added since the
last oil change
SEBU8603-04 101
Maintenance Section
Engine Oil and Filter - Change
Ensure that the container for the sample is clean and Drain the Engine Lubricating Oil
dry. Also ensure that the container for the sample is
clearly labelled. Note: Ensure that the vessel that will be used is large
enough to collect the waste oil.
To ensure that the sample is representative of the oil
in the crankcase, obtain a warm, well mixed oil After the engine has been run at the normal
sample. operating temperature, stop the engine. Use one of
To avoid contamination of the oil samples, the tools the following methods to drain the engine oil pan:
and the supplies that are used for obtaining oil
samples must be clean.
The sample can be checked for the following: the
quality of the oil, the existence of any coolant in the
oil, the existence of any ferrous metal particles in the
oil and the existence of any nonferrous metal
particles in the oil.
i04021983
Engine Oil and Filter - Change
Hot oil and hot components can cause personal

contact the skin.
NOTICE
Care must be taken to ensure that fluids are con- Typical example
nance, testing, adjusting and repair of the product. • If the engine is equipped with a drain valve, turn
Be prepared to collect the fluid with suitable contain- the drain valve knob counterclockwise in order to
ers before opening any compartment or disassem- drain the oil. After the oil has drained, turn the
bling any component containing fluids. drain valve knob clockwise in order to close the
Dispose of all fluids according to local regulations drain valve.
and mandates.
• If the engine is not equipped with a drain valve,
remove the oil drain plug (1) in order to allow the
oil to drain. If the engine is equipped with a
NOTICE shallow oil pan, remove the bottom oil drain plugs
from both ends of the oil pan.
component life. After the oil has drained, the oil drain plugs should be
cleaned and installed. If necessary, replace the O
Do not drain the engine lubricating oil when the ring seal. Tighten the drain plug to 34 N·m (25 lb ft).
engine is cold. As the engine lubricating oil cools,
suspended waste particles settle on the bottom of the Replace the Oil Filter
oil pan. The waste particles are not removed with
draining cold oil. Drain the oil pan with the engine
stopped. Drain the oil pan with the oil warm. This NOTICE
draining method allows the waste particles that are Perkins oil filters are manufactured to Perkins specifi-
suspended in the oil to be drained properly. cations. Use of an oil filter that is not recommended
by Perkins could result in severe damage to the en-
Failure to follow this recommended procedure will gine bearings, crankshaft, etc., as a result of the larg-
cause the waste particles to be recirculated through er waste particles from unfiltered oil entering the
the engine lubrication system with the new oil. engine lubricating system. Only use oil filters recom-
mended by Perkins.
102 SEBU8603-04
Maintenance Section
Fuel System - Prime
1. Place a suitable container below the oil filter

assembly. Remove the oil filter with a suitable tool.
2. Clean sealing surface of the oil filter base (2).
3. Apply clean engine oil to O ring seal (3) for the new
oil filter.
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contami-
nated. Contaminated oil can cause accelerated wear
to engine components.
4. Install the new oil filter. Spin on the oil filter until the
O ring contacts the sealing surface (2). Then
rotate the oil filter ¾ of a full turn.
4. Remove the engine oil level gauge in order to
Fill the Oil Pan check the oil level. Maintain the oil level between
the “L” and “H” marks on the engine oil level
1. Remove the oil filler cap. Refer to this Operation gauge. Do not fill the crankcase above the “H”
and Maintenance Manual, “Fluid mark.
Recommendations” for more information on
suitable oils. Fill the oil pan with the correct i05774864
amount of new engine lubricating oil. Refer to this
Operation and Maintenance Manual, “Refill Fuel System - Prime
Capacities” for more information on refill
capacities.
Note: Refer to Systems Operation, Testing, and
NOTICE Adjusting, “Cleanliness of Fuel System
If equipped with an auxiliary oil filter system or a re-
mote filter system, follow the OEM or the filter manu- Components” for detailed information on the
factures recommendations. Under filling or over filling standards of cleanliness that must be observed
the crankcase with oil can cause engine damage. during ALL work on the fuel system.
Ensure that all adjustments and repairs are
2. Start the engine and run the engine at “LOW IDLE” performed by authorized personnel that have had the
for 2 minutes. Perform this procedure in order to correct training.
ensure that the lubrication system has oil and that
NOTICE
the oil filters are filled. Inspect the oil filter for oil Do not crank the engine continuously for more than
leaks. 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
3. Stop the engine and allow the oil to drain back to
the oil pan for a minimum of 10 minutes.
If air enters the fuel system, the air must be purged
from the fuel system before the engine can be
started. Air can enter the fuel system when the
following events occur:
• The fuel tank is empty or the fuel tank has been
partially drained.
• The low-pressure fuel lines are disconnected.

• A leak exists in the low-pressure fuel system.
• The fuel filter has been replaced.

Use the following procedures in order to remove air
from the fuel system:
SEBU8603-04 103
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
1. Ensure that the fuel system is in working order. Note: Refer to Systems Operation, Testing, and
Check that the fuel supply valve (if equipped) is in Adjusting, “Cleanliness of Fuel System
the “ON” position. Components” for detailed information on the
standards of cleanliness that must be observed
2. Turn the keyswitch to the “RUN” position. during ALL work on the fuel system.
3. The keyswitch will allow the electric priming pump
to operate. Operate the electric priming pump. The NOTICE
ECM will stop the pump after 2 minutes.
4. Turn the keyswitch to the “OFF” position. The fuel
system should now be primed and the engine
should be able to start. Remove the Element
5. Operate the engine starter and crank the engine. 1. Turn the fuel supply valve (if equipped) to the OFF
After the engine has started, operate the engine at position before performing this maintenance.
low idle for a minimum of 5 minutes. Ensure that
the fuel system is free from leaks. 2. Place a suitable container under the water
separator in order to catch any fuel that might spill.
Note: Operating the engine for this period will help Clean up any spilled fuel. Clean the outside body
ensure that the fuel system is free of air. DO NOT of the filter assembly.
loosen the high-pressure fuel lines in order to
purge air from the fuel system. This procedure is 3. Make a temporary Mark (A) across the filter before
not required. the assembly is removed.
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. The 10 minute wait will also allow static charge
to dissipate from the low-pressure fuel system. If
necessary, perform minor adjustments. Repair any
leaks from the low-pressure fuel system and from the
cooling, lubrication, or air systems. Replace any high-
pressure fuel line that has leaked. Refer to
Disassembly and Assembly Manual, “Fuel Injection
Lines - Install”.
If you inspect the engine in operation, always use the
proper inspection procedure in order to avoid a fluid
If the engine will not start, refer to Troubleshooting,
“Engine Cranks but will not Start”.
i04224203
Fuel System Primary Filter Illustration 67 g02148376
(Water Separator Element - Typical example
Replace 4. Install a suitable tube onto drain (3). Open the

