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i07482989

Maintenance

 

Interval

 

Schedule

When

 

Required

“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . 104

“ Battery or Battery Cable - Disconnect” . . . . . . . . 105

“

 

DEF

 

Filler

 

Screen

 

-

 

Clean”

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

111

“ Diesel Exhaust Fluid - Fill”. . . . . . . . . . . . . . . . . . 112

“ Diesel Exhaust Fluid Tank - Flush” . . . . . . . . . . . 114

“

 

Engine

 

-

 

Clean”

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

115

“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . 120

“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . 125

Daily

“ Coolant Level - Check” . . . . . . . . . . . . . . . . . . . . 110

“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . 114

“

 

Engine

 

Air

 

Precleaner

 

-

 

Check/Clean”

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

117

“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . 119

“ Fuel System Primary Filter/Water Separator -
Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

“Walk-Around

 

Inspection”

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

134

Every Week

“

 

Hoses

 

and

 

Clamps

 

-

 

Inspect/Replace” .

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

130

Every 50 Service Hours or Weekly

“ Fuel Tank Water and Sediment - Drain” . . . . . . . 130

Every 500 Service Hours

“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . 120

“ Fan Clearance - Check” . . . . . . . . . . . . . . . . . . . 123

Every 500 Service Hours or 1 Year

“ Fuel System Primary Filter (Water Separator)
Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . 126

“ Fuel System Secondary Filter - Replace”. . . . . . 128

“

 

Radiator

 

-

 

Clean”

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

131

Every 1000 Service Hours

“ Belt - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

“ Belt Tensioner - Check” . . . . . . . . . . . . . . . . . . . . 106

“ Water Pump - Inspect”. . . . . . . . . . . . . . . . . . . . . 136

Every 1500 Service Hours

“ Diesel Exhaust Fluid Filter - Clean/Replace” . . . 113

“Engine Crankcase Breather Element -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Every 2000 Service Hours

“

 

Engine

 

Mounts

 

-

 

Inspect”

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

.

 

119

Every 3000 Service Hours

“ Alternator and Fan Belts - Replace” . . . . . . . . . . 104

Every 3000 Service Hours or Two
Years

“ Coolant (DEAC) - Change” . . . . . . . . . . . . . . . . . 107

Every 4000 Service Hours

“ Aftercooler Core - Clean/Test” . . . . . . . . . . . . . . 104

Every 4500 Service Hours

“ Turbocharger - Inspect” . . . . . . . . . . . . . . . . . . . . 132

Every 6000 Service Hours

“ Coolant Extender (ELC) - Add” . . . . . . . . . . . . . . 110

Every 10 000 Service Hours

“ DEF Manifold Filters - Replace” . . . . . . . . . . . . . 112

Every 12 000 Service Hours or 6
Years

“ Coolant (ELC) - Change”. . . . . . . . . . . . . . . . . . . 109

Commissioning

“ Fan Clearance - Check” . . . . . . . . . . . . . . . . . . . 123

SEBU9063-07

103

Maintenance Section

Maintenance Interval Schedule

Содержание 1204F-E44TA

Страница 1: ...Operation and Maintenance Manual 1204F E44TA and 1204F E44TTA Industrial Engines MT Engine MU Engine MW Engine SEBU9063 07 en us December 2020...

Страница 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...

Страница 3: ...Engine Electronics 21 Product Information Section General Information 22 Product Identification Information 32 Operation Section Lifting and Storage 35 Features and Controls 42 Engine Diagnostics 63 E...

Страница 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...

Страница 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...

Страница 6: ...g signs that are loosened could drop off the engine Replace any warning sign that is damaged or missing If a warning sign is attached to a part of the engine that is replaced install a new warning sig...

Страница 7: ...fuel may cause fluid penetration and burn hazards High pressure fuel spray may cause a fire hazard Failure to follow these inspection maintenance and service in structions may cause personal injury or...

Страница 8: ...l will be installed on the air cleaner or close to the air cleaner The location will depend on the application Do not operate or work on this equipment unless you have read and understand the instruct...

