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Perkins 1706J-E93TA Operation And Maintenance Manual Download Page 38

Aftertreatment System Views

Illustration 36

g06263677

Typical example

(1) Diesel Exhaust Fluid (DEF) injector
(2) Post NOx sensor

(3) Differential pressure sensor
(4) NOx sensor

(5) Temperature sensor

38

M0087475-03

Operation Section
Sensors and Electrical Components

Summary of Contents for 1706J-E93TA

Page 1: ...Operation and Maintenance Manual 1706J E93TA Industrial Engine NGK Engine M0087475 03 en us December 2020...

Page 2: ...rmation that was available at the time that the publication was written The specifications torques pressures measurements adjustments illustrations and other items can change at any time These changes...

Page 3: ...ne Electronics 19 Product Information Section Model Views 20 Product Identification Information 25 Operation Section Lifting and Storage 28 Features and Controls 34 Engine Diagnostics 46 Engine Starti...

Page 4: ...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 Safety This safety sect...

Page 5: ...the engine as a convenient reminder Perkins also recommends that a maintenance record be maintained as part of the permanent record of the engine Your authorized Perkins dealer or your Perkins distri...

Page 6: ...d 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 mes...

Page 7: ...on this engine The exact location of the messages and the description of the information are reviewed in this section Become familiar with all messages Make sure that all the messages are legible Clea...

Page 8: ...red When work is performed around an engine that is operating wear protective devices for ears to help prevent damage to hearing Do not wear loose clothing or jewelry that can snag on controls or on o...

Page 9: ...at opposite ends of the cover plate or the device Before removing the last two bolts or nuts pry the cover loose to relieve any spring pressure or other pressure Illustration 6 g00702020 Wear a hard h...

Page 10: ...fur Diesel Fuel The removal of sulfur and other compounds in Ultra Low Sulfur Diesel fuel ULSD fuel decreases the conductivity of ULSD and increases the ability of ULSD to store static charge Refineri...

Page 11: ...nt PPE Wash your hands and face with soap and water prior to eating drinking or smoking and also during rest room breaks to prevent ingestion of any yellow powder Never use compressed air for cleaning...

Page 12: ...aters or to the engine contain 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 that the...

Page 13: ...ials such as fuel oil and debris from the engine Do not allow any flammable combustible materials or conductive materials to accumulate on the engine Store fuels and lubricants in correctly marked con...

Page 14: ...Never check the battery charge by placing a metal object across the terminal posts Use a voltmeter or a hydrometer Incorrect jumper cable connections can cause an explosion that can result in injury...

Page 15: ...ntion 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...

Page 16: ...e high pressure fuel lines Deformation or damage of the high pressure fuel lines may cause a point of weakness and potential failure Do not check the high pressure fuel lines with the engine or the st...

Page 17: ...ork properly if equipped 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 caus...

Page 18: ...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 ignitin...

Page 19: ...ll 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 mo...

Page 20: ...ation Section Model Views Model View Illustrations Illustration 16 g06275201 View of the top of a typical 1706J Engine 1 Oil pan 2 Lifting eyes 3 Turbocharger 4 Oil cap 20 M0087475 03 Product Informat...

Page 21: ...g06275205 View of the left side of a typical 1706J Engine 5 Oil filler tube 6 Fuel Injection pump 7 Electronic Control module ECM 8 Starting motor M0087475 03 21 Product Information Section Model Vie...

Page 22: ...706J Engine 9 Secondary fuel filters 10 Primary fuel filter water separator 11 Fuel pump switch assembly 12 Crankcase ventilation filter 13 Crankcase breather 14 Flywheel housing 15 Oil dipstick 22 M0...

Page 23: ...ristics Four stroke cycle Turbocharged Engine Specifications Note The front end of the engine is opposite the flywheel end of the engine The left and the right sides of the engine are determined from...