drain valve (2). Rotate the drain valve
counterclockwise. Two full turns are required.
Loosen vent screw (1).
Note: Two complete rotations of the valve will
Fuel leaked or spilled onto hot surfaces or electri- release the valve from the filter element.
cal components can cause a fire. To help prevent
possible injury, turn the start switch off when 5. Allow the fuel to drain into the container. Remove
changing fuel filters or water separator elements.
Clean up fuel spills immediately. the tube and install the valve into the filter element.
Engage the threads of the valve into the filter
element. Do not secure the valve.
104 SEBU8603-04
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
6. Tighten the vent screw (1) securely . Remove the 8. Rotate the filter element counterclockwise and
wiring harness from connection (4). remove the filter element (5). Clean the filter bowl.
7. Remove the filter bowl (6). Rotate the filter
assembly counterclockwise in order to remove the
Install the Element
filter assembly. Use a suitable tool in order to
remove the filter assembly.
Typical example
Typical example 1. Locate the thread in the filter element (8) onto the
threads (9). Spin on the element. Do not tighten.
2. Lubricate the O ring seal (7) with clean engine oil.
Do NOT fill the bowl with fuel before the assembly
is installed.
3. Do not use a tool in order to install the filter
assembly. Tighten the filter bowl (6) by hand.
Install the filter bowl (6) and align with your
temporary marks (A).
4. Tighten the valve (2) securely. Remove the
container and dispose of the fuel in a safe place.
SEBU8603-04 105
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain
5. The secondary filter element must be replaced at

the same time as the primary filter element. Refer
to the Operation and Maintenance Manual , “Fuel
System Filter - Replace”.
In-line Strainer
The fuel system has an in-line strainer installed
before the electric priming pump. Perkins
recommended that the in-line strainer be replaced
when required.
The location of the in-line strainer will depend on the
application.
i03980098
Fuel System Primary Filter/

Water Separator - Drain
Typical example
Fuel leaked or spilled onto hot surfaces or electri- 3. Install a suitable tube onto drain (3). Open the
possible injury, turn the start switch off when drain valve (2). Rotate the drain valve
changing fuel filters or water separator elements. counterclockwise. Two full turns are required.
Clean up fuel spills immediately. Loosen vent screw (1).
NOTICE release the valve from the filter element.
ing or repair is performed. 4. Allow the fluid to drain into the container.
5. Engage the threads of the valve into the filter
element and tighten the drain valve by hand
NOTICE
The water separator can be under suction during nor- pressure only. Remove the tube and remove the
mal engine operation. Ensure that the drain valve is container.
tightened securely to help prevent air from entering
the fuel system. 6. Tighten vent screw securely.
i04380994
1. Place a suitable container under the water
separator in order to catch any fluid that might Fuel System Secondary Filter -
spill. Clean up any spilled fluid.
Replace
2. Ensure that the outer body of the filter assembly is
clean and free from dirt.
Fuel leaked or spilled onto hot surfaces or electri-

possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
106 SEBU8603-04
Maintenance Section
Fuel System Secondary Filter - Replace
6. Remove the filter bowl (2). Rotate the filter

NOTICE
Ensure that the engine is stopped before any servic- assembly counterclockwise in order to remove the
ing or repair is performed. assembly. Use a suitable tool in order to remove
the filter bowl.
Refer to Systems Operation, Testing, and
Adjusting, “Cleanliness of Fuel System
Components” for detailed information on the
standards of cleanliness that must be observed
during ALL work on the fuel system.
Remove the Element

1. Turn the fuel supply valve (if equipped) to the OFF
position before performing this maintenance.
2. Place a suitable container under the fuel filter in
order to catch any fuel that might spill. Clean up
any spilled fuel. Clean the outside body of the filter
assembly.
Typical example
7. Rotate the filter element counterclockwise and

remove the filter element (5). Clean the filter bowl.
Install the Element
Typical example
3. Make a temporary Mark (A) across the filter before

the assembly is removed. Install a suitable tube
onto drain (4). Open the drain valve (3). Rotate the
drain valve counterclockwise. Two full turns are
required. Loosen vent screw (1).

release the valve from the filter element.
4. Allow the fuel to drain into the container. Remove

the tube and install the valve into the filter element.
Engage the threads of the valve into the filter
element. Do not secure the valve. Illustration 73 g02148528
Typical example
5. Tighten the vent screw (1) securely.
SEBU8603-04 107
Maintenance Section
Fuel Tank Water and Sediment - Drain
1. Locate the thread in the filter element (7) onto the Condensation occurs during the heating and cooling
threads (8). Spin on the element. Do not tighten. of fuel. The condensation occurs as the fuel passes
through the fuel system and the fuel returns to the
2. Lubricate the O ring seal (6) with clean engine oil. fuel tank. This causes water to accumulate in fuel
Do NOT fill the filter bowl (2) with fuel before the tanks. Draining the fuel tank regularly and obtaining
filter assembly is installed. fuel from reliable sources can help to eliminate water
in the fuel.
3. Do not use a tool in order to install the filter
assembly. Tighten the assembly by hand. Install Drain the Water and the Sediment
the filter bowl (2) and align with your temporary
Marks. Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
4. Tighten the drain valve (3). Turn the fuel supply fuel tanks.
valve to the ON position.
Open the drain valve on the bottom of the fuel tank in
5. The Primary filter element must be replaced at the order to drain the water and the sediment. Close the
same time as the secondary filter element. Refer drain valve.
to the Operation and Maintenance Manual , “Fuel Check the fuel daily. Allow five minutes after the fuel
System Primary Filter (Water Separator) Element - tank has been filled before draining water and
Replace”. sediment from the fuel tank.
6. Prime the fuel system. Refer to the Operation and Fill the fuel tank after operating the engine in order to
Maintenance Manual, “Fuel System - Prime” for drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The fuel
more information.
expands as the fuel gets warm. The tank may
overflow.
i02348492
Some fuel tanks use supply pipes that allow water
Fuel Tank Water and Sediment and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
- Drain take fuel directly from the bottom of the tank. If the
engine is equipped with this system, regular
maintenance of the fuel system filter is important.
NOTICE
Fuel Storage Tanks
nance, testing, adjusting and repair of the product. Drain the water and the sediment from the fuel
storage tank at the following intervals:
ers before opening any compartment or disassem- • Weekly
bling any component containing fluids.
• Service intervals
Dispose of all fluids according to local regulations
and mandates. • Refill of the tank
This will help prevent water or sediment from being
Fuel Tank pumped from the storage tank into the engine fuel
tank.
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system.
Water can be introduced into the fuel tank when the
fuel tank is being filled.
108 SEBU8603-04
Maintenance Section
Hoses and Clamps - Inspect/Replace
If a bulk storage tank has been refilled or moved Due to extreme temperature changes, the hose will
recently, allow adequate time for the sediment to harden. Hardening of the hoses will cause hose
settle before filling the engine fuel tank. Internal clamps to loosen. This can result in leaks. A constant
baffles in the bulk storage tank will also help trap torque hose clamp will help to prevent loose hose
sediment. Filtering fuel that is pumped from the clamps.
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used. Each installation application can be different. The
differences depend on the following factors:
i07819616
• Type of hose
Hoses and Clamps - Inspect/ • Type of fitting material
Replace • Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the
fittings
Contact with high pressure fuel may cause fluid Replace the Hoses and the Clamps
spray may cause a fire hazard. Failure to follow Refer to the OEM information for further information
these inspection, maintenance and service in- on removing and replacing fuel hoses (if equipped).
structions may cause personal injury or death. The following text describes a typical method of
If you inspect the engine in operation, always use the replacing coolant hoses. Refer to the OEM
proper inspection procedure to avoid a fluid information for further information on the coolant
system and the hoses for the coolant system.
Maintenance Manual, “General hazard Information”
and Operation and Maintenance Manual, “High
Pressure Fuel Lines” for the correct procedures.
Inspect all hoses for leaks that are caused by the ous burns. To open the cooling system filler cap,
following conditions: stop the engine and wait until the cooling system
• Cracking pressure cap slowly in order to relieve the
pressure.
• Softness
• Loose clamps 1. Stop the engine. Allow the engine to cool.

