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Products
Perkins 1206E-E66TA operation and maintenance (English)


Detailed Description:

Operation and

Maintenance

Manual

1206E-E66TA Industrial Engine

BK (Engine)

This document is printed from SPI². Not for RESALE


Important Safety Information

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

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

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

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

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

could result in injury or death.

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

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

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

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

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

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

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

Attention! Become Alert! Your Safety is Involved.

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

pictorially presente d.

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

this pub lication.

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

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

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

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

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

repair procedures that you choose.

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

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

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

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

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

When replacement parts are required for this

product Perkins recommends using Perkins

replacement parts.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

This document is printed from SPI². Not for RESALE


SEBU8603-01

3

Table of Contents

Table of Contents

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

Warranty Section

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

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

Safety Section

Reference Information Section

Safety Messages ... .... 5

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

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

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

Crushing Prevention and Cutting Prevention .. 14

Mounting and Dismounting ... 14

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

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

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

Engine Stopping ... ... 16

Electrical System ... .. 17

Engine Electronics ... 18

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

Index Section

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

Product Information Section

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

Product Identi fi cation Information ...

Operation Section

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

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

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

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

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

Engine Operation ... .. 54

Engine Stopping ... ... 56

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

Maintenance Section

Re fi ll Capacities ... .... 62

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

This document is printed from SPI². Not for RESALE


4

SEBU8603-01

Foreword

Foreword

Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance

Interval Schedule. The actual operating environment

of the engine also governs the Maintenance Interval

Schedule. Therefore, under extremely severe,

dusty, wet or freezing cold operating conditions,

more frequent lubrication and maintenance than is

speci fi ed in the Maintenance Interval Schedule may

be necessary.

Literature Information

This manual contains safety, operation instructions,

lubrication and maintenance information. This

manual should be stored in or near the engine area

in a literature holder or literature storage area. Read,

study and keep it with the literature and engine

information.

The maintenance schedule items are organized for

a preventive maintenance management program. If

the preventive maintenance program is followed, a

periodic tune-up is not required. The implementation

of a preventive maintenance management program

should minimize operating costs through cost

avoidances resulting from reductions in unscheduled

downtime and failures.

English is the primary language for all Perkins

publications. The English used facilitates translation

and consistency.

Some photographs or illustrations in this manual

show details or attachments that may be different

from your engine. Guards and covers may have

been removed for Illustrative purposes. Continuing

improvement and advancement of product design

may have caused changes to your engine which are

not included in this manual. Whenever a question

arises regarding your engine, or this manual, please

consult with your Perkins dealer or your Perkins

distributor for the latest available information.

Maintenance Intervals

Perform maintenance on items at multiples of

the original requirement. We recommend that the

maintenance schedules be reproduced and displayed

near the engine as a convenient reminder. We also

recommend that a maintenance record be maintained

as part of the engine's permanent record.

Safety

Your authorized Perkins dealer or your Perkins

distributor can assist you in adjusting your

maintenance schedule to meet the needs of your

operating environment.

This safety section lists basic safety precautions.

In addition, this section identi fi es hazardous,

warning situations. Read and understand the basic

precautions listed in the safety section before

operating or performing lubrication, maintenance and

repair on this product.

Overhaul

Major engine overhaul details are not covered in

the Operation and Maintenance Manual except

for the interval and the maintenance items in that

interval. Major repairs should only be carried out by

Perkins authorized personnel. Your Perkins dealer

or your Perkins distributor offers a variety of options

regarding overhaul programs. If you experience

a major engine failure, there are also numerous

after failure overhaul options available. Consult with

your Perkins dealer or your Perkins distributor for

information regarding these options.

Operation

Operating techniques outlined in this manual are

basic. They assist with developing the skills and

techniques required to operate the engine more

ef fi ciently and economically. Skill and techniques

develop as the operator gains knowledge of the

engine and its capabilities.

The operation section is a reference for operators.

Photographs and illustrations guide the operator

through procedures of inspecting, starting, operating

and stopping the engine. This section also includes a

discussion of electronic diagnostic information.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents

are known to the State of California to cause cancer,

birth defects, and other reproductive harm. Battery

posts, terminals and related accessories contain lead

and lead compounds. Wash hands after handling.

Maintenance

The maintenance section is a guide to engine care.

The illustrated, step-by-step instructions are grouped

by service hours and / or calendar time maintenance

intervals. Items in the maintenance schedule are

referenced to detailed instructions that follow.

This document is printed from SPI². Not for RESALE


SEBU8603-01

5

Safety Section

Safety Messages

Safety Section

The Universal Warning label (1) is located in two

positions. The warning labels are located on the font

right side of the valve mechanism cover and located

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

i04220089

Safety Messages

There may be several speci fi c warning signs on your

engine. The exact location and a description of the

warning signs are reviewed in this section. Please

become familiar with all warning signs.

Ensure that all of the warning signs are legible. Clean

the warning signs or replace the warning signs if

the words cannot be read or if the illustrations are

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

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

other harsh chemicals. Solvents, gasoline, or harsh

chemicals could loosen the adhesive that secures the

warning signs. The warning signs that are loosened

could drop off the engine.

