Perkins 1206J-E70TA and 1206J-E70TTA Industrial Engines. Operation Manual (2021)

M0082024-03

Table of Contents

Cold Weather Operation

Engine Stopping

Foreword

Maintenance Section

Safety Section

Refill Capacities

Safety Messages

Maintenance Recommendations

102

Additional Messages

Maintenance Interval Schedule

105

General Hazard Information

Warranty Section

Burn Prevention

Warranty Information

147

Fire Prevention and Explosion Prevention

Reference Information Section

Crushing Prevention and Cutting Prevention.. 18

Reference Materials

148

Mounting and Dismounting

High Pressure Fuel Lines

Index Section

Before Starting Engine

Index

151

Engine Starting

Engine Stopping

Electrical System

Engine Electronics

Product Information Section

General Information

Product Identification Information

Operation Section

Lifting and Storage

Features and Controls

Engine Diagnostics

Engine Starting

Engine Operation

Aftertreatment Operation

M0082024-03

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

may have caused changes to your engine which are

Diesel engine exhaust and some of its

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

distributor for the latest available information.

and other reproductive harm.

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

Operation

Do not ingest this chemical. Wash hands

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

engine.

compounds, which are known to the

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.

The illustrated, step-by-step instructions are grouped

Literature Information

by service hours and/or calendar time maintenance

intervals. Items in the maintenance schedule are

This manual contains safety, operation instructions,

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.

M0082024-03

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.

M0082024-03

Safety Section

Safety Messages

Safety Section

i07702838

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. Become

familiar with all warning signs.

Ensure that all 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 dealer or your

Perkins distributor can provide new warning signs.

Universal Warning 1

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

M0082024-03

Safety Section

Additional Messages

Illustration 5

g02382677

Typical example

Illustration 6

g06224838

Typical example

The hand high-pressure warning label is a wrap

Make sure that all the messages are legible. Clean

around label installed on the main injection line, refer

the messages or replace the messages if the

to illustration 6 .

messages are not legible. Replace the illustrations if

the illustrations are not legible. When cleaning the

i07676530

messages, use a cloth, water, and soap. Do not use

solvent, gasoline, or other harsh chemicals to clean

the messages. Solvents, gasoline, or harsh

Additional Messages

chemicals could loosen the adhesive that secures the

messages. Loose adhesive will allow the messages

to fall.

There are several specific messages on this engine.

Replace any message that is damaged, or missing. If

The exact location of the messages and the

a message is attached to a part that is replaced,

description of the information are reviewed in this

install a message on the replacement part.

section. Become familiar with all messages.

Replacement labels may be obtained from Perkins

distributors.

M0082024-03

Safety Section

General Hazard Information

•

Tampering with the engine installation or

tampering with the OEM supplied wiring can be

dangerous. Personal injury, death and/or engine

damage could result.

•

Vent the engine exhaust to the outside when the

engine is operated in an enclosed area.

•

If the engine is not running, do not release the

secondary brake or the parking brake systems

unless the vehicle is blocked or unless the vehicle

is restrained.

•

Wear a hard hat, protective glasses, and other

protective equipment, as required.

Illustration 7

g03422039

•

When working around an engine, the engine must

Purge notice message

not be in operation. You may only be near a

running engine to carry out maintenance

This notice should be located next to the battery

procedures that require the engine to be in

disconnect switch.

operation.

NOTICE

•

Do not wear loose clothing or jewelry that can

Do not turn the battery power disconnect switch off

snag on controls or on other parts of the engine.

until indicator lamp has turned off. If the switch is

turned off when the light is illuminated then the DEF

•

Ensure that all protective guards and all covers

system will not purge and DEF could freeze and

are secured in place on the engine.

cause damage to the pump and lines.

•

Never put maintenance fluids into glass

containers. Glass containers can break.

i08312804

•

Use all cleaning solutions with care.

General Hazard Information

•

Report all necessary repairs.

Unless other instructions are provided, perform the

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.