Replace hoses that are cracked or soft. Tighten any 2. Loosen the cooling system filler cap slowly to
loose clamps. relieve any pressure. Remove the cooling system
filler cap.
Check for the following conditions:
Note: Drain the coolant into a suitable, clean
• End fittings that are damaged or leaking
container. The coolant can be reused.
• Outer covering that is chafed or cut
3. Drain the coolant from the cooling system to a
• Exposed wire that is used for reinforcement level that is below the hose that is being replaced.
• Outer covering that is ballooning locally 4. Remove the hose clamps.

5. Disconnect the old hose.
• Flexible part of the hose that is kinked or crushed
6. Replace the old hose with a new hose.
• Armoring that is embedded in the outer covering
7. Install the hose clamps with a torque wrench.
A constant torque hose clamp can be used in place
of any standard hose clamp. Ensure that the constant Note: For the correct coolant, see this Operation and
torque hose clamp is the same size as the standard Maintenance Manual, “Fluid Recommendations”.
clamp.
8. Refill the cooling system. Refer to the OEM
information for further information on refilling the
cooling system.
SEBU8603-04 109
Maintenance Section
Radiator - Clean
9. Clean the cooling system filler cap. Inspect the After cleaning the radiator, start the engine. Allow the
cooling system filler cap's seals. Replace the engine to operate at low idle speed for 3 to 5 minutes.
cooling system filler cap if the seals are damaged. Accelerate the engine to high idle. The high idle
Install the cooling system filler cap. speed will help in the removal of debris and the
drying of the core. Slowly reduce the engine speed to
10. Start the engine. Inspect the cooling system for low idle and then stop the engine. Use a light bulb
leaks. behind the core in order to inspect the core for
cleanliness. Repeat the cleaning, if necessary.
i04245214 Inspect the fins for damage. Bent fins may be opened
with a “comb”. Inspect these items for good condition:
Radiator - Clean Welds, mounting brackets, air lines, connections,
clamps and seals. Make repairs, if necessary.
The radiator is not usually supplied by Perkins. The i02335775

following text describes a typical cleaning procedure
for the radiator. Refer to the OEM information for Severe Service Application -
further information on cleaning the radiator.
Check
Note: Some application will require a fuel cooler to
be installed. The fuel cooler is a type of radiator that
uses air to cool the fuel and the fuel cooler will Severe service is the application of an engine that
require cleaning. exceeds the current published standards for that
engine. Perkins maintains standards for the following
Note: Adjust the frequency of cleaning according to engine parameters:
the effects of the operating environment.
• Performance such as power range, speed range,
Inspect the radiator for these items: Damaged fins, and fuel consumption
corrosion, dirt, grease, insects, leaves, oil and other
debris. Clean the radiator, if necessary. • Fuel quality
• Operational Altitude
Personal injury can result from air pressure. • Maintenance intervals
Personal injury can result without following prop- • Oil selection and maintenance
protective face shield and protective clothing. • Coolant type and maintenance
Maximum air pressure at the nozzle must be less • Environmental qualities

than 205 kPa (30 psi) for cleaning purposes.
• Installation
Pressurized air is the preferred method for removing • The temperature of the fluid in the engine
loose debris. Direct the air in the opposite direction to
the fans air flow. Hold the nozzle approximately 6 mm Refer to the standards for the engine or consult your
(0.25 inch) away from the radiator fins. Slowly move Perkins dealer or your Perkins distributor in order to
the air nozzle in a direction that is parallel with the determine if the engine is operating within the defined
radiator tube assembly. The pressurized air will parameters.
remove debris that is between the tubes. Severe service operation can accelerate component
Pressurized water may also be used for cleaning. wear. Engines that operate under severe conditions
The maximum water pressure for cleaning purposes may need more frequent maintenance intervals in
must be less than 275 kPa (40 psi). Use pressurized order to ensure maximum reliability and retention of
water in order to soften mud. Clean the core from full service life.
both sides.
Due to individual applications, it is not possible to
Use a degreaser and steam for removal of oil and identify all of the factors which can contribute to
grease. Clean both sides of the core. Wash the core severe service operation. Consult your Perkins
with detergent and hot water. Thoroughly rinse the dealer or your Perkins distributor for the unique
core with clean water. maintenance that is necessary for the engine.
If the radiator is blocked internally, refer to the OEM
Manual for information regarding flushing the cooling
system.
110 SEBU8603-04
Maintenance Section
Starting Motor - Inspect
The operating environment, incorrect operating Check the starting motor for correct operation. Check
procedures and incorrect maintenance procedures the electrical connections and clean the electrical
can be factors which contribute to a severe service connections. Refer to the Systems Operation, Testing
application. and Adjusting Manual, “Electric Starting System -
Test” for more information on the checking procedure
Environmental Factors and for specifications consult your Perkins dealer or
your Perkins distributor for assistance.
Ambient temperatures – The engine may be
exposed to extended operation in extremely cold i04287011
environments or hot environments. Valve
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
Turbocharger - Inspect
cold temperatures. Extremely hot intake air reduces
engine performance.
Quality of the air – The engine may be exposed to
extended operation in an environment that is dirty or
dusty, unless the equipment is cleaned regularly. Hot engine components can cause injury from
Mud, dirt and dust can encase components. burns. Before performing maintenance on the en-
Maintenance can be very difficult. The buildup can gine, allow the engine and the components to
contain corrosive chemicals. cool.
Buildup – Compounds, elements, corrosive
chemicals and salt can damage some components.
NOTICE
Altitude – Problems can arise when the engine is Turbocharger bearing failures can cause large quan-
operated at altitudes that are higher than the tities of oil to enter the air intake and exhaust sys-
intended settings for that application. Necessary tems. Loss of engine lubricant can result in serious
adjustments should be made. engine damage.
Minor leakage of oil into a turbocharger under ex-
tended low idle operation should not cause problems
Incorrect Operating Procedures as long as a turbocharger bearing failure has not
occurred.
• Extended operation at low idle
If a turbocharger failure is suspected do not operate
• Frequent hot shutdowns the engine. A failure of the turbocharger can be sig-
naled by significant loss of engine performance and
• Operating at excessive loads erratic RPM at no load. Also, large quantities of en-
gine oil could pass into the engine air intake. This oil
• Operating at excessive speeds would have been seen as smoke from the engine ex-
haust. Applications that have a DPF installed will filter
• Operating outside the intended application the engine exhaust.
Incorrect Maintenance Procedures A visual inspection of the turbocharger or