Replace any warning sign that is damaged or

missing. If a warning sign is attached to a part of the

engine that is replaced, install a new warning sign on

the replacement part. Your Perkins distributor can

provide new warning signs.

(1) Universal Warning

Do not operate or work on this equipment unless

you have read and understand the instructions

and warnings in the Operation and Maintenance

Manuals. Failure to follow the instructions or

heed the warnings could result in serious injury

or death.

g01154807

Illustration 1

Typical example

This document is printed from SPI². Not for RESALE


6

SEBU8603-01

Safety Section

Safety Messages

g02382617

Illustration 2

Typical example

(1) Universal warning

(2) Hand (High Pressure)

Contact with high pressure fuel may cause fl uid

penetration and burn hazards. High pressure fu-

el spray may cause a fi re hazard. Failure to fol-

low these inspection, maintenance and service in-

structions may cause personal injury or death.

This document is printed from SPI². Not for RESALE


SEBU8603-01

7

Safety Section

Safety Messages

g02382677

Illustration 3

Typical example

The warning label for the Hand (High Pressure)

(3) is a wrap around label that is installed on the

high-pressure fuel line.

g02382618

Illustration 4

Typical example

Ether Warning

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and

personal injury.

This document is printed from SPI². Not for RESALE


8

SEBU8603-01

Safety Section

General Hazard Information

• Vent the engine exhaust to the outside when the

engine is operated in an enclosed area.

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

secondary brake or the parking brake systems

unless the vehicle is blocked or unless the vehicle

is restrained.

• Wear a hard hat, protective glasses, and other

protective equipment, as required.

• When work is performed around an engine that is

operating, wear protective devices for ears in order

to help prevent damage to hearing.

g01154809

Illustration 5

Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

Typical example

An ether warning label will be installed on the air

cleaner or close to the air cleaner. The location will

depend on the application.

Ensure that all protective guards and all covers are

secured in place on the engine.

• Never put maintenance fl uids into glass containers.

Glass containers can break.

i03566024

General Hazard Information

• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, perform the

maintenance under the following conditions:

• The engine is stopped. Ensure that the engine can

not be started.

• The protective locks or the controls are in the

applied position.

• Engage the secondary brakes or parking brakes.

• Block the vehicle or restrain the vehicle before

maintenance or repairs are performed.

g00104545

• Disconnect the batteries when maintenance

is performed or when the electrical system is

serviced. Disconnect the battery ground leads.

Tape the leads in order to help prevent sparks.

Illustration 6

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

warning tag to the start switch or to the controls

before the engine is serviced or before the engine is

repaired. Attach the warning tags to the engine and to

each operator control station. When it is appropriate,

disconnect the starting controls.

• Disconnect the connector for the unit injector that

is located on the valve cover base. This will help

prevent personal injury from the high voltage to the

unit injectors. Do not come in contact with the unit

injector terminals while the engine is operating.

Do not allow unauthorized personnel on the engine,

or around the engine when the engine is being

serviced.

• Do not attempt any repairs or any adjustments to

the engine while the engine is operating.

• Tampering with the engine installation or tampering

with the OEM supplied wiring can be dangerous.

Personal injury, death and / or engine damage could

result.

• Do not attempt any repairs that are not understood.

Use the proper tools. Replace any equipment that

is damaged or repair the equipment.

This document is printed from SPI². Not for RESALE


SEBU8603-01

9

Safety Section

General Hazard Information

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

engine that has been serviced, make provisions to

stop the engine if an overspeed occurs. This may

be accomplished by shutting off the fuel supply

and / or the air supply to the engine.

• Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

• Ensure that all protective guards and all covers are

secured in place on the engine.

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

Never short across the starting motor terminals or

the batteries. This could bypass the engine neutral

start system and / or the electrical system could be

damaged.

• Never put maintenance fl uids into glass containers.

Glass containers can break.

• Use all cleaning solutions with care.

• Report all necessary repairs.

Engine exhaust contains products of combustion

which may be harmful to your health. Always start the

engine and operate the engine in a well ventilated

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

engine exhaust to the outside.

Unless other instructions are provided, perform

the maintenance under the following conditions:

• The engine is stopped. Ensure that the engine

cannot be started.

Cautiously remove the following parts. To help

prevent spraying or splashing of pressurized fl uids,

hold a rag over the part that is being removed.

• Disconnect the batteries when maintenance

is performed or when the electrical system is

serviced. Disconnect the battery ground leads.

Tape the leads in order to help prevent sparks.

• Filler caps

• Grease fi ttings

• Pressure taps

• Breathers

• Do not attempt any repairs that are not understood.

Use the proper tools. Replace any equipment that

is damaged or repair the equipment.

Pressurized Air and Water

• Drain plugs

Pressurized air and / or water can cause debris

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

personal injury.

Use caution when cover plates are removed.

Gradually loosen, but do not remove the last two

bolts or nuts that are located at opposite ends of

the cover plate or the device. Before removing the

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

relieve any spring pressure or other pressure.