Page 24: ...vide increased engine fuel economy and serviceability Cold starting capability Tampering detection Diagnostics Engine Service Life Engine efficiency and maximum utilization of engine performance depen...

Page 25: ...llustration 21 g06251121 Typical example 1 Engine serial number plate location Viewed from the rear of the engine the serial number plate is on the right side of the cylinder block below the turbochar...

Page 26: ...achieve the rated power horsepower high idle full load rpm fuel settings and other information The Clean Emission Module CEM identification plate is on the bracket assembly on the CEM Illustration 24...

Page 27: ...al plates The information will be required by your Perkins distributor to identify replacement part numbers i05951816 Emissions Certification Film Note This information is pertinent in the United Stat...

Page 28: ...ng if components are damaged 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 chai...

Page 29: ...ied spreader bar Follow the safety instructions for the selected tool to ensure a safe lift Remove any ATAAC lines air cleaners or other attachments that would otherwise interfere with the lift chains...

Page 30: ...identify the center of gravity of the CEM NOTICE Do not attempt to use the radiator or CEM lift points to aid in the engine package lift Pump Tank Unit PTU Illustration 31 g06251429 4 Diesel Exhaust F...

Page 31: ...n any water and dirt from the fuel tank Apply a spray of calibration fluid or kerosene at the rate of 30 mL per 30 L 1 oz per 7 50 gal US of fuel tank capacity to prevent rust in the fuel tank Add 0 1...

Page 32: ...utside protective covers 2 Change the oil and filters 3 Check the condition of the fan and alternator belts Replace the belts if necessary Refer to this Operation and Maintenance Manual Belts Inspect...

Page 33: ...the tank must be tested with a refractometer The DEF in the tank must meet the requirements defined in ISO 22241 1 and comply with table 2 1 If necessary drain the tank and fill with DEF that meets IS...

Page 34: ...fault has been detected by the monitoring system Diesel Particulate Filter DPF This indicator will illuminate to show that regeneration is needed Regeneration Active This indicator will illuminate to...

Page 35: ...e sensor 3 Fuel rail pressure sensor 4 Atmospheric pressure sensor 5 Intake throttle valve 6 Fuel pressure before filter 7 Fuel temperature sensor 8 Fuel pressure after filter 9 Remote fuel priming sw...

Page 36: ...1 Intake manifold temperature sensor 12 Engine electronic control module 13 Starting motor 14 Oil pressure sensor 15 Camshaft spped timing sensor 16 fuel suction control valve 36 M0087475 03 Operation...

Page 37: ...Illustration 35 g06263610 Typical example 17 Coolant temperature 18 Crankshaft speed timing sensor M0087475 03 37 Operation Section Sensors and Electrical Components...

Page 38: ...Illustration 36 g06263677 Typical example 1 Diesel Exhaust Fluid DEF injector 2 Post NOx sensor 3 Differential pressure sensor 4 NOx sensor 5 Temperature sensor 38 M0087475 03 Operation Section Sensor...

Page 39: ...position while the engine is operating Serious dam age to the electrical system could result Battery Disconnect Switch The battery disconnect switch can be used in order to disconnect the battery from...

Page 40: ...power too soon will prevent purging of the DEF lines after the engine is shut down Definitions Observe the following definitions Self correct Fault condition no longer exists An active fault code will...

Page 41: ...1 inducement event will occur The check engine lamp and the emissions malfunction indicator lamp will illuminate The amber indicator next to the DEF level gauge on the dash will remain lit Illustratio...

Page 42: ...r a duration of 10 hours There is no repeat occurrence for level 1 faults Reduced Time The check engine and emissions malfunction indicator lamp will illuminate for a level 1 inducement related fault...

Page 43: ...nate solid The engine will have a 100 derate and be limited to 1000 rpm or low idle whichever is greater If the final inducement action in Perkins EST is set to Idle Down then engine will continue to...