Illustration 8

g00104545

Tape the leads to help prevent sparks. If equipped,

allow the diesel exhaust fluid to be purged before

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

disconnecting the battery.

warning tag to the start switch or to the controls

before the engine is serviced or before the engine is

• If equipped, disconnect the connectors for the unit

repaired. Attach the warning tags to the engine and

injectors that are on the valve cover base. This

to each operator control station. When appropriate,

action will help prevent personal injury from the

disconnect the starting controls.

high voltage to the unit injectors. Do not come in

contact with the unit injector terminals while the

Do not allow unauthorized personnel on the engine,

engine is operating.

or around the engine when the engine is being

serviced.

M0082024-03

Safety Section

General Hazard Information

• Do not attempt any repairs or any adjustments to

the engine while the engine is operating.

• Do not attempt any repairs that are not

understood. Use the proper tools. Replace any

equipment that is damaged or repair the

equipment.

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

an engine that has been serviced, make

provisions to stop the engine if an overspeed

occurs. The stopping of the engine may be

accomplished by shutting off the fuel supply and/

or the air supply to the engine. Ensure that only

the fuel supply line is shut off. Ensure that the fuel

return line is open.

Illustration 9

g00702020

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

• Wear a hard hat, protective glasses, and other

Never short across the starting motor terminals or

protective equipment, as required.

the batteries. This action could bypass the engine

neutral start system and/or the electrical system

• Perkins recommend that you do not stand next to

could be damaged.

an exposed running engine unless it is necessary

when carrying out daily checks or maintenance

Engine exhaust contains products of combustion

procedures. The appropriate Personal Protective

which may be harmful to your health. Always start the

Equipment (PPE) must be worn when standing

engine and operate the engine in a well ventilated

next to an exposed running engine.

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

engine exhaust to the outside.

• Do not wear loose clothing or jewelry that can

snag on controls or on other parts of the engine.

Cautiously remove the following parts. To help

prevent spraying or splashing of pressurized fluids,

• Ensure that all protective guards and all covers

hold a rag over the part that is being removed.

are secured in place on the engine.

• Filler caps

• Never put maintenance fluids into glass

• Grease fittings

containers. Glass containers can break.

• Pressure taps

• Use all cleaning solutions with care.

• Breathers

• Report all necessary repairs.

• Drain plugs

Unless other instructions are provided, perform

the maintenance under the following conditions:

Use caution when cover plates are removed.

Gradually loosen, but do not remove the last two

• The engine is stopped. Ensure that the engine

bolts or nuts that are at opposite ends of the cover

cannot be started.

plate or the device. Before removing the last two

bolts or nuts, pry the cover loose to relieve any spring

• Disconnect the batteries when maintenance is

pressure or other pressure.

performed or when the electrical system is

serviced. Disconnect the battery ground leads.

Tape the leads to help prevent sparks.

• Do not attempt any repairs that are not

understood. Use the proper tools. Replace any

equipment that is damaged or repair the

equipment.

Pressurized Air and Water

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

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

personal injury.

M0082024-03

Safety Section

General Hazard Information

When pressurized air and/or pressurized water is

Dispose of all fluids according to local regulations

used for cleaning, wear protective clothing, protective

and mandates.

shoes, and eye protection. Eye protection includes

goggles or a protective face shield.

Static Electricity Hazard when

The maximum air pressure for cleaning purposes

Fueling with Ultra-low Sulfur Diesel

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

Fuel

water pressure for cleaning purposes must be below

275 kPa (40 psi).

The removal of sulfur and other compounds in ultra-

low sulfur diesel fuel (ULSD fuel) decreases the

Fluid Penetration

conductivity of ULSD and increases the ability of

ULSD to store static charge. Refineries may have

Pressure can be trapped in the hydraulic circuit long

treated the fuel with a static dissipating additive.

after the engine has been stopped. The pressure can

Many factors can reduce the effectiveness of the

cause hydraulic fluid or items such as pipe plugs to

additive over time. Static charges can build up in

escape rapidly if the pressure is not relieved

ULSD fuel while the fuel is flowing through fuel

correctly.

delivery systems. Static electricity discharge when

combustible vapors are present could result in a fire

Do not remove any hydraulic components or parts

or explosion. Ensure that the entire system used to

until pressure has been relieved or personal injury

refuel your machine (fuel supply tank, transfer pump,

may occur. Do not disassemble any hydraulic

transfer hose, nozzle, and others) is properly

components or parts until pressure has been relieved

grounded and bonded. Consult with your fuel or fuel

or personal injury may occur. Refer to the OEM

system supplier to ensure that the delivery system

information for any procedures that are required to

complies with fueling standards for proper grounding

relieve the hydraulic pressure.

and bonding.

Illustration 10

g00687600

Always use a board or cardboard when you check for

a leak. Leaking fluid that is under pressure can

penetrate body tissue. Fluid penetration can cause

serious injury and possible death. A pin hole leak can

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

you must get treatment immediately. Seek treatment

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

Containing Fluid Spillage

Care must be taken to ensure that fluids are

contained during performance of inspection,

maintenance, testing, adjusting, and repair of the

product. Be prepared to collect the fluid with suitable

containers before opening any compartment or

disassembling any component containing fluids.

M0082024-03

Safety Section

General Hazard Information

If such yellow deposits are found on the engine,

engine component parts, or associated equipment or

packages, Perkins recommends following local

Avoid static electricity risk when fueling. Ultra-

health and safety regulations and guidelines, utilizing

low sulfur diesel fuel (ULSD fuel) poses a greater

good hygiene, and adhering to safe work practices

static ignition hazard than earlier diesel formula-

when handling the equipment or parts. Perkins also

tions with a higher sulfur contents. Avoid death

recommends the following:

or serious injury from fire or explosion. Consult

with your fuel or fuel system supplier to ensure

• Wear appropriate Personal Protective Equipment

the delivery system is in compliance with fueling

(PPE)

standards for proper grounding and bonding

practices.

• Wash your hands and face with soap and water

prior to eating, drinking, or smoking, and also

during rest room breaks, to prevent ingestion of

Inhalation

any yellow powder

• Never use compressed air for cleaning areas

suspected of containing hexavalent chromium

• Avoid brushing, grinding, or cutting materials

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

Illustration 11

g00702022

shipped from Perkins engine company limited are

asbestos free. Perkins recommends the use of only

Exhaust

genuine Perkins replacement parts. Use the following

guidelines when you handle any replacement parts

Use caution. Exhaust fumes can be hazardous to

that contain asbestos or when you handle asbestos

health. If you operate the equipment in an enclosed

debris.

area, adequate ventilation is necessary.

Use caution. Avoid inhaling dust that might be

generated when you handle components that contain

Hexavalent Chromium

asbestos fibers. Inhaling this dust can be hazardous

to your health. The components that may contain

Perkins equipment and replacement parts comply

asbestos fibers are brake pads, brake bands, lining

with applicable regulations and requirements where

material, clutch plates, and some gaskets. The

originally sold. Perkins recommends the use of only

asbestos that is used in these components is usually

genuine Perkins replacement parts.

bound in a resin or sealed in some way. Normal

handling is not hazardous unless airborne dust that

Hexavalent chromium has occasionally been

detected on exhaust and heat shield systems on

contains asbestos is generated.

Perkins engines. Although laboratory testing is the

If dust that may contain asbestos is present, there

only accurate way to know if hexavalent chromium is,

are several guidelines that should be followed:

in fact, present, the presence of a yellow deposit in

areas of high heat (for example, exhaust system

• Never use compressed air for cleaning.

components or exhaust insulation) may be an

indication of the presence of hexavalent chromium.

• Avoid brushing materials that contain asbestos.

Use caution if you suspect the presence of

• Avoid grinding materials that contain asbestos.

hexavalent chromium. Avoid skin contact when

handling items that you suspect may contain

• Use a wet method to clean up asbestos materials.

hexavalent chromium, and avoid inhalation of any

dust in the suspect area. Inhalation of, or skin contact

• A vacuum cleaner that is equipped with a high

with, hexavalent chromium dust may be hazardous to

efficiency particulate air filter (HEPA) can also be

your health.

used.

M0082024-03

Safety Section

Burn Prevention

• Use exhaust ventilation on permanent machining

Always use leakproof containers when you drain

jobs.

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

drain, or into any source of water.

• Wear an approved respirator if there is no other

way to control the dust.

Diesel Exhaust Fluid

• Comply with applicable rules and regulations for

the work place. In the United States, use

Occupational Safety and Health Administration

(OSHA) requirements. These OSHA requirements

DEF is an aqueous solution of urea which can re-

lease ammonia vapors. Always wear the appro-

can be found in “29 CFR 1910.1001”.

priate Personal Protective Equipment (PPE) that

• Obey environmental regulations for the disposal of

is noted on a material safety data sheet (MSDS)

asbestos.

for Diesel Exhaust Fluid (DEF).