When pressurized air and / or pressurized water is

used for cleaning, wear protective clothing, protective

shoes, and eye protection. Eye protection includes

goggles or a protective face shield.

The maximum air pressure for cleaning purposes

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

water pressure for cleaning purposes must be below

275 kPa (40 psi).

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long

after the engine has been stopped. The pressure can

cause hydraulic fl uid or items such as pipe plugs to

escape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or parts

until pressure has been relieved or personal injury

may occur. Do not disassemble any hydraulic

components or parts until pressure has been relieved

or personal injury may occur. Refer to the OEM

information for any procedures that are required to

relieve the hydraulic pressure.

g00702020

Illustration 7

• Wear a hard hat, protective glasses, and other

protective equipment, as required.

• When work is performed around an engine that is

operating, wear protective devices for ears in order

to help prevent damage to hearing.

This document is printed from SPI². Not for RESALE


10

SEBU8603-01

Safety Section

General Hazard Information

Perkins replacement parts that are shipped from

Perkins are asbestos free. Perkins recommends

the use of only genuine Perkins replacement parts.

Use the following guidelines when you handle any

replacement parts that contain asbestos or when you

handle asbestos debris.

Use caution. Avoid inhaling dust that might be

generated when you handle components that contain

asbestos fi bers. Inhaling this dust can be hazardous

to your health. The components that may contain

asbestos fi bers are brake pads, brake bands, lining

material, clutch plates, and some gaskets. The

asbestos that is used in these components is usually

bound in a resin or sealed in some way. Normal

handling is not hazardous unless airborne dust that

contains asbestos is generated.

g00687600

Illustration 8

Always use a board or cardboard when you check

for a leak. Leaking fl uid that is under pressure can

penetrated body tissue. Fluid penetration can cause

serious injury and possible death. A pin hole leak can

cause severe injury. If fl uid is injected into your skin,

you must get treatment immediately. Seek treatment

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

If dust that may contain asbestos is present, there

are several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

Containing Fluid Spillage

• Use a wet method in order to clean up asbestos

materials.

NOTICE

Care must be taken to ensure that fl uids are contained

during performance of inspection, maintenance, test-

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

collect the fl uid with suitable containers before open-

ing any compartment or disassembling any compo-

nent containing fl uids.

• A vacuum cleaner that is equipped with a high

ef fi ciency particulate air filter (HEPA) can also be

used.

• Use exhaust ventilation on permanent machining

jobs.

Dispose of all fl uids according to local regulations and

mandates.

• Wear an approved respirator if there is no other

way to control the dust.

Asbestos Information

• Comply with applicable rules and regulations

for the work place. In the United States, use

Occupational Safety and Health Administration

(OSHA) requirements. These OSHA requirements

can be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposal

of asbestos.

• Stay away from areas that might have asbestos

particles in the air.

g00702022

Illustration 9

This document is printed from SPI². Not for RESALE


SEBU8603-01

11

Safety Section

Burn Prevention

Dispose of Waste Properly

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

the hydraulic system, in the lubrication system, or

in the cooling system before any lines, fittings, or

related items are disconnected.

Induction System

Sulfuric Acid Burn Hazard may cause serious per-

sonal injury or death.

The exhaust gas cooler may contain a small

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

fur levels greater than 15 ppm may increase the

amount of sulfuric acid formed. The sulfuric acid

may spill from the cooler during service of the

engine. The sulfuric acid will burn the eyes, skin

and clothing on contact. Always wear the appro-

priate personal protective equipment (PPE) that

is noted on a material safety data sheet (MSDS)

for sulfuric acid. Always follow the directions for

fi rst aid that are noted on a material safety data

sheet (MSDS) for sulfuric acid.

g00706404

Illustration 10

Improperly disposing of waste can threaten the

environment. Potentially harmful fl uids should be

disposed of according to local regulations.

Always use leakproof containers when you drain

fl uids. Do not pour waste onto the ground, down a

drain, or into any source of water.

i04224009

Coolant

Burn Prevention

When the engine is at operating temperature, the

engine coolant is hot. The coolant is also under

pressure. The radiator and all lines to the heaters or

to the engine contain hot coolant.

Do not touch any part of an operating engine

system. The engine, the exhaust, and the engine

aftertreatment system surface temperatures can

reach temperatures of approximately 600 ° C

(1112 ° F) under normal operating conditions.

Any contact with hot coolant or with steam can cause

severe burns. Allow cooling system components to

cool before the cooling system is drained.

Check that the coolant level after the engine has

stopped and the engine has been allowed to cool.

Allow the engine system to cool before any

maintenance is performed.

Ensure that the fi ller cap is cool before removing the

fi ller cap. The fi ller cap must be cool enough to touch

with a bare hand. Remove the fi ller cap slowly in

order to relieve pressure.

Relieve all pressure in the following systems,

hydraulic system, lubrication system, fuel system,

and the coolant system before the related items are

disconnected.

Cooling system conditioner contains alkali. Alkali can

cause personal injury. Do not allow alkali to contact

the skin, the eyes, or the mouth.

