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Products
Perkins2206-E13 operation maintenance


Detailed Description:

Operation and

Maintenance

Manual

2206-E13 Industrial Engine

TGB (Engine)

TGD (Engine)

TGF (Engine)

Table of Contents

Warranty Section

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

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

Index Section

Safety Section

Index ............................. ..... 83

Safety Messages ... .... 5

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

Burn Prevention ................................................ ... 7

Fire Prevention and Explosion Prevention .............. 8

Crushing Prevention and Cutting Prevention .......... 9

Mounting and Dismounting ... 10

Before Starting Engine ................ 10

Engine Starting ................................................ ..... 10

Engine Stopping ... .... 11

Electrical System ... ... 11

Engine Electronics ... 12

Product Information Section

General Information .............................. 13

Model Views ... ......... 14

Product Identi fi cation Information .............. 17

Operation Section

Lifting and Storage ............... . twenty one

Gauges and Indicators ...

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

Engine Diagnostics ............... 29

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

Engine Operation ... .. 33

Engine Stopping ... ... 34

Cold Weather Operation ............. 35

Maintenance Section

Re fi ll Capacities ... .... 38

Maintenance Interval Schedule ............ 54

This document has been printed from SPI². Not for Resale


4

SEBU8337

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 has been printed from SPI². Not for Resale


SEBU8337

5

Safety Section

Safety Messages

Safety Section

i02767956

Safety Messages

g01384682

Illustration 1

Location of safety message

There may be several speci fi c safety messages on

your engine. The exact location and a description of

the safety messages are reviewed in this section.

Please become familiar with all safety messages.

Universal Warning (1)

The safety message for the universal warning is

located on both sides of the valve cover base.

Ensure that all of the safety messages are legible.

Clean the safety messages or replace the safety

messages if the words cannot be read or if the

illustrations are not visible. Use a cloth, water,

and soap to clean the safety messages. Do not

use solvents, gasoline, or other harsh chemicals.

Solvents, gasoline, or harsh chemicals could loosen

the adhesive that secures the safety messages. The

safety messages that are loosened could drop off

of the engine.

Replace any safety message that is damaged or

missing. If a safety message is attached to a part

of the engine that is replaced, install a new safety

message on the replacement part. Your Perkins

distributor can provide new safety messages.

g00934493

Illustration 2

This document has been printed from SPI². Not for Resale


6

SEBU8337

Safety Section

General Hazard Information

Keep the engine free from foreign material. Remove

debris, oil, tools, and other items from the deck, from

walkways, and from steps.

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.

Never put maintenance fl uids into glass containers.

Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care.

Report all necessary repairs.

i02328435

General Hazard Information

Do not allow unauthorized personnel on the

equipment.

Ensure that the power supply is disconnected before

you work on the bus bar or the glow plugs.

Perform maintenance on the engine with the

equipment in the servicing position. Refer to the

OEM information for the procedure for placing the

equipment in the servicing position.

Pressure Air and Water

Pressurized air and / or water can cause debris

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

personal injury.

g00104545

Illustration 3

The direct application of pressurized air or

pressurized water to the body could result in personal

injury.

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

warning tag to the start switch or to the controls

before you service the equipment or before you

repair the equipment.

When pressurized air and / or 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.

g00702020

Illustration 4

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.

Wear a hard hat, protective glasses, and other

protective equipment, as required.

Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

Make sure that all protective guards and all covers

are secured in place on the engine.

This document has been printed from SPI². Not for Resale


SEBU8337

7

Safety Section

Burn Prevention

Coolant

When the engine is at operating temperature, the

engine coolant is hot. The coolant is also under

pressure. The radiator and all lines to the heaters or

to the engine contains hot coolant. Any contact with

hot coolant or with steam can cause severe burns.

Allow cooling system components to cool before the

cooling system is drained.

Check the coolant level after the engine has stopped

and the engine has been allowed to cool. 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.

g00687600

Illustration 5

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.

Cooling system conditioner contains alkali. Alkali can

cause personal injury. Do not allow alkali to contact

the skin, the eyes, or the mouth.

Oils

Hot oil and hot lubricating components can cause

personal injury. Do not allow hot oil or hot components

to contact the skin.

Containing Fluid Spillage

Care must be taken in order to ensure that fl uids

are contained during performance of inspection,

maintenance, testing, adjusting and repair of the

engine. Make provision to collect the fl uid with a

suitable container before any compartment is opened

or before any component is disassembled.

If the application has a makeup tank, remove the cap

for the makeup tank after the engine has stopped.

The fi ller cap must be cool to the touch.

Batteries

The liquid in a battery is an electrolyte. Electrolyte is

an acid that can cause personal injury. Do not allow

electrolyte to contact the skin or the eyes.

• Only use the tools that are suitable for collecting

fl uids and equipment that is suitable for collecting

fl uids.

Do not smoke while checking the battery electrolyte

levels. Batteries give off fl ammable fumes which can

explode.

• Only use the tools that are suitable for containing

fl uids and equipment that is suitable for containing

fl uids.

Always wear protective glasses when you work with

batteries. Wash hands after touching batteries. The

use of gloves is recommended.

Obey all local regulations for the disposal of liquids.

i02088921

Burn Prevention

Do not touch any part of an operating engine.

Allow the engine to cool before any maintenance

is performed on the engine. Relieve all pressure in

the appropriate system before any lines, fi ttings or

related items are disconnected.

This document has been printed from SPI². Not for Resale


8

SEBU8337

Safety Section

Fire Prevention and Explosion Prevention

Exhaust shields (if equipped) protect hot exhaust

i02813488

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

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

installed correctly.

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 6

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.

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. Tighten all connections to the

recommended torque. Leaks can cause fi res.

A fl ash fi re may result if the covers for the engine

crankcase are removed within fi fteen minutes after

an emergency shutdown.

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

The fi lter housings must be tightened to the correct

torque.

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.

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.

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.

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.

Do not expose the engine to any fl ame.

g00704059

Illustration 7

This document has been printed from SPI². Not for Resale


SEBU8337

9

Safety Section

Crushing Prevention and Cutting Prevention

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.

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high

pressure lines. Do not install any lines that are bent

or damaged. Do not clip any other items to the high

pressure lines.

Repair any lines that are loose or damaged. Leaks

can cause fi res. Consult your Perkins dealer or your

Perkins distributor for repair or for replacement parts.

Check lines, tubes and hoses carefully. Do not use

your bare hand to check for leaks. Use a board or

cardboard to check for leaks. Tighten all connections

to the recommended torque.

Replace the parts if any of the following conditions

are present:

• 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 8

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.

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.

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.

i01359666

Crushing Prevention and

Cutting Prevention

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.

Support the component properly when work beneath

the component is performed.

Fire Extinguisher

Unless other maintenance instructions are provided,

never attempt adjustments while the engine is

running.

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.

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.

This document has been printed from SPI². Not for Resale


10

SEBU8337

Safety Section

Mounting and Dismounting

When objects are struck, wear protective glasses in

order to avoid injury to the eyes.

If equipped, ensure that the lighting system for the

engine is suitable for the conditions. Ensure that all

lights work correctly, if equipped.

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.

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.

i01372247

Mounting and Dismounting

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.

Inspect the steps, the handholds, and the work area

before mounting the engine. Keep these items clean

and keep these items in good repair.

See the Service Manual for repairs and for

adjustments.

Mount the engine and dismount the engine only at

locations that have steps and / or handholds. Do not

climb on the engine, and do not jump off the engine.

i02583384

Face the engine in order to mount the engine or

dismount the engine. Maintain a three-point contact

with the steps and handholds. Use two feet and one

hand or use one foot and two hands. Do not use any

controls as handholds.

Engine Starting

Do not stand on components which cannot support

your weight. Use an adequate ladder or use a work

platform. Secure the climbing equipment so that the

equipment will not move.

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and

personal injury.

Do not carry tools or supplies when you mount the

engine or when you dismount the engine. Use a hand

line to raise and lower tools or supplies.

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.

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 operator's compartment or

from the engine start switch.

Always start the engine according to the procedure

that is described in the Operation and Maintenance

Manual, “Engine Starting” topic in the Operation

Section. Knowing the correct procedure will help to

prevent major damage to the engine components.

Knowing the procedure will also help to prevent

personal injury.

Overspeed shutdown should occur automatically for

engines that are controlled electronically. If automatic

shutdown does not occur, press the emergency 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)

is working correctly, check the water temperature

gauge and / or 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.

This document has been printed from SPI². Not for Resale


SEBU8337

11

Safety Section

Engine Stopping

Engine exhaust contains products of combustion

which can be harmful to your health. Always start the

engine and operate the engine in a well ventilated

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

vent the engine exhaust to the outside.

Check the electrical wires daily for wires that

are loose or frayed. Tighten all loose electrical

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.