• Stay away from areas that might have asbestos

• Do not inhale ammonia vapor or mist

particles in the air.

• Do not eat, drink, or smoke in presence of DEF

Dispose of Waste Properly

• Avoid DEF contact with eyes, skin, and

clothing

• Wash thoroughly after handling DEF

Always follow the directions for first aid that are

noted on a material safety data sheet (MSDS) for

Diesel Exhaust Fluid (DEF).

DEF is not expected to produce significant adverse

health effects when the recommended instructions

for use are followed.

• Draining DEF must be carried out in a well

ventilated area.

• Do not allow the DEF to be spilled onto hot

surfaces.

Illustration 12

g00706404

i07277507

Improperly disposing of waste can threaten the

environment. Potentially harmful fluids should be

Burn Prevention

disposed of according to local regulations.

Do not touch any part of an operating engine system.

The engine, the exhaust, and the engine

aftertreatment system can exceed 650° C (1202° F)

under normal operating conditions.

Allow the engine system to cool before any

maintenance is performed. Relieve all pressure in the

air system, hydraulic system, lubrication system, fuel

system, and the cooling system before the related

items are disconnected.

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.

M0082024-03

Safety Section

Burn Prevention

After the engine has stopped, wait for 10 minutes to

Cooling system conditioner contains alkali. Alkali can

allow the fuel pressure to be purged from the high-

cause personal injury. Do not allow alkali to contact

pressure fuel lines before any service or repair is

the skin, the eyes, or the mouth.

performed on the engine fuel lines. The 10 minute

wait will also allow static charge to dissipate from the

Oils

low-pressure fuel system.

Skin may be irritated following repeated or prolonged

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

exposure to mineral and synthetic base oils. Refer to

the hydraulic system, in the lubrication system, or in

your suppliers Material Safety Data Sheets for

the cooling system before any lines, fittings, or

detailed information. Hot oil and lubricating

related items are disconnected.

and the engine has been allowed to cool.

Ensure that the filler cap is cool before removing the

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

with a bare hand. Remove the filler cap slowly to

relieve pressure.

M0082024-03

Safety Section

Fire Prevention and Explosion Prevention

Aftertreatment System and Diesel

Store fuels and lubricants in correctly marked

containers away from unauthorized persons. Store

Exhaust Fluid

oily rags and any flammable materials in protective

containers. Do not smoke in areas that are used for

Diesel Exhaust Fluid (DEF) temperatures can reach

storing flammable materials.

65° to 70°C (149.° to 126°F) during normal engine

operation. Stop the engine. Wait for 15 minutes to

Do not expose the engine to any flame.

allow the DEF system to be purged and the DEF to

cool before service or repair is performed.

Exhaust shields (if equipped) protect hot exhaust

components from oil or fuel spray if there was a line,

i07817010

a tube, or a seal failure. Exhaust shields must be

installed correctly.

Fire Prevention and Explosion

Do not weld on lines or tanks that contain flammable

Prevention

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

bypass any fuses and/or circuit breakers.

Arcing or sparking could cause a fire. Secure

connections, recommended wiring, and correctly

maintained battery cables will help to prevent arcing

or sparking.

Illustration 13

g00704000

All fuels, most lubricants, and some coolant mixtures

are flammable.

Contact with high pressure fuel may cause fluid

Flammable fluids that are leaking or spilled onto hot

penetration and burn hazards. High pressure fuel

surfaces or onto electrical components can cause a

spray may cause a fire hazard. Failure to follow

fire. Fire may cause personal injury and property

these inspection, maintenance and service in-

damage.

structions may cause personal injury or death.

After the emergency stop button is operated, ensure

that you allow 15 minutes, before the engine covers

After the engine has stopped, you must wait for 10

are removed.

minutes to allow the fuel pressure to be purged from

Determine whether the engine will be operated in an

the high-pressure fuel lines before any service or

environment that allows combustible gases to be

repair is performed on the engine fuel lines. The 10

minute wait will also allow static charge to dissipate

drawn into the air inlet system. These gases could

from the low-pressure fuel system.

cause the engine to overspeed. Personal injury,

property damage, or engine damage could result.