turbochargers can minimize unscheduled downtime.
A visual inspection of the turbocharger or
• Extending the maintenance intervals turbochargers can also reduce the chance for
• Failure to use recommended fuel, lubricants and potential damage to other engine parts. Do not
inspect the engine with the engine in operation.
coolant/antifreeze
i07888480
Starting Motor - Inspect
Perkins recommends a scheduled inspection of the

starting motor. If the starting motor fails, the engine
may not start in an emergency situation.
SEBU8603-04 111
Maintenance Section
Walk-Around Inspection
i04156712
Inspect the Tube of the Crankcase

Breather
Typical example
1. Ensure that the turbocharger is clean and free from

dirt before removing components for inspection.
2. Remove the pipe from the turbocharger exhaust
outlet and remove the air intake pipe (1). Visually
inspect the piping for the presence of oil. Clean the
interior of the pipes in order to prevent dirt from Illustration 75 g02351425
entering during reassembly. Typical example
3. Check for abnormal heat discoloration of the Inspect the breather tube (1) for damage. Ensure that
turbocharger. Check for any loose bolts or any the outlet (2) is clean and free from any obstructions.
missing bolts. Check for damage to the oil supply Ice can cause obstructions in adverse weather
line and the oil drain line. Check for cracks in the conditions.
housing of the turbocharger. Ensure that the
compressor wheel can rotate freely. Check for Inspect the Engine for Leaks and
signs of damage to the compressor wheel, or for Loose Connections
contact of the compressor wheel to the body of the
compressor housing. A walk-around inspection should only take a few
minutes. When the time is taken to perform these
4. Check for the presence of oil. If oil is leaking from checks, costly repairs and accidents can be avoided.
the back side of the compressor wheel, there is a
possibility of a failed turbocharger oil seal. For maximum engine service life, make a thorough
inspection of the engine compartment before starting
The presence of oil may be the result of extended the engine. Look for items such as oil leaks or
engine operation at low idle. The presence of oil coolant leaks, loose bolts, worn belts, loose
connections, and trash buildup. Make repairs, as
may also be the result of a restriction of the line for
needed:
the intake air (clogged air filters), which causes the
turbocharger to slobber. For more information, • The guards must be in the correct place. Repair
refer to Systems Operation, Testing, and damaged guards or replace missing guards.
Adjusting, “Turbocharger - Inspect”.
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
112 SEBU8603-04
Maintenance Section
Belts for multiple groove pulleys must be replaced as

NOTICE matched sets. If only one belt is replaced, the belt will
For any type of leak (coolant, lube, or fuel) clean up
the fluid. If leaking is observed, find the source and carry more load than the belts that are not replaced.
correct the leak. If leaking is suspected, check the flu- The older belts are stretched. The additional load on
the new belt could cause the belt to break.
id levels more often than recommended until the leak
is found or fixed, or until the suspicion of a leak is
proved to be unwarranted. High Pressure Fuel Lines
NOTICE
Accumulated grease and/or oil on an engine is a fire
hazard. Remove the accumulated grease and oil. Re- Contact with high pressure fuel may cause fluid
fer to this Operation and Maintenance Manual, “En- penetration and burn hazards. High pressure fuel
gine - Clean” for more information. spray may cause a fire hazard. Failure to follow
• Ensure that the cooling system hoses are correctly
clamped and that the cooling system hoses are After the engine has stopped, you must wait for 10
minutes in order to allow the fuel pressure to be
tight. Check for leaks. Check the condition of all purged from the high-pressure fuel lines before any
pipes. service or repair is performed on the engine fuel
lines. If necessary, perform minor adjustments.
• Inspect the water pump for coolant leaks.
Repair any leaks from the low-pressure fuel system
Note: The water pump seal is lubricated by the and from the cooling, lubrication or air systems.
Replace any high-pressure fuel line that has leaked.
coolant in the cooling system. It is normal for a small
Refer to Disassembly and Assembly Manual, “Fuel
amount of leakage to occur as the engine cools down Injection Lines - Install”.
and the parts contract.
If you inspect the engine in operation, always use the
Excessive coolant leakage may indicate the need to proper inspection procedure in order to avoid a fluid
replace the water pump. Remove the water pump. penetration hazard. Refer to Operation and
Refer to Disassembly and Assembly , “Water Pump - Maintenance Manual, “General hazard Information”.
Remove and Install”. For more information, consult
your Perkins dealer or your Perkins distributor. Visually inspect the high-pressure fuel lines for
damage or signs of fuel leakage. Replace any
• Inspect the lubrication system for leaks at the front damaged high-pressure fuel lines or high-pressure
crankshaft seal, the rear crankshaft seal, the oil fuel lines that have leaked.
pan, the oil filters, and the rocker cover.
Ensure that all clips on the high-pressure fuel lines
• Inspect the piping for the air intake system and the are in place and that the clips are not loose.
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other • Inspect the rest of the fuel system for leaks. Look
hoses, tubes, wiring harnesses, etc. for loose fuel line clamps.
• Ensure that the areas around the rotating parts are • Drain the water and the sediment from the fuel
clear. tank on a daily basis in order to ensure that only
clean fuel enters the fuel system.
• Inspect the alternator belts and any accessory
drive belts for cracks, breaks, or other damage. • Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
• Inspect the wiring harness for damage. wires. Check for any loose tie-wraps or missing
tie-wraps.
• Inspect the ground strap for a good connection
and for good condition.
• Disconnect any battery chargers that are not
protected against the current drain of the starting
motor. Check the condition and the electrolyte
level of the batteries, unless the engine is
equipped with a maintenance free battery.
SEBU8603-04 113
Maintenance Section
Water Pump - Inspect
• Check the condition of the gauges. Replace any Note: If engine coolant enters the engine lubricating
gauges that are cracked. Replace any gauge that system the lubricating oil and the engine oil filter must
cannot be calibrated. be replaced. This will remove any contamination that
is caused by the coolant and this will prevent any
i03570653 irregular oil samples.
Water Pump - Inspect The water pump is not a serviceable item. In order to
install a new water pump, refer to the Disassembly
and Assembly Manual, “Water Pump - Remove and
Install”.
A failed water pump may cause severe engine
overheating problems that could result in the
following conditions:
• Cracks in the cylinder head