Note: The engine may be equipped with a device for

cold starting. If the engine will be operated in very

cold conditions, then an extra cold starting aid may

be required. Normally, the engine will be equipped

with the correct type of starting aid for your region

of operation.

Grounding Practice

i01462046

Engine Stopping

Stop the engine according to the procedure in

the Operation and Maintenance Manual, "Engine

Stopping (Operation Section) ”in order to avoid

overheating of the engine and accelerated wear of

the engine components.

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.

g01403749

Illustration 9

Typical example

Stop the engine if an overspeed condition occurs

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

that has been overhauled. This may be accomplished

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

shutting off the air supply to the engine.

(1) Starting motor to engine block

(2) Starting motor to battery negative

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.

To stop an electronically controlled engine, cut the

power to the engine.

Uncontrolled electrical circuit paths can result in

damage to the crankshaft bearing journal surfaces

and to aluminum components.

i02814681

Electrical System

Engines that are installed without engine-to-frame

ground straps can be damaged by electrical

discharge.

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 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.

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 negative “−” terminal

of the starting motor. If the starting motor is not

equipped with a negative “−” terminal, connect the

cable to the engine block.

The connections for the grounds should be tight and

free of corrosion. The engine alternator must be

grounded to the negative “-” battery terminal with

a wire that is adequate to handle the full charging

current of the alternator.

This document has been printed from SPI². Not for Resale


12

SEBU8337

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.

i02773399

Engine Electronics

Tampering with the electronic system installation

or the OEM wiring installation can be dangerous

and could result in personal injury or death and / or

engine damage.

This engine has a comprehensive, programmable

Engine Monitoring System. The Engine Control

Module (ECM) has the ability to monitor the engine

operating conditions. If any of the engine parameters

extend outside an allowable range, the ECM will

initiate an immediate action.

The following actions are available for engine

monitoring control: WARNING, ACTION ALERT, and

SHUTDOWN.

Many of the parameters that are monitored by the

ECM can be programmed for the engine monitoring

functions. The following parameters can be monitored

as a part of the Engine Monitoring System:

• Atmospheric Pressure

• Intake Manifold Air Pressure

• Coolant Temperature

• Engine Oil Pressure

• Crankshaft Position

• Camshaft Position

• Fuel Temperature

• Intake Manifold Temperature

• System Voltage

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.

This document has been printed from SPI². Not for Resale


SEBU8337

13

Product Information Section

General Information

Product Information

Section

General Information

i01889424

Welding on Engines with

Electronic Controls

NOTICE

Proper welding procedures are necessary in order

to avoid damage to the engine's ECM, sensors, and

associated components. When possible, remove the

component from the unit and then weld the compo-

nent. If removal of the component is not possible,

the following procedure must be followed when you

weld with a unit that is equipped with an Electronic

Engine. The following procedure is considered to be

the safest procedure to weld a component. This pro-

cedure should provide a minimum risk of damage to

electronic components.

g00765012

Illustration 10

Use the example above. The current fl ow from the welder to

the ground clamp of the welder will not cause damage to any

associated components.

(1) Engine

(2) Welding rod

(3) Keyswitch in the OFF position

(4) Battery disconnect switch in the open position

(5) Disconnected battery cables

(6) Battery

NOTICE

(7) Electrical / Electronic component

(8) Maximum distance between the component that is being

welded and any electrical / electronic component

(9) The component that is being welded

(10) Current path of the welder

(11) Ground clamp for the welder

Do not ground the welder to electrical components

such as the ECM or sensors. Improper grounding can

cause damage to the drive train bearings, hydraulic

components, electrical components, and other com-

ponents.

4. Connect the welding ground cable directly to the

part that will be welded. Place the ground cable as

close as possible to the weld in order to reduce the

possibility of welding current damage to bearings,

hydraulic components, electrical components, and

ground straps.

Clamp the ground cable from the welder to the com-

ponent that will be welded. Place the clamp as close

as possible to the weld. This will help reduce the pos-

sibility of damage.

1. Stop the engine. Turn the switched power to the

OFF position.

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 fl ow from the welder could

severely damage the component.

2. Disconnect the negative battery cable from the

battery. If a battery disconnect switch is provided,

open the switch.

5. Protect the wiring harness from welding debris

and spatter.

3. Disconnect the J1 / P1 connectors from the ECM.

Move the harness to a position that will not allow

the harness to accidentally move back and make

contact with any of the ECM pins.

