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

M0082024-03

Operation Section

Engine Diagnostics

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Engine Diagnostics

Fault Logging

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Self-Diagnostics

The system provides the capability of Fault Logging.

When the Electronic Control Module (ECM)

generates an active diagnostic code, the code will be

Perkins Electronic Engines have the capability to

logged in the memory of the ECM. The codes that

perform a self-diagnostics test. When the system

have been logged by the ECM can be identified by

detects an active problem, a diagnostic lamp is

the electronic service tool. The active codes that

activated. Diagnostic codes will be stored in

have been logged will be cleared when the fault has

permanent memory in the Electronic Control Module

been rectified or the fault is no longer active. The

(ECM). The diagnostic codes can be retrieved by

following logged faults cannot be cleared from the

using Perkins electronic service tools.

memory of the ECM without using a factory

password: Overspeed, low engine oil pressure, high

Some installations have electronic displays that

engine coolant temperature, and aftertreatment

provide direct readouts of the engine diagnostic

codes.

codes. Refer to the manual that is provided by the

OEM for more information on retrieving engine

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diagnostic codes.

Engine Operation with Active

Active codes represent problems that currently exist.

These problems should be investigated first.

Diagnostic Codes

Logged codes represent the following items:

• Intermittent problems

If a diagnostic lamp illuminates during normal engine

operation, the system has identified a situation that is

• Recorded events

not within the specification. Use electronic service

tools to check the active diagnostic codes.

• Performance history

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

The problems may have been repaired since the

there is a low oil pressure condition, the Electronic

logging of the code. These codes do not indicate that

Control Module (ECM) will limit the engine power

a repair is needed. The codes are guides or signals

until the problem is corrected. If the oil pressure is

when a situation exists. Codes may be helpful to

within the normal range, the engine may be operated

troubleshoot problems.

at the rated speed and load. However, maintenance

should be performed as soon as possible.

When the problems have been corrected, the

corresponding logged fault codes should be cleared.

The active diagnostic code should be investigated.

The cause of the problem should be corrected as

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soon as possible. If the cause of the active diagnostic

code is repaired and there is only one active

diagnostic code, the diagnostic lamp will turn off.

Diagnostic Lamp

Operation of the engine and performance of the

engine can be limited as a result of the active

A diagnostic lamp is used to indicate the existence of

diagnostic code that is generated. Acceleration rates

an active fault. A fault diagnostic code will remain

may be significantly slower. Refer to the

active until the problem is repaired. The diagnostic

Troubleshooting Guide for more information on the

code may be retrieved by using the electronic service

relationship between these active diagnostic codes

tool.

and engine performance.

M0082024-03

Operation Section

Engine Operation with Intermittent Diagnostic Codes

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Engine Operation with

Intermittent Diagnostic Codes

If a diagnostic lamp illuminates during normal engine

operation and the diagnostic lamp shuts off, an

intermittent fault may have occurred. If a fault has

occurred, the fault will be logged into the memory of

the Electronic Control Module (ECM).

In most cases, it is not necessary to stop the engine

because of an intermittent code. However, the

operator should retrieve the logged fault codes and

the operator should reference the appropriate

information in order to identify the nature of the event.

The operator should log any observation that could

have caused the lamp to light.

• Low power

• Limits of the engine speed

• Excessive smoke, etc

This information can be useful to help troubleshoot

the situation. The information can also be used for

future reference. For more information on diagnostic

codes, refer to the Troubleshooting Guide for this

engine.

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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 to alter the

configuration parameters.

System Configuration Parameters

System configuration parameters affect the

emissions of the engine and/or the power of the

engine. System configuration parameters are

programmed at the factory. Normally, system

configuration parameters would never require

changing through the life of the engine. System

configuration parameters must be reprogrammed if

an ECM is replaced. System configuration

parameters do not require reprogrammed if the ECM

software is changed. Factory passwords are required

to change these parameters.

M0082024-03

Operation Section

Configuration Parameters

Table 5

System Configuration Parameters

Configuration Parameters

Record

Engine Serial Number

Factory Installed Aftertreatment #1 Identification Number

DPF #1 Soot Loading Sensing System Configuration Code

Limp Home Engine Speed Ramp Rate

System Operating Voltage Configuration

Rating Number

CAN Communication Protocol Write Security

Engine Emissions Operator Inducement Progress Configuration

Engine Emissions Operator Inducement Regulation Configuration

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 to alter the

customer configuration parameters.

Customer parameters may be changed repeatedly as

operational requirements change.

Table 6

Customer Specified Parameters

Specified Parameters

Record

Throttle Type Channel 1

Throttle Type Channel 2

IVS Channel 1

IVS Channel 2

Continuous Position Throttle Configuration 1

Continuous Position Throttle Configuration 2

Multi Position Throttle Switch Configuration

Throttle Arbitration

Equipment ID

Low Idle Speed

Ether Solenoid Configuration

Engine Idle Shutdown Minimum Ambient Air Temperature

Engine Idle Shutdown Maximum Ambient Air Temperature

Engine Idle Shutdown Enable Status

Engine Idle Shutdown Delay Time

(continued)

M0082024-03

Operation Section

Configuration Parameters

(Table 6, contd)

Engine Idle Shutdown Ambient Temperature Override Enable Status

High Soot Load Aftertreatment Protection Enable Status

Air Shutoff

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

Intermediate Engine Speed

Fan

Engine Fan Control

Engine Fan Type Configuration

Engine Cooling Fan Temperature Error Increasing Hysteresis

Engine Cooling Fan Temperature Error Decreasing Hysteresis

Engine Cooling Fan Current Ramp Rate

Engine Cooling Fan Speed

Top Engine Fan Speed

Minimum Desired Engine Cooling Fan Speed

Engine Cooling Fan Solenoid Minimum Current

Engine Cooling Fan Solenoid Maximum Current

Engine cooling Fan solenoid Dither Frequency

Engine Cooling Fan Solenoid Dither Amplitude

Fan Temperatures

Engine Fan Control Charge Air Cooler Outlet Temperature Input Enable

Engine Cooling Fan Maximum Air Flow Charge Air Cooler Outlet Temperature

Engine Cooling Fan Minimum Air Flow Charge Air Cooler Outlet Temperature

Engine Cooling Fan Control Coolant Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Coolant Temperature

(continued)

M0082024-03

Operation Section

Configuration Parameters

(Table 6, contd)

Engine Cooling Fan Minimum Air Flow Coolant Temperature

Engine Cooling Fan Control Transmission Oil Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Transmission Oil Temperature

Engine Cooling Fan Minimum Air Flow Transmission Oil Temperature

Engine Cooling Fan Control Hydraulic Oil Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Hydraulic Oil Temperature

Engine Cooling Fan Minimum Air Flow Hydraulic Oil Temperature

Engine Cooling Fan Control Auxiliary #1 Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Auxiliary #1 Temperature

Engine Cooling Fan Minimum Air Flow Auxiliary #1 Temperature

Engine Cooling Fan Control Auxiliary #2 Temperature Input Enable Status

Engine Cooling Fan Maximum Air Flow Auxiliary #2 Temperature

Engine Cooling Fan Minimum Air Flow Auxiliary #2 Temperature

Other Parameters

Maintenance Indicator Mode

Maintenance Level 1 Cycle Interval Hours

Coolant Level Sensor

Air Filter Restriction Switch Installation Status

Air Filter Restriction Switch Configuration

Fuel/Water Separator Switch Installation Status

User Defined Switch Installation Status

Auxiliary Temperature Sensor Installation Status

Auxiliary Pressure Sensor Installation Status

Remote Torque Speed Control Enable Status

Number of Engine Operating Mode Switches

Engine Operating Mode Configuration

Glow Plug Start Aid Installation Status

High Idle Configuration

Throttle Channel 1 Droop %

Throttle Channel 2 Droop %

TSC 1 Droop %

Min Max / All Speed Governing

Rated Speed Configuration

M0082024-03

Operation Section

Engine Starting

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Engine Starting

Cold Weather Starting

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Before Starting Engine

Perform the required daily maintenance and other

Do not use aerosol types of starting aids such as

periodic maintenance before the engine is started.

ether. Such use could result in an explosion and

Inspect the engine compartment. This inspection can

personal injury.

help prevent major repairs later. Refer to the

The ability to start the engine will be improved at

Operation and Maintenance Manual, “Maintenance

temperatures below -18 °C (0 °F) by the use of a

Interval Schedule” for more information.

jacket water heater or a battery with extra capacity.

• Ensure that the engine has an adequate fuel

The following items provide a means of minimizing

supply.

starting problems and fuel problems in cold weather:

Engine oil pan heaters, jacket water heaters, fuel

• Ensure that the engine has an adequate diesel

heaters, and fuel line insulation.

exhaust fluid supply

Use the procedure that follows for cold weather

• Open the fuel supply valve (if equipped).

starting.

• Drain the water separators.

Note: Do not adjust the engine speed control during

start-up. The electronic control module (ECM) will

NOTICE

control the engine speed during start-up.

All valves in the fuel return line must be open and fuel

supply lines must be open. Damage to the fuel sys-

1. Disengage any driven equipment.

tem can occur if fuel lines are closed with the engine

in operation.

Note: During key-ON, the indicator lamps will be

illuminated for 2 seconds to check the lamp

operation. If any of the indicator lamps do not

If the engine has not been started for several weeks,

illuminate check the bulb. If any indicator lamps stay

fuel may have drained from the fuel system. Air may

illuminated or flash, refer to Troubleshooting,

have entered the filter housing. Also, when fuel filters

“Indicator Lamp Circuit - Test”.

have been changed, some air pockets will be trapped

in the engine. In these instances, prime the fuel

2. Turn the keyswitch to the RUN position. Leave the

system. Refer to the Operation and Maintenance

Manual, “Fuel System - Prime” for more information

keyswitch in the RUN position until the warning

on priming the fuel system. Also, check that the fuel

light for the glow plugs is extinguished.

specification is correct and that the fuel condition is

3. When the warning light for the glow plugs is

correct. Refer to the Operation and Maintenance

Manual, “Fuel Recommendations”.