• A piston seizure
• Other potential damage to the engine
(A) Weep hole
(B) Vent hole
Note: The water pump seals are lubricated by the

coolant in the cooling system. It is normal for a small
amount of leakage to occur. Refer to illustration 76
for the position of the weep hole and the vent hole.
Visually inspect the water pump for leaks.
114 SEBU8603-04
Warranty Section
Warranty Information
Warranty Section As a condition of reimbursement, replaced parts and

receipted invoices must be presented at a place of
business of a Perkins distributor or your Perkins
dealer. Or other establishment authorized by Perkins
Warranty Information Engine Company limited
This warranty covers the following emission-related
i04021284 parts and components:
Federal Emission Control • Turbocharger System

Warranty • Inlet Manifold
• Fuel Injection System
Emissions Warranty • Crankcase Ventilation System
The 1206E-E66TA diesel engine is a nonroad • Electronic Engine Control System

compression ignition engine. Perkins Engine
Company limited warrants to the initial owner and to • Engine Aftertreatment System
the subsequent owner of the 1206E-E66TA diesel
engine that such an engine is: • NOx Reduction System
1. Designed, built, and equipped so that the engine • Aftertreatment Regeneration Device
conforms, at the time of sale, with all applicable
• Miscellaneous valves, switches, hoses, clamps,
regulations adopted by the United States connectors, tubing, and sealing devices that are
Environmental Protection Agency (EPA). used in the above systems
2. Free from defects in materials and workmanship in
specific emission-related parts for the following Limitations and Responsibilities
period:
The warranty is subject to the following conditions:
• The warranty period is for 3000 hours or for 5
Perkins Engine Company limited Responsibilities
years, whichever occurs first. After the date of
delivery to the owner that operates the engine. During the emission warranty period, if a defect in
material or workmanship of an emission-related part
If an emission-related part fails during any of the or component is found, Perkins Engine Company
warranty periods, the part will be repaired or limited will provide the following:
replaced. Any such part repaired or replaced under
warranty is warranted for the remainder of the • New, Remanufactured or repaired parts and/or
warranty period. components, approved pursuant to EPA
During the term of this warranty, Perkins Engine Regulations, required to correct the defect.
Company limited will provide through a Perkins
distributor or your Perkins dealer or other • Reasonable and customary labor, during normal
establishment authorized by Perkins Engine working hours that is required to make the
Company limited , repair or replacement of any warranty repair. This will include labor in order to
warranted part at no charge to the engine owner. remove an engine and install the engine, if
necessary.
In an emergency, repairs may be performed at any
service establishment, or by the owner, using any Note: Items that are replaced under this warranty
replacement part. Perkins recommended that become the property of Perkins Engine Company
emission-related parts be replaced with genuine limited .
Perkins Engine Company limited parts.
Owner Responsibilities
Perkins Engine Company limited will reimburse the
owner. This reimbursement will include diagnostic During the emission warranty period, the owner is
charges for such an emergency repair. These responsible for the following items:
expenses shall not exceed the Perkins Engine
Company limited suggested retail price for all • The costs in order to investigate complaints which
warranted parts replaced, and labor charges based are not caused by a defect in Perkins Engine
on Perkins Engine Company limited recommended Company limited material or Perkins Engine
time allowance for the warranty repair and the Company limited workmanship.
geographically appropriate hourly labor rate.
SEBU8603-04 115
Warranty Section
Emissions Warranty Information
• Providing timely notice of a warrantable failure and Maintenance Recommendations

promptly making the product available for repair
Perkins Engines Company Limited engines are
Limitations certified by the EPA and the CARB in order to comply
with exhaust emission standards and gaseous
Perkins Engine Company limited is not responsible emission standards that are prescribed by the law at
for resultant damages to an emission-related part or the time of manufacture.
component resulting from the following items:
Efficiency of the emission control and the engine
• Any application or any installation that Perkins performance depends on adherence to proper
Engine Company limited deems improper. operation and maintenance recommendations and
use of recommended fuels and lubricating oils.
• Attachments, accessory items, or parts not sold According to recommendations, major adjustments
nor approved by Perkins Engine Company limited and repairs should be made by your authorized
Perkins distributor or your authorized Perkins dealer.
• Improper engine maintenance, repair, or abuse.
Various chemical fuel additives which claim to reduce
• Use of improper fuel, lubricants, or fluids. visible smoke are available commercially. Although
additives have been used to solve some isolated
smoke problems in the field, additives are not
• Owners unreasonable delay in making the product
recommended for general use. The engines should
available after being notified of a potential product be certified without smoke depressants according to
problem. federal smoke regulations.
This warranty is in addition to Perkins Engine Take corrective steps immediately after worn parts
Company limited standard warranty, applicable to the which may affect the emissions level are discovered
engine product involved. in order to ensure the proper operation of the
Remedies under this warranty are limited to the emission control systems. The use of genuine
provision of material and services as specified Perkins components is recommended. If the owner
herein. Perkins Engine Company limited is not uses non-Perkins components, then the non-Perkins
components must not adversely affect the emissions
responsible for incidental or consequential damages,
level of the engine.
including but not limited to downtime or loss-of-use of
engine. For information on the use of Aftermarket Products
and Perkins Engines, refer to this Operation and
i04711150 Maintenance Manual, “Engine Description”.
Emissions Warranty Regular maintenance intervals with a special