6. Use standard welding practices to weld the

materials.

This document has been printed from SPI². Not for Resale


14

SEBU8337

Product Information Section

Model Views

Model Views

i02770579

Model View Illustrations

g01385634

Illustration 11

Typical example

Left side engine view

(1) Connection for the breather

(2) Electronic control module (ECM)

(3) Fuel priming pump

(4) Secondary fuel fi lter

(5) Primary fuel fi lter

(6) Fuel pump

(7) Crankshaft damper

(8) Oil filer

This document has been printed from SPI². Not for Resale


SEBU8337

15

Product Information Section

Model Views

g01385635

Illustration 12

Typical example

Right side engine view

(9) Water temperature regulator housing

(10) Alternator

(12) Turbocharger

(13) Oil filter

(15) Oil cooler

(16) Exhaust manifold

(11) Water pump

(14) Oil drain plug

The electronic engines that are covered by this

manual have the following characteristics: direct fuel

injection, electronic unit injection that is mechanically

actuated, turbocharged, and air-to-air aftercooled

(ATAAC).

i02770677

Engine Description

Table 1

The electronic engine control system provides the

following functions: electronic governing, automatic

air to fuel ratio control, injection timing control, and

system diagnostics.

2206 Engine Specifications

Cylinders and Arrangement

Bore

In-line six cylinder

130 mm (5.2 inch)

157 mm (6.2 inch)

An electronic governor controls the output of the unit

injectors in order to maintain the engine rpm that is

desired.

Stroke

Displacement

Firing Order

12.5 L (763 in)

3

1-5-3-6-2-4

Rotation (fl ywheel end)

Counterclockwise

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16

SEBU8337

Product Information Section

Model Views

Very high injection pressures are produced by

electronically controlled, mechanically actuated unit

injectors. The injectors combine the pumping and the

electronic fuel metering (duration and timing) during

injection. The unit injectors accurately control smoke

limiting, white smoke, and engine acceleration rates.

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

engine performance depend on adherence to proper

operation and maintenance recommendations. This

includes the use of recommended fuels, coolants

and lubrication oils.

Aftermarket Products and Perkins

Engines

There is one unit injector per cylinder. Individual unit

injectors meter the fuel. The individual unit injectors

also pump the fuel. The metering and the pumping is

done under high pressure. High injection pressures

help to reduce fuel consumption and emissions.

The use of this type of unit injector provides total

electronic control of injection timing. The injection

timing varies with engine operating conditions. The

engine performance is optimized in the following

areas:

When auxiliary devices, accessories, or consumables

(fi lters, additives, catalysts, etc) 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.

• Starting

• Emissions

• Noise

• Fuel consumption

The timing advance is achieved through precise

control of the injector fi ring. Engine speed is

controlled by adjusting the fi ring duration. The

information is provided to the Electronic Control

Module (ECM) by the crankshaft position sensor and

the camshaft position sensor. The information is for

detection of cylinder position and engine speed.

The engines have built-in diagnostics in order to

ensure that all of the components are functioning

and operating properly. In the event of a system

component deviation from the programmed limits,

the operator will be alert to the condition by a

DIAGNOSTIC lamp that is mounted on the control

panel. An electronic service tool that is provided by

Perkins may be used to read the diagnostic codes.

These codes are logged and stored in the ECM.

Refer to Operation and Maintenance Manual, "Engine

Diagnostics ”for additional information.

The cooling system consists of the following items:

a centrifugal pump that is driven by a gear, water

temperature regulator, an oil cooler, and a radiator

that incorporates a shunt system.

The engine lubricating oil is supplied by a gear

type pump. The engine lubricating oil is cooled and

fi ltered. Bypass valves provide unrestricted fl ow

of lubrication oil to the engine parts when the oil

viscosity is high or if either the oil cooler or the oil

fi lter elements (paper cartridge) becomes plugged.

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SEBU8337

17

Product Information Section

Product Identi fi cation Information

Product Identi fi cation

Information

i02770689

Plate Locations and Film

Locations

g01385686

Illustration 13

(1) Serial number plate

Perkins engines are identi fi ed by serial numbers.

These numbers are shown on the engine serial

number plate. Perkins distributors need these

numbers in order to determine the components that

were included with the engine. This permits accurate

identi fi cation of replacement part numbers.