Contact with high pressure fuel may cause fl uid

penetration and burn hazards. High pressure fu-

el spray may cause a fi re hazard. Failure to fol-

low these inspection, maintenance and service in-

structions may cause personal injury or death.

Oils

Hot oil and hot lubricating components can cause

personal injury. Do not allow hot oil to contact the

skin. Also, do not allow hot components to contact

the skin.

After the engine has stopped, you must wait for 10

minutes in order to allow the fuel pressure to be

purged from the high-pressure fuel lines before any

service or repair is performed on the engine fuel lines.

This document is printed from SPI². Not for RESALE


12

SEBU8603-01

Safety Section

Fire Prevention and Explosion Prevention

Batteries

Store fuels and lubricants in correctly marked

containers away from unauthorized persons. Store

oily rags and any fl ammable materials in protective

containers. Do not smoke in areas that are used for

storing fl ammable materials.

Electrolyte is an acid. Electrolyte can cause personal

injury. Do not allow electrolyte to contact the skin or

the eyes. Always wear protective glasses for servicing

batteries. Wash hands after touching the batteries

and connectors. Use of gloves is recommended.

Do not expose the engine to any fl ame.

Exhaust shields (if equipped) protect hot exhaust

components from oil or fuel spray in case of a line,

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

installed correctly.

i03652933

Fire Prevention and Explosion

Prevention

Do not weld on lines or tanks that contain fl ammable

fl uids. Do not fl ame cut lines or tanks that contain

fl ammable fl uid. Clean any such lines or tanks

thoroughly with a non fl ammable solvent prior to

welding or fl ame cutting.

Wiring must be kept in good condition. All electrical

wires must be correctly routed and securely attached.

Check all electrical wires daily. Repair any wires

that are loose or frayed before you operate the

engine. Clean all electrical connections and tighten

all electrical connections.

Eliminate all wiring that is unattached or unnecessary.

Do not use any wires or cables that are smaller than

the recommended gauge. Do not bypass any fuses

and / or circuit breakers.

g00704000

Illustration 11

Arcing or sparking could cause a fi re. Secure

connections, recommended wiring, and correctly

maintained battery cables will help to prevent arcing

or sparking.

All fuels, most lubricants, and some coolant mixtures

are fl ammable.

Flammable fl uids that are leaking or spilled onto hot

surfaces or onto electrical components can cause

a fi re. Fire may cause personal injury and property

damage.

Contact with high pressure fuel may cause fl uid

penetration and burn hazards. High pressure fu-

el spray may cause a fi re hazard. Failure to fol-

low these inspection, maintenance and service in-

structions may cause personal injury or death.

After the emergency stop button is operated ensure

that you allow 15 minutes, before the engine covers

are removed.

Determine whether the engine will be operated in an

environment that allows combustible gases to be

drawn into the air inlet system. These gases could

cause the engine to overspeed. Personal injury,

property damage, or engine damage could result.

After the engine has stopped, you must wait for 10

minutes in order to allow the fuel pressure to be

purged from the high pressure fuel lines before any

service or repair is performed on the engine fuel lines.

If the application involves the presence of combustible

gases, consult your Perkins dealer and / or your

Perkins distributor for additional information about

suitable protection devices.

Ensure that the engine is stopped. Inspect all lines

and hoses for wear or for deterioration. The hoses

must be correctly routed. The lines and hoses must

have adequate support and secure clamps.

Remove all fl ammable combustible materials or

conductive materials such as fuel, oil, and debris from

the engine. Do not allow any fl ammable combustible

materials or conductive materials to accumulate on

the engine.

Oil fi lters and fuel fi lters must be correctly installed.

The fi lter housings must be tightened to the correct

torque. Refer to the Disassembly and Assembly

manual for more information.

This document is printed from SPI². Not for RESALE


SEBU8603-01

13

Safety Section

Fire Prevention and Explosion Prevention

Incorrect jumper cable connections can cause

an explosion that can result in injury. Refer to

the Operation Section of this manual for speci fi c

instructions.

Do not charge a frozen battery. This may cause an

explosion.

The batteries must be kept clean. The covers

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

recommended cables, connections, and battery box

covers when the engine is operated.

Fire Extinguisher

Make sure that a fi re extinguisher is available. Be

familiar with the operation of the fi re extinguisher.

Inspect the fi re extinguisher and service the fi re

extinguisher regularly. Obey the recommendations

on the instruction plate.

g00704059

Illustration 12

Lines, Tubes and Hoses

Use caution when you are refueling an engine. Do

not smoke while you are refueling an engine. Do not

refuel an engine near open fl ames or sparks. Always

stop the engine before refueling.

Do not bend high pressure lines. Do not strike high

pressure lines. Do not install any lines that are

damaged.

Leaks can cause fi res. Consult your Perkins dealer

or your Perkins distributor for replacement parts.

Replace the parts if any of the following conditions

are present:

• High pressure fuel line or lines are removed.

• End fi ttings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fi ttings are displaced.

g00704135

Illustration 13

Make sure that all clamps, guards, and heat shields

are installed correctly. During engine operation, this

will help to prevent vibration, rubbing against other

parts, and excessive heat.