Page 44: ...amp will illuminate for a level 1 inducement related fault There are three inducement categories If the inducement is a result of a category 1 fault then a level 1 inducement will occur for a duration...

Page 45: ...t occurrence a category 1 level 2 inducement fault will occur for a duration of 5 minutes If the inducement is a result of a category 2 fault then a level 2 inducement will occur for a duration of 5 h...

Page 46: ...y The problems may have been repaired since the logging of the code These codes do not indicate that a repair is needed The codes are guides or signals when a situation exists Codes may be helpful to...

Page 47: ...engine in a well ventilated area and if in an enclosed area vent the exhaust to the outside Do not start the engine or move any of the controls if there is a DO NOT OPERATE warning tag or similar warn...

Page 48: ...rmal If oil pressure is not indicated on the gauge within 15 seconds DO NOT operate the engine STOP the engine investi gate and correct the cause 5 Allow the engine to idle for approximately 3 minutes...

Page 49: ...tenance Manual Fuel System Prime Maintenance Section for more information on priming the fuel system Ether Injection System If Equipped The ether injection system is controlled by the ECM The ECM moni...

Page 50: ...of the electrical source 3 Connect one negative end of the jump start cable to the negative cable terminal of the electrical source Connect the other negative end of the jump start cable to the engine...

Page 51: ...C 32 F for extended periods The purpose of the automatic speed change is threefold to maintain the desired operation of the NOx reduction system to maintain the desired operation of the regeneration...

Page 52: ...696 g kWh was determined to be the CO2 value determined during the EU type approval process and recorded in EU type approval certificate This CO2 measurement results from testing over a fixed test cy...

Page 53: ...8 Once the amount of soot or sulfur collected reaches a critical threshold level a red STOP lamp will illuminate in addition to the DPF indicator and CEL 5 minutes after reaching the critical level th...

Page 54: ...ays increase the engine rpm to the rated rpm before the load is applied 5 Apply the load Begin operating the engine at low load Check the gauges and equipment for proper operation After normal oil pre...

Page 55: ...t water system and the exhaust system when possible Keep cooling system components clean and keep cooling system components in good repair Never operate the engine without water temperature regulators...

Page 56: ...d do not shut off the engine Refer to Operation and Maintenance Manual Monitoring System for more information on indicators 2 Turn the engine key switch to OFF position 2 and remove the key Note The e...

Page 57: ...premature engine and aftertreatment component damage Use for Emergency Situations only For more information on the engine key switch refer to Operation and Maintenance Manual Operator Controls Immedi...

Page 58: ...in the fuel Do not overfill the fuel tank NOTICE Only use antifreeze coolant mixtures recommended in this Operation and Maintenance Manual Refill Capacities and Recommendations topic or in this Operat...

Page 59: ...inter in the colder climates During cold weather operation if No 1 diesel fuel is not available use No 2 diesel fuel if necessary There are three major differences between No 1 and No 2 diesel fuel No...

Page 60: ...fuel filter Select a fuel heater that is mechanically simple yet adequate for the application The fuel heater should also help to prevent overheating of the fuel High fuel temperatures reduce engine...

Page 61: ...neral Information Diesel Exhaust Fluid DEF is a liquid that is injected into the aftertreatment system before Selective Catalytic Reduction SCR This system of injecting the DEF into the exhaust will r...

Page 62: ...o hot components will cause harmful vapors Storage Do not store DEF in direct sunlight Follow all local regulations covering bulk storage tanks Follow proper tank construction guidelines Tank volume t...

Page 63: ...ng Point BTL Biomass to liquid GTL Gas to liquid CTL Coal to liquid HVO Hydrotreated Vegetable Oil General Information NOTICE Every attempt is made to provide accurate up to date information By use of...

Page 64: ...mum and 4 5 maximum D445 ISO 3405 Water and sediment weight 0 05 maximum D1796 ISO 3734 Water weight 0 05 maximum D1744 No equivalent test Sediment weight 0 05 maximum D473 ISO 3735 Gums and Resins 5...