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18

SEBU8337

Product Information Section

Product Identi fi cation Information

Serial Number Plate (1)

Total Lubrication System Capacity _____________________

Total Cooling System Capacity _________________________

Air Cleaner Element _______________________________________

Fan Drive Belt ______________________________________________

Alternator Belt ______________________________________________

g01403841

Illustration 14

Typical example

The engine serial number plate is located on the right

side of the engine block.

Engine serial number _____________________________________

Designation _________________________________________________

Engine Rating ______________________________________________

i02563635

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

Engine Model _______________________________________________

Engine Serial number _____________________________________

Engine rpm __________________________________________________

Primary Fuel Filter _________________________________________

Secondary Fuel Filter Element __________________________

Lubrication Oil Filter Element ___________________________

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SEBU8337

19

Product Information Section

Product Identi fi cation Information

i02770895

Emissions Certi fi cation Film

g01385765

Illustration 15

Typical example

The emission certi fi cation fi lm is located on the left

hand side of the valve mechanism cover.

Programmable Monitoring System

(PMS)

The Programmable Monitoring System determines

the level of action that is taken by the ECM in

response to a condition that can damage the engine.

These conditions are identi fi ed by the ECM from the

signals that are produced from the following sensors.

i02817239

Customer Speci fi ed

Parameters

• Inlet Manifold Temperature Sensor

• Coolant Temperature Sensor

• Engine Oil Pressure Sensor

• Engine Crankshaft / Camshaft Sensors

• Inlet Manifold Pressure Sensor

• Fuel Temperature Sensor

To record programmed speci fi cations, use the

following blanks.

Customer Passwords (If required).

• First Password ___________________________________________

• Second Password ______________________________________

Rating Selection (LN) __________________________________

Equipment ID ______________________________________________

This document has been printed from SPI². Not for Resale


20

SEBU8337

Product Information Section

Product Identi fi cation Information

Table 2

Event Code

Parameter

State

Trip Point

Delay Time

E162

-1

High Boost Pressure

Warn Operator (1)

On

300 kPa (43.5 psi) 60 seconds

-2

Action Alert (2)

Always On

Map

5 seconds

E360

-1

Low Engine Oil Pressure

Warn Operator (1)

On

200 kPa (29 psi)

60 seconds

2 seconds

2 seconds

-2

Action Alert (2)

Always On

Always On

Map

Map

-3

Engine Shutdown (3)

High Engine Coolant Temperature

Warn Operator (1)

E361

-1

On

104 ° C (2190 ° F)

105 ° C (221 ° F)

108 ° C (226 ° F)

60 seconds

10 seconds

10 seconds

-2

Action Alert (2)

Always On

Always On

-3

Engine Shutdown (3)

Engine Overspeed

Warn Operator (1)

E362

-1

On

2000 RPM

2050 RPM

2140 RPM

1 second

0 second

0 second

-2

Action Alert (2)

Always On

Always On

-3

Engine Shutdown (3)

High Fuel Supply Temperature

Warn Operator (1)

E363

-1

On

60 ° C (140 ° F)

68 ° C (154 ° F)

60 seconds

60 seconds

-2

Action Alert (2)

Always On

E368

-1

High Engine Intake Manifold Air Temperature

Warn Operator (1)

Action Alert (2)

On

75 ° C (167 ° F)

78 ° C (172 ° F)

60 seconds

10 seconds

-2

Always On

Refer to Troubleshooting, "System Con fi guration

Parameters ”for additional information for the

Programmable Monitoring System.

This document has been printed from SPI². Not for Resale


SEBU8337

twenty one

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

i02848873

Product Storage

Refer to Perkins Engine Company limited, Stafford

for information on engine storage.

i02513632

Product Lifting

There is three different levels of engine storage.

Level “A, B and C”.

Level “A”

Level “A” will give protection for 12 month for diesel

engines and 12 month protection for gas engines.

This is for engines that are transported by a container

or a truck. Level “A” is for the transportation of items

that are within the United kingdom and within Europe.

Level “B”

This level is additional to level “A”. Level “B” will

give protection under normal storage condition

from −15 ° to + 55 ° C (5 ° to 99 ° F) and “90%”

relative humidity for two year. Level “B” is for the

transportation of items overseas.

g00103219

Illustration 16

NOTICE

Level “C”

Never bend the eyebolts and the brackets. Only load

the eyebolts and the brackets under tension. Remem-

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

between the supporting members and the object be-

comes less than 90 degrees.

In order to protect the product to Level “C”, contact

Perkins Engines Company Limited Stafford.

When it is necessary to remove a component at an

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

the weight.

Use a hoist to remove heavy components. Use

an adjustable lifting beam to lift the engine. All

supporting members (chains and cables) should be

parallel to each other. The chains and cables should

be perpendicular to the top of the object that is being

lifted.

Some removals require lifting the fi xtures in order to

obtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes that

are on the engine.

Lifting eyes are designed and installed for speci fi c

engine arrangements. Alterations to the lifting eyes

and / or the engine make the lifting eyes and the lifting

fi xtures obsolete. If alterations are made, ensure

that proper lifting devices are provided. Consult your

Perkins dealer for information regarding fi xtures for

proper engine lifting.

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twenty two

SEBU8337

Operation Section

Gauges and Indicators

Gauges and Indicators

i02773410

Gauges and Indicators

Your engine may not have the same gauges or all of

the gauges that are described. For more information

about the gauge package, see the OEM information.

Gauges provide indications of engine performance.

Ensure that the gauges are in good working order.

Determine the normal operating range by observing

the gauges over a period of time.

Noticeable changes in gauge readings indicate

potential gauge or engine problems. Problems may

also be indicated by gauge readings that change

even if the readings are within speci fi cations.

Determine and correct the cause of any signi fi cant

change in the readings. Consult your Perkins

distributor for assistance.

NOTICE

If no oil pressure is indicated, STOP the engine. If

maximum coolant temperature is exceeded, STOP

the engine. Engine damage can result.

Engine Oil Pressure – The range for the

engine oil pressure is 420 kPa (61 psi).

Jacket Water Coolant Temperature –

Typical water temperature into the engine

is 88 ° C (190 ° F). Higher temperatures

may occur under certain conditions. The water

temperature reading may vary according to load. The

reading should never exceed 107 ° C (224 ° F).

1. A high water temperature switch is installed in the

cooling system.

Tachometer – This gauge indicates engine

speed (rpm).

Ammeter – This gauge indicates the

amount of charge or discharge in the

battery charging circuit. Operation of the

indicator should be to the right side of “0” (zero).

Service Hour Meter – The gauge indicates

operating hours of the engine.

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SEBU8337

twenty three

Operation Section

Features and Controls

Features and Controls

Warning Alarm

The Warning alarm informs the user that the engine

is approaching a critical condition.

i02780670

Monitoring System

If the engine is in the Warning condition, then the

event will be logged in the memory of the ECM.

A event code will be transmitted over the Perkins

Data link and the hard wired Warning output will be

energized. If the engine is in the Warning condition,

the event code and output will remain while the the

condition exists. The electronic service tool is used to

remove the event code from the memory of the ECM.

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

factory default in production. The electronic service

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

within prede fi ned limits.

The engine has protection in three stages:

• Warning

• Action Alert

• Shutdown

The engine protection may be overridden by the

critical condition mode.

Action Alert

The Electronic Control Module (ECM) monitors the

following parameters:

The Action Alert informs the OEM that the engine is

approaching a critical condition. The engine should

be stopped in a controlled manner. Further running of

the engine may result in an immediate shutdown.

• Engine Temperatures

• Engine Pressures

• Engine Speed

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

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

code will be transmitted over the Perkins Data link

and the hard wired Action Alert will be energized. If

the engine is in the Action Alert condition the event

code and output will remain while the condition exists.

The event code can not be cleared from the memory

of the ECM without using a factory password.

If the parameters exceed a trip point for a period of

time that is longer than the delay period, the ECM

logs an event code and the indicator switches ON.

The following parameters are monitored for event

codes:

Shutdown

• Lubricating Oil Pressure

• Coolant Temperature

• Overspeed

If the engine reaches the Shutdown condition, one of

the following events has occurred: low lubricating oil

pressure, high coolant temperature or overspeed.

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

The engine will be shut down. A event code will

be transmitted over the Perkins Data link and the

hard wired Shutdown output will be energized. The

Shutdown condition will latch until the ECM is reset.

The event code for the shutdown can not be cleared

from the memory of the ECM without using a factory

password.

• Intake Manifold Temperature

• Intake Manifold Pressure

• Fuel Temperature

The temperature protection is disabled for a period

of time when the engine is cranking in order to

compensate for heat soak solutions.

Critical Protection Override

If the engine is in an application that is critical for

safety, the protection system can be overridden in

order to ensure the continuation of the power supply

during engine fault conditions.

The ECM has dedicated alarm outputs for each of the

three stages of protection. There are also dedicated

alarm outputs for oil pressure, coolant temperature

and overspeed events which are energized at any

stage of protection.

