Perkins 904D-E28T Operation And Maintenance Manual Download Page 39

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Illustration 30

g06538269

Typical example

(12) NRS valve
(13) Injector 1, 2, 3 and injector 4

(14) Crankshaft speed/timing sensor
(15) Engine oil pressure switch

(16) Fuel rail pressure sensor

M0108133-04

Operation Section

Sensors and Electrical Components

Summary of Contents for 904D-E28T

Page 1: ...Operation and Maintenance Manual 904D E28T and 904D E36TA Industrial Engine FT Engine FE Engine M0108133 04 en us January 2021...

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: ...Engine Electronics 21 Product Information Section General Information 23 Product Identification Information 31 Operation Section Lifting and Storage 33 Features and Controls 35 Engine Diagnostics 41...

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: ...ations are not visible Use a cloth water and soap to clean the warning signs Do not use solvents gasoline or other harsh chemicals Solvents gasoline or harsh chemicals could loosen the adhesive that s...

Page 7: ...904D E36TA Industrial Engine Illustration 1 g06504861 Typical example 1 Universal Warning label 2 Hand High Pressure Warning label M0108133 04 7 Safety Section Safety Messages...

Page 8: ...Warning 1 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...

Page 9: ...hazard Failure to follow these inspection maintenance and service in structions may cause personal injury or death Illustration 4 g02382677 Typical example The hand high pressure label is on the high...

Page 10: ...rs can break Use all cleaning solutions with care Report all necessary repairs Unless other instructions are provided perform the maintenance under the following conditions The engine is stopped Ensur...

Page 11: ...ll necessary repairs Unless other instructions are provided perform the maintenance under the following conditions The engine is stopped Ensure that the engine cannot be started Disconnect the batteri...

Page 12: ...grounded and bonded Consult with your fuel or fuel system supplier to ensure that the delivery system complies with fueling standards for proper grounding and bonding Avoid static electricity risk whe...

Page 13: ...se components is usually bound in a resin or sealed in some way Normal handling is not hazardous unless airborne dust that contains asbestos is generated If dust that may contain asbestos is present t...

Page 14: ...d Always follow the directions for first aid that are noted on a material safety data sheet MSDS for sulfuric acid Coolant When the engine is at operating temperature the engine coolant is hot The coo...

Page 15: ...move all flammable combustible materials or conductive materials such as fuel oil and debris from the engine Do not allow any flammable combustible materials or conductive materials to accumulate on t...

Page 16: ...tions with a higher sulfur content Avoid death or serious injury from fire or explosion Consult your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling stand...

Page 17: ...ent correctly when work beneath the component is performed Unless other maintenance instructions are provided never attempt adjustments while the engine is running Stay clear of all rotating parts and...

Page 18: ...fuel lines Do not bend or strike the high pressure fuel lines Deformation or damage of the high pressure fuel lines may cause a point of weakness and potential failure Do not check the high pressure...

Page 19: ...st be installed if the engine must be started to perform service procedures To help prevent an accident that is caused by parts in rotation work around the parts carefully Do not bypass the automatic...

Page 20: ...art the engine until the problem that caused the emergency stop has been corrected Stop the engine if an overspeed condition occurs during the initial start up of a new engine or an engine that has be...

Page 21: ...grounded to the negative battery terminal The wire used must be adequate to handle the full charging current of the alternator The power supply connection for the engine electronics should always be f...

Page 22: ...ent engine models and different engine applications However the monitoring system and the engine monitoring control will be similar for all engines Note Many of the engine control systems and display...

Page 23: ...nformation Model View Illustrations The following model views show typical features of the engine Due to individual applications your engine may appear different from the illustrations M0108133 04 23...

Page 24: ...rness interface 2 NOx Reduction System NRS valve 3 Air intake from air charge cooler 4 Alternator 5 Oil filter assembly 6 Oil filler lower 7 Oil gauge Dipstick 8 Oil drain tap 9 Starting motor 10 High...

Page 25: ...ntake from air cleaner 15 Electronic Control Module ECM location for transportation only 16 Adjuster for drive belt 17 Coolant pump pulley 18 Coolant intake 19 Fan drive pulley 20 Drive belt 21 Coolan...

Page 26: ...rness interface 2 NOx Reduction System NRS valve 3 Air intake from air charge cooler 4 Alternator 5 Oil filter assembly 6 Oil filler lower 7 Oil gauge Dipstick 8 Oil drain tap 9 Starting motor 10 High...

Page 27: ...Turbocharger 15 Air intake from air cleaner 16 Electronic Control Module ECM location for transportation only 17 Adjuster for drive belt 18 Coolant pump pulley 19 Coolant intake 20 Fan drive pulley 21...

Page 28: ...6 Inlet temperature sensor 7 Exhaust assembly i08185938 Product Description 904D E28T Industrial Engine The Perkins 904D E28T industrial engine is a single turbocharged engine with an engine prefix of...