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.

Engine exhaust contains products of combustion

which may be harmful to your health. Always

Note: The operating period of the warning light for

start and operate the engine in a well ventilated

the glow plugs will vary according to the ambient air

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

temperature.

to the outside.

NOTICE

Do not engage the starting motor when flywheel is

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

turning. Do not start the engine under load.

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

similar warning tag attached to the start switch or

If the engine fails to start within 30 seconds, release

to the controls.

the starter switch or button and wait two minutes to

allow the starting motor to cool before attempting to

• Reset all the shutoffs or alarm components.

start the engine again.

• Ensure that any driven equipment has been

disengaged. Minimize electrical loads or remove

4. Allow the keyswitch to return to the RUN position

any electrical loads.

after the engine starts.

M0082024-03

Operation Section

Starting the Engine

5. Repeat step 2 through step 4 if the engine fails to

3. When the warning light for the glow plugs is

start.

extinguished, turn the keyswitch to the START

position to engage the electric starting motor and

Note: After starting, the engine may be held at low

crank the engine.

speed for a duration of between 1 and 25 seconds to

allow engine systems to stabilize. The duration will

Note: The operating period of the warning light for

depend on ambient temperature, time since last run

the glow plugs will change due to the temperature of

and other factors. The glow plug warning lamp will

the engine.

flash to indicate that the engine is being held at low

speed.

NOTICE

Do not engage the starting motor when flywheel is

6. The engine should not be raced to speed up the

turning. Do not start the engine under load.

engine warming up process. Allow the engine to

idle for 3 to 5 minutes, or allow the engine to idle

If the engine fails to start within 30 seconds, release

until the water temperature indicator begins to rise.

the starter switch or button and wait two minutes to

allow the starting motor to cool before attempting to

When idling after the engine has started in cold

start the engine again.

weather, increase the engine rpm from 1000 to

1200 rpm. This operation will warm up the engine

more quickly.

4. Allow the keyswitch to return to the RUN position

after the engine starts.

7. Operate the engine at low load until all systems

reach operating temperature. Check the gauges

5. Repeat step 2 through step 4 if the engine fails to

during the engine warming up period.

start.

6. After starting, the engine may be held at low speed

Following a cold start white smoke can be seen from

the tailpipe. This smoke is normal and caused by

for a duration between 1 and 60 seconds to allow

condensation leaving the exhaust system after

engine systems to stabilize. The duration will

warming up. The white smoke should clear following

depend on ambient temperature, time since last

working of the engine.

run and other factors. The glow plug warning light

will flash to indicate that the engine is being held at

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low speed in some applications.

Starting the Engine

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Starting with Jump Start

Note: Do not adjust the engine speed control during

Cables

start-up. The electronic control module (ECM) will

control the engine speed during start-up.

(Do Not Use This Procedure in

Hazardous Locations that have

Starting the Engine

Explosive Atmospheres)

1. Disengage any equipment that is driven by the

engine.

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.

The connection of battery cables to a battery and

the disconnection of battery cables from a battery

Note: If the keyswitch has been left in the RUN

may cause an explosion which may result in in-

position for a long period of time without engaging the

jury or death. The connection and the disconnec-

electric starting motor, turn the keyswitch from the

tion of other electrical equipment may also cause

RUN position to the OFF position and then back to

an explosion which may result in injury or death.

the RUN position to reactivate the glow plug preheat

The procedures for the connection and the dis-

stage.

connection of battery cables and other electrical

equipment should only be performed in a nonex-

Note: During the key on, the indicator lamps will be

plosive atmosphere.

illuminated for 2 seconds to check lamp operation. If

any of the lamps do not illuminate, check the bulb. If

any indicator lamps stay illuminated or flash, refer to

Troubleshooting, “Indicator Lamp Circuit - Test”.

M0082024-03

Operation Section

After Starting Engine

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

to the negative cable terminal of the electrical

Improper jump start cable connections can cause

source. Connect the other negative end of the

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

Never attempt to start an engine from an external

proper voltage with a battery charger after the engine

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.

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For 904D-E36TA industrial engines, ensure that a 12

VDC or 24 VDC battery source is used to start the

After Starting Engine

engine.

After starting, the engine may be held at low speed

NOTICE

for a duration between 1 and 25 seconds to allow

Using a battery source with the same voltage as the

engine systems to stabilize. Holding the engine

electric starting motor. Use ONLY equal voltage for

speed low is controlled by the Electronic Control

jump starting. The use of higher voltage will damage

Module (ECM). The duration will depend on ambient

the electrical system.

temperature, time since last run and other factors.

Do not reverse the battery cables. The alternator can

Note: In ambient temperatures from 0°C to 60°C

be damaged. Attach ground cable last and remove

(32°F to 140°F), the warm-up time is approximately 3

first.

minutes. In temperatures below 0°C (32°F),

additional warm-up time may be required.

Turn all electrical accessories OFF before attaching

the jump start cables.

When the engine idles during warm-up, observe the

following conditions:

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

tion before attaching the jump start cables to the en-

Do not check the high-pressure fuel lines with the

gine being started.

engine or the starting motor in operation. If you

inspect the engine in operation, always use the

correct inspection procedure to avoid a fluid

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

penetration hazard. Refer to Operation and

OFF position. Turn off all the engines accessories.

Maintenance Manual, “General hazard Information”.

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

• Check for any fluid or for any air leaks at idle rpm

the positive cable terminal of the discharged

and at one-half full rpm (no load on the engine)

battery. Connect the other positive end of the

before operating the engine under load. This

jump-start cable to the positive cable terminal of

check may not be possible in some applications.

the electrical source.

M0082024-03

Operation Section

Engine Operation

Carbon Dioxide (CO2) Emissions

Engine Operation

Emissions regulations require that the value of the

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CO2 emissions be reported to the end user. For this

engine, 727.598 g/kWh was determined to be the

Engine Operation

CO2 value during the EU type approval process. This

value was recorded in EU type approval certificate.

This CO2 measurement results from testing over a

fixed test cycle, under laboratory conditions, with a(n)

(parent) engine representative of the engine type

NOTICE

The engine and emissions control system shall be

(engine family). This value shall not imply, or express

operated, used, and maintained in accordance with

any guarantee of the performance of a particular

the instructions provided. Failure to follow the instruc-

engine.

tions could result in emissions performance that does

not meet the requirements applicable to the category

Engine Operation and the

of the engine. No deliberated tampering with, or mis-

use of the engine emissions control system should

Aftertreatment System

take place. Prompt action is critical to rectify any in-

correct operation, use, or maintenance of the emis-

The exhaust gases and hydrocarbon particles from

sions control system.

the engine first pass through the Diesel Oxidation

Catalyst (DOC). Some of the gases and matter are

Correct operation and maintenance are key factors in

oxidized as they pass through the DOC. The gases

obtaining the maximum life and economy of the

then pass through the Diesel Particulate Filter (DPF).

engine. If the directions in the Operation and

The DPF collects the soot and any ash that is

Maintenance Manual are followed, costs can be

produced by the combustion in the engine. During

minimized and engine service life can be maximized.

regeneration, the soot is converted into a gas and the

ash remains in the DPF. The gases finally pass

The time that is needed for the engine to reach

through the Selective Catalytic Reduction (SCR).

normal operating temperature can be less than the

Before the gases pass through the SCR, Diesel

time taken for a walk-around inspection of the

Exhaust Fluid (DEF) is injected into the gas stream.

engine.

The DEF is stored in the Pump Tank Unit (PTU)

which is controlled by the Electronic Control Module

The engine can be operated at the rated rpm after

(ECM). The mixtures of DEF and the exhaust gas

the engine is started and after the engine reaches

pass through the SCR, reducing the NOx in the

operating temperature. The engine will reach normal

exhaust emissions.

operating temperature sooner during a low engine

speed (rpm) and during a low-power demand. This

The DPF may require the exhaust gas temperature to

procedure is more effective than idling the engine at

rise to remove the soot. If necessary, the back

no load. The engine should reach operating

pressure valve operates to create the rise in

temperature in a few minutes.

temperature. In some applications, the operation of

the back pressure valve will make the engine tone

Avoid excess idling. Excessive idling causes carbon

different.

buildup, engine slobber, and soot loading of the

Diesel Particulate Filter (DPF). These issues are

The engine software will control the amount of DEF

harmful to the engine.

that will be required to keep the exhaust emission

compliant.

Gauge readings should be observed and the data

should be recorded frequently while the engine is

This design of DPF will not require a service

operating. Comparing the data over time will help to

maintenance interval. The DPF can be expected to

determine normal readings for each gauge.

function properly for the useful life of the engine

Comparing data over time will also help detect

(emissions durability period), as defined by

abnormal operating developments. Significant

regulation, subject to prescribed maintenance

changes in the readings should be investigated.

requirements being followed.

M0082024-03

Operation Section

Engaging the Driven Equipment

A fault code will be active for any DPF system-related

i07677865

issue. Follow Troubleshooting to rectify the issue. If

the DPF loses function, or is tampered with in any

Fuel Conservation Practices

way, the check engine lamp, and an amber action

lamp (if equipped) will illuminate. A fault code will

also annunciate. The lamps and fault code will

The efficiency of the engine can affect the fuel

remain active until the problem is rectified.

economy. Perkins design and technology in

manufacturing provides maximum fuel efficiency in

i01646335

all applications. Follow the recommended procedures

to attain optimum performance for the life of the

Engaging the Driven

engine.

Equipment

• Avoid spilling fuel.

Fuel expands when it is warmed up. The fuel may

overflow from the fuel tank. Inspect fuel lines for

1. Operate the engine at one-half of the rated rpm,

leaks. Repair the fuel lines, as needed.

when possible.

• Be aware of the properties of different fuels. Use

2. Engage the driven equipment without a load on the

only the recommended fuels. Refer to the

equipment, when possible.