Ensure that the engine is stopped. Inspect all lines

If the application involves the presence of

and hoses for wear or for deterioration. Ensure that

the hoses are correctly routed. The lines and hoses

combustible gases, consult your Perkins dealer and/

must have adequate support and secure clamps. If

or your Perkins distributor for additional information

any fuel lines or fuel hoses become kinked, the fuel

about suitable protection devices.

line or fuel hose must be replaced. Refer to the

Remove all flammable combustible materials or

Disassembly and Assembly manual for more

conductive materials such as fuel, oil, and debris

information.

from the engine. Do not allow any flammable

combustible materials or conductive materials to

Oil filters and fuel filters must be correctly installed.

accumulate on the engine.

The filter housings must be tightened to the correct

torque. Refer to the Disassembly and Assembly

manual for more information.

M0082024-03

Safety Section

Fire Prevention and Explosion Prevention

Illustration 14

g00704059

Illustration 15

g00704135

Use caution when you are refueling an engine. Do

Gases from a battery can explode. Keep any open

not smoke while you are refueling an engine. Do not

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

refuel an engine near open flames or sparks. Always

not smoke in battery charging areas.

stop the engine before refueling.

Never check the battery charge by placing a metal

Avoid static electricity risk when fueling. Ultra-low

object across the terminal posts. Use a voltmeter or a

Sulfur Diesel fuel (ULSD fuel) poses a greater static

hydrometer.

ignition hazard than earlier diesel formulations with a

higher sulfur content. Avoid death or serious injury

Incorrect jumper cable connections can cause an

from fire or explosion. Consult your fuel or fuel

explosion that can result in injury. Refer to the

system supplier to ensure that the delivery system is

Operation Section of this manual for specific

in compliance with fueling standards for proper

instructions.

grounding and bonding practices.

Do not charge a frozen battery. A frozen battery may

cause an explosion.

The batteries must be kept clean. The covers (if

equipped) must be kept on the cells. Use the

recommended cables, connections, and battery box

covers when the engine is operated.

Fire Extinguisher

Make sure that a fire extinguisher is available. Be

familiar with the operation of the fire extinguisher.

Inspect the fire extinguisher and service the fire

extinguisher regularly. Obey the recommendations

on the instruction plate.

Ether

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and

personal injury.

Ether is flammable and poisonous.

M0082024-03

Safety Section

Crushing Prevention and Cutting Prevention

Do not smoke while you are replacing an ether

When objects are struck, wear protective glasses in

cylinder.

order to avoid injury to the eyes.

Do not store ether cylinders in living areas or in the

Chips or other debris may fly off objects when objects

engine compartment. Do not store ether cylinders in

are struck. Before objects are struck, ensure that no

direct sunlight or in temperatures above 49° C

one will be injured by flying debris.

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

flames or sparks.

i05768982

Lines, Tubes, and Hoses

Mounting and Dismounting

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

pressure lines. Do not install any lines that are

Do not climb on the engine or the engine

damaged.

aftertreatment system. The engine and

aftertreatment system have not been designed with

Leaks can cause fires. Consult your Perkins dealer or

mounting or dismounting locations.

your Perkins distributor for replacement parts.

Refer to the OEM for the location of foot and hand

Replace the parts if any of the following conditions

holds for your specific application.

are present:

• High-pressure fuel line or lines are removed.

i07671624

• End fittings are damaged or leaking.

High Pressure Fuel Lines

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel

• Flexible parts of the hoses are kinked.

spray may cause a fire hazard. Failure to follow

these inspection, maintenance and service in-

• Outer covers have embedded armoring.

structions may cause personal injury or death.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shields

are installed correctly. During engine operation,

correct installation will help to prevent vibration,

rubbing against other parts, and excessive heat.

i02143194

Crushing Prevention and

Cutting Prevention

Support the component correctly when work beneath

the component is performed.

Unless other maintenance instructions are provided,

never attempt adjustments while the engine is

running.

Stay clear of all rotating parts and of all moving parts.

Leave the guards in place until maintenance is

performed. After the maintenance is performed,

reinstall the guards.

Keep objects away from moving fan blades. The fan

blades will throw objects or cut objects.