Gases from a battery can explode. Keep any open

fl ames or sparks away from the top of a battery. Do

not smoke in battery charging areas.

Never check the battery charge by placing a metal

object across the terminal posts. Use a voltmeter or

a hydrometer.

This document is printed from SPI². Not for RESALE


14

SEBU8603-01

Safety Section

Crushing Prevention and Cutting Prevention

i02143194

Crushing Prevention and

Cutting Prevention

Support the component correctly when work beneath

the component is performed.

Unless other maintenance instructions are provided,

never attempt adjustments while the engine is

running.

Stay clear of all rotating parts and of all moving

parts. Leave the guards in place until maintenance

is performed. After the maintenance is performed,

reinstall the guards.

Keep objects away from moving fan blades. The fan

blades will throw objects or cut objects.

When objects are struck, wear protective glasses in

order to avoid injury to the eyes.

Chips or other debris may fl y off objects when objects

are struck. Before objects are struck, ensure that no

one will be injured by fl ying debris.

i04016709

Mounting and Dismounting

Do not climb on the engine or the engine

aftertreatment. The engine and aftertreatment have

not been designed with mounting or dismounting

locations.

Refer to the OEM for the location of foot and hand

holds for your speci fi c application.

i03550790

High Pressure Fuel Lines

Contact with high pressure fuel may cause fl uid

penetration and burn hazards. High pressure fu-

el spray may cause a fi re hazard. Failure to fol-

low these inspection, maintenance and service in-

structions may cause personal injury or death.

This document is printed from SPI². Not for RESALE


SEBU8603-01

15

Safety Section

High Pressure Fuel Lines

g01877473

Illustration 14

(1) High pressure line

(2) High pressure line

(3) High pressure line

(4) High pressure line

(5) High pressure line

(6) High pressure line

(7) High pressure fuel manifold (rail)

(8) High pressure line

(9) Fuel transfer line that is high pressure

The high pressure fuel lines are the fuel lines that

are between the high pressure fuel pump and the

high pressure fuel manifold and the fuel lines that are

between the fuel manifold and cylinder head. These

fuel lines are different from fuel lines on other fuel

systems.

Visually inspect the high pressure fuel lines before

the engine is started. This inspection should be each

day.

If you inspect the engine in operation, always use

the proper inspection procedure in order to avoid

a fl uid penetration hazard. Refer to Operation and

Maintenance Manual, "General hazard Information".

This is because of the following items:

• The high pressure fuel lines are constantly charged

with high pressure.

• Inspect the high pressure fuel lines for damage,

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

• The internal pressures of the high pressure fuel

lines are higher than other types of fuel system.

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

is a leak do not tighten the connection in order

to stop the leak. The connection must only be

tightened to the recommended torque. Refer to

Disassembly and Assembly, "Fuel injection lines-

Remove and Fuel injection lines-Install ".

• The high pressure fuel lines are formed to shape

and then strengthened by a special process.

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

de fl ect the high pressure fuel lines. Do not bend or

strike the high pressure fuel lines. Deformation or

damage of the high pressure fuel lines may cause a

point of weakness and potential failure.

• If the high pressure fuel lines are torqued correctly

and the high pressure fuel lines are leaking the

high pressure fuel lines must be replaced.

• Ensure that all clips on the high pressure fuel lines

are in place. Do not operate the engine with clips

that are damaged, missing or loose.

Do not check the high pressure fuel lines with the

engine or the starting motor in operation. After the

engine has stopped, you must wait for 10 minutes in

order to allow the fuel pressure to be purged from the

high pressure fuel lines before any service or repair

is performed on the engine fuel lines.

• Do not attach any other item to the high pressure

fuel lines.

• Loosened high pressure fuel lines must be

replaced. Also removed high pressure fuel lines

must be replaced. Refer to Disassembly and

assembly manual, “Fuel Injection Lines-Install”.

Do not loosen the high pressure fuel lines in order

to remove air from the fuel system. This procedure

is not required.

This document is printed from SPI². Not for RESALE


16

SEBU8603-01

Safety Section

Before Starting Engine

i02813489

All protective guards and all protective covers must

be installed if the engine must be started in order

to perform service procedures. To help prevent an

accident that is caused by parts in rotation, work

around the parts carefully.

Before Starting Engine

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

serviced or repaired, make provision to shut the

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

be accomplished by shutting off the air and / or fuel

supply to the engine.

Start the engine from the operators compartment or

from the engine start switch.

Always start the engine according to the procedure

that is described in the Operation and Maintenance

Manual, “Engine Starting” topic in the Operation

Section. Knowing that the correct procedure will help

to prevent major damage to the engine components.

Knowing that the procedure will also help to prevent

personal injury.

Overspeed shutdown should occur automatically for

engines that are controlled electronically. If automatic

shutdown does not occur, press the emerg, ency stop

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

Inspect the engine for potential hazards.

To ensure that the jacket water heater (if equipped)

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

correctly, check the water temperature gauge. Also,

check the oil temperature gauge during the heater

operation.

