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i06769711

Maintenance

Interval

Schedule

When

Required

“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . . 64

“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 65

“ Battery or Battery Cable - Disconnect” . . . . . . . . . 66

“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

“ Engine Air Cleaner Element (Dual Element) -
Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . . 74

“ Engine Air Cleaner Element (Single Element) -
Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . . 76

“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . . 83

“ Fuel Tank Water and Sediment - Drain” . . . . . . . . 91

“ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Daily

“ Air Tank Moisture and Sediment - Drain” . . . . . . . 64

“ Coolant Level - Check” . . . . . . . . . . . . . . . . . . . . . 71

“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . . 73

“ Engine Air Cleaner Service Indicator - Inspect” . . 77

“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 78

“ Fuel System Primary Filter/Water Separator -
Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

“ Power Take-Off Clutch - Check” . . . . . . . . . . . . . . 93

“Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . . 94

Every 500 Service Hours

“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . . 66

“ Engine Air Cleaner Element (Dual Element) -
Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . . 74

“ Engine Air Cleaner Element (Single Element) -
Inspect/Clean/Replace” . . . . . . . . . . . