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Perkins 4006D-E23TA Operation And Maintenance Manual Download Page 52

“ Water Pump - Inspect”. . . . . . . . . . . . . . . . . . . . . . 82

Every 12 000 Service Hours or 6
Years

“ Cooling System Coolant (ELC) - Change” . . . . . . 59

52

M0088207

Maintenance Section
Maintenance Interval Schedule

Summary of Contents for 4006D-E23TA

Page 1: ...Operation and Maintenance Manual 4006D E23TA and 4008D E30TA Industrial Engines DE6 Engine DE8 Engine M0088207 en us July 2018...

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: ...13 Electrical System 14 Engine Electronics 14 Product Information Section Model Views 15 Operation Section Lifting and Storage 21 Features and Controls 25 Engine Diagnostics 32 Engine Starting 33 Engi...

Page 4: ...s 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 sec...

Page 5: ...ar 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 dist...

Page 6: ...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 eng...

Page 7: ...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 in...

Page 8: ...to protect your skin The hot surface warning labels 3 are located in two locations The oil cooler and heat shield of the coolant rail 4 Hot Fluid Under Pressure Illustration 6 g01371640 Pressurized s...

Page 9: ...lustration 8 g02781437 Rotating shaft pinch hazard The shaft under this cover is rotating anytime the engine is running Contact with a rotating shaft could cause injury or death Keep hands away The ro...

Page 10: ...ure that the components have cooled Use Neoprene gloves and discard the gloves safely after use Wash the area with calcium hydroxide solution and then with clean water Disposal of components and glove...

Page 11: ...onflammable solvent prior to welding or flame cutting Wiring must be kept in good condition Ensure that all electrical wires are correctly installed and securely attached Check all electrical wires da...

Page 12: ...es and Hoses Do not bend high pressure lines Do not strike high pressure lines Do not install any lines that are damaged Leaks can cause fires Consult your Perkins distributor for replacement parts Re...

Page 13: ...o provided in order to help prevent engine damage i06545901 Engine Starting Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury If a warni...

Page 14: ...engine to frame ground straps can be damaged by electrical discharge To ensure that the engine and the engine electrical systems function properly an engine to frame ground strap with a direct path t...

Page 15: ...ollowing model views show typical features of the engine Due to individual applications your engine may appear different from the illustrations Illustration 12 g06257338 Typical example of engine view...

Page 16: ...rnator 4 Oil filler 5 Coolant pump 6 Module for 3 primary fuel filters 7 Electric priming pump 8 Oil gauge Dipstick 9 Twin secondary fuel filters 10 Oil filters 11 Starting motor 12 Rear lifting eyes...

Page 17: ...6257405 Typical example 14 Fan belts 15 Front lifting eye 16 Thermostat housing 17 Twin turbochargers 18 Breather 19 Oil drain plug 20 Crankshaft damper M0088207 17 Product Information Section Model V...

Page 18: ...ne has the following characteristics Four stroke cycle Mechanically actuated electronically controlled fuel injection system Turbocharged Air to air charged cooled Engine Specifications Note The front...

Page 19: ...e Features The engine is designed for electronic controls The integral on board computer controls the operation of the engine Current operating conditions are monitored The Electronic Control Module E...

Page 20: ...aintenance Manual Overhaul Considerations topic Aftermarket Products and Perkins Engines Perkins does not warrant the quality or performance of non Perkins fluids and filters When auxiliary devices ac...

Page 21: ...under normal conditions of storage from 15 to 55 C 5 to 99 F and 90 relative humidity for a maximum of 2 year Level C This level is additional to level B Level C will give protection for five years in...

Page 22: ...Illustration 17 g06253337 Typical example of a 4006 engine 1 Rear lifting eye 2 Rear lifting eye 3 Front lifting eye 22 M0088207 Operation Section Product Lifting...

Page 23: ...Illustration 18 g06325366 Typical example of a 4008 engine 1 Rear lifting eye 2 Rear lifting eye 3 Front lifting eye M0088207 23 Operation Section Product Lifting...