Page 29: ...er 1 cylinder is the front cylinder Illustration 23 g06297997 Typical example A Inlet valves B Exhaust valves Table 2 904D E36TA Engine Specifications Operating Range rpm 800 to 2400 1 Number of Cylin...

Page 30: ...ce depend on adherence to proper operation and maintenance recommendations Engine performance and efficiency also depend on the use of recommended fuels lubrication oils and coolants Refer to this Ope...

Page 31: ...rmine the components that were included with the engine This information permits accurate identification of replacement part numbers The numbers for fuel setting information for electronic engines are...

Page 32: ...formation 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 Low Idle rpm Engine Ful...

Page 33: ...dicular engine lifting 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...

Page 34: ...ptable fuels refer to this Operation and Maintenance Manual Fluid recommendations Operate the engine for 15 minutes in order to remove all biodiesel from the system 2 Drain any water from the primary...

Page 35: ...ECM will Check the pressure Engine oil pressure The engine oil pressure switch indicates when oil pressure drops below rated system pressure at a set engine speed Engine overspeed If the engine rpm ex...

Page 36: ...Stop the engine 3 Check and maintain the oil level Jacket Water Coolant Temperature Typical temperature range is 82 to 96 C 147 6 to 172 8 F The maximum allowable temperature with the pressurized coo...

Page 37: ...ill flash to show that the engine is being held at low speed This function will be performed at engine starting and the duration will depend on ambient temperature and engine temperature The lamps wil...

Page 38: ...erature sensor 4 Alternator 5 Control valve for high pressure fuel pump 6 Fuel temperature sensor 7 Starting motor 8 Camshaft speed timing sensor 9 Pre NRS temperature sensor 10 Inlet manifold tempera...

Page 39: ...9 Typical example 12 NRS valve 13 Injector 1 2 3 and injector 4 14 Crankshaft speed timing sensor 15 Engine oil pressure switch 16 Fuel rail pressure sensor M0108133 04 39 Operation Section Sensors an...

Page 40: ...trical Components Illustration 31 g06481423 Typical example 1 ECM 2 If equipped Air intake temperature sensor Air Cleaner 3 Priming pump 4 Water in fuel switch 40 M0108133 04 Operation Section Sensors...

Page 41: ...ing lamp will flash once 3 A flashing YELLOW lamp indicates a 3 digit diagnostic code for the engine The sequence of flashes represents the system diagnostic message Count the first sequence of flashe...

Page 42: ...een these active diagnostic codes and engine performance i01797063 Engine Operation with Intermittent Diagnostic Codes If a diagnostic lamp illuminates during normal engine operation and the diagnosti...

Page 43: ...trical loads or remove any electrical loads i08165229 Cold Weather Starting Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury The abilit...

Page 44: ...ote During the key on the indicator lamps will be illuminated for 2 seconds to check lamp operation If any of the lamps do not illuminate check the bulb If any indicator lamps stay illuminated or flas...

Page 45: ...e to the negative cable terminal of the electrical source Connect the other negative end of the jump start cable to the engine block or to the chassis ground This procedure helps to prevent potential...

Page 46: ...idle option is not available then operate the engine at operational speed with no load for 2 minutes Note Gauge readings should be observed and the data should be recorded frequently while the engine...

Page 47: ...CO2 Emissions Statement Emissions regulations require that the value of the CO2 emissions be reported to the end user For the 904D E28T engine 831 2 g kWh was determined to be the CO2 value during th...

Page 48: ...p the air cleaner elements clean Ensure that the turbocharger is operating correctly For more information refer to this Operation and Maintenance Manual Turbocharger Inspect Maintain a good electrical...

Page 49: ...low loads until a minimum operating temperature of 80 C 176 F is achieved Achieving operating temperature will help prevent the intake valves and exhaust valves from sticking The cooling system and t...

Page 50: ...of a light load parasitic load will help in achieving the minimum operating temperature The minimum operating temperature is 80 C 176 F Recommendations for Coolant Warm Up Warm up an engine that has c...

Page 51: ...flow over components will also affect under hood temperatures Reducing air flow can increase surface temperatures and could affect component reliability If an airflow restriction device must be used...

Page 52: ...nd sediment from the bottom of the tanks Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel...

Page 53: ...u check the engine oil do not operate the engine Wait for at least 30 minutes after the engine has stopped to allow the engine oil to return to the oil pan Contact with high pressure fuel may cause fl...

Page 54: ...eeze protection and the correct corrosion protection Add the correct coolant water mixture if necessary Perform all required periodic maintenance on all driven equipment This maintenance is outlined i...

Page 55: ...the capacity of the auxiliary oil filter The design of the oil pan can change the oil capacity of the oil pan Cooling System Refer to the OEM specifications for the External System capacity This capac...

Page 56: ...om conventional sources Satisfactory engine performance depends on the use of a good quality fuel The use of a good quality fuel will give the following results long engine life and acceptable exhaust...

Page 57: ...cting a fuel for a given engine application LSD fuel with less than 0 05 percent 500 ppm mg kg sulfur is recom mended for use in these engine models Diesel fuel with more than 0 05 percent 500 ppm mg...

Page 58: ...from gravity flow viscometers at standard temperatures Refer to ISO 3104 for the test method The viscosity of the fuel is significant because fuel serves as a lubricant for the fuel system components...

Page 59: ...dations for additives to use and for the proper level of treatment Distillation Distillation will give an indication of the mixture of different hydrocarbons in the fuel A high ratio of lightweight hy...

Page 60: ...includes up to B5 5 percent biodiesel European distillate diesel fuel specification EN590 2010 includes up B7 7 percent biodiesel Note Engines that are manufactured by Perkins are certified by use of...

Page 61: ...r standby generator sets and emergency vehicles that cannot avoid use of biodiesel blends fuel quality in the engine fuel tank must be sampled and checked monthly Test should include acid number EN141...

Page 62: ...el cleaner that is recommended by Perkins Perkins Diesel Fuel Cleaner part number T400012 is the only fuel cleaner that is recommended by Perkins If biodiesel or biodiesel blends of fuel are to be use...

Page 63: ...ection hoses fittings and dispensing nozzles Consult your local Perkins distributor for additional information on Perkins designed and produced filtration products Renewable and Alternative Fuels Perk...

Page 64: ...any protection against boiling or freezing Water is used in the cooling system to transfer heat Distilled water or deionized water is recommended for use in engine cooling systems DO NOT use the foll...

Page 65: ...ed Life Coolant A coolant that relies on organic inhibitors for corrosion and cavitation protection Also known as Organic Acid Technology OAT coolant ELI Extended Life Inhibitor SCA Supplement Coolant...

Page 66: ...for the part numbers ELC Cooling System Maintenance Correct additions to the Extended Life Coolant NOTICE Mixing Extended Life Coolant with other products re duces the Extended Life Coolant service li...

Page 67: ...cleaner must be thoroughly flushed from the cooling system Cooling system cleaner that is left in the system will contaminate the coolant The cleaner may also corrode the cooling system 8 Repeat Steps...

Page 68: ...s the amount of SCA that is needed Use the equation that is in Table 14 to determine the amount of SCA that is required if necessary Table 14 Equation for Adding the SCA to the Commercial Heavy Duty C...

Page 69: ...icensing and Certification System by the American Petroleum Institute API is recognized by Perkins For detailed information about this system see the latest edition of the API publication No 1509 Engi...

Page 70: ...are no industry standard tests that evaluate the performance or the compatibility of aftermarket additives in finished oil Aftermarket additives may not be compatible with the finished oils additive...

Page 71: ...oil to the properties of the used oil sample This analysis allows technicians to determine the amount of deterioration of the oil during use This analysis also allows technicians to verify the perform...

Page 72: ...f the high pressure fuel lines are higher than other types of fuel system Before any service or repair is performed on the engine fuel lines perform the following tasks 1 Stop the engine 2 Wait for 10...

Page 73: ...ectrode 3 Keyswitch in the OFF position 4 Battery disconnect switch in the open position 5 Disconnected battery cables 6 Battery 7 Electrical Electronic component 8 The component that is being welded...

Page 74: ...edures and incorrect maintenance procedures can be factors which contribute to a severe service application Environmental Factors Ambient temperatures The engine may be exposed to extended operation i...

Page 75: ...1 Year Battery Electrolyte Level Check 77 Engine Air Cleaner Element Replace 85 Engine Oil and Filter Change 89 Fuel System Primary Filter Water Separator Element Replace 94 Fuel System Secondary Fil...

Page 76: ...brackets air lines connections clamps and seals Make repairs if necessary i02322311 Alternator Inspect Perkins recommends a scheduled inspection of the alternator Inspect the alternator for loose conn...

Page 77: ...d 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 protective clothing when working on...

Page 78: ...fluid contamination The belt must be replaced if the following conditions are present The belt has a crack in more than one rib More than one section of the belt is displaced in one rib of a maximum l...

Page 79: ...y servicing or repair of the engine cooling system is performed the procedure must be per formed with the engine on level ground Level ground will allow you to check accurately the coolant level This...

Page 80: ...ne to cool Loosen the cooling system filler cap slowly to relieve any pressure Remove the cooling system filler cap Remove the connection hose or remove the cooling system drain plugs Allow the water...

Page 81: ...o 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 pressure 1 Stop the eng...

Page 82: ...engine speed to low idle Stop the engine 3 Maintain the coolant level at the maximum mark that is correct for your application 4 Clean the cooling system filler cap Inspect the gasket that is on the...

Page 83: ...m air locks may result in engine damage 3 Fill the cooling system with distilled or deionized water Install the cooling system filler cap 4 Start and run the engine at low idle until the temperature r...

Page 84: ...any servicing or repair of the engine cooling system is performed the procedure must be per formed with the engine on level ground This proce dure will allow you to check accurately the coolant level...

Page 85: ...age to engine components Air cleaner elements help to pre vent airborne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow di...

Page 86: ...or more information i02335405 Engine Air Cleaner Service Indicator Inspect Some engines may be equipped with a different service indicator Some engines are equipped with a differential gauge for inlet...

Page 87: ...nts Inspect Note The engine mounts may not have been supplied by Perkins Refer to the Original Equipment Manufacturer OEM information for further details on the engine mounts and the correct bolt torq...

Page 88: ...the oil filler cap 4 If necessary drain a small quantity of oil from the crankcase to reduce the oil level The oil level needs to be between the mark L and the mark H before operating the engine Refer...

Page 89: ...checked for the following the quality of the oil the existence of any coolant in the oil the existence of any ferrous metal particles in the oil and the existence of any nonferrous metal particles in...

Page 90: ...se the following method to drain the engine oil pan Illustration 49 g06512019 Typical example of a nonmetallic oil pan 1 Place container below oil drain plug 1 Remove the oil drain plug and allow the...

Page 91: ...drain plug 5 from engine oil pan 3 and allow the oil to drain into the container for storage or disposal 3 Remove drain plug seal 2 and drain plug seal 4 Discard the seals 4 Clean the oil drain plugs...

Page 92: ...p and filter body are clean and free from dirt or damage Inspect new filter element for damage before installing 4 Install new O ring seal 2 onto cap 1 Install new filter element 3 into cap 1 Install...

Page 93: ...pty or the fuel tank has been partially drained The low pressure fuel lines are disconnected A leak exists in the low pressure fuel system The fuel filter has been replaced Electric Fuel Priming Pump...

Page 94: ...o the OFF position before performing this maintenance 2 Place a suitable container under the water separator to catch any fuel that might spill Clean up any spilled fuel Clean the outside body of the...

Page 95: ...wiring harness to connection 3 6 The secondary filter element if equipped must be replaced at the same time as the primary filter element Refer to the Operation and Maintenance Manual Fuel System Seco...

Page 96: ...ine is stopped before any servic ing or repair is performed Refer to Systems Operation Testing and Adjusting Cleanliness of Fuel System Components for detailed information on the standards of cleanlin...

Page 97: ...to ensure that fluids are con tained during performance of inspection mainte nance testing adjusting and repair of the product Be prepared to collect the fluid with suitable contain ers before openin...

Page 98: ...Operation and Maintenance Manual General hazard Information and Operation and Maintenance Manual High Pressure Fuel Lines for the correct procedures Inspect all hoses for leaks that are caused by the...

Page 99: ...clean the electrical connections Refer to the Systems Operation Testing and Adjusting Manual Electric Starting System Test for more information on the checking procedure and for specifications consult...

Page 100: ...checks costly repairs and accidents can be avoided For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks or...

Page 101: ...nce Manual General hazard Information Visually inspect the high pressure fuel lines for damage or signs of fuel leakage Replace any damaged high pressure fuel lines or high pressure fuel lines that ha...

Page 102: ...are prescribed by the law at the time of manufacture This engine may be covered by an Emissions Warranty For a full warranty statement contact your Perkins dealer or your Perkins distributor For cust...

Page 103: ...ence Materials Maintenance Log Table 17 Engine Model Customer Identifier Serial Number Arrangement Number Service Hours Quantity Of Fuel Service Item Date Authorization continued M0108133 04 103 Refer...

Page 104: ...ighly trained technicians carry out all repairs 5 Transferable coverage should you sell your machine Flexible coverage provides the right level of protection for your Perkins Engine Coverage can be ex...

Page 105: ...41 Diagnostic Lamp 41 Driven Equipment Check 84 E Electrical System 20 Grounding Practices 20 Emergency Stopping 53 Emissions Certification Film 31 Emissions Warranty Information 102 Engaging the Dri...

Page 106: ...Procedure 95 Fuel System Secondary Filter Replace 96 Install the Element 97 Remove the Element 96 Fuel Tank Water and Sediment Drain 97 Drain the Water and the Sediment 97 Fuel Storage Tanks 98 Fuel T...

Page 107: ...e 8 904D E36TA Industrial Engine 7 Ether Warning 9 Hand High Pressure 2 9 Universal Warning 1 8 Safety Section 6 Self Diagnostics 41 Sensors and Electrical Components 37 Off Engine Sensors and Electri...

Page 108: ......

Page 109: ...aintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Inf...

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