emphasis on the following items are necessary in
Information order to keep exhaust emissions within acceptable
limits for the useful life of the engine. Refer to the
Operation and Maintenance Manual, “Severe Service
Application - Check” topic (Maintenance Section). If
The aftertreatment system can be expected to the engine is operating under severe conditions,
function properly for the life-time of the engine adjust the maintenance schedule accordingly. See
(emissions durability period) subject to prescribed your authorized Perkins distributor/dealer in order to
maintenance requirements being followed. help analyze your specific application, operating
environment, and maintenance schedule
• EPA United States Environmental adjustments.
Protection Agency
The following information is an explanation of
• CARB California Air Resources Board maintenance items for emission-related components.
See the Operation and Maintenance Manual,
Note: The warranty of the engine applies to engines “Maintenance Interval Schedule” (Maintenance
that are operated within the areas of the world where Section) for the specific interval for the following
the following regulations apply: US EPA Tier 4 items.
Interim, EU Stage IIIB or Japanese MLIT Step 4. If an
engine is operated in regions of the world where ENGINE AFTERTREATMENT SYSTEM – The
these regulations do not apply the warranty will be Engine Aftertreatment Systems are sensitive to the
void. Contact your Perkins dealer or your Perkins type of fuel and lubricants that is used. Also, the
engine aftertreatment systems are sensitive to the
distributor for more information. operating schedule. Low quality fuel, lubricants, or
fluids may cause increases in exhaust back pressure
or clogging resulting in loss of power. An authorized
Perkins distributor/dealer can determine if the engine
aftertreatment systems require a service.
116 SEBU8603-04
Warranty Section
California Emission Control Warranty Statement
NOx Reduction System (NRS) – The NRS is In California, new motor vehicle engines must be
monitored. An authorized Perkins distributor/dealer designed, built, and equipped in order to meet the
can determine if the NRS needs service. state's stringent anti-smog standards. Perkins
Engines Company Limited must warrant the emission
FUEL INJECTORS – Fuel injector tips are subject to control system on your engine for the duration of time
wear as a result of fuel contamination. This damage listed below. Provided, there has not been any
can cause the following conditions: an increase in abuse, neglect, or improper maintenance of your
fuel consumption, black smoke, misfire and rough engine or your engine aftertreatment system.
running engine. The fuel injector should be
inspected, tested, and replaced, if necessary. Fuel Perkins Engines Company Limited warrants to the
injectors can be tested by an authorized Perkins initial owner and to the subsequent owner of the
distributor/dealer . 1206E-E66TA diesel engine that such an engine is:
1. Designed, built, and equipped so that the engine
TURBOCHARGER – Refer to this Operation and
Maintenance Manual, “Turbocharger - Inspect” for conforms, at the time of sale, with all applicable
information on inspection of the turbocharger. regulations adopted by the California Air
Resources Board (CARB).
ELECTRONIC ENGINE CONTROL (ECM) – The
ECM is the control computer of the engine. The ECM 2. Free from defects in materials and workmanship in
provides power to the electronics. The ECM monitors specific emission-related parts for the following
data that is input from the sensors of the engine. The period:
ECM acts as a governor in order to control the speed
and the power of the engine. The ECM adjusts • The warranty period is for 3000 hours or for 5
injection timing and fuel pressure for the best engine years, whichever occurs first. After the date of
performance, the best fuel economy, and the best
delivery to the owner that operates the engine.
control of exhaust emissions.
If an emission-related part fails during any of the
Erratic behavior of the engine may indicate a need for warranty periods, the part will be repaired or
repair to the ECM. Your Perkins distributor/dealer is replaced. Any such part repaired or replaced
equipped with the necessary tools, personnel, and under warranty is warranted for the remainder of
procedures in order to perform this service.
the warranty period.
The owner is encouraged to keep adequate During the term of this warranty, Perkins Engines
maintenance records. However, the absence of such
records will not invalidate the warranty. Refer to the Company Limited will provide through a Perkins
Operation and Maintenance Manual, “Maintenance distributor or your Perkins dealer or other
Log” (Reference Materials Section). establishment authorized by Perkins Engines
Company Limited , repair or replacement of any
The owner may perform routine maintenance,
warranted part at no charge to the engine owner.
repairs, and other work that is outside of the
warranty. The work may be done at any repair facility. In an emergency, repairs may be performed at any
Such work does not need to be performed at a service establishment, or by the owner, using any
designated station that is determined by the warranty
in order for the warranty to remain in force. replacement part. Perkins recommended that
emission-related parts be replaced with genuine
i04021417
Perkins Engines Company Limited parts.
Perkins Engines Company Limited will reimburse
California Emission Control the owner. This reimbursement will include
Warranty Statement diagnostic charges for such an emergency repair.
These expenses shall not exceed the Perkins
Engines Company Limited suggested retail price
for all warranted parts replaced, and labor charges
Emissions Warranty based on Perkins Engines Company Limited
recommended time allowance for the warranty
The 1206E-E66TA is a nonroad compression ignition repair and the geographically appropriate hourly
engine.
labor rate.
The California Air Resources Board (CARB) and As a condition of reimbursement, replaced parts
Perkins Engines Company Limited are pleased to
explain the emission control system warranty on your and receipted invoices must be presented at a
1206E-E66TA diesel engine. place of business of a Perkins distributor or your
Perkins dealer or other establishment authorized
by Perkins Engines Company Limited .
SEBU8603-04 117
Warranty Section
California Emission Control Warranty Statement
This warranty covers the following emission- Limitations

related parts and components:
Perkins Engines Company Limited is not responsible
• Turbocharger System for resultant damages to an emission-related part or
component resulting from the following items:
• Inlet Manifold
• Any application or any installation that Perkins
• Fuel Injection System Engines Company Limited deems improper.
• Crankcase Ventilation System • Attachments, accessory items, or parts not sold

nor approved by Perkins Engines Company
• Electronic Engine Control System Limited
• Engine Aftertreatment System • Improper engine maintenance, repair, or abuse.

• Use of improper fuel, lubricants, or fluids.
• NOx Reduction System
• Owners unreasonable delay in making the product
• Aftertreatment Regeneration Device available after being notified of a potential product
problem.
• Miscellaneous valves, switches, hoses,
clamps, connectors, tubing, and sealing This warranty is in addition to Perkins Engines
devices that are used in the above systems Company Limited standard warranty, applicable to
the engine product involved.
Limitations and Responsibilities
Remedies under this warranty are limited to the
The warranty is subject to the following conditions: provision of material and services as specified
herein. Perkins Engines Company Limited is not
Perkins Engines Company Limited responsible for incidental or consequential damages,
Responsibilities including but not limited to downtime or loss-of-use of
engine.
During the emission warranty period, if a defect in
material or workmanship of an emission-related part
or component is found, Perkins Engines Company
Limited will provide the following:
• New, Remanufactured or repaired parts and/or
components, approved pursuant to (CARB)
Regulations, required to correct the defect.
• Reasonable and customary labor, during normal
working hours that is required to make the
warranty repair. Included will be labor in order to
remove an engine and install the engine, if
necessary.
Note: Items that are replaced under this warranty
become the property of Perkins Engines Company
Limited .
Owner Responsibilities
During the emission warranty period, the owner is

responsible for the following items:
• The costs in order to investigate complaints which
are not caused by a defect in Perkins Engines
Company Limited material or Perkins Engines
Company Limited workmanship.
• Providing timely notice of a warrantable failure and

promptly making the product available for repair
118 SEBU8603-04
Reference Information Section
Reference Materials
Reference Information www.perkins.com
Section NOTICE
Dependant upon engine type and application.
Reference Materials
i04224089
Engine Protection Plans

(Extended Service Contract)
Extended Service Contracts-purchased in minutes,

protected for years.
Extended Service Contracts (ESC) protect you from
the stress that unexpected repair work brings to your
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reality.
Why buy an Extended Service Contract?
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repair cost (parts, labor, and travel).
2. Enjoy longer lasting product support from Perkins
global network.
3. Genuine Perkins parts ensure continued engine
performance.
4. Highly trained technicians carry out all repairs.
5. Transferable coverage should you sell your
machine.
Flexible coverage provides the right level of
protection for your Perkins Engine. Coverage can be
extended to 2 years/ 1,000 hours right up to 10 year/
40,000
You can buy an ESC at any time during standard
warranty - even the last day!
Each Perkins Distributor has highly trained and
experienced Perkins Product Support Service
Technicians. The Support Service are equipped, and
available around the clock to get your engine running
again with the minimum of downtime. Buying an ESC
means that you get all this for free.
To purchase an Extended Service Contract, is quick
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now and the distributor can provide you with a quote
in minutes. You can locate your nearest Perkins
Distributor by visiting:
SEBU8603-04 119
Index Section
Index
A Engines Without a Coolant Recovery
Tank............................................................ 89
After Starting Engine ....................................... 54
Cooling System Supplemental Coolant
After Stopping Engine ..................................... 57
Additive (SCA) - Test/Add.............................. 90
Aftercooler Core - Clean/Test (Air-To-Air
Add the SCA, If Necessary .......................... 90
Aftercooler) .................................................... 82
Test for SCA Concentration ......................... 90
Aftercooler Core - Inspect ............................... 82
Crushing Prevention and Cutting Prevention.. 15
Alternator - Inspect .......................................... 82
Alternator and Fan Belts - Replace ................. 82
D
B Diagnostic Flash Code Retrieval..................... 45
Diagnostic Lamp.............................................. 45
Battery - Replace............................................. 82
Driven Equipment - Check .............................. 90
Battery Electrolyte Level - Check .................... 83
Battery or Battery Cable - Disconnect............. 83
Before Starting Engine .............................. 17, 51 E
Belt - Inspect.................................................... 84 Electrical System............................................. 18
Belt Tensioner - Inspect................................... 84 Grounding Practices .................................... 19
Burn Prevention............................................... 12 Emergency Stopping....................................... 57
Batteries....................................................... 13 Emissions Certification Film ............................ 29
Coolant ........................................................ 13 Emissions Warranty Information ....................115
Induction System ......................................... 13 Maintenance Recommendations................115
Oils............................................................... 13 Engine - Clean................................................. 91
Aftertreatment .............................................. 91
C Engine Air Cleaner Element (Dual Element)
- Clean/Replace............................................. 91
California Emission Control Warranty
Cleaning the Primary Air Cleaner
Statement .....................................................116
Elements .................................................... 92
Emissions Warranty....................................116
Servicing the Air Cleaner Elements............. 91
Cold Weather Operation ................................. 59
Engine Air Cleaner Element (Single
Hints for Cold-Weather Operation ............... 59
Element) - Inspect/Replace ........................... 93
Idling the Engine .......................................... 60
Engine Air Cleaner Service Indicator -
Recommendations for Coolant Warm Up.... 60
Inspect ........................................................... 94
Recommendations for the Coolant.............. 60
Test the Service Indicator ............................ 94
Viscosity of the Engine Lubrication Oil ........ 60
Engine Air Precleaner - Check/Clean (If
Cold Weather Starting ..................................... 52
Equipped) ...................................................... 94
Configuration Parameters ............................... 47
Engine Crankcase Breather Element -
Customer Specified Parameters ................. 48
Replace (Type 1) ........................................... 95
System Configuration Parameters .............. 47
Bottom Service ............................................ 96
Cooling System Coolant (Commercial
Check the System........................................ 98
Heavy-Duty) - Change................................... 85
Top Service .................................................. 95
Drain ............................................................ 85
Engine Crankcase Breather Element -
Fill ................................................................ 86
Replace (Type 2) ........................................... 98
Flush ............................................................ 86
Check the System........................................ 99
Cooling System Coolant (ELC) - Change ....... 86
Engine Description .......................................... 25
Drain ............................................................ 87
Aftermarket Products and Perkins
Fill ................................................................ 88
Engines ...................................................... 27
Flush ............................................................ 87
Aftertreatment System................................. 26
Cooling System Coolant Level - Check........... 88
Electronic Engine Features ......................... 26
Engines With a Coolant Recovery Tank ...... 88
120 SEBU8603-04
Index Section
Engine Cooling and Lubrication .................. 26 California Proposition 65 Warning ................. 4

Engine Diagnostics...................................... 26 Literature Information .................................... 4
Engine Service Life...................................... 27 Maintenance .................................................. 4
Engine Specifications .................................. 25 Maintenance Intervals ................................... 5
Engine Diagnostics ......................................... 45 Operation ....................................................... 4
Engine Electronics........................................... 20 Overhaul ........................................................ 5
Engine Mounts - Inspect.................................. 99 Safety............................................................. 4
Engine Oil and Filter - Change ...................... 101 Fuel and the Effect from Cold Weather ........... 61
Drain the Engine Lubricating Oil................ 101 Fuel Conservation Practices ........................... 55
Fill the Oil Pan............................................ 102 Fuel Related Components in Cold Weather ... 62
Replace the Oil Filter ................................. 101 Fuel Filters ................................................... 62
Engine Oil Level - Check............................... 100 Fuel Heaters ................................................ 62
Engine Oil Sample - Obtain........................... 100 Fuel Tanks ................................................... 62
Obtain the Sample and the Analysis ......... 100 Fuel System - Prime...................................... 102
Engine Operation ............................................ 55 Fuel System Primary Filter (Water
Reduction of Particulate Emissions............. 55 Separator) Element - Replace..................... 103
Engine Operation with Active Diagnostic In-line Strainer ........................................... 105
Codes ............................................................ 46 Install the Element ..................................... 104
Engine Operation with Intermittent Remove the Element ................................. 103
Diagnostic Codes .......................................... 47 Fuel System Primary Filter/Water
Engine Protection Plans (Extended Service Separator - Drain ......................................... 105
Contract).......................................................118 Fuel System Secondary Filter - Replace ...... 105
Engine Shutoffs and Engine Alarms ............... 43 Install the Element ..................................... 106
Alarms.......................................................... 43 Remove the Element ................................. 106
Shutoffs........................................................ 43 Fuel Tank Water and Sediment - Drain ......... 107
Testing ......................................................... 44 Drain the Water and the Sediment ............ 107
Engine Starting.......................................... 18, 51 Fuel Storage Tanks.................................... 107
Engine Stopping ........................................ 18, 57 Fuel Tank ................................................... 107
F G
Fault Logging................................................... 46 Gauges and Indicators .................................... 33
Features and Controls..................................... 35 Indicator Lamps ........................................... 34
Federal Emission Control Warranty ...............114 Instrument panels and Displays .................. 34
Emissions Warranty....................................114 General Hazard Information.............................. 9
Fire Prevention and Explosion Prevention...... 13 Containing Fluid Spillage..............................11
Ether ............................................................ 15 Dispose of Waste Properly .......................... 12
Fire Extinguisher.......................................... 15 Fluid Penetration ......................................... 10
Lines, Tubes, and Hoses ............................. 15 Inhalation ......................................................11
Fluid Recommendations ........................... 71, 76 Pressurized Air and Water........................... 10
ELC Cooling System Maintenance.............. 74 Static Electricity Hazard when Fueling with
Engine Oil .................................................... 76 Ultra-low Sulfur Diesel Fuel ........................11
General Coolant Information ....................... 71
General Lubricant Information..................... 76 H
Fluid Recommendations (General Fuel
Information) ................................................... 63 High Pressure Fuel Lines ................................ 16
Contamination Control Recommendations for Hoses and Clamps - Inspect/Replace........... 108
Fuels .......................................................... 70 Replace the Hoses and the Clamps .......... 108
Diesel Fuel Characteristics.......................... 66
Diesel Fuel Requirements ........................... 64 I
General Information..................................... 63
Important Safety Information............................. 2
Foreword ........................................................... 4
SEBU8603-04 121
Index Section
L Reference Information Section ......................118

Reference Materials .......................................118
Lifting and Storage .......................................... 30
Reference Numbers ........................................ 28
Record for Reference .................................. 28
M Refill Capacities............................................... 63
Maintenance Interval Schedule....................... 81 Cooling System............................................ 63
Daily ............................................................. 81 Lubrication System ...................................... 63
Every 1000 Service Hours........................... 81
Every 12 000 Service Hours or 6 Years....... 81 S
Safety Messages............................................... 6
(1) Universal Warning .................................... 6
(2) Hand (High Pressure) .............................. 7
Every 3000 Service Hours or 2 Years ......... 81
Ether Warning ................................................ 8
Safety Section ................................................... 6
Every 50 Service Hours or Weekly.............. 81
Self-Diagnostics .............................................. 45
Every 500 Service Hours ............................. 81
Sensors and Electrical Components............... 37
Every 500 Service Hours or 1 Year ............. 81
Every Week ................................................. 81
(Aftertreatment) ............................................. 37
When Required............................................ 81
Severe Service Application - Check.............. 109
Maintenance Recommendations .................... 79
Environmental Factors................................110
Maintenance Section....................................... 63
Incorrect Maintenance Procedures ............110
Model View Illustrations .................................. 21
Incorrect Operating Procedures .................110
Engine Aftertreatment System .................... 25
Starting Motor - Inspect ..................................110
Engine views................................................ 21
Starting the Engine.......................................... 51
Model Views .................................................... 21
Starting the Engine ...................................... 51
Monitoring System........................................... 36
Starting with Jump Start Cables (Do Not
Programmable Options and Systems
Use This Procedure in Hazardous
Operation ................................................... 36
Locations that have Explosive
Monitoring System (Table for the Indicator
Atmospheres) ................................................ 53
lamps) ............................................................ 35
Stopping the Engine ........................................ 57
Mounting and Dismounting ............................. 16
System Pressure Release............................... 79
Coolant System ........................................... 79
O Engine Oil .................................................... 79
Operation Section............................................ 30 Fuel System................................................. 79
Overspeed....................................................... 44
T
P Table of Contents .............................................. 3
Plate Locations and Film Locations (Engine Turbocharger - Inspect ...................................110
Aftertreatment System ) ................................ 28
Product Identification Information ................... 28 W
Product Information Section............................ 21
Walk-Around Inspection ................................. 111
Product Lifting (Clean Emission Module)........ 31
High Pressure Fuel Lines ...........................112
Product Lifting (Engine)................................... 30
Inspect the Engine for Leaks and for Loose
Product Storage (Engine and
Connections .............................................. 111
Aftertreatment) .............................................. 31
Inspect the Tube of the Crankcase
Condition for Storage................................... 31
Breather .................................................... 111
Warranty Information......................................114
R Warranty Section ............................................114
Radiator - Clean ............................................ 109 Water Pump - Inspect.....................................113
122 SEBU8603-04
Index Section
Welding on Engines with Electronic

Controls ......................................................... 79
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identification Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name: Branch:
Address:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
SEBU8603
©2021 Perkins Engines Company Limited
All Rights Reserved
124 March 2021

Operation and Maintenance Manual: 1206E-E66TA Industrial Engine

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Operation and Maintenance Manual: 1206E-E66TA Industrial Engine

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SEBU8603-04 (en-us)

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Cold Weather Operation ................................. 59

Foreword ........................................................... 4 Maintenance Section

Burn Prevention............................................... 12 Warranty Section

Fire Prevention and Explosion Prevention...... 13 Warranty Information......................................114

Crushing Prevention and Cutting Prevention.. 15 Reference Information Section

Mounting and Dismounting ............................. 16 Reference Materials .......................................118

High Pressure Fuel Lines ................................ 16 Index Section

Before Starting Engine .................................... 17 Index...............................................................119

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

Product Information Section

Model Views .................................................... 21

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

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

Gauges and Indicators .................................... 33

Features and Controls..................................... 35

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

Engine Operation ............................................ 55

Engine Stopping .............................................. 57

Foreword Some photographs or illustrations in this manual

WARNING – This product can Safety

Wash hands after handling components Maintenance

The maintenance schedule items are organized for a

There may be several specific warning signs on your

(1) Universal Warning

Do not operate or work on this equipment unless

The Universal Warning label (1) is located in two

(2) Hand (High Pressure)

Contact with high pressure fuel may cause fluid

The warning label for the Hand (High Pressure) (3) is

Do not use aerosol types of starting aids such as

• If the engine is not running, do not release the

• When work is performed around an engine that is

• Ensure that all protective guards and all covers

i08315538 • Report all necessary repairs.

• Engage the secondary brakes or parking brakes.

• Vent the engine exhaust to the outside when the

• Breathers Pressurized Air and Water

Avoid static electricity risk when fueling. Ultra-

Always use a board or cardboard when you check for

Containing Fluid Spillage

Static Electricity Hazard when Hexavalent Chromium

• Avoid brushing, grinding, or cutting materials Dispose of Waste Properly

• Obey environmental regulations for the disposal of

• Stay away from areas that might have hexavalent

Sulfuric Acid Burn Hazard may cause serious

All fuels, most lubricants, and some coolant mixtures

After the engine has stopped, you must wait for 10

Do not smoke while you are replacing an ether

Lines, Tubes, and Hoses

When objects are struck, wear protective glasses in

Mounting and Dismounting

Do not climb on the engine or the engine

High Pressure Fuel Lines

Contact with high pressure fuel may cause fluid