Page 65: ...the European Certification Perkins does not certify diesel engines on any other fuel Note The owner and the operator of the engine has the responsibility of using the fuel that is prescribed by the E...

Page 66: ...w viscosity is used cooling of the fuel may be required to maintain 1 4 cSt or greater viscosity at the fuel injection pump Fuels with a high viscosity might require fuel heaters to lower the viscosit...

Page 67: ...e The percentages given are volume based The U S distillate diesel fuel specification ASTM D975 09a includes up to B5 5 percent biodiesel European distillate diesel fuel specification EN590 2010 inclu...

Page 68: ...t engines with limited operational time either not use B20 biodiesel blends or whilst accepting some risk limit biodiesel blend to a maximum of B5 Examples of applications that should limit the use of...

Page 69: ...y 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 devi...

Page 70: ...absolute filter Beta 4 75 up to 200 to reach the recommended cleanliness level This filtration should be installed at the device that dispenses the fuel to the fuel tank In addition filtration at the...

Page 71: ...te The water must be used with an inhibitor to protect the engine Distilled water or deionized water is recommended for use in engine cooling systems DO NOT use the following types of water in cooling...

Page 72: ...and Materials ELC extended life coolant A coolant that relies on organic inhibitors for corrosion and cavitation protection Also called OATcoolant Organic Acid Technology SCA supplemental coolant add...

Page 73: ...form pitting from cavitation from erosion and from deposits NOTICE Do not use a conventional coolant to top off a cooling system that is filled with Extended Life Coolant ELC Do not use supplemental c...

Page 74: ...ter temperature regulators help to maintain the engine coolant at the correct operating temperature Cooling system prob lems can develop without water temperature regulators Check the glycol concentra...

Page 75: ...st commercial cooling system cleaning agents are corrosive and their use is not recommended by Perkins The cooling system must be thoroughly flushed with clean water after using cleaning agents Cleani...

Page 76: ...tem is defined by the accumulation of ash on the surface of the filter Ash is the inert part of the particulate matter The system is designed to collect this particulate matter There is a small percen...

Page 77: ...m to the following guidelines See the appropriate Lubricant Viscosities Refer to the illustration 62 to find the correct oil viscosity grade for your engine At the specified interval service the engin...

Page 78: ...e lubricating system turn off the engine i07915408 Welding on Engines with Electronic Controls NOTICE Because the strength of the frame may decrease some manufacturers do not recommend welding onto a...

Page 79: ...mponents are used as a ground for the welder or electrical electronic components are located between the welder ground and the weld current flow from the welder could severely damage the component 6 P...

Page 80: ...ality of the air The engine may be exposed to extended operation in an environment that is dirty or dusty unless the equipment is cleaned regularly Mud dirt and dust can encase components Maintenance...

Page 81: ...Engine Clean Fuel System Prime 111 Fuel Tank Water and Sediment Drain 114 Radiator Clean Daily Air Tank Moisture and Sediment Drain 83 Cooling System Coolant Level Check 90 Driven Equipment Check 98...

Page 82: ...Diesel Exhaust Fluid Injector Emission Related Component Replace 98 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 90 Every 10 000 Service Hours DEF Manifold Filters Emiss...

Page 83: ...utoff Test To ensure that the air shutoff valve always shuts down when the engine ingests gaseous fumes perform the test below at each oil change A test failure can indicate wear in the block off plat...

Page 84: ...place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal i...

Page 85: ...the OFF position Turn the ignition switch if equipped to the OFF position and remove the key and all electrical loads Note After the engine has stopped allow 2 minutes in order for the diesel exhaust...

Page 86: ...ons that require multiple drive belts replace the belts in matched sets Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched The addi...

Page 87: ...ould result in accelerated wear of the piston rings and wear of the cylinder liner NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine d...