Page 24: ...llustration 19 g06253324 Typical example of a 4006 radiator 1 Radiator lifting eyes Illustration 20 g06325384 Typical example of a 4008 radiator 1 Radiator lifting eyes 24 M0088207 Operation Section P...

Page 25: ...ill be set to a factory default in production The electronic service tool may be used to alter the trip point for a Warning within predefined limits Action Alert The Action Alert informs the OEM that...

Page 26: ...gine shuts down on overspeed the dedicated output and the shutdown output will be energized Shutdown Reset The cause of an engine shutdown must be investigated Corrective action must be taken before t...

Page 27: ...eed sensors while the engine is running The engine continues to run by using the other timing sensor for reference i07212416 Sensors and Electrical Components Sensors Only The illustrations within the...

Page 28: ...nsor Views Illustration 21 g06256139 Typical example 1 Coolant temperature sensor 2 Air inlet temperature sensor 3 Oil pressure sensor 4 Camshaft speed timing sensor 28 M0088207 Operation Section Sens...

Page 29: ...e sensor 7 Fuel pressure sensor after primary fuel filters 8 Fuel pressure sensor after secondary fuel filter 9 Fuel pressure sensor before secondary fuel filter 10 Fuel temperature sensor 11 Flywheel...

Page 30: ...stration 23 g06256949 12 Barometric pressure sensor i07218875 Sensors and Electrical Components Electrical Components The engine view shown is a typical examples only 30 M0088207 Operation Section Sen...

Page 31: ...6256232 Typical example 1 Alternator 2 Fuel priming pump with remote switch 3 Starter relay 4 Starting motor 5 Electronic Control Module ECM 6 Injector wiring harness M0088207 31 Operation Section Ele...

Page 32: ...erature i01797063 Engine Operation with Intermittent Diagnostic Codes If a diagnostic lamp illuminates during normal engine operation and the diagnostic lamp shuts off an intermittent fault may have o...

Page 33: ...types of starting aids such as ether Such use could result in an explosion and personal injury Startability will be improved at temperatures below 10 C 50 F from the use of a jacket water heater or ex...

Page 34: ...id spilling fuel Fuel expands when the fuel is warmed up The fuel may overflow from the fuel tank Inspect fuel lines for leaks Repair the fuel lines as needed Be aware of the properties of the differe...

Page 35: ...uipped with a service hour meter note the reading Perform the maintenance that is in the Operation and Maintenance Manual Maintenance Interval Schedule Check the crankcase oil level Maintain the oil l...

Page 36: ...are available in the countries and territories with severe winters For more information refer to the Operation and Maintenance Manual Fuel For Cold Weather Operation Another important fuel property w...

Page 37: ...can heat the fuel in excess of 65 C 149 F A loss of engine power can occur if the fuel supply temperature exceeds 37 C 100 F Note Heat exchanger type fuel heaters should have a bypass provision in or...

Page 38: ...US gal Table 5 4008 30 Engine and Engine with Radiator Engine Only 48 L 10 5 Imp gal Engine and Radiator 140 L 30 8 Imp gal Fuel System Refer to the OEM specifications for additional information on t...

Page 39: ...be replaced periodically Additives must be added at the correct concentration Over concentration of additives can cause the inhibitors to drop out of solution The deposits can enable the following pro...

Page 40: ...the correct amount of these additives to provide superior corrosion protection for all metals in engine cooling systems ELC is available in a premixed cooling solution with distilled water ELC is a 1...

Page 41: ...Contamination NOTICE Mixing ELC with other products reduces the effective ness of the ELC and shortens the ELC service life Use only Perkins Products for premixed or concen trate coolants Failure to...

Page 42: ...ermine the amount of SCA that is required if necessary Table 12 Equation For Adding The SCA To The Heavy Duty Coolant For Maintenance V 0 014 X V is the total volume of the cooling system X is the amo...