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

underneath, or close to the engine. Ensure that the

area is free of personnel.

If equipped, ensure that the lighting system for the

engine is suitable for the conditions. Ensure that all

lights work correctly, if equipped.

Engine exhaust contains products of combustion

which can be harmful to your health. Always start the

engine and operate the engine in a well ventilated

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

vent the engine exhaust to the outside.

All protective guards and all protective covers must

be installed if the engine must be started in order

to perform service procedures. To help prevent an

accident that is caused by parts in rotation, work

around the parts carefully.

Note: The engine is equipped with a device for cold

starting. If the engine will be operated in very cold

conditions, then an extra cold starting aid may be

required. Normally, the engine will be equipped with

the correct type of starting aid for your region of

operation.

Do not bypass the automatic shutoff circuits. Do not

disable the automatic shutoff circuits. The circuits are

provided in order to help prevent personal injury. The

circuits are also provided in order to help prevent

engine damage.

These engines are equipped with a glow plug starting

aid in each individual cylinder that heats the intake air

in order to improve starting. Some Perkins engines

may have a cold starting system that is controlled by

the ECM that allows a controlled fl ow of ether into

the engine. The ECM will disconnect the glow plugs

before the ether is introduced. This system would

be installed at the factory.

See the Service Manual for repairs and for

adjustments.

i03996487

Engine Starting

i02234873

Engine Stopping

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and

personal injury.

Stop the engine according to the procedure in

the Operation and Maintenance Manual, "Engine

Stopping (Operation Section) ”in order to avoid

overheating of the engine and accelerated wear of

the engine components.

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

or to the controls DO NOT start the engine or move

the controls. Consult with the person that attached

the warning tag before the engine is started.

This document is printed from SPI². Not for RESALE


SEBU8603-01

17

Safety Section

Electrical System

Grounding Practices

Use the Emergency Stop Button (if equipped) ONLY

in an emergency situation. Do not use the Emergency

Stop Button for normal engine stopping. After an

emergency stop, DO NOT start the engine until the

problem that caused the emergency stop has been

corrected.

Stop the engine if an overspeed condition occurs

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

that has been overhauled.

To stop an electronically controlled engine, cut the

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

to the engine.

i04193189

Electrical System

Never disconnect any charging unit circuit or battery

circuit cable from the battery when the charging unit

is operating. A spark can cause the combustible

gases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible

gases that are produced by some batteries, the

negative “−” cable should be connected last from

the external power source to the primary position for

grounding.

g02383098

Illustration 15

Typical example

(1) Ground to the battery

Check the electrical wires daily for wires that

are loose or frayed. Tighten all loose electrical

connections before the engine is started. Repair all

frayed electrical wires before the engine is started.

See the Operation and Maintenance Manual for

speci fi c starting instructions.

(2) Primary position for grounding

(3) Ground to the starting motor

(4) Ground to the engine block

This document is printed from SPI². Not for RESALE


18

SEBU8603-01

Safety Section

Engine Electronics

The power supply connections and the ground

connections for the engine electronics should always

be from the isolator to the battery.

i03642610

Engine Electronics

Tampering with the electronic system installation

or the OEM wiring installation can be dangerous

and could result in personal injury or death and / or

engine damage.

Electrical Shock Hazard. The electronic unit injec-

tors use DC voltage. The ECM sends this voltage

to the electronic unit injectors. Do not come in

contact with the harness connector for the elec-

tronic unit injectors while the engine is operating.

Failure to follow this instruction could result in

personal injury or death.

g02383099

Illustration 16

Typical example

This engine has a comprehensive, programmable

Engine Monitoring System. The Electronic Control

Module (ECM) has the ability to monitor the engine

operating conditions. If any of the engine parameters

extend outside an allowable range, the ECM will

initiate an immediate action.

(5) Ground to the battery

(6) Ground to the cylinder block

Correct grounding for the engine electrical system

is necessary for optimum engine performance

and reliability. Incorrect grounding will result in

uncontrolled electrical circuit paths and in unreliable

electrical circuit paths.

The following actions are available for engine

monitoring control:

Uncontrolled electrical circuit paths can result in

damage to the crankshaft bearing journal surfaces

and to aluminum components.

• Warning

• Derate

Engines that are installed without engine-to-frame

ground straps can be damaged by electrical

discharge.

• Shutdown

The following monitored engine operating conditions

have the ability to limit engine speed and / or the

engine power:

To ensure that the engine and the engine electrical

systems function correctly, an engine-to-frame

ground strap with a direct path to the battery must be

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

engine ground to the frame.

• Engine Coolant Temperature

• Engine Oil Pressure

The connections for the grounds should be tight and

free of corrosion. The engine alternator must be

grounded to the negative “-” battery terminal. The

grounding wire must be adequate to handle the full

charging current of the alternator.