Страница 9: ...er parts of the engine Ensure that all protective guards and all covers are secured in place on the engine Never put maintenance fluids into glass containers Glass containers can break Use all cleanin...

Страница 10: ...ecks or maintenance procedures The appropriate Personal Protective Equipment PPE must be worn when standing next to an exposed running engine Do not wear loose clothing or jewelry that can snag on con...

Страница 11: ...d with suitable containers before opening any compartment or disassembling any component containing fluids Dispose of all fluids according to local regulations and mandates Static Electricity Hazard w...

Страница 12: ...s when handling the equipment or parts Perkins also recommends the following Wear appropriate Personal Protective Equipment PPE Wash your hands and face with soap and water prior to eating drinking or...

Страница 13: ...Do not inhale ammonia vapor or mist Do not eat drink or smoke in presence of DEF Avoid DEF contact with eyes skin and clothing Wash thoroughly after handling DEF Always follow the directions for firs...

Страница 14: ...that the filler cap is cool before removing the filler cap The filler cap must be cool enough to touch with a bare hand Remove the filler cap slowly to relieve pressure Cooling system conditioner cont...

Страница 15: ...d on lines or tanks that contain flammable fluids Do not flame cut lines or tanks that contain flammable fluid Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or...

Страница 16: ...ck 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 Refer to t...

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

Страница 18: ...performed on the engine fuel lines The 10 minute wait will also allow static charge to dissipate from the low pressure fuel system Do not loosen the high pressure fuel lines in order to remove air fro...

Страница 19: ...d the warning tag before the engine is started All protective guards and all protective covers must be installed if the engine must be started to perform service procedures To help prevent an accident...

Страница 20: ...gases that are produced by some batteries the negative cable should be connected last from the external power source to the primary position for grounding Check the electrical wires daily for wires t...

Страница 21: ...rs while the engine is operating Failure to follow this instruction could result in personal injury or death This engine has a comprehensive programmable Engine Monitoring System The Electronic Contro...

Страница 22: ...ypical features of the engine and the aftertreatment system Due to individual applications your engine and your aftertreatment may appear different from the illustrations 1204F E44 TA Single Turbochar...

Страница 23: ...ther 3 Secondary fuel filter 4 Primary fuel filter 5 Electronic Control Module 6 Priming tranfer fuel pump 7 In line fuel filter 8 Oil level gauge dipstick 9 Oil drain plug 10 Oil filter 11 Oil sampli...

Страница 24: ...Illustration 19 g03404423 Typical example 14 Air intake 15 Coolant outlet 16 Water pump 17 Coolant intake 18 Tensioner 19 Belt 24 SEBU9063 07 Product Information Section Model View Illustrations...

Страница 25: ...g eye Aftertreatment Systems Two different types of aftertreatment are available the aftertreatment must be matched to the engine power Diesel Oxidation Catalyst DOC and Selective Catalytic Reduction...

Страница 26: ...l example 1 SCR 2 Identification module 3 Outlet for Exhaust gas 4 Mixer 5 DOC 6 Inlet for Exhaust gas The identification module will be installed on all aftertreatment systems 26 SEBU9063 07 Product...

Страница 27: ...DOC DPF and SCR Illustration 22 g03713347 Typical example 1 Intake for exhaust gas 2 DPF 3 Mixer 4 SCR 5 Outlet for exhaust gas SEBU9063 07 27 Product Information Section Model View Illustrations...

Страница 28: ...R aftertreatment system and the engine model is MT The 1204F E44TTA engine can have two different aftertreatment systems For the DOC and SCR system the engine model is MU The aftertreatment systems Di...

Страница 29: ...The Electronic Control Module ECM controls the response of the engine to these conditions and to the demands of the operator These conditions and operator demands determine the precise control of fue...

Страница 30: ...he mixture then enters the SCR catalyst Here the NOx in the exhaust reacts with the ammonia from the injected urea to split the gases into nitrogen and oxygen constituents The SCR catalyst includes an...