Operations and Maintenance Manual, “Fuel

Interrupted starts put excessive stress on the drive

Recommendations” for further information.

train. Interrupted starts also waste fuel. To get the

• Avoid unnecessary idling.

driven equipment in motion, engage the clutch

smoothly with no load on the equipment. This

Shut off the engine rather than allowing the engine to

method should produce a start that is smooth and

idle for long periods of time.

easy. The engine rpm should not increase and the

• Observe the service indicator frequently. Keep the

clutch should not slip.

air cleaner elements clean.

3. Ensure that the ranges of the gauges are normal

• Ensure that the turbocharger is operating

when the engine is operating at one-half of the

correctly. For more information refer to this

rated rpm. Ensure that all gauges operate

Operation and Maintenance Manual,

properly.

“Turbocharger - Inspect”

4. Increase the engine rpm to the rated rpm. Always

• Maintain a good electrical system.

increase the engine rpm to the rated rpm before

the load is applied.

One faulty battery cell will overwork the alternator.

This fault will consume excess power and excess

5. Apply the load. Begin operating the engine at low

fuel.

load. Check the gauges and equipment for proper

operation. After normal oil pressure is reached and

• The belt should be in good condition. Refer to the

the temperature gauge begins to move, the engine

Systems Operation, Testing and Adjusting, “V-Belt

may be operated at full load. Check the gauges

Test” for further information.

and equipment frequently when the engine is

• Ensure that all the connections of the hoses are

operated under load.

tight. The connections should not leak.

Extended operation at low idle or at reduced load

• Ensure that the driven equipment is in good

may cause increased oil consumption and carbon

working order.

buildup in the cylinders. This carbon buildup

results in a loss of power and/or poor

• Cold engines consume excess fuel. Utilize heat

performance.

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.

M0082024-03

Operation Section

Aftertreatment Operation

i07622619

Selective Catalytic Reduction

Warning System

The Selective Catalytic Reduction (SCR) system is a

system used to reduce Nitrogen Oxide (NOx)

emissions from the engine. Diesel Exhaust Fluid

(DEF) is pumped from the DEF tank and is sprayed

into the exhaust stream. The DEF reacts with the

SCR catalyst to reduce NOx and leaves a nitrogen

Illustration 56

g03069862

and water vapor.

(1) DEF gauge

The engine and emissions control system shall be

(A) Low-level warning lamp

operated, used, and maintained in accordance with

the instructions provided to the end user to maintain

the emissions performance of the engine within the

requirements applicable to the category of the

engine. No deliberate tampering with, or misuse of

the engine emissions control system should take

place. In particular regarding deactivating, or not

maintaining the SCR system.

NOTICE

Stopping the engine immediately after the engine has

Illustration 57

g02852336

been working under load can result in overheating of

Emission malfunction lamp

SCR components.

Refer to the Operation and Maintenance Manual,

Warning Levels

“Engine Stopping” procedure to allow the engine to

cool and to prevent excessive temperatures in the

The SCR has three levels of warning. The time that

turbocharger housing and the DEF injector.

the system will stay at each warning level depends

on the fault detected and the type of software

enabled.

NOTICE

Any warning should be investigated immediately.

Allow at least 2 minutes after shutting down the en-

Contact your Perkins dealer or your Perkins

gine before you turn the battery disconnect switch to

Distributor if further assistance is required. The

OFF. Disconnecting the battery power too soon will

system is equipped with an override option. If the

prevent purging of the DEF lines after the engine is

override option has been used and the fault still

shutdown.

exists, the engine will be locked in de-rate or

shutdown mode.

Note: For information on DEF, refer to this Operation

and Maintenance Manual, “Fluid Recommendations”.

Definitions

• Self-correct Fault condition no longer exists. An

Warning Strategy

active fault code will no longer be active.

The Electronic Control Module (ECM) will be enabled

• Notification Action taken by the system to alert

with a world-wide warning strategy.

the operator of pending Inducement.

Warning Indicators

• Inducement Engine derates, vehicle speed

limits, or other actions intended to prompt the

The warning indicators consist of a level gauge for

operator to repair or maintain the emission control

the DEF, a low-level lamp for the DEF, an emission

system.

malfunction lamp, and the application stop lamp.

M0082024-03

Operation Section

Selective Catalytic Reduction Warning System

• Inducement Categories The Inducements are

• At Level 3 cycling the keyswitch will give 20

separated into categories. DEF Levels have

minutes override at full power, before the

inducement fault codes separate from the other

shutdown or idle is triggered. The emission

inducement categories. DEF level inducements

malfunction lamp will continue to flash.

are based on the DEF level, the other inducement

categories are based on escalating time. The

escalating time inducements will always have an

associated fault code along with the inducement

fault code. The associated fault is the root cause.

The escalating time inducement fault code is just

an indicator of what level of inducement the

engine is in. The escalating time inducement fault

code also indicates how much time remains until

the next level of inducement. There are three

inducement categories that will trigger an

escalating time inducement fault code.

Note: The associated codes for each of the

escalating time categories can be found in

Troubleshooting, SCR Warning System Problem.

• First Time When an escalating time inducement

fault code becomes active for the first time.

• Repeat occurrence When any escalating time

inducement fault code becomes active again

within 40 hours of the first occurrence. Engine

must run for 40 hours without tripping any

escalating time inducement fault before returning

back to first occurrence times.

• Safe Harbor Mode (Worldwide) Safe Harbor

Mode is a 20 minute engine run time period. Once

in level 3 inducement, the operator can perform a

key cycle and the engine will enter Safe Harbor

Mode. Safe Harbor Mode can only be

implemented once. Safe Harbor Mode is not

allowed for DEF level inducements with Worldwide

configuration.

NOTICE

It is essential to take prompt action to rectify any in-

correct operation, use, or maintenance of the emis-

sions SCR control system in accordance with the

rectification measures indicated by the warnings

listed on the following pages.

World-Wide SCR Warnings

• At Level 1 the emission malfunction lamp will be

on solid.

• At Level 2 the emission malfunction lamp will

flash.

• At Level 3 the emission malfunction lamp will flash

and the stop lamp will activate.

• At Level 3 the engine may shut down, or operate

at 1000 Revolutions Per Minute (RPM).

M0082024-03

Operation Section

Selective Catalytic Reduction Warning System

World-Wide Reduced Performance Setting

Table 7

World-Wide Reduced Performance Setting

Category 1 Fault (Tampering Dosing Interruption and Quality)

Normal operation

Level 1

Level 2

Level 3

Override

Inducement Time

None

2.5 Hours

70 minutes

50 Percent torque

Cycling the keyswitch

First Occurrence

Shut down or idle

will give 20 minutes

Until fault heals

of full power

The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then

the repeat occurrence inducement time will be triggered.

The override can only be used once

Inducement Time

None

5 minutes

75 Percent torque

50 Percent torque

Cycling the keyswitch

Repeat Occurrence

Shut down or idle

will give 20 minutes

Until fault heals

of full power

Inducement

None

Notification

None

Emission malfunction

lamp will be on solid

lamp will flash

The stop lamp will be

on solid

Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.

Table 8

World-Wide Reduced Performance Setting

Category 2 Fault (Non-Tampering Dosing and Interruption)

Normal operation

Level 1

Level 2

Level 3

Override

Inducement Time

None

10 Hours

50 Percent torque

Cycling the keyswitch

First Occurrence

Shut down or idle

will give 20 minutes

Until fault heals

of full power

The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then

the repeat occurrence inducement time will be triggered.

The override can only be used once

Inducement Time

None

2 Hours

50 Percent torque

Cycling the keyswitch

Repeat Occurrence

Shut down or idle

will give 20 minutes

Until fault heals

of full power

Inducement

None

75 Percent of torque

Notification

None

Emission malfunction

lamp will be on solid

lamp will flash

The stop lamp will be

on solid

Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.

Table 9

World-Wide Reduced Performance Setting

Category 3 Fault (Non-Tampering NOx Control Monitoring and Impeded EGR)

Normal operation

Level 1

Level 2

Level 3

Override

(continued)

M0082024-03

Operation Section

Selective Catalytic Reduction Warning System

(Table 9, contd)

Inducement Time

None

36 Hours

64 Hours

50 Percent torque

Cycling the keyswitch

First Occurrence

Shut down or idle

will give 20 minutes

Until fault heals

of full power

The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then

the repeat occurrence inducement time will be triggered.

The override can only be used once

Inducement Time

None

5 Hours

50 Percent torque

Cycling the keyswitch

Repeat Occurrence

Shut down or idle

will give 20 minutes

Until fault heals

of full power

Inducement

None

75 Percent of torque

Notification

None

Emission malfunction

lamp will be on solid

lamp will flash

The stop lamp will be

on solid

Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.

M0082024-03

Operation Section

Selective Catalytic Reduction Warning System

World-Wide Reduce Time Setting

Table 10

World-Wide Reduced Time Setting

Category 1 Fault (Tampering Dosing Interruption and Quality)

Normal operation

Level 1

Level 2

Level 3

Override

Inducement Time

None

2.5 Hours

70 minutes

50 Percent torque

Cycling the keyswitch

First Occurrence

Shut down or idle

will give 20 minutes

Until fault heals

of full power

The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then

the repeat inducement time will be triggered.

The override can only be used once.

Inducement Time

None

5 minutes

50 Percent torque

Cycling the keyswitch

Repeat Occurrence

Shut down or idle

will give 20 minutes

Until fault heals

of full power

Inducement

None

Notification

None

Emission malfunction

lamp will be on solid

lamp will flash

The stop lamp will

activate

Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.

Table 11

World-Wide Reduced Time Setting

Category 2 Fault (Non-Tampering Dosing Interruption)

Normal operation

Level 1

Level 2

Level 3

Override

Inducement Time

None

5 Hours

50 Percent torque

Cycling the keyswitch

First Occurrence

Shut down or idle

will give 20 minutes

Until fault heals

of full power

The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then

the repeat inducement time will be triggered.

The override can only be used once.

Inducement Time

None

1 Hour

50 Percent torque

Cycling the keyswitch

Repeat Occurrence

Shut down or idle

will give 20 minutes

Until fault heals

of full power

Inducement

None

Notification

None

Emission malfunction

lamp will be on solid

lamp will flash

The stop lamp will

activate

Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.

Table 12

World-Wide Reduced Time Setting

Category 3 Fault (Non-Tampering NOx Control Monitoring and Impeded EGR)

Normal operation

Level 1

Level 2

Level 3

Override

(continued)

M0082024-03

Operation Section

Selective Catalytic Reduction Warning System

(Table 12, contd)

Inducement Time

None

18 Hours

50 Percent torque

Cycling the keyswitch

First Occurrence

Shut down or idle

will give 20 minutes

Until fault heals

of full power

The system must be fault free for 40 hours before the system will reset to zero. If the fault is intermittent, and returns within the 40 hours, then

the repeat inducement time will be triggered.

The override can only be used once.

Inducement Time

None

108 Minutes

50 Percent torque

Cycling the keyswitch

Repeat Occurrence

Shut down or idle

will give 20 minutes

Until fault heals

of full power

Inducement

None

Notification

None

Emission malfunction

lamp will be on solid

lamp will flash

The stop lamp will

activate

Contact your Perkins dealer or your Perkins Distributor at level 1 warning, do not let the fault develop.

World-Wide DEF Level Warnings

Two options are available but only one option will be

enabled.

• The low-level warning lamp will operate when DEF

level reaches the trigger point of below 20 percent.

• At Level 1 the low-level warning lamp in the DEF

gauge will illuminate and the emission malfunction

lamp will be on solid.

• At Level 2 the low-level warning lamp for the DEF

is active and the emission malfunction lamp will

flash.

• At Level 3 all level 2 warning lamps are active,

plus the stop lamp will become active. The engine

will shut down or will only operate at 1000 RPM.

Filling the DEF tank will remove the warning from the

system.

Table 13

World-Wide DEF Level Option 1

Normal operation

Initial indication

Level 1

Level 2

Level 3

Inducement Trigger

Above 19 percent

Below 19 percent

Below 12.5 percent

0 Percent reading

Empty tank

Inducement

None

Engine may be de-

The engine may be

rated by 25 percent

derated by 50 percent

torque

torque.

A shutdown or low

idle only will be en-

forced after 5

minutes.

Notification

None

Low-level lamp

illuminated

Emission malfunction

lamp on solid

lamp flashing

Stop lamp on solid

M0082024-03

Operation Section

Cold Weather Operation

•

Achieving operating temperature will help prevent

Cold Weather Operation

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

within the engine will allow the engine readily start.

Perkins Diesel Engines can operate effectively in

cold weather. During cold weather, the starting and

•

Install the correct specification of engine lubricant

the operation of the diesel engine depends on the

before the beginning of cold weather. Refer to this

following items:

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.

Check the air intake more often when you operate

This section will cover the following information:

in snow.

• Potential problems that are caused by cold-

•

Ensure that the glow plugs are in working order.

weather operation

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

Do not use aerosol types of starting aids such as

practices. The information that is contained in this

ether. Such use could result in an explosion and

section provides guidelines for cold-weather

personal injury.

operation.

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.

M0082024-03

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

Recommendations for Coolant

Oil

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.

When the engine is operated below normal operating

Recommendations for the Coolant

temperatures, fuel and oil are not burned completely

Provide cooling system protection for the lowest

in the combustion chamber. This fuel and oil causes

soft carbon deposits to form on the valve stems.

expected outside temperature. Refer to this

Generally, the deposits do not cause problems and

Operation and Maintenance Manual, “Fluid

the deposits are burned off during operation at

Recommendations” for the recommended coolant

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

• Valves become stuck.

jacket water that surrounds the combustion

chambers. This heat provides the following functions:

• Pushrods may become bent.

• Startability is improved.

• Other damage to valve train components can

result.

• Warm up time is reduced.

For these reasons, when the engine is started, the

An electric block heater can be activated once the

engine must be operated until the coolant

engine is stopped. A block heater can be 110 V dc or

temperature is 80° C (176° F) minimum. Carbon

240 V dc. The output can be 750/1000W. Consult

deposits on the valve stems will be kept at a

your Perkins dealer or your Perkins distributor for

minimum. The free operation of the valves and the

more information.

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.

M0082024-03

Operation Section

Radiator Restrictions

The Water Temperature Regulator and

Consult with your Perkins dealer or your Perkins

distributor for the recommended breather

Insulated Heater Lines

components for operation from -25° to -40°C

(-13° to -72.°F).

The engine is equipped with a water temperature

regulator. When the engine coolant is below the

correct operating temperature, jacket water circulates

i07622821

through the engine cylinder block and into the engine

cylinder head. The coolant then returns to the

Radiator Restrictions

cylinder block via an internal passage that bypasses

the valve of the coolant temperature regulator. This

return ensures that coolant flows around the engine

Perkins discourages the use of airflow restriction

under cold operating conditions. The water

devices that are mounted in front of radiators. Airflow

temperature regulator begins to open when the

restriction can cause the following conditions:

engine jacket water has reached the correct

minimum operating temperature. As the jacket water

• High exhaust temperatures

coolant temperature rises above the minimum

operating temperature, the water temperature

• Power loss

regulator opens further allowing more coolant

through the radiator to dissipate excess heat.

• Excessive fan usage

The progressive opening of the water temperature

• Reduction in fuel economy

regulator operates the progressive closing of the

bypass passage between the cylinder block and

Reducing air flow over components will also affect

head. This action ensures maximum coolant flow to

under hood temperatures. Reducing air flow can

the radiator to achieve maximum heat dissipation.

increase surface temperatures during an

aftertreatment regeneration and could affect

Note: Do not restrict the air flow. Restriction of the air

component reliability.

flow can damage the fuel system. Perkins

discourages the use of all air flow restriction devices

If an airflow restriction device must be used, the

such as radiator shutters. Restriction of the air flow

device should have a permanent opening directly in

can result in the following: high exhaust

line with the fan hub. The device must have a

temperatures, power loss, excessive fan usage, and

minimum opening dimension of at least 770 cm²

reduction in fuel economy.

(120 in²).

A centered opening that is directly in line with the fan

A cab heater is beneficial in very cold weather. The

feed from the engine and the return lines from the

hub is specified to prevent an interrupted airflow on

cab should be insulated to reduce heat loss to the

the fan blades. Interrupted airflow on the fan blades

outside air.

could cause a fan failure.

Perkins recommends a warning device for the inlet

Recommendation for Crankcase

manifold temperature and/or the installation of an

Breather Protection

inlet air temperature gauge. The warning device for

the inlet manifold temperature should be set at 75 °C

Crankcase ventilation gases contain a large quantity

(167 °F). The inlet manifold air temperature should

of water vapor. This water vapor can freeze in cold

not exceed 75 °C (167 °F). Temperatures that

ambient conditions and can plug or damage the

exceed this limit can cause power loss and potential

crankcase ventilation system. If the engine is

engine damage.

operated in temperatures below -25° C (-13° F),

measures must be taken to prevent freezing and

i07818744

plugging of the breather system. Insulated hoses and

a heated canister assembly should be installed.

Fuel and the Effect from Cold

Weather

Note: Only use grades of fuel that are recommended

by Perkins. Refer to this Operation and Maintenance

Manual, “Fluid Recommendations”.

Properties of the diesel fuel can have a significant

effect on the engine cold start capability. It is critical

that the low temperature properties of diesel fuel are

acceptable for the minimum ambient temperature the

engine is expected to see in operation.

M0082024-03

Operation Section

Fuel Related Components in Cold Weather

Following properties are used to define fuels low

Fuel tanks should contain some provision for draining

temperature capability:

water and sediment from the bottom of the tanks.

• Cloud point

Some fuel tanks use supply pipes that allow water

and sediment to settle below the end of the fuel

• Pour point

supply pipe.

Some fuel tanks use supply lines that take fuel

• Cold Filter Plugging Point (CFPP)

directly from the bottom of the tank. If the engine is

The cloud point of the fuel is the temperature at

equipped with this system, regular maintenance of

which waxes naturally found in the diesel fuel begin

the fuel system filter is important.

to form crystals. The cloud point of the fuel must be

Drain the water and sediment from any fuel storage

below lowest ambient temperature to prevent filters

from plugging.

tank at the following intervals: weekly, service

intervals and refueling of the fuel tank. Draining will

Pour point is the last temperature before the fuel flow

help prevent water and/or sediment from being

stops and waxing of the fuel will start.

pumped from the fuel storage tank and into the

engine fuel tank.

Cold Filter Plugging Point (CFPP) is a temperature at

which a particular fuel will pass through a

Fuel Filters

standardized filtration device. This CFPP gives an

estimate of the lower operability temperature of fuel

After you change the fuel filter, always prime the fuel

system in order to remove air bubbles from the fuel

Be aware of these properties when diesel fuel is

system. Refer to the Operation and Maintenance

purchased. Consider the average ambient air

Manual in the Maintenance Section for more

temperature for the engines application. Engines that

information on priming the fuel system.

are fueled in one climate may not operate well if the

engines are shipped to colder climate. Problems can

The micron rating and the location of a primary fuel

result due to changes in temperature.

filter is important in cold-weather operation. The In-

line filter, primary fuel filter, and the fuel supply line

Before troubleshooting for low power or for poor

are the most common components that are affected

performance in the winter, check the fuel for waxing

by cold fuel.

The following components can provide a means of

minimizing fuel waxing problems in cold weather:

Fuel Heaters

• Fuel heaters, which may be an OEM option

Note: The OEM may equip the application with fuel

heaters. If so, the temperature of the fuel must not

• Fuel line insulation, which may be an OEM option

exceed 73 °C (163 °F) at the fuel transfer pump. The

fuel heater should be installed before the electric lift

Winter and arctic grades of diesel fuel are available in

pump.

the countries and territories with severe winters. For

more information refer to the Operation and

For more information about fuel heaters (if equipped),

Maintenance Manual, “Fuel For Cold-Weather

refer to the OEM information.