M0082024-03

Safety Section

High Pressure Fuel Lines

Illustration 16

g01877473

(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

The high-pressure fuel lines are the fuel lines that are

Do not loosen the high-pressure fuel lines to remove

between the high-pressure fuel pump and the high-

air from the fuel system. This procedure is not

pressure fuel manifold and the fuel lines that are

required.

between the fuel manifold and cylinder head. These

fuel lines are different from fuel lines on other fuel

Visually inspect the high-pressure fuel lines before

systems.

the engine is started. This inspection should be

performed each day.

The differences are as follows:

If the engine is inspected whilst in operation, always

• The high-pressure fuel lines are constantly

use the correct inspection procedure to avoid a fluid

charged with high pressure while the engine is in

penetration hazard. Refer to Operation and

operation and up to 10 minutes after the engine

Maintenance Manual, “General hazard Information”.

has stopped.

• Inspect the high-pressure fuel lines for damage,

• The internal pressures of the high-pressure fuel

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

lines are higher than other types of fuel system.

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

• The high-pressure fuel lines are formed to shape

is a leak, do not tighten the connection, to stop the

and then strengthened by a special process.

leak. The connection must only be tightened to the

recommended torque. Refer to Disassembly and

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

Assembly, “Fuel injection lines - Remove and Fuel

deform the high-pressure fuel lines. Do not bend or

injection lines - Install”.

strike the high-pressure fuel lines. Deformation or

damage of the high-pressure fuel lines may cause a

• If the high-pressure fuel lines are torqued correctly

point of weakness and potential failure.

and the high-pressure fuel lines are leaking, the

high-pressure fuel lines must be replaced.

Do not check the high-pressure fuel lines with the

engine or the starting motor in operation. After the

• Ensure that all clips on the high-pressure fuel lines

engine has stopped, you must wait for 10 minutes to

are in place. Do not operate the engine with clips

allow the fuel pressure to be purged from the high-

that are damaged, missing, or loose.

pressure fuel lines before any service or repair is

performed on the engine fuel lines. The 10 minute

• Do not attach any other item to the high-pressure

wait will also allow static charge to dissipate from the

fuel lines.

low-pressure fuel system.

M0082024-03

Safety Section

Before Starting Engine

• Loosened high-pressure fuel lines must be

i08185623

replaced. High-pressure fuel lines that have been

removed must be replaced. Refer to Disassembly

Engine Starting

and assembly manual, “Fuel Injection Lines -

Install”.

i05874054

Do not use aerosol types of starting aids such as

Before Starting Engine

ether. Such use could result in an explosion and

personal injury.

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

NOTICE

or to the controls DO NOT start the engine or move

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

the controls. Consult with the person that attached

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

the warning tag before the engine is started.

provision to shut the engine off should an overspeed

occur. This may be accomplished by shutting off the

All protective guards and all protective covers must

air and/or fuel supply to the engine.

be installed if the engine must be started to perform

service procedures. To help prevent an accident that

is caused by parts in rotation, work around the parts

carefully.

Start the engine from the operator's compartment or

Engine exhaust contains products of combustion

from the engine start switch.

which may be harmful to your health. Always

start and operate the engine in a well ventilated

Always start the engine according to the procedure

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

described in the Operation and Maintenance Manual,

to the outside.

“Engine Starting” topic in the Operation Section.

Knowing the correct procedure will help to prevent

Inspect the engine for potential hazards.

major damage to the engine components. Knowing

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

the procedure will also help to prevent personal

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

injury.

warning tag attached to the start switch or to the

To ensure that the jacket water heater (if equipped)

controls.

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

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

correctly, check the water temperature gauge. Also,

underneath, or close to the engine. Ensure that the

check the oil temperature gauge during the heater

area is free of personnel.

operation.