• Engine Speed

• Intake Manifold Air Temperature

• Engine Intake Throttle Valve Fault

• Wastegate Regulator

This document is printed from SPI². Not for RESALE


SEBU8603-01

19

Safety Section

Engine Electronics

• Supply Voltage to Sensors

• Fuel Pressure in Manifold (Rail)

• NOx Reduction System

• Engine Aftertreatment System

The Engine Monitoring package can vary for different

engine models and different engine applications.

However, the monitoring system and the engine

monitoring control will be similar for all engines.

Note: Many of the engine control systems and display

modules that are available for Perkins Engines will

work in unison with the Engine Monitoring System.

Together, the two controls will provide the engine

monitoring function for the speci fi c engine application.

Refer to Troubleshooting for more information on the

Engine Monitoring System.

This document is printed from SPI². Not for RESALE


20

SEBU8603-01

Product Information Section

Model Views

Product Information

Section

Model Views

i04171351

Model View Illustrations

The following model views show typical features

of the engine. Due to individual applications, your

engine may appear different from the illustrations.

Engine views

g02361696

Illustration 17

Typical example

(1) Secondary fuel filter

(2) Crankcase breather

(5) Fuel strainer

(6) Oil filter

(9) Primary fuel fi lter

(10) High-pressure fuel pump

(3) Electronic control module (ECM)

(4) Oil sampling valve

(7) Fuel priming pump

(8) Oil gauge (Dipstick)

This document is printed from SPI². Not for RESALE


SEBU8603-01

twenty one

Product Information Section

Model Views

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

pump (7) will depend on the application.

g02361697

Illustration 18

Typical example

(11) Rear lifting eye

(15) Back pressure valve

(19) Flywheel housing

(12) NOx reduction system (NRS)

(13) Front lifting eye

(14) Turbocharger

(16) Engine oil pan (Sump)

(17) Starting motor

(18) Engine oil drain plug

(20) Flywheel

(21) Exhaust outlet

(22) Exhaust gas cooler

This document is printed from SPI². Not for RESALE


twenty two

SEBU8603-01

Product Information Section

Model Views

g02379457

Illustration 19

Typical example

(23) Belt

(27) Water pump

(32) Alternator

(24) Connection for air inlet

(25) Outlet connection for the coolant

(26) Water temperature regulator housing

(Thermostat housing)

(28) Oil filer

(29) Inlet connection for the Coolant

(30) Vibration damper

(31) Belt tensioner

This document is printed from SPI². Not for RESALE


SEBU8603-01

twenty three

Product Information Section

Model Views

g02381218

Illustration 20

Typical example

(33) Coolant drain plug for cylinder block

(34) Coolant drain plug for exhaust gas

cooler

This document is printed from SPI². Not for RESALE


twenty four

SEBU8603-01

Product Information Section

Model Views

Engine Aftertreatment System

g02384560

Illustration 21

Typical example

(1) Clean emissions module (CEM)

(2) Inlet connection

(3) Outlet connection

(4) Mounting cradle

(5) Flexible exhaust pipe from engine to

CEM

i04340730

Engine Description

The Perkins 1206-E66 Industrial Engine has the

following characteristics.

• In-line Six cylinder

• Four stroke cycle

• Turbocharged charge cooled

g01127295

Engine Speci fi cations

Illustration 22

Cylinder and valve location

Note: The front end of the engine is opposite the

fl ywheel end of the engine. The left and the right

sides of the engine are determined from the fl ywheel

end. The number 1 cylinder is the front cylinder.

(A) Exhaust valves

(B) Inlet valves

This document is printed from SPI². Not for RESALE


SEBU8603-01

25

Product Information Section

Model Views

Table 1

Engine Diagnostics

Engine Speci fi cations

The engine has built-in diagnostics in order to ensure

that the engine systems are functioning correctly. The

operator will be alert to the condition by a "Stop or

Warning ”lamp. Under certain conditions, the engine

horsepower and the vehicle speed may be limited.

The electronic service tool may be used to display

the diagnostic codes.

Operating Range (rpm)

Number of Cylinders

Bore

900 to 2800

(1)

6 In-Line

105 mm (4.13 inch)

127 mm (5 inch)

Stroke

Power

129.4 kW (173.52 hp)

There are three types of diagnostic codes: active,

logged, and event.

Aspiration

Turbocharged charge

cooled

Compression Ratio

Displacement

16.5: 1

Most of the diagnostic codes are logged and stored

in the ECM. For additional information, refer to

the Operation and Maintenance Manual, "Engine

Diagnostics ”topic (Operation Section).

6.6 L (402.7 cubic inch)

1-5-3-6-2-4

Firing Order

Rotation (fl ywheel end)

Counterclockwise

The ECM provides an electronic governor that

controls the injector output in order to maintain the

desired engine rpm.

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

application, and the con fi guration of the throttle.

Electronic Engine Features

Engine Cooling and Lubrication

The engine operating conditions are monitored.