Operation”

Another important fuel property which can affect cold

i07677871

start and operation of diesel engine is Cetane

number. Detail and requirements of this property are

Diesel Exhaust Fluid in Cold

given in this Operation and Maintenance Manual,

“Fluid Recommendations”.

Weather

i05359588

Due to the freezing point of Diesel Exhaust Fluid

Fuel Related Components in

(DEF) the aftertreatment system is equipped with

electrically heated DEF lines. The system also has a

Cold Weather

coolant heated element in the DEF tank.

During periods of weather in which DEF can freeze

the application should be stood on level ground when

not in use. DEF can start to freeze at -11° C

Fuel Tanks

(12.2° F).

Condensation can form in partially filled fuel tanks.

Top off the fuel tanks after you operate the engine.

M0082024-03

Operation Section

Engine Stopping

The OEM may have equipped the application with an

Engine Stopping

emergency stop button. For more information about

the emergency stop button, refer to the OEM

i07161953

information.

Ensure that any components for the external system

Stopping the Engine

that support the engine operation are secured after

the engine is stopped.

i05402556

NOTICE

Stopping the engine immediately after the engine has

been working under load, can result in overheating

After Stopping Engine

and accelerated wear of the engine components.

Avoid accelerating the engine prior to shutting down

the engine.

Note: Before you check the engine oil, do not

operate the engine. Wait for at least 10 minutes after

Avoiding hot engine shutdowns will maximize turbo-

the engine has stopped in order to allow the engine

charger shaft and bearing life. Also, selective cata-

oil to return to the oil pan.

lytic reduction component life.

Note: Individual applications will have different

Contact with high pressure fuel may cause fluid

control systems. Ensure that the shutoff procedures

penetration and burn hazards. High pressure fuel

are understood. Use the following general guidelines

spray may cause a fire hazard. Failure to follow

to stop the engine.

these inspection, maintenance and service in-

structions may cause personal injury or death.

1. Remove the load from the engine. Reduce the

engine speed to low idle. Allow the engine to idle

for 5 minutes to cool the engine.

• Diesel Exhaust Fluid (DEF) purge, do not

disconnect the battery disconnect switch until the

2. Stop the engine after the cool down period

DEF purge has been completed. The procedure is

according to the shutoff system on the engine and

automatically controlled and will take

turn the ignition keyswitch to the OFF position. If

approximately 2 minutes.

necessary, refer to the instructions that are

provided by the OEM.

• After the engine has stopped, you must wait for 10

minutes in order to allow the fuel pressure to be

Note: Some applications the engine will continue to

purged from the high-pressure fuel lines before

operate after the keyswitch is turned to the OFF

any service or repair is performed on the engine

position. The engine will operate for a short time to

fuel lines. If necessary, perform minor

allow engine components to cool.

adjustments. Repair any leaks from the low-

pressure fuel system and from the cooling,

3. Allow at least 2 minutes after the engine has

lubrication, or air systems. Replace any high-

stopped before you turn the battery disconnect

pressure fuel line that has leaked. Refer to

switch to OFF. Disconnecting the battery power

Disassembly and Assembly Manual, “Fuel

too soon will prevent purging of the DEF fluid lines

Injection Lines - Install”.

after the engine is shut down. Also, during the 2

• Check the crankcase oil level. Maintain the oil

minutes the engine electronic control module is

level between the “MIN” mark and the “MAX” mark

active, storing information from the engine and

on the engine oil level gauge.

aftertreatment sensors.

• If the engine is equipped with a service hour

i05195199

meter, note the reading. Perform the maintenance

that is in the Operation and Maintenance Manual,

Emergency Stopping

“Maintenance Interval Schedule”.

• Fill the fuel tank, in order to help prevent

accumulation of moisture in the fuel. Do not overfill

NOTICE

the fuel tank.

Emergency shutoff controls are for EMERGENCY

use ONLY. DO NOT use emergency shutoff devices

• Fill the DEF tank, a low level of DEF in the tank

or controls for normal stopping procedure.

can result in engine de-rate.

M0082024-03

Maintenance Section

Refill Capacities

(Table 16, contd)

Maintenance Section

⁽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

of the External System in this row.

Refill Capacities

i07636462

i07277426

Fluid Recommendations

Refill Capacities

(Diesel Exhaust Fluid (DEF))

Lubrication System

General Information

The refill capacities for the engine crankcase reflect

the approximate capacity of the crankcase or sump

Diesel Exhaust Fluid (DEF) is a liquid that is injected

into the aftertreatment system before Selective

plus standard oil filters. Auxiliary oil filter systems will

require more oil. Refer to the OEM specifications for

Catalytic Reduction (SCR). This system of injecting

the capacity of the auxiliary oil filter. Refer to the

the DEF into the exhaust will cause a chemical

reaction in the SCR system. The Nitrogen Oxide

Operation and Maintenance Manual, “Maintenance

(NOx) molecules in the exhaust are converted to

Section” for more information on Lubricant

Specifications.

elemental nitrogen and water. This conversion will

reduce the emission of the engine.

Table 15

Engine

Specification

Refill Capacities

DEF that is used in Perkins engines must meet the

Compartment or System

Minimum

Maximum

ISO specification 22241-1 for quality. The ISO

13.5 L

16.5 L

specification 22241-1 requirements are met by many

Crankcase Oil Sump⁽¹⁾

(3.56 US gal)

(4.36 US gal)

brands of DEF, including the ones that carry the

AdBlue or API certification."

⁽¹⁾ These values are the approximate capacities for the crankcase

oil sump (aluminum) which includes the standard factory in-

The document series ISO standard 22241 will give

stalled oil filters. Engines with auxiliary oil filters will require

information on quality requirements, test methods,

more oil. Refer to the OEM specifications for the capacity of the

handling, transportation, storage, and refilling

auxiliary oil filter. The design of the oil pan can change the oil

capacity of the oil pan.

interface.

Spillage

Cooling System

Care should be taken when dispensing DEF. Spills

Refer to the OEM specifications for the External

should be cleaned immediately. All surfaces should

System capacity. This capacity information will be

be wiped clean and rinsed with water.

needed to determine the amount of coolant/

antifreeze that is required for the Total Cooling

DEF that has been spilt will crystallize when the

System.

water within the liquid evaporates. Spilt DEF will

Table 16

attack paint and metal. If DEF is spilt, wash the area

with water.

Engine

Refill Capacities

Caution should be used when dispensing DEF near

an engine that has recently been running. Spilling

Compartment or System

Liters

DEF onto hot components may cause the release of

12.4 L

ammonia vapors. Do not breathe ammonia vapors.

1206J-E70TA Engine only

(3.28 US gal)

Do not clean up any spills with bleach.

13.2 L

1206J-E70TTA Engine Only

Filling the DEF Tank

(3.49 US gal)

External System Per OEM⁽¹⁾

The fill cap on the DEF tank must be colored blue.

The DEF level is important, allowing the DEF tank to

run dry or operate at a low level can affect the engine

operation. Because of the corrosive nature of DEF,

(continued)

the correct materials must be used when filling a DEF

tank.

M0082024-03

Maintenance Section

Fluid Recommendations

DEF Quality

• Chromium Nickel Molybdenum (CrNiMo)

The quality of DEF can be measured by using a

• Titanium

refractometer. The DEF must comply with ISO

Non-metallic materials:

standard 22241-1 with the urea solution of 32.5

percent. Perkins offer a T400195 Refractometer for

• Polyethylene

checking the concentration of the DEF.

• Polypropylene

Cleanliness

• Polyisobutylene

Contaminants can degrade the quality and life of

DEF. Filtering DEF is recommended when dispensed

• Teflon (PFA)

into the DEF tank. Filters should be compatible with

DEF and should be used exclusively with DEF.

• Polyfluoroethylene (PFE)

Check with the filter supplier to confirm compatibility

with DEF before using. Mesh-type filters using

• Polyvinylidene fluoride (PVDF)

compatible metals, such as stainless steel, are

recommended. Paper (cellulose) media and some

• Polytetrafluoroethylene (PTFE)

synthetic filter media are not recommended because

of degradation during use.

Materials NOT compatible with DEF solutions include

Aluminum, Magnesium, Zinc, Nickel coatings, Silver,

Care should be taken when dispensing DEF. Spills

and Carbon steel and Solders containing any of the

should be cleaned immediately. Machine or engine

above. Unexpected reactions may occur if DEF

surfaces should be wiped clean and rinsed with

solutions come in contact with any non-compatible

water. Caution should be used when dispensing DEF

material or unknown materials.

near an engine that has recently been running.

Spilling DEF onto hot components will cause harmful

vapors.

i07671780

Storage

Fluid Recommendations

Do not store DEF in direct sunlight.

(General Fuel Information)

Table 17

Storage Temperature

Expected DEF Life

• Glossary

Below 25° C (77° F)

18 months

• ISO

International Standards Organization

25° C (77° F) to 30° C (86° F)

12 months

• ASTM

American Society for Testing and

30° C (86° F) to 35° C (95° F)

6 months

Materials

Above 35° C (95° F)

test quality before use

• HFRR

High Frequency Reciprocating Rig

for Lubricity testing of diesel fuels

Perkins recommend that all DEF taken from storage

should be checked to ensure that the DEF meets ISO

• FAME

Fatty Acid Methyl Esters

standard 22241-1.

• CFR

Co-ordinating Fuel Research

Materials compatibility

• ULSD

Ultra Low Sulfur Diesel

DEF is corrosive. Due to the corrosion caused, DEF

must be stored in tanks constructed of approved

• RME

Rape Methyl Ester

materials. Recommended storage materials:

• SME

Soy Methyl Ester

Stainless Steels:

• EPA

Environmental Protection Agency of

•

304 (S30400)

the United States

•

304L (S30403)

• PPM

Parts Per Million

•

316 (S31600)

• DPF

Diesel Particulate Filter

•

316L (S31603)

• v/v

(volume of solute)/(volume of solution)

Alloys and metals:

• CFPP

Cold Filter Plugging Point

• Chromium Nickel (CrNi)

M0082024-03

Maintenance Section

General Fuel Information

• BTL

Biomass to liquid

• GTL

Gas to liquid

• CTL

Coal to liquid

• HVO

Hydrotreated Vegetable Oil

General Information

NOTICE

Every attempt is made to provide accurate, up-to-

date information. By use of this document you agree

that Perkins Engines Company Limited is not respon-

sible for errors or omissions.