If equipped, ensure that the lighting system for the

Engine exhaust contains products of combustion

engine is suitable for the conditions. Ensure that all

which can be harmful to health. Always start the

lights work properly, if equipped.

engine and operate the engine in a well ventilated

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

All protective guards and all protective covers must

vent the engine exhaust to the outside.

be installed if the engine must be started in order to

perform service procedures. To help prevent an

Note: The engine is equipped with a device for cold

accident that is caused by parts in rotation, work

starting. If the engine will be operated in very cold

around the parts carefully.

conditions, an extra cold starting aid may be

required. Normally, the engine will be equipped with

Do not bypass the automatic shutoff circuits. Do not

the correct type of starting aid for the region of

disable the automatic shutoff circuits. The circuits are

operation.

provided in order to help prevent personal injury. The

circuits are also provided in order to help prevent

These engines are equipped with a glow plug starting

engine damage.

aid in each cylinder which heats the intake air to

improve starting. Some Perkins engines may have a

See the Service Manual for repairs and for

cold starting system that is controlled by the ECM

adjustments.

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.

M0082024-03

Safety Section

Engine Stopping

i02234873

Grounding Practices

Engine Stopping

Stop the engine according to the procedure in the

Operation and Maintenance Manual, “Engine

Stopping (Operation Section)” in order to avoid

overheating of the engine and accelerated wear of

the engine components.

Use the Emergency Stop Button (if equipped) ONLY

in an emergency situation. Do not use the

Emergency Stop Button for normal engine stopping.

After an emergency stop, DO NOT start the engine

until the problem that caused the emergency stop

has been corrected.

Stop the engine if an overspeed condition occurs

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

engine that has been overhauled.

To stop an electronically controlled engine, cut the

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

to the engine.

i07676578

Electrical System

Illustration 17

g01888534

Never disconnect any charging unit circuit or battery

circuit cable from the battery when the charging unit

Typical example

is operating. A spark can cause the combustible

(1) Ground to battery

gases that are produced by some batteries to ignite.

(2) Ground to starting motor

(3) Starting motor to engine block

To help prevent sparks from igniting combustible

gases that are produced by some batteries, the

negative “-” cable should be connected last from the

external power source to the primary position for

grounding.

Check for frayed or loose electrical wiring daily.

Tighten all loose electrical connections before the

engine is started. Repair all frayed electrical wires

before the engine is started. See the Operation and

Maintenance Manual for specific starting instructions.

M0082024-03

Safety Section

Engine Electronics

The power supply connections and the ground

connections for the engine electronics should always

be from the isolator to the battery.

i07943840

Engine Electronics

Tampering with the electronic system installation

or the OEM wiring installation can be dangerous

and could result in personal injury or death and/

or engine damage.

Electrical Shock Hazard. The electronic unit injec-

tors use DC voltage. The ECM sends this voltage

to the electronic unit injectors. Do not come in

contact with the harness connector for the elec-

tronic unit injectors while the engine is operating.

Failure to follow this instruction could result in

personal injury or death.

This engine has a comprehensive, programmable

Illustration 18

g03027396

Engine Monitoring System. The Electronic Control

Typical example

Module (ECM) monitors the engine operating

conditions. If any of the engine parameters extend

(5) Ground to the battery

(6) Ground to the engine block

outside an allowable range, the ECM will initiate an

(7) Primary position for grounding

immediate action.

The following actions are available for engine

Correct grounding for the engine electrical system is

monitoring control:

necessary for optimum engine performance and

reliability. Incorrect grounding will result in

• Warning: A warning light could be illuminated or a

uncontrolled electrical circuit paths and in unreliable

electrical circuit paths.

sound warning could be activated (horn)

Uncontrolled electrical circuit paths can result in

• Derate: The engine power could be reduced by 50

damage to the crankshaft bearing journal surfaces

percent

and to aluminum components.

• Shutdown: The engine could be shut down or only

Engines that are installed without engine-to-frame

operate at low idle

ground straps can be damaged by electrical

discharge.

The following monitored engine operating conditions

and components can limit engine speed and/or the

To ensure that the engine and the engine electrical

engine power:

systems function correctly, an engine-to-frame

ground strap with a direct path to the battery must be

• Engine Coolant Temperature

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

engine ground to the frame.

• Engine Oil Pressure

The connections for the grounds should be tight and

• Engine Speed

free of corrosion. The engine alternator must be

grounded to the negative “-” battery terminal. The

• Intake Manifold Air Temperature

wire used must be adequate to handle the full

charging current of the alternator.

• Intake Manifold Air Pressure

• Wastegate Actuator

• Supply Voltage to Sensors

Perkins 1206J-E70TA and 1206J-E70TTA Industrial Engines. Operation Manual (2021) - page 1