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twenty four

SEBU8337

Operation Section

Features and Controls

Shutdown Reset

Critical Protection Override will be set by a switch

input from the OEM. For example, this may be

a switch to battery + in order to disable a critical

override. Critical Protection Override input can be

enabled in the electronic service tool by use of a

factory password.

The cause of an engine shutdown must be

investigated. Corrective action must be taken before

the system is reset in order to operate the engine.

After an engine shutdown, operate the reset input of

the ECM or power down the controller.

When the Critical Protection Override feature is

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

shutdown conditions with the exception of Overspeed

shutdown. If the shutdown is overridden a event code

is generated. The ECM will log the event code. The

ECM will energize the following: Warning, Action

Alert, Shutdown, oil pressure, coolant temperature,

and overspeed outputs as normal. The warranty of

the engine will be invalidated if the engine is operated

in the following conditions: active event code and

Critical Protection Override mode.

Powering down the electronic control module can be

achieved by the operation of the keyswitch into sleep

mode. The electronic control module can be powered

down by isolating the power supply to the electronic

control module.

Note: It is not possible to reset the ECM by using the

Reset input until the engine has come to rest.

Altitude derate

Standard Warning Outputs

At high altitudes or high ambient temperatures, the

engine will be derated. The engine derate information

can be obtained from the Applications Department at

Perkins Engines Company Limited Stafford.

The ECM provides individual outputs in order to

drive warning lamps or relays to indicate each of the

following fault conditions:

• Diagnostic Fault

• Oil Pressure

• Coolant Temperature

• Overspeed

Diagnostic

If there is a fault with an engine protection sensor on

the engine, the engine activates a diagnostic code.

The engine communicates the diagnostic code to the

operator via the Diagnostic output. The diagnostic

code provides an indication to the operator of a fault

with the engine protection system. Running of the

engine for a prolonged period in this condition may

result in engine failure. The output is generally used

to drive lamps or relays.

• Action Alert

• Warning

• Shutdown

The following sensors are monitored in order to

determine if the sensors are out of the normal range,

an open circuit or a short circuit:

If the ECM detects a warning for the coolant

temperature, the output on the coolant temperature

will be energized and the warning output will be

energized. If the ECM detects a warning for the low

oil pressure, the output on the oil pressure will be

energized and the warning output will be energized.

• Atmosphere Pressure

• Lubricating Oil Pressure

• Inlet Manifold Pressure

• Inlet Manifold Temperature

• Fuel Temperature

If the Action Alert alarms are enabled and the ECM

detects a coolant temperature condition, the output

on the coolant Temperature will be energized and the

output on the Action Alert will be energized.

If the engine shuts down on low oil pressure the

output on the low oil pressure will be energized and

the output on the shutdown will be energized. If the

engine shuts down on coolant temperature or the

engine shuts down on overspeed the dedicated

output and the shutdown output will be energized.

• Coolant Temperature

• Engine Speed

• Desired Speed Input

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SEBU8337

25

Operation Section

Features and Controls

The Diagnostic output differs from the Warning and

Shutdown outputs. The Warning and Shutdown

outputs refer to the operation of the engine. The

Diagnostic output refers to the condition of the

electronic system and software system.

A diagnostic fault may develop on the lubricating

oil pressure or coolant temperature sensors. For

example, if a Shutdown protection sensor has a fault,

this will result in an engine shutdown, unless the

system is in critical protection override. If a diagnostic

fault occurs with one of the engine speed sensors

while the engine is running. The engine continues to

run by using the other timing sensor for reference.

i02772006

Sensors and Electrical

Components

Sensor Locations

Illustration 17 shows the typical locations of the

sensors on the engine. Speci fi c engines may appear

different from the illustration due to differences in

applications.

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26

SEBU8337

Operation Section

Features and Controls

g01386180

Illustration 17

(1) Engine coolant temperature sensor

(2) Intake manifold pressure sensor

(3) Intake manifold air temperature sensor

(4) Atmospheric pressure sensor

(5) Secondary position sensor (Camshaft)

(6) Engine oil pressure sensor

(7) Fuel temperature sensor

(8) Primary position sensor (Crankshaft)

(9) Electronic control module (ECM)

Failure of Sensors

Programmable Monitoring System

(PMS)

All Sensors

The Programmable Monitoring System determines

the level of action that is taken by the Engine Control

Module (ECM) in response to a condition that can

damage the engine. These conditions are identi fi ed

by the ECM from the signals that are produced from

the following sensors.