Страница 31: ...missions durability period as defined by regulation subject to prescribed maintenance requirements being followed Aftermarket Products and Perkins Engines Perkins does not warrant the quality or perfo...

Страница 32: ...front engine mounting Perkins distributors need all the information on the serial plate in order to determine the components that were included with the engine This information permits accurate identi...

Страница 33: ...ustration 29 g03700583 The serial plate 1 for the pump electronic unit is installed beside the diesel exhaust fluid filter i05673571 Emissions Certification Film The label for the emission is installe...

Страница 34: ...ull Load rpm In Line Fuel Filter Primary Fuel Filter Secondary Fuel Filter Element Lubrication Oil Filter Element Auxiliary Oil Filter Element Total Lubrication System Capacity Total Cooling System Ca...

Страница 35: ...form product lifting if components are damaged Ensure that the correct clothing is worn refer to this Operation and Maintenance Manual General Hazard Information There are two different types of Clean...

Страница 36: ...of the low powered CEM is 42 kg 93 lb Two suitable double looped slings are required to lift the CEM Also a suitable hoist will be required to remove and install the assembly The slings must be attac...

Страница 37: ...jig to lift the CEM A frame or jig must only be connected to the cradle of the CEM Refer to the original equipment manufacture for more information i07434759 Product Lifting NOTICE Always inspect lif...

Страница 38: ...that proper lifting devices are provided There are several different designs of lifting eyes The following sections give examples of lifting eyes on the engine engine and aftertreatment and factory i...

Страница 39: ...tored in a water proof building The building must be kept at a constant temperature Engines that are filled with Perkins ELC will have coolant protection to an ambient temperature of 36 C 32 8 F The e...

Страница 40: ...outlet DEF in Tank Storage DEF should be drained and replenished if the application is left idle for 2 months or longer at 40 C 104 F DEF should be drained and replenished if the application is left...

Страница 41: ...ture Duration 10 C 50 F 36 months 25 C 77 F 18 months 30 C 86 F 12 months 35 C 95 F 1 6 months 1 At 35 C significant degradation can occur Check every batch before use SEBU9063 07 41 Operation Section...

Страница 42: ...Engine oil pressure The engine oil pressure sensor indicates when oil pressure drops below rated system pressure at a set engine speed Engine overspeed If the engine rpm exceeds the overspeed setting...

Страница 43: ...the DEF injector operation correctly Dosing Control Unit DCU The DCU controls the injection of the DEF and will signal the ECM if the injection has been interrupted The DEF level sensor DEF temperatur...

Страница 44: ...code is just an indicator of what level of inducement the engine is in The escalating time inducement fault code also indicates how much time remains until the next level of inducement There are thre...

Страница 45: ...4 World Wide Reduced Performance Setting Category 2 Fault Non Tampering Dosing and Interruption Normal operation Level 1 Level 2 Level 3 Override Inducement Time First Occurrence None 10 Hours 10 Hou...

Страница 46: ...y be used once Inducement Time Repeat Occurrence None None 5 Hours 50 Percent torque Shut down or idle Until fault heals Cycling the keyswitch will give 20 minutes of full power Inducement None None 7...

Страница 47: ...p Table 7 World Wide Reduced Time Setting Category 2 Fault Non Tampering Dosing Interruption Normal operation Level 1 Level 2 Level 3 Override Inducement Time First Occurrence None 5 Hours 5 Hours 50...

Страница 48: ...0 percent At Level 1 the low level warning lamp in the DEF gauge will illuminate and the emission malfunction lamp will be on solid At Level 2 the low level warning lamp for the DEF is active and the...

Страница 49: ...w 15 minutes after the engine has stopped before you turn the battery off If digital communication is lost the wait to disconnect lamp will operate for minutes 15 minutes on both aftertreatment system...

Страница 50: ...down immediately or if the engine can be cooled by reducing the load 3 Inspect the cooling system for leaks If necessary consult your Perkins distributor for assistance Tachometer This gauge indicates...