NOTICE

These recommendations are subject to change with-

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 18 .

NOTICE

The footnotes are a key part of the Perkins "Specifi-

cation for Distillate Diesel Fuel" Table. Read ALL of

the footnotes.

Table 18

"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

0.20% maximum

“D524”

“ISO 4262”

Bottoms

(continued)

M0082024-03

Maintenance Section

General Fuel Information

(Table 18, contd)

Cetane Number⁽¹⁾

40 minimum in North

“D613 or D6890”

“ISO 5165”

America

45 minimum in European

Union

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

50% at 250° C (482° F)

“D86”

“ISO 3405”

minimum

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)

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

0.02% 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

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⁾ A fuel with a higher cetane number than 45 is recommended to operate at a higher altitude 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 sulfur and ultra low sulfur fuel. Fuel with higher wear scar diameter than 0.52 mm (0.0205 inch)

will lead to reduced service life and premature failure of the fuel system. Refer to the lubricity section of this “Operation and Maintenance

Manual” Fluid Recommendations for more information.

(continued)

M0082024-03

Maintenance Section

General Fuel Information

(Table 18, contd)

⁽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.

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

Operating with fuels that do not meet the Perkins rec-

ommendations can cause the following effects: Start-

ing difficulty, reduced fuel filter service life, poor

combustion, deposits in the fuel injectors, signifi-

cantly reduce service life of the fuel system. Also, the

creation of deposits in the combustion chamber and

reduced service life of the engine.

NOTICE

The Perkins EU Stage V compliant 1200J Series of

diesel engine must be operated using Ultra Low Sul-

fur Diesel. The sulphur content of this fuel must be

lower than 15 PPM. This fuel complies with the emis-

sions regulations that are prescribed by the Environ-

mental Protection Agency of the United States.

Illustration 58

g02157153

Illustration 58 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 19

are released as acceptable to use on all 1200J series

of engine.

Table 19

Acceptable Fuel Specification for the 1206J Series of Engines⁽¹⁾

Fuel Specification

Comments

EN590

European Automotive Diesel Fuel (DERV)

(continued)

M0082024-03

Maintenance Section

General Fuel Information

(Table 19, contd)

“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 lubricity section of this “Operation and Maintenance Manual” Fluid

Recommendations.

“BS 2869: 2010 CLASS A2 or EU equivalent”

UK Off-Road Diesel fuel

“CEN TS15940”

“Paraffinic diesel fuel from synthesis or hydrotreatment”, “Biomass-to-

liquid” (BTL), “Gas-to-liquid” (GTL), called Hydrotreated Vegetable Oil

(HVO). Refer to the Renewable and Alternative Fuels section of this

“Operation and Maintenance Manual” Fluid Recommendations for

more information.

B20 Biodiesel Blend

Refer to the Recommendation for Biodiesel and Using B20 section of

this “Operation and Maintenance Manual” Fluid Recommendations for

more information.

⁽¹⁾ All the fuels must comply with the specification in the table for the Perkins Specification Distillate Diesel Fuel.

Diesel Fuel Characteristics

The viscosity of the fuel is significant because fuel

serves as a lubricant for the fuel system components.

Cetane Number

Fuel must have sufficient viscosity to lubricate the

fuel system in both extremely cold temperatures and

Cetane number is a measure of the ignition quality of

extremely hot temperatures. If the kinematic viscosity

diesel fuel. Fuel that has a higher cetane number will

of the fuel is lower than “1.4 cSt” at the fuel injection

give a shorter ignition delay and will produce a better

pump, damage to the fuel injection pump can occur.

ignition quality. Cetane numbers are derived for fuels

This damage can be excessive scuffing and seizure.

against proportions of cetane and

Low viscosity may lead to difficult hot restarting,

heptamethylnonane in the standard CFR engine.

stalling, and loss of performance. High viscosity may

Refer to “ISO 5165” for the test method.

result in seizure of the pump.

In Europe for non-road Stage V emissions

Perkins recommends kinematic viscosities of 1.4 and

regulations require minimum cetane number of 45. In

4.5 mm2/sec that is delivered to the fuel injection

the North America, minimum cetane number

pump. If a fuel with a low viscosity is used, cooling of

requirement is 40.

the fuel may be required to maintain 1.4 cSt or

greater viscosity at the fuel injection pump. Fuels with

Cetane number affect engine cold start ability,

a high viscosity might require fuel heaters to lower

exhaust emissions, combustion noise, and altitude

performance. Fuel with a higher cetane number is

the viscosity to 4.5 cSt at the fuel injection pump.

desirable and recommended. This is particularly

important for operations in cold weather and at high

Density

altitude.

Density is the mass of the fuel per unit volume at a

Viscosity

specific temperature. This parameter has a direct

influence on engine performance and a direct

influence on emissions. This influence determines

Viscosity is the property of a liquid of offering

from a heat output given injected volume of fuel. This

resistance to shear or flow. Viscosity decreases with

parameter is quoted in the following kg/m³ at 15 °C

increasing temperature. This decrease in viscosity

(59 °F).

follows a logarithmic relationship for normal fossil

fuel. The common reference is to kinematic viscosity.

Perkins recommends a density of 841 kg/m³ to

Kinematic viscosity is the quotient of the dynamic

obtain the correct power output. Lighter fuels are

viscosity that is divided by the density. The

acceptable but these fuels will not produce the rated

determination of kinematic viscosity is normally by

power.

readings from gravity flow viscometers at standard

temperatures. Refer to “ISO 3104” for the test

method.

M0082024-03

Maintenance Section

General Fuel Information

Sulfur

Fuel additives can enhance the lubricity of a fuel.

Contact your fuel supplier for those circumstances

The level of sulfur is governed by emissions

when fuel additives are required. Your fuel supplier

legislations. Regional regulation, national

can make recommendations for additives to use, and

regulations, or international regulations can require a

for the proper level of treatment.

fuel with a specific sulfur limit. The sulfur content of

the fuel and the fuel quality must comply with all

Distillation

existing local regulations for emissions.

Distillation is an indication of the mixture of different

Perkins 1200J series diesel engines have been

hydrocarbons in the fuel. A high ratio of lightweight

designed to operate only with Ultra Low Sulfur Diesel

hydrocarbons can affect the characteristics of

(ULSD) fuel. By using the test methods “ASTM

combustion.

D5453, or ISO 20846”, the content of sulfur in ULSD

fuel must be below 15 PPM (mg/kg) or 0.0015%

Recommendation for Biodiesel and

mass.

Using B20

In the USA, EPA regulations require the use ULSD

fuel with less than 0.0015 percent (15 PPM) (mg/kg))

Biodiesel is a fuel that can be defined as mono-alkyl

sulfur content.

esters of fatty acids. Biodiesel is a fuel that can be

made from various feedstocks. The most commonly

In Europe, sulfur free diesel fuels with sulphur

available biodiesel in Europe is Rape Methyl Ester

content less than 0.0010 percent (10 PPM) (mg/kg))

(RME). This biodiesel is derived from rapeseed oil.

is required by regulation for use in engines certified to

Soy Methyl Ester (SME) is the most common

EU nonroad Stage V emissions.

biodiesel in the United States. This biodiesel is

derived from soybean oil. Soybean oil or rapeseed oil

NOTICE

are the primary feedstocks. These fuels are together

Use of diesel fuel with higher than 15 PPM sulphur

known as Fatty Acid Methyl Esters (FAME).

limit in these engines will harm or permanently dam-

age emissions control systems and/or shorten serv-

Raw pressed vegetable oils are NOT acceptable for

ice interval.

use as a fuel in any concentration in compression

engines. Without esterification, these oils solidify in

the crankcase and the fuel tank. These fuels may not

Lubricity

be compatible with many of the elastomers that are

used in engines that are manufactured today. In

Lubricity is the capability of the fuel to prevent pump

original forms, these oils are not suitable for use as a

wear. The fluids lubricity describes the ability of the

fuel in compression engines. Alternate base stocks

fluid to reduce the friction between surfaces that are

for biodiesel may include animal tallow, waste

under load. This ability reduces the damage that is

cooking oils, or various other feedstocks. To use any

caused by friction. Fuel injection systems rely on the

of the products that are listed as fuel, the oil must be

lubricating properties of the fuel. Until fuel sulfur limits

esterified.

were mandated, the fuels lubricity was generally

Fuel made of 100 percent FAME is generally referred

believed to be a function of fuel viscosity.

to as B100 biodiesel or neat biodiesel.

The lubricity has particular significance to the current

Biodiesel can be blended with distillate diesel fuel.

ultra low sulfur fuel, and low aromatic fossil fuels.

The blends can be used as fuel. The most commonly

These fuels are made to meet stringent exhaust

available biodiesel blends are B5, which is 5 percent

emissions.

biodiesel and 95 percent distillate diesel fuel. B20,

The lubricity of these fuels must not exceed wear

which is 20 percent biodiesel and 80 percent distillate

scar diameter of 0.52 mm (0.0205 inch). The fuel

diesel fuel.

lubricity test must be performed on an HFRR,

Note: The percentages given are volume-based.

operated at 60 °C (140 °F). Refer to “ISO 12156-1”.

The U.S. distillate diesel fuel specification “ASTM

NOTICE

D975” includes up to B5 (5 percent) biodiesel.

The fuels system has been qualified with fuel having

lubricity up to 0.52 mm (0.0205 inch) wear scar diam-

European distillate diesel fuel specification EN590

eter as tested by “ISO 12156-1”. Fuel with higher

includes up B7 (7 percent) biodiesel.

wear scar diameter than 0.52 mm (0.0205 inch) will

lead to reduced service life and premature failure of

the fuel system.

M0082024-03

Maintenance Section

General Fuel Information

Note: Engines that are manufactured by Perkins are

• Crankcase oil fuel dilution can be higher when

certified by use of the prescribed Environmental

biodiesel or biodiesel blends are used. This

Protection Agency (EPA) and European Certification

increased level of fuel dilution when using

fuels. Perkins does not certify engines on any other

biodiesel or biodiesel blends is related to the

fuel. The user of the engine has the responsibility of

typically lower volatility of biodiesel. In-cylinder

using the correct fuel that is recommended by the

emissions control strategies utilized in many of the

manufacturer and allowed by the EPA and other

industrial latest engine designs may lead to a

appropriate regulatory agencies.

higher level of biodiesel concentration in the

sump. The long-term effect of biodiesel

Specification Requirements

concentration in crankcase oil is unknown

currently.

The neat biodiesel must conform to the latest

“EN14214 or ASTM D6751” (in the USA). The

• Perkins recommend the use of oil analysis to

biodiesel can only be blended in mixture of up to 20%

check the quality of the engine oil if biodiesel fuel

by volume in acceptable mineral diesel fuel meeting

is used. Ensure that the level of biodiesel in the

latest edition of “EN590 or ASTM D975 S15”

fuel is noted when the oil sample is taken.

designation.

Performance Related Issues

In United States Biodiesel blends of B6 to B20 must

meet the requirements listed in the latest edition of

Due to the lower energy content than the standard

“ASTM D7467” (B6 to B20) and must be of an API

distillate fuel B20 will cause a power loss in order of 2

gravity of 30-45.

to 4 percent. In addition, over time the power may

In North America biodiesel and biodiesel blends must

deteriorate further due to deposits in the fuel

be purchased from the BQ-9000 accredited

injectors.

producers and BQ-9000 certified distributors.

Biodiesel and biodiesel blends are known to cause

In other areas of the world, the use of biodiesel that is

an increase in fuel system deposits, most significant

BQ-9000 accredited and certified, or that is

of which are deposits within the fuel injector. These

accredited and certified by a comparable biodiesel

deposits can cause a loss in power due to restricted

quality body to meet similar biodiesel quality

or modified fuel injection or cause other functional

standards is required.

issues associated with these deposits.

Engine Service Requirements

Note: Perkins Fuel Cleaner (part number T400012)

is most effective in cleaning and preventing the

Aggressive properties of biodiesel fuel may cause

formation of deposits. Perkins Diesel Fuel

debris in the fuel tank and fuel lines. The aggressive

Conditioner helps to limit deposit issues by improving

properties of biodiesel will clean the fuel tank and fuel

the stability of biodiesel and biodiesel blends. For

lines. This cleaning of the fuel system can

more information refer to Perkins Diesel Fuel

prematurely block the fuel filters. Perkins recommend

Cleaner.

that after the initial usage of B20 biodiesel blended

fuel the fuel filters must be replaced at 50 hours.

Biodiesel fuel contains metal contaminants (sodium,

potassium, calcium, and/or magnesium) that form

Glycerides present in biodiesel fuel will also cause

ash products upon combustion in the diesel engine.

fuel filters to become blocked more quickly. Therefore

The ash can have an impact on the life and

the regular service interval should be reduced to 250

performance of aftertreatment emissions control

hours.

devices and can accumulate in DPF. The ash

accumulation may cause the need for more frequent

When biodiesel fuel is used, crank case oil and

ash service intervals and cause loss of performance

aftertreatment systems may be influenced. This

influence is due to the chemical composition and

General Requirements

characteristics of biodiesel fuel, such as density and

volatility, and to chemical contaminants that can be

Biodiesel has poor oxidation stability, which can

present in this fuel, such as alkali and alkaline metals

result in long-term problems in the storage of

(sodium, potassium, calcium, and magnesium).

biodiesel. Biodiesel fuel should be used within 6

months of manufacture. Equipment should not be

stored with the B20 biodiesel blends in the fuel

system for longer than 3 months.

M0082024-03

Maintenance Section

General Fuel Information

It is strongly recommended that engines with limited

BTL and HVO fuels are considered to be low carbon

operational time either do not use B20 biodiesel

fuels as they reduce carbon foot print compared to

blends or, whilst accepting some risk, limit biodiesel

fossil fuels and are commonly referred to as

blend to a maximum of B5 due to poor oxidation

renewable fuels. These fuels must not be confused

stability and other potential issues that this might

with biodiesel FAME which is fundamentally different

cause. Examples of applications that should limit the

fuel and is discussed in a separate section in this

use of biodiesel are standby generator sets and

manual.

certain emergency vehicles.

These paraffinic diesel fuels have virtually no sulphur

or aromatics and have very high cetane numbers

For standby generator sets and emergency vehicles

which 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 from petroleum.

monthly. Test should include acid number

(EN14104), oxidation stability (EN 15751 commonly

Paraffinic diesel fuels are considered as acceptable

know as the Rancimant test), and sediment

to use as a directed replacement to petroleum diesel

(ISO12937). For standby generator sets oxidation

or as a blendstock for petroleum diesel fuel in Perkins

stability of biodiesel blend must be 20 hours or more

diesel engines provided they meet latest edition of

as per EN 15751. If the test shows that the fuel has

the paraffinic diesel fuel specification “CENTS

degraded, fuel tank must be drained and engine

15940”. The fuel should also meet requirements

flashed by running with the fresh high-quality diesel

described in table 18 , Perkins Specification for

fuel.

Distillate Diesel Fuel, EN590, or latest ASTM D975

specification with the exception of density, which is

Perkins strongly recommend that seasonally

inherently lower for paraffinic fuels. Due to lower

operated engines have the fuel systems, including

density, some rated power loss might be

fuel tanks, flushed with conventional diesel fuel

noticeable.

before prolonged shutdown periods. An example of

an application that should seasonally flush the fuel

Ensure that the fuel has got appropriate cold flow

system is a combine harvester.

properties (cloud point and CFPP) for the minimum

statistical ambient temperature the engine is

Microbial contamination and growth can cause

expected to see in the operation. The fuel must also

corrosion in the fuel system and premature plugging

meet lubricity requirements as specified in the

of the fuel filter. Consult your supplier of fuel for

lubricity section of this “Operation and Maintenance

assistance in selecting appropriate anti-microbial

Manual” Fluid Recommendations

additive.

Water accelerates microbial contamination and

Fuel for Cold-Weather Operation

growth. When biodiesel is compared to distillate

fuels, water is naturally more likely to exist in the

The European standard “EN590” contains climate

biodiesel. Therefore check frequently and if

dependant requirements and a range of options. The

necessary, drain the water separator.

options can be applied differently in each country.

There are five classes that are given to arctic

Materials such as brass, bronze, copper, lead, tin,

climates and severe winter climates. 0, 1, 2, 3 and 4.

and zinc accelerate the oxidation process of the

biodiesel fuel. The oxidation process can cause

Fuel that complies with “EN590” CLASS 4 can be

deposits formation therefore these materials must not

used at temperatures as low as -44 °C (-47.2 °F).

be used for fuel tanks and fuel lines.

Refer to “EN590” for a detailed discretion of the

physical properties of the fuel.

Renewable and Alternative Fuels

The diesel fuel “ASTM D975 1-D” used in the United

States of America may be used in very cold

Perkins supports development and use of renewable

temperatures that are below -18 °C (-0.4 °F).

fuels through sustainability initiatives. In recent years

various forms of renewable and alternative

(synthetic) diesel fuels have started to emerge.

Synthetic diesel fuels are produced by gasification of

various feedstock and then synthesis to liquid to

obtain paraffinic diesel fuel. Based on the feedstock

used these fuels are commonly referred to as

Biomass to liquid (BTL), Gas to liquid (GTL) and Coal

to liquid (CTL). Hydrotreating of vegetable oils and

animal fats is another emerging process for

production of bio based diesel fuel called

Hydrotreated Vegetable Oil (HVO).

M0082024-03

Maintenance Section

General Fuel Information

Aftermarket Fuel Additives

Details instruction on the rate of which the fuel

cleaner is to be used 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.

Perkins fuel system cleaner contains less than 15

When auxiliary devices, accessories, or consum-

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 action 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.

systems and unit injectors. These fuels systems

Your fuel supplier or the fuel manufacturer will add

utilize higher fuel injection pressures and have tight

the appropriate supplemental diesel fuel additives.

clearances between moving parts to meet required

stringent emissions regulations. Peak injection

Perkins recognizes the fact that additives may be

pressures in current fuel injection systems may

required in some special circumstances.

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

contaminants as small as 4 µm can cause scoring

injector fouling, this fouling can cause the injector to

and scratching of internal pump and injector surfaces

operate incorrectly.

and of injector nozzles.

Contact your fuel supplier for those circumstances

Water in the fuel causes cavitation, corrosion of fuel

when fuel additives are required. Your fuel supplier

system parts, and provides an environment where

can recommend the appropriate fuel additive and the

microbial growth in the fuel can flourish. Other

correct level of treatment.

sources of fuel contamination are soaps, gels, or

other compounds that may result from undesirable

Note: For the best results, your fuel supplier should

chemical interactions in the fuels, particularly in

treat the fuel when additives are required. The

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 18 .

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 Fuel Cleaner (part number T400012) 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

systems. When you refuel the tank, filter the fuel

Perkins fuel cleaner will remove deposits that can

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.

M0082024-03

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

Fluid Recommendations

recommended service requirements or as needed.

•

Drain your water separators daily.

General Coolant Information

•

Drain your fuel tanks of sediment and water per

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”

Clean the cooling system for the following reasons:

cleanliness level. Bulk filter / coalescers are

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

Never operate an engine without water temperature

Filtration from the storage tank to the application

regulators in the cooling system. Water temperature

promotes the delivery of clean fuel. Fuel filtration

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.