Page 88: ...Fill NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling system with coolant antifreeze Refer to this Operation and Maintenance Manual Fluid Re...

Page 89: ...cooling system is cleaned only clean water is needed when the ELC is drained and replaced Note Inspect the water pump and the water temperature regulator after the cooling system has been drained Illu...

Page 90: ...s 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap Only install the used filler cap if the gasket is not damaged Test the cap for the correct pressure...

Page 91: ...could also result in radiator tube blockage overheating and or accelerated water pump seal wear Never use both liquid supplemental coolant additive and the spin on element if equipped at the same time...

Page 92: ...ve carbon buildup could result in accelerated wear of the piston rings and wear of the cylinder liner NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could ca...

Page 93: ...e taken to ensure that Diesel Exhaust Fluid DEF for the system are contained during per formance of inspection maintenance testing adjust ing and repair of the product Be prepared to collect the fluid...

Page 94: ...that the band clamp is aligned as shown in illustration 75 to the flat section on the filter base Tighten the band clamp to 4 5 0 7 N m 40 6 lb in 1 Ensure that the filter does not bunch when tighteni...

Page 95: ...ws 7 Tighten screws 7 to a torque of 1 1 N m 9 8 lb in 7 Install new outer filter 3 onto DEF tank header 1 Ensure that the clamp 2 is located between the location points A 8 Tighten clamp 2 to a torqu...

Page 96: ...introduced into the tank during filling Do not over fill the tank The DEF may require room for expansion Note Always fill the DEF tank on level ground Cold weather can affect DEF refer to this Operati...

Page 97: ...er element 2 from DEF pump assembly 1 Note Avoid twisting the diesel exhaust fluid filter upon removal Twisting may cause a tear 4 Lubricate seals of new DEF filter 2 with diesel exhaust fluid or dist...

Page 98: ...es that one of the following actions be taken when the DPF needs to be cleaned The DPF from your engine can be replaced with a new DPF The DPF from your engine can be replaced with a remanufactured DP...

Page 99: ...ids cannot enter the aftertreatment system If cleaning fluids enters the aftertreatment system damage could occur i07003542 Engine Air Cleaner Element Replace NOTICE Never run the engine without an ai...

Page 100: ...element not shown from air cleaner body 1 Ensure that the inner body of the air cleaner is clean and free from dirt Ensure that the inner of the air cleaner cover 3 is clean and free from dirt 4 Insta...

Page 101: ...cator to a torque of 2 N m 18 lb in i07819538 Engine Mounts Inspect Note The engine mounts may not have been supplied by Perkins Refer to the Original Equipment Manufacturer OEM information for furthe...

Page 102: ...on helps to provide the most accurate oil analysis i01907674 Engine Oil Sample Obtain The condition of the engine lubricating oil may be checked at regular intervals as part of a preventive maintenanc...

Page 103: ...in the oil pan with the oil warm This draining method allows the waste particles that are suspended in the oil to be drained properly Failure to follow this recommended procedure will cause the waste...

Page 104: ...he operating conditions and recommended oil types that are listed in this table are met Ifthe type of oil the quality of the oil and the operating conditions fails to meet certain standards the oil ch...

Page 105: ...a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters rec ommended by Perkins 1 Remove the oil filter with a suitable tool Note The fo...

Page 106: ...erform this procedure to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oil leaks 3 Stop the engine and allow the oil to drain back to the oi...

Page 107: ...the air filter element or elements Turn the engine at cranking speed with the throttle control in FUEL OFF position Use a sprayer to add a mixture of 50 percent VCI oil and 50 percent engine oil into...

Page 108: ...ot leave any exposed air space within the radiator All exposed surface areas will rust Table 19 Perkins Minimum Acceptable Water Requirements Property Maximum Limit Chloride Cl 40 mg L 2 4 grains US g...