Страница 51: ...t to disconnect lamp will be illuminated during engine operation and will be extinguished after the engine has stopped Do not disconnect the battery disconnect switch during the period the lamp is ill...

Страница 52: ...e in operation this issue indicates one of the following conditions 1 One or more of the shutdown values for the engine protection strategy has been exceeded 2 A serious active diagnostic code has bee...

Страница 53: ...overspeed can be set from 2600 rpm to 3000 rpm This setting depends on the application i05769077 Sensors and Electrical Components The illustration within the section shows the typical locations of t...

Страница 54: ...Intake Manifold Pressure Sensor 5 Electronic Control Module ECM 6 Atmospheric Pressure Sensor Barometric Pressure Sensor 7 Priming Transfer pump 8 Primary Speed Timing sensor Crankshaft Position Senso...

Страница 55: ...tegate Regulator 13 Inlet Pressure Sensor for the NOx Reduction System NRS 14 Control Valve for the NRS 15 Temperature Sensor for the NRS 16 Differential Pressure Sensor for the NRS SEBU9063 07 55 Ope...

Страница 56: ...19 Starting Motor 20 Starter Relay 21 Low Oil Level Switch if Equipped 22 Inlet Air Temperature Sensor 23 Water in Fuel Switch 24 Secondary Speed Timing Sensor Camshaft Position Sensor 25 Back Pressu...

Страница 57: ...nsor 5 Electronic Control Module ECM Illustration 43 g03420558 Typical example 6 Atmospheric Pressure Sensor Barometric Pressure Sensor 7 Priming Transfer pump 8 Primary Speed Timing sensor Crankshaft...

Страница 58: ...14 Control Valve for the NRS 15 Temperature Sensor for the NRS 16 Differential Pressure Sensor for the NRS Illustration 45 g03421147 Typical example 17 Alternator 18 Starter Solenoid 19 Starting Moto...

Страница 59: ...25 Back Pressure Valve Aftertreatment Views DOC Diesel Oxidation Catalyst SCR Selective Catalytic Reduction DPF Diesel Particulate Filter DEF Diesel Exhaust Fluid Two different types of aftertreatment...

Страница 60: ...nd SCR Illustration 47 g03421173 Typical example 1 SCR Temperature Sensor 2 Identification Module 3 DEF Injector 4 DOC Temperature Sensor 60 SEBU9063 07 Operation Section Sensors and Electrical Compon...

Страница 61: ...le 1 SCR Temperature Sensor 2 Soot Sensor Connection 3 DPF Temperature Sensor 4 DOC Temperature Sensor 5 Identification Module 6 Soot Sensor Connection 7 DEF Injector 8 NOx Sensor location SEBU9063 07...

Страница 62: ...Sensors and Aftertreatment Components Illustration 49 g03659936 Typical example 1 DEF Pump and electronic unit 2 Coolant Diverter Valve 3 DEF Tank level and Temperature Sensor 4 NOx Sensors 5 Ammonia...

Страница 63: ...The sequence of flashes represents the system diagnostic message Count the first sequence of flashes in order to determine the first digit of the flash code After a two second pause the second sequenc...

Страница 64: ...e etc This information can be useful to help troubleshoot the situation The information can also be used for future reference For more information on diagnostic codes refer to the Troubleshooting Guid...

Страница 65: ...Action Customer Specified Parameters Customer specified parameters allow the engine to be configured to the exact needs of the application The electronic service tool is required in order to alter the...

Страница 66: ...eed Decelerating Ramp Rate Intermediate Engine Speed Fan Engine Fan Control Engine Fan Type Configuration Engine Cooling Fan Temperature Error Increasing Hysteresis Engine Cooling Fan Temperature Erro...

Страница 67: ...e Engine Cooling Fan Minimum Air Flow Hydraulic Oil Temperature Engine Cooling Fan Control Auxiliary 1 Temperature Input Enable Status Engine Cooling Fan Maximum Air Flow Auxiliary 1 Temperature Engin...