M0082024-03

Maintenance Section

Fluid Recommendations

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

against the following conditions:

DO NOT use the following types of water in cooling

systems: Hard water, softened water that has been

• Boiling

conditioned with salt and sea water.

If distilled water or deionized water is not available,

• Freezing

use water with the properties that are listed in Table

20 .

• Cavitation of the water pump

Table 20

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

against the lowest ambient temperature.

Chloride (Cl)

40 mg/L

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 21 and refer to table 22 .

For a water analysis, consult one of the following

Table 21

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 22

• Formation of mineral deposits

Propylene Glycol

• Rust

Concentration

Freeze Protection

• Scale

50 Percent

-29 °C (-20 °F)

• 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

M0082024-03

Maintenance Section

Fluid Recommendations

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

glycol. This mixture of water and glycol will provide

Perkins, use of PDO, glycerine or other alternative

optimum heavy-duty performance as an antifreeze.

coolants is not recommended in Perkins diesel

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 23

Materials

Coolant Service Life

ELC - extended life coolant. A coolant that relies on

Coolant Type

Service Life⁽¹⁾

organic inhibitors for corrosion and cavitation

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

Water

Conventional Coolant - a coolant that relies on

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

Perkins ELC

cavitation protection is based on a mixture of organic

and inorganic inhibitors.

Perkins provides ELC for use in the following

applications:

The following coolants are recommended for used in

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.

M0082024-03

Maintenance Section

Fluid Recommendations

Containers of several sizes are available. Consult

NOTICE

your Perkins distributor for the part numbers.

Care must be taken to ensure that all fluids are con-

tained during performance of inspection, mainte-

ELC Cooling System Maintenance

nance, testing, adjusting and the repair of the

product. Be prepared to collect the fluid with suitable

containers before opening any compartment or disas-

Correct additions to the Extended Life

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

the thermostat opens. Stop the engine and allow

antifreeze and the additives, you must maintain the

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

corrosive and their use is not recommended by

are only required if the system has been

Perkins.

contaminated by the addition of some other type of

coolant or by cooling system damage.

6. Fill the cooling system with the Perkins Premixed

Clean water is the only cleaning agent that is

ELC. Operate the engine. Ensure that all coolant

required when ELC is drained from the cooling

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:

M0082024-03

Maintenance Section

Fluid Recommendations

• Drain the cooling system into a suitable container.

Table 24

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

V × 0.07 = X

with the Perkins ELC.

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 25 is an example for using the equation that is

Coolant.

in Table 24 .

Table 25

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)

Adding The SCA to The Heavy-Duty

NOTICE

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 26 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 26

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.

X is the amount of SCA that is required.

Do not mix SCAs and Extenders.

Only use SCAs or Extender approved by coolant

Table 27 is an example for using the equation that is

manufacturer and compatible with coolant.

in Table 26 .

Table 27

Example Of The Equation For Adding The SCA To The Heavy-

Adding the SCA to Heavy-Duty Coolant

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 24 to determine the

amount of SCA that is required when the cooling

system is initially filled.

M0082024-03

Maintenance Section

Fluid Recommendations

Cleaning the System of Heavy-Duty

Licensing

Antifreeze

The Engine Oil Licensing and Certification System by

the American Petroleum Institute (API) and the

Note: Before corrosion inhibitors can be effective the

Association des Constructers European Automobiles

cooling system must be free from rust, scale and

(ACEA) is recognized by Perkins. For detailed

deposits.

information about this system, see the latest edition

of the “API publication No. 1509”. Engine oils that

• Drain the cooling system.

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 59

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

definitions that will be of assistance in purchasing

check for signs of oil and deposits. If oil and

lubricants. Recommended oil viscosities can be

deposits are still present repeat the procedure.

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

Perkins recommends use of Perkins Diesel Engine

Fluid Recommendations

Oil for all Perkins engines. Perkins unique oil

formulations have been developed to provide full

performance and maximum service life of your

engine, and in tests have been shown to provide

General Lubricant Information

superior protection. Available in suitable API

classifications to meet the emissions requirements

Because of government regulations regarding the

and performance of your engine, Refer to 28 for the

certification of exhaust emissions from the engine,

correct oil specification for your engine. Consult your

the lubricant recommendations must be followed.

Perkins distributor for more information on these

multi-grade oils.

• API

American Petroleum Institute

• 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

specification of engine oil will reduce the life of

European Automobiles.

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.

100

M0082024-03

Maintenance Section

Fluid Recommendations

Table 28

Classifications for the 1200 Series Industrial Engine

Refer to illustration 60 (minimum temperature) to

determine the required oil viscosity for starting a cold

Oil Specification

engine.

API CK-4

ACEA E9

Refer to illustration 60 (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 28 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 60

g03329707

specification that is listed in table 28 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

not necessary to achieve the engines maximum

Perkins and these engine oils must not be used:

service life or rated performance. Fully formulated,

CC, CD, CD-2, CF-4, CG-4, CH-4, and CI-4.

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.

M0082024-03

101

Maintenance Section

Fluid Recommendations

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 60 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.

102

M0082024-03

Maintenance Section

Maintenance Recommendations

• The high-pressure fuel lines are constantly

Maintenance

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

Electronic Controls

engine can start at any moment. To avoid person-

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.

M0082024-03

103

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

Illustration 61

g06477753

• 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.

104

M0082024-03

Maintenance Section

Severe Service Application

i07014325

Maintenance can be very difficult. The buildup can

contain corrosive chemicals.

Severe Service Application

Buildup - Compounds, elements, corrosive

chemicals, and salt can damage some components.

Altitude - Problems can arise when the engine is

Severe service is the application of an engine that

operated at altitudes that are higher than the

either exceeds the current published standards for

that engine range. Or results in the engine being

intended settings for that application. Necessary

adjustments should be made.

used at the extremes of certain operating conditions.

• Performance such as power range, speed range,

and fuel consumption

Incorrect Operating Procedures

• Fuel quality

• Extended operation at low idle

• Operational Altitude

• Frequent hot shutdowns

• Maintenance intervals

• Operating at excessive loads

• Oil selection and maintenance

• Operating at excessive speeds

• Coolant type and maintenance

• Operating outside the intended application

• Environmental qualities

Incorrect Maintenance Procedures

• Installation

• Extending the maintenance intervals

• The temperature of the fluid in the engine

• Failure to use recommended fuel, lubricants, and

Refer to the standards for the engine or consult your

coolant/antifreeze

Perkins distributor to determine if the engine is

operating within the defined parameters.

Severe service operation can accelerate component

wear. Engines that operate under severe conditions

may need more frequent maintenance intervals to

ensure maximum reliability and retention of full

service life.

Due to individual applications, identification is not

possible for all the factors which can contribute to

severe service operation. Consult your Perkins

distributor for the unique maintenance that is

necessary for the engine.

The operating environment, incorrect operating

procedures, and incorrect maintenance procedures

can be factors which contribute to a severe service

application.

Environmental Factors

Ambient temperatures - The engine may be

exposed to extended operation in extremely cold

environments or hot environments. Valve

components can be damaged by carbon buildup if

the engine is frequently started and stopped in very

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.

Mud, dirt, and dust can encase components.

M0082024-03

105

Maintenance Section

Maintenance Interval Schedule

i08415813

“ Fuel System Primary Filter (Water Separator)

Element - Replace“

136

Maintenance Interval Schedule

“ Fuel System Secondary Filter - Replace“

138

“ Radiator - Clean“

142

When Required

Every 1000 Service Hours

“ Battery - Replace“

107

“ Belt - Inspect“

109

“ Battery or Battery Cable - Disconnect“

108

“ Belt Tensioner - Check“

109

“ DEF Filler Screen (Emission Related Component) -

“ Water Pump - Inspect“

146

Clean“

118

“ Diesel Exhaust Fluid (Emission Related

Every 1500 Service Hours

Component) - Fill“

120

“ Engine Crankcase Breather Element (Emission

“ Diesel Exhaust Fluid Tank - Flush“

122

Related Component) - Replace“

125

“ Engine - Clean“

123

“ Engine Crankcase Breather Element (Emission

“ Engine Air Cleaner Element - Replace“

123

Related Component) - Replace“

127

“ Engine Oil Sample - Obtain“

131

Every 2000 Service Hours

“ Fuel System - Prime“

135

“ Aftercooler Core - Inspect“

107

Daily

“ Engine Mounts - Inspect“

130

“ Driven Equipment - Check“

123

“ Starting Motor - Inspect“

142

“ Engine Air Cleaner Service Indicator -

Every 3000 Service Hours

Inspect“

124

“ Alternator - Inspect“

107

“ Engine Air Precleaner - Check/Clean“

125

“ Alternator and Fan Belts - Replace“

107

“ Engine Oil Level - Check“

130

“ Fuel System Primary Filter/Water Separator -

Every 3000 Service Hours or 1 Year

Drain“

138

“ Cooling System Supplemental Coolant Additive

“ Walk-Around Inspection“

144

(SCA) - Test/Add“

117

Every 50 Service Hours or Weekly

Every 3000 Service Hours or 2

“ Fuel Tank Water and Sediment - Drain“

140

Years

“ Hoses and Clamps - Inspect/Replace“

140

“ Coolant (Commercial Heavy-Duty) - Change“ . . 110

Every 500 Service Hours

Every 4000 Service Hours

“ Engine Oil and Filter - Change“

131

“ Aftercooler Core - Clean/Test“

107

“ Fan Clearance - Check“

133

Every 4500 Service Hours

Every 500 Service Hours or 1 Year

“ Turbocharger - Inspect“

143

“ Battery Electrolyte Level - Check“

108

Every 5000 Service Hours

“ Crankshaft Vibration Damper - Inspect“

118

“ Diesel Exhaust Fluid Filter (Emission Related

“ Engine Air Cleaner Element - Replace“

123

Component) - Replace“

121

“ Fuel Filter (In-Line) - Replace“

134

Perkins 1206J-E70TA and 1206J-E70TTA Industrial Engines. Operation Manual (2021) - page 3