A failure of any of the sensors may be caused by one

of the following malfunctions:

• Sensor output is open.

• Sensor output is shorted to “-battery” or “+ battery”.

Engine Coolant Temperature

Sensor 1

• Measured reading of the sensor is out of the

speci fi cation.

The coolant temperature sensor monitors engine

coolant temperature. The output of the ECM can

indicate a high coolant temperature through a relay

or a lamp. The coolant temperature sensor is used

by the ECM to determine initiation of the Cold Start

Condition.

This document has been printed from SPI². Not for Resale


SEBU8337

27

Operation Section

Features and Controls

Failure of the Coolant Temperature

Sensor

Low Oil Pressure Warning

The setpoint for the low pressure warning is

dependent upon the engine speed. The fault will be

active and logged only if the engine has been running

for more than 8 seconds.

The ECM will detect a failure of the coolant

temperature sensor. The diagnostic lamp will

warn the operator about the status of the coolant

temperature sensor. A failure of the coolant

temperature sensor will cause a shutdown of the

engine. The faulty sensor should be replaced. Refer

to Disassembly and Assembly Manual, "Coolant

Temperature Sensor-Remove and Install ".

Low Oil Pressure

The very low oil pressure setpoint is dependent upon

the engine speed. If very low oil pressure is detected,

the ECM will stop the engine immediately unless

Critical Events Override is active.

Intake Manifold Pressure Sensor 2

Failure of the Engine Oil Pressure Sensor

The intake manifold pressure sensor measures boost

pressure in the intake manifold. A signal is sent to the

ECM. A failure of the inlet manifold pressure sensor

will limit the power of the engine.

The ECM will detect failure of the engine oil pressure

sensor. The diagnostic lamp warns the user about the

status of the engine oil pressure sensor. The engine

oil pressure related strategies will be disabled in the

event of a failure of the engine oil pressure sensor.

A failure of the engine oil pressure sensor will cause

a shutdown of the engine. The faulty sensor should

be replaced. Refer to Disassembly and assembly

Manual, "Engine Oil Pressure Sensor-Remove and

Install ".

Intake Manifold Air Temperature

Sensor 3

The Intake manifold air temperature sensor measures

the intake air temperature. A signal is sent to the

ECM. The intake manifold air temperature sensor is

also used by the ECM to determine initiation of the

Cold Start Strategy.

Fuel Temperature Sensor 7

Atmospheric Pressure Sensor 4

The fuel temperature sensor monitors the fuel

temperature. The signal from the sensor allows

the ECM to compensate for changes in the fuel

temperature by adjusting the fuel rate for constant

power.

All the output signals from the pressure sensors are

matched to the output signal of the atmospheric

pressure sensor during calibration. The signal from

the atmospheric pressure sensor is used by the ECM

in order to determine the operating altitude of the

engine. If necessary, the ECM can derate the engine.

Primary Speed / Timing Sensor 8

If the ECM does not receive a signal from the primary

speed / timing sensor, the “DIAGNOSTIC” lamp will

indicate a diagnostic fault code which will be logged

in the ECM memory.

Secondary Speed / Timing Sensor 5

The signal from the secondary speed / timing sensor

is used by the ECM on engine start-up in order to

determine the stroke that the pistons are on. The

secondary speed / timing sensor may be used by the

ECM in order to operate the engine if the primary

speed / timing sensor is faulty.

If the ECM does not receive a signal from the primary

speed / timing sensor (9), the ECM will read the signal

from the secondary speed / timing sensor (2). The

ECM continually checks in order to determine if

there is a signal from both sensors. If either sensor

fails, the faulty sensor should be replaced. Refer to

Disassembly and Assembly Manual, "Crankshaft

Position Sensor-Remove and Install ”or refer to

Disassembly and Assembly Manual, "Camshaft

Position Sensor-Remove and Install ".

In order to check the correct operation of the sensor,

refer to Troubleshooting, "Engine speed / Timing

sensor-Test ".

Engine Oil Pressure Sensor 6

Intermittent failure of the sensors will cause erratic

engine control.

The engine oil pressure sensor is an absolute

pressure sensor that measures the engine oil

pressure in the main oil gallery. The engine oil

pressure sensor detects engine oil pressure for

diagnostic purposes. The engine oil pressure sensor

sends a signal to the ECM.

This document has been printed from SPI². Not for Resale

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