Page 109: ...drain plugs and zinc plugs Fill the system The raw water system pumps may need priming before operation 12 On the first day of operation check the entire engine several times for leaks and correct op...

Page 110: ...isted in the following table Table 21 Storage Temperature Expected DEF Life Below 25 C 77 F 18 months 25 C 77 F to 30 C 86 F 12 months 30 C 86 F to 35 C 95 F 6 months Above 35 C 95 F test quality befo...

Page 111: ...rate measurement allow the valves to cool before this maintenance is performed During valve adjustment visibly inspect the valve train of wear or damage Refer to Systems Operation Testing and Adjustin...

Page 112: ...r disconnect the battery starting motor when maintenance is performed on a fuel filter 2 Shut off the fuel supply Illustration 94 g06264328 1 filter body 2 bowl 3 drain valve Note Refer to this Operat...

Page 113: ...fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be discon...

Page 114: ...turn by hand Do not overtighten the filter i02348492 Fuel Tank Water and Sediment Drain NOTICE Care must be taken to ensure that fluids are con tained during performance of inspection mainte nance tes...

Page 115: ...ter Element Emission Related Component Replace The filter for the Open Crankcase Ventilation OCV system may be located toward the front or toward the rear of the left side of the engine A filter that...

Page 116: ...re caused by the following conditions Cracking Softness Loose clamps Replace hoses that are cracked or soft Tighten any loose clamps Check for the following conditions End fittings that are damaged or...

Page 117: ...laced Check that connections and hoses are secure check for leaks If parts are to be removed or tightened refer to the Disassembly and Assembly manual for more information i05971077 Overhaul Considera...

Page 118: ...Inspect Perkins recommends a scheduled inspection of the starting motor If the starting motor fails the engine may not start in an emergency situation Check the starting motor for proper operation Che...

Page 119: ...personal injury or death After the engine has stopped you must wait for 10 minutes to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed...

Page 120: ...quipped so as to conform at the time of sale to all applicable regulations adopted by the California Air Resources Board ARB b Free from defects in materials and workmanship which cause the failure of...

Page 121: ...e corresponding times below rated rpm Refer to this Operation and Maintenance Manual Configuration Parameters for information about the rating for this engine Note The examples of the applications are...

Page 122: ...rkins engine investment When you order parts specify the following information Part number Part name Quantity If there is a question concerning the part number provide your dealer with a complete desc...

Page 123: ...r local Perkins Distributor now and the distributor can provide you with a quote in minutes You can locate your nearest Perkins Distributor by visiting www perkins com NOTICE Dependant upon engine typ...

Page 124: ...Dealer work orders and itemized bills Owners repair costs Owners receipts Maintenance log 124 M0087475 03 Reference Information Section Maintenance Records...

Page 125: ...A Test Add 91 Add the SCA If Necessary 91 Test for SCA Concentration 91 Cooling System Water Temperature Regulator Replace 92 Crushing Prevention and Cutting Prevention 15 Customer Service 122 D DEF F...

Page 126: ...Information 63 Foreword 4 California Proposition 65 Warning 4 Literature Information 4 Maintenance 4 Maintenance Intervals 5 Operation 4 Overhaul 5 Safety 4 Fuel and the Effect from Cold Weather 59 Fu...

Page 127: ...ne and Factory Mounted CEM 29 Engine and Installed Radiator Only 30 Pump Tank Unit PTU 30 Radiator Only 30 Product Storage Engine and Aftertreatment 30 Condition for Storage 30 R Radiator Clean 118 Ra...

Page 128: ...7 System Pressure Release 78 Coolant System 78 Engine Oil 78 Fuel System 78 T Table of Contents 3 W Walk Around Inspection 118 Inspect the Engine for Leaks and for Loose Connections 118 Warranty Infor...

Page 129: ...aintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Inf...

Page 130: ...M0087475 2020 Perkins Engines Company Limited All Rights Reserved 130 December 2020...

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