The Electronic Control Module (ECM) controls the

response of the engine to these conditions and to

the demands of the operator. These conditions and

operator demands determine the precise control of

fuel injection by the ECM. The electronic engine

control system provides the following features:

The cooling system and lubrication system consists

of the following components:

• Gear-driven centrifugal water pump

• Water temperature regulator which regulates the

engine coolant temperature

• Engine monitoring

• Gear-driven rotor type oil pump

• Oil cooler

• Engine speed governing

• Control of the injection pressure

• Cold start strategy

The engine lubricating oil is supplied by a rotor type

oil pump. The engine lubricating oil is cooled and the

engine lubricating oil is fi ltered. The bypass valve

can provide unrestricted fl ow of lubrication oil to

the engine if the oil fi lter element should become

plugged.

• Automatic air / fuel ratio control

• Torque rise shaping

Engine ef fi ciency, ef fi ciency of emission controls, and

engine performance depend on adherence to proper

operation and maintenance recommendations.

Engine performance and ef fi ciency also depend on

the use of recommended fuels, lubrication oils, and

coolants. Refer to this Operation and Maintenance

Manual, “Maintenance Interval Schedule” for more

information on maintenance items.

• Injection timing control

• System diagnostics

• Low temperature regeneration

For more information on electronic engine features,

refer to the Operation and Maintenance Manual,

“Features and Controls” topic (Operation Section).

Aftertreatment System

The aftertreatment system is approved for use by

Perkins. In order to be emission-compliant only the

approved Perkins aftertreatment system must be

used on a Perkins engine.

This document is printed from SPI². Not for RESALE


26

SEBU8603-01

Product Information Section

Model Views

Clean Emission Module (CEM)

The CEM includes of two main components in a

single unit, the Diesel Oxidation Catalyst DOC and

the Diesel Particulate Filter DPF. The function of the

CEM is to ensure that the engine exhaust meets

the required emissions regulation for the country of

operation.

The engine exhaust is connected by a fl exible pipe to

the CEM. The exhaust gases pass through the DOC

in order to remove contaminants, carbon monoxide,

and hydrocarbons. The exhaust gases then enter the

DPF where any particulate matter soot and ash will

be trapped.

The CEM uses a passive regeneration process to

ensure that normal operation of the engine removes

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

which the soot is captured. The ash remains in the

DPF and must be removed at an engine overhaul.

Engine Service Life

Engine efciciency and maximum utilization of engine

performance depend on the adherence to proper

operation and maintenance recommendations. In

addition, use recommended fuels, coolants, and

lubricants. Use the Operation and Maintenance

Manual as a guide for required engine maintenance.

Expected engine life is generally predicted by the

average power that is demanded. The average power

that is demanded is based on fuel consumption of

the engine over a period of time. Reduced hours of

operation at full throttle and / or operating at reduced

throttle settings result in a lower average power

demand. Reduced hours of operation will increase

the length of operating time before an engine

overhaul is required. For more information, refer to

the Operation and Maintenance Manual, "Overhaul

Considerations ”topic (Maintenance Section).

Aftermarket Products and Perkins

Engines

Perkins does not warrant the quality or performance

of non-Perkins fl uids and fi lters.

When auxiliary devices, accessories, or consumables

(fi lters, additives, catalysts,) which are made by other

manufacturers are used on Perkins products, the

Perkins warranty is not affected simply because of

such use.

However, failures that result from the installation

or use of other manufacturers devices,

accessories, or consumables are NOT Perkins

defects. Therefore, the defects are NOT covered

under the Perkins warranty.

This document is printed from SPI². Not for RESALE


SEBU8603-01

27

Product Information Section

Product Identi fi cation Information

Product Identi fi cation

Information

i03865704

Plate Locations and Film

Locations

(Engine Aftertreatment System

)

g02109488

Illustration 23

Typical example

The module arrangement exhaust plate is installed

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

arrangement plate mounting plate can alter

depending on the application.

Record the information that is on the plate. This

information identi fi es the engine aftertreatment

system. This information will be required by your

Perkins distributor. The information is essential in

order to be emissions complaint.

i03867276

Reference Numbers

Information for the following items may be needed to

order parts. Locate the information for your engine.

Record the information in the appropriate space.

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

information for future reference.

Record for Reference

g02109493

Illustration 24

Module Arrangement Exhaust Plate

Engine Model _______________________________________________

This document is printed from SPI². Not for RESALE


28

SEBU8603-01

Product Information Section

Product Identi fi cation Information

Engine Serial number _____________________________________

Engine Low Idle rpm ______________________________________

Engine Full Load rpm _____________________________________

Primary Fuel Filter _________________________________________

Water Separator Element ________________________________

Secondary Fuel Filter Element __________________________

Lubrication Oil Filter Element ___________________________

Auxiliary Oil Filter Element _______________________________

Total Lubrication System Capacity _____________________

Total Cooling System Capacity _________________________

Air Cleaner Element _______________________________________

Drive Belt ____________________________________________________

Engine Aftertreatment System

Part Number ________________________________________________

Serial Number ______________________________________________

i04274850

Emissions Certi fi cation Film

g02443596

Illustration 25

Typical example

An emission label is installed on the front gear cover.

Note: A second emission label will be supplied with

the engine. If necessary, the second emission label

will be installed on the application by the original

equipment manufacturer.

This document is printed from SPI². Not for RESALE


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