Страница 68: ...g Rated Speed Configuration Droop No Load Fuel Offset PM1 Interval Engine Oil Level Sensor Installation Status Engine Change Air cooler 1 Outlet temperature Sensor Installation Status 68 SEBU9063 07 O...

Страница 69: ...electrical loads or remove any electrical loads i07677844 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 a...

Страница 70: ...t stage Note 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 illuminate...

Страница 71: ...ive 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 block or to the chassis ground This procedu...

Страница 72: ...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...

Страница 73: ...regeneration event to consider On DPF equipped aftertreatment system the DPF will reduce particulate emissions The DPF collects the soot and any ash that is produced by the combustion in the engine Du...

Страница 74: ...res to attain optimum performance for the life of the engine Avoid spilling fuel Fuel expands when it is warmed up The fuel may overflow from the fuel tank Inspect fuel lines for leaks Repair the fuel...

Страница 75: ...at 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 an...

Страница 76: ...ication of a light load parasitic load will assist in achieving the minimum operating temperature The minimum operating temperature is 80 C 176 F Recommendations for Coolant Warm Up Warm up an engine...

Страница 77: ...atures below 25 C 13 F measures must be taken to prevent freezing and plugging of the breather system Insulated hoses and a heated canister assembly should be installed Consult with your Perkins deale...

Страница 78: ...nks Top off the fuel tanks after you operate the engine Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks Some fuel tanks use supply pipes that allo...

Страница 79: ...zes the DEF tank vent could block A blocked vent in the DEF tank assembly will cause operational difficulties For information on DEF refer to this Operation and Maintenance Manual Fluid Recommendation...

Страница 80: ...High pressure fuel spray may cause a fire hazard Failure to follow these inspection maintenance and service in structions may cause personal injury or death Diesel Exhaust Fluid DEF purge do not disc...

Страница 81: ...ly in order to relieve the pressure Allow the engine to cool Check the coolant level Check the coolant for correct antifreeze protection and the correct corrosion protection Add the correct coolant wa...

Страница 82: ...iliary oil filters will require additional oil Refer to the OEM specifications for the capacity of the auxiliary oil filter The design of the oil pan can change the oil capacity of the oil pan 2 Appro...

Страница 83: ...ment you agree that Perkins Engines Company Limited is not respon sible for errors or omissions NOTICE These recommendations are subject to change with out notice Contact your local Perkins distributo...

Страница 84: ...imum 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...

Страница 85: ...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 EPA an...

Страница 86: ...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...

Страница 87: ...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...

Страница 88: ...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...

Страница 89: ...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...

Страница 90: ...level or cleaner in particular for engines with common rail and unit injection systems When you refuel the tank filter the fuel through a 4 m absolute filter Beta 4 75 up to 200 to reach the recommend...

Страница 91: ...dry or operate at a low level can affect the engine operation Because of the corrosive nature of DEF the correct materials must be used when filling a DEF tank DEF Quality The quality of DEF can be me...

Страница 92: ...coolant at the proper operating temperature Cooling system prob lems can develop without water temperature regulators Many engine failures are related to the cooling system The following problems are...

Страница 93: ...ceed 50 percent glycol because of the reduced heat transfer capability of propylene glycol Use ethyl ene glycol in conditions that require additional protec tion against boiling or freezing Table 21 P...

Страница 94: ...C contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite Perkins ELC has been formulated with the correct amount of these additives to provide superior corrosion protect...

Страница 95: ...e Perkins Premixed ELC Operate the engine Ensure that all coolant valves open then stop the engine When cool check the coolant level ELC Cooling System Contamination NOTICE Mixing ELC with other produ...

Страница 96: ...in Table 25 to determine the amount of SCA that is required if necessary Table 25 Equation For Adding The SCA To The Heavy Duty Coolant For Maintenance V 0 023 X V is the total volume of the cooling...

Страница 97: ...topic Maintenance Section Engine Oil Commercial Oils Perkins recommends use of Perkins Diesel Engine Oil for all Perkins engines Perkins unique oil formulations have been developed to provide full pe...