Page 43: ...maximum D482 ISO 6245 IS 1448 P 4 Carbon Residue on 10 Bottoms Weight 0 3 maximum D524 ISO 4262 IS 1448 P 8 Cetane Number 1 51 minimum D613 or D6890 ISO 5165 IS 1448 P 9 Cetane Index 46 minimum D4737...

Page 44: ...r greater viscosity at the fuel injection pump Fuels with a high viscosity might require fuel heaters to lower the viscosity to 4 5 cSt at the fuel injection pump 5 Follow the test conditions and proc...

Page 45: ...existing local regulations for emissions In India fuel meeting sulphur limits of Bharat stage 3 and Bharat stage 4 specifications must be used in these engine models Bharat stage 3 regulations require...

Page 46: ...should be used This action will reduce risk of power loss fuel system failures and related down time of engines This cleanliness level is important for new fuel system designs such as common rail inje...

Page 47: ...ngine Oil Specification General Lubricant Information Because of government regulations regarding the certification of exhaust emissions from the engine the lubricant recommendations must be followed...

Page 48: ...to help provide finished oils with performance characteristics that meet industry standards There are no industry standard tests that evaluate the performance or the compatibility of aftermarket addi...

Page 49: ...is used to compare the properties of new oil to the properties of the used oil sample This analysis allows technicians to determine the amount of deterioration of the oil during use This analysis also...

Page 50: ...t incorrect operating procedures and incorrect maintenance procedures can be factors which contribute to a severe service application Environmental Factors Ambient temperatures The engine may be expos...

Page 51: ...ct Adjust 69 Fuel Injector Inspect Adjust 70 Every 500 Service Hours or 1 Year Battery Electrolyte Level Check 54 Belts Inspect Adjust Replace 57 Belts Inspect Adjust Replace 58 Engine Crankcase Breat...

Page 52: ...Water Pump Inspect 82 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 59 52 M0088207 Maintenance Section Maintenance Interval Schedule...

Page 53: ...e engine When the engine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge A battery with a low charge will freeze more easily than a bat...

Page 54: ...rged the ammeter reading should be very near zero when the engine is in operation All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and prote...

Page 55: ...fan guards for ware or damage Repair as necessary Illustration 28 g06022928 Typical example 3 Remove the inspection guard X and inspection guard Y Illustration 29 g02025316 Typical example 4 Inspect t...

Page 56: ...he pulley 2 is toward the center of the engine 4 Remove the belts 1 Installation of the Fan Drive Belts 1 Install new belts 1 over the pulleys 2 Rotate the rod 3 to achieve an initial tension of 77 N...

Page 57: ...e inspect fan guards for ware or damage Repair as necessary Remove the fan guards 1 3 Inspect the belts for cracks splits glazing grease displacement of the cord and evidence of fluid contamination If...

Page 58: ...ive V Belts Remove and Install for more information i07212767 Belts Inspect Adjust Replace Alternator Belt Inspection 1 Isolate the electrical supply to the engine Illustration 34 g06253717 Illustrati...

Page 59: ...he cover guards refer to Inspection for more information When all checking of the belt or tensioning of the belt are completed and the all guards cover are installed restore the electrical power i0722...

Page 60: ...rical supply to the engine Loosen the cooling system filler cap 1 slowly to relieve any pressure Remove the cooling system filler cap 2 Clean the cooling system filler cap 1 and inspect the seal 2 If...

Page 61: ...the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 3 Fill the cooling system with clean water Install the cooling system...

Page 62: ...n cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the...

Page 63: ...f fluid leaks Maximum heat transfer characteristics Ease of maintenance Note Caution must be used to prevent electrical components from being damaged by excessive water when the engine is cleaned Pres...

Page 64: ...free from dirt before installing end cover 4 Then secure clips 3 The engine is equipped with 2 filter elements when performing maintenance both filter elements must be changed 6 Connect the electrical...

Page 65: ...ctrical supply to the engine 2 Ensure that the outer casing of the breather is clean and free from dirt Remove the bolts 2 and remove cover 1 from breather body 5 3 Remove O ring seal 3 and discard 4...

Page 66: ...ult in the loss of power Illustration 49 g06255129 Typical example Illustration 50 g01165836 Y Min mark X Max mark 1 Maintain the oil level between the Min mark Y and the Max mark X on the engine oil...

Page 67: ...les in the oil i07425870 Engine Oil and Filter Change Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensur...

Page 68: ...t all 3 oil filters are changed as a set 1 Use Tooling A to remove the oil filters 3 2 Ensure that the sealing face of the filter base 1 is clean and free from dirt 3 Lubricate the O rings 4 with clea...

Page 69: ...s dealer should perform the tests Visual Inspection Visually check the condition of all gauges sensors and wiring Look for wiring and components that are loose broken or damaged Damaged wiring or comp...

Page 70: ...TICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any disconnected fuel system components NOT...

Page 71: ...n also be primed by using the key switch Turn the key to the ON position for 2 minutes After 2 minutes the fuel system should be primed If necessary by cycling the key switch the system will prime aga...

Page 72: ...pair is performed NOTICE The water separator can be under suction during nor mal engine operation Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system Il...

Page 73: ...rs before opening any compartment or disassem bling any component containing fluids Dispose of all fluids according to local regulations and mandates Fuel Tank Fuel quality is critical to the performa...

Page 74: ...to avoid a fluid penetration hazard Refer to Operation and Maintenance Manual General hazard Information Inspect all hoses for leaks that are caused by the following conditions Cracking Softness Loose...

Page 75: ...he coolant from the cooling system to a level that is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose 6 Replace the old hose with a new hose 7 Install the hose...

Page 76: ...Start the engine Inspect the cooling system for leaks Clamps and V Band Locations Illustration 59 g06329247 1 Clamp torque 7 N m 62 lb in 76 M0088207 Maintenance Section Hoses and Clamps Inspect Repla...

Page 77: ...Illustration 60 g06329566 1 Clamp torque 7 N m 62 lb in 2 Clamp torque 9 N m 79 lb in M0088207 77 Maintenance Section Hoses and Clamps Inspect Replace...

Page 78: ...the engine The wear metal analysis of the lube oil An increase in the levels of noise and vibration An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear m...

Page 79: ...sion must include the costs of additional downtime that is caused by this procedure Perform an economic analysis to determine if cylinder heads should be serviced as a group or divided into smaller gr...

Page 80: ...t bulb behind the core to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins may be opened with a comb Inspect these items for good condition Welds...

Page 81: ...e to the turbocharger compressor wheel and or to the engine may occur Damage to a turbocharger compressor wheel could allow parts from the compressor wheel to enter an engine cylinder This debris can...

Page 82: ...harness for damage Belts for multiple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts a...

Page 83: ...aseous emission standards that are prescribed by the law at the time of manufacture This engine may be covered by an Emissions Warranty Consult your authorized Perkins dealer or distributor to determi...

Page 84: ...ent Check 63 E Electrical System 14 Grounding Practices 14 Emergency Stopping 35 Emissions Warranty Information 83 Engine Clean 63 Engine Air Cleaner Element Replace 63 Engine Air Cleaner Service Indi...

Page 85: ...72 Fuel System Secondary Filter Replace 72 Fuel Tank Water and Sediment Drain 73 Drain the Water and the Sediment 73 Fuel Storage Tanks 74 Fuel Tank 73 Fuel Transfer Pump Lift Pump Inspect 74 H Hoses...

Page 86: ...zard 9 Safety Section 6 Self Diagnostics 32 Sensors and Electrical Components Electrical Components 30 Sensors and Electrical Components Sensors Only 27 Engine Sensor Views 28 Severe Service Applicati...

Page 87: ...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 88: ...M0088207 2018 Perkins Engines Company Limited All Rights Reserved 88 July 2018...

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