Страница 98: ...re to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated Generally use the highest oil viscosity that is available to meet the requirement for the tem...

Страница 99: ...e following tests The Wear Rate Analysis monitors the wear of the engines metals The amount of wear metal and type of wear metal that is in the oil is analyzed The increase in the rate of engine wear...

Страница 100: ...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...

Страница 101: ...2 Welding electrode 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 b...

Страница 102: ...dures 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 in...

Страница 103: ...or 1 Year Fuel System Primary Filter Water Separator Element Replace 126 Fuel System Secondary Filter Replace 128 Radiator Clean 131 Every 1000 Service Hours Belt Inspect 106 Belt Tensioner Check 106...

Страница 104: ...rackets 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 conne...

Страница 105: ...g If batteries are correctly charged 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 Alw...

Страница 106: ...g grease displacement of the cord and evidence of 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...

Страница 107: ...nance interval if the following conditions exist The engine overheats frequently Foaming is observed The oil has entered the cooling system and the coolant is contaminated The fuel has entered the coo...

Страница 108: ...3 Fill the cooling system with clean water and install the cooling system filler cap 4 Start and run the engine at low idle for a minimum of 30 minutes The coolant temperature should be at least 82 C...

Страница 109: ...conditions exist The engine overheats frequently Foaming is observed The oil has entered the cooling system and the coolant is contaminated The fuel has entered the cooling system and the coolant is...

Страница 110: ...ation on cooling system specifications Do not install the cooling system filler cap 2 Start and run the engine at low idle Increase the engine rpm to high idle Operate the engine in order to open the...

Страница 111: ...Fluid DEF tank requires coolant flow around the tank The Coolant Diverter Valve CDV will turn the flow on or off If the coolant system has been filled with the CDV in the closed position coolant leve...

Страница 112: ...surfaces should be wiped clean and rinsed with water DEF that has been split will crystallize when the water within the liquid evaporates Split DEF will attack paint and metal If DEF is split wash th...

Страница 113: ...e At key on the DEF level gauge will show the last known DEF level and will transition to the new DEF level value 6 Install the DEF cap Check visually the DEF tank for leakage i07395225 Diesel Exhaust...

Страница 114: ...ion The key switch must be OFF to allow the DEF pump to purge ensuring the system is free of pressurized distilled water Note In certain circumstances allow for a maximum of 15 minutes after turning t...

Страница 115: ...t system damage could occur i08154921 Engine Air Cleaner Element Replace NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do...

Страница 116: ...install new primary air filter element 3 6 Install end cover 4 to air cleaner body 2 and secure end cover If necessary reset the air service indicator refer to this Operation and Maintenance Manual En...

Страница 117: ...o not tap or strike the air cleaner element i05926015 Engine Crankcase Breather Element Replace Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact t...

Страница 118: ...69 g01884135 B Alignment position Note The cut away from section 5 in the cap allows access to the seal 4 Remove the old seal 4 and install a new seal 5 Install a new filter element into the breather...

Страница 119: ...terioration should be replaced Refer to the OEM information for the recommended torques When the engine mounts are supplied by Perkins the maintenance procedure will be supplied in the Disassembly and...

Страница 120: ...e last oil change Ensure that the container for the sample is clean and dry Also ensure that the container for the sample is clearly labelled To ensure that the sample is representative of the oil in...

Страница 121: ...owing methods to drain the engine oil pan Illustration 73 g02131361 Typical example If the engine is equipped with a drain valve 2 turn the drain valve knob counterclockwise to drain the oil After the...

Страница 122: ...new oil filter 4 6 Install the new oil filter Spin on the oil filter 4 until the O ring contacts the sealing surface 2 Then rotate the oil filter of a full turn Remove the container and disposal of th...

Страница 123: ...th the radiator empty Illustration 77 g03609316 Typical example A is the fan tip clearance 1 Set the fan tip clearance at position 1 to 16 mm 0 63 inch 2 Set the fan tip clearance at position 4 to 12...

Страница 124: ...fan tip clearance should be 14 2 mm 0 55 0 079 inch 7 Fan tip clearance at position 2 and 3 must be 14 2 mm 0 55 0 079 inch In Service Information Ensure that the engine is stopped Ensure that the coo...

Страница 125: ...l the hose clips 3 Turn the fuel supply valve if equipped to the ON position 5 The in line fuel filter must be changed with the primary filter and the secondary fuel filter The fuel system will need t...

Страница 126: ...ill not Start i06217529 Fuel System Primary Filter Water Separator Element Replace Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire To help prevent possible injury t...

Страница 127: ...ads 9 Spin on the filter element and tighten the drain valve 2 securely 2 Lubricate the O ring seal 7 with clean engine oil Do NOT fill the bowl with fuel before the assembly is installed 3 Do not use...

Страница 128: ...ht spill Clean up any spilled fluid 2 Ensure that the outer body of the filter assembly is clean and free from dirt Illustration 83 g03858194 Typical example 3 Install a suitable tube onto drain 3 Ope...

Страница 129: ...ve counterclockwise Two full turns are required Loosen vent screw 1 4 Allow the fuel to drain into the container and remove the tube 5 Tighten the vent screw 1 to a torque of 2 5 N m 22 lb in 6 Remove...

Страница 130: ...of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Check the fuel daily Allow five minutes after the fuel tank ha...

Страница 131: ...s for the coolant system Pressurized System Hot coolant can 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...

Страница 132: ...idle rpm This procedure will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core to inspect the core for cleanliness Repeat the cleaning if necessary...

Страница 133: ...nded engine operation at low idle The presence of oil may also be the result of a restriction of the line for the intake air clogged air filters which causes the turbocharger to slobber 5 Install the...

Страница 134: ...turbocharger to slobber 6 Inspect the bore of the housing of the turbine outlet for corrosion 7 Install the air intake pipe and the exhaust outlet pipe to the turbocharger housing Ensure that all clam...

Страница 135: ...arry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break High Pressure Fuel Lines Contact with high pressure...

Страница 136: ...tions Cracks in the cylinder head A piston seizure Other potential damage to the engine Illustration 91 g01904773 A Weep hole B Vent hole Note The water pump seals are lubricated by the coolant in the...

Страница 137: ...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...

Страница 138: ...ting cost Records should be kept for the following items Fuel Consumption A record of fuel consumption is essential in order to determine when the load sensitive components should be inspected or repa...

Страница 139: ...ntenance Log Table 28 Engine Model Customer Identifier Serial Number Arrangement Number Service Hours Quantity Of Fuel Service Item Date Authorization SEBU9063 07 139 Reference Information Section Mai...

Страница 140: ...ained 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 extended t...

Страница 141: ...ush 110 Coolant Extender ELC Add 110 Coolant Level Check 110 Crushing Prevention and Cutting Prevention 17 D DEF Filler Screen Clean 111 DEF Manifold Filters Replace 112 Diagnostic Flash Code Retrieva...

Страница 142: ...77 Fuel Conservation Practices 74 Fuel Filter In Line Replace 125 Fuel Related Components in Cold Weather 78 Fuel Filters 78 Fuel Heaters 78 Fuel Tanks 78 Fuel System Prime 125 Fuel System Primary Fil...

Страница 143: ...entification Information 32 Product Information Section 22 Product Lifting 37 Engine and Aftertreatment Lifting Eyes 38 Engine Only Lifting Eyes 38 Engines with Factory Installed Radiators 39 Product...

Страница 144: ...Pressure and Low Pressure Turbochargers 133 Inspecting 133 Single Turbocharger 133 W Walk Around Inspection 134 Engine Aftertreatment 136 High Pressure Fuel Lines 135 Inspect the Engine for Leaks and...

Страница 145: ...aintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Inf...

Страница 146: ...SEBU9063 2020 Perkins Engines Company Limited All Rights Reserved 146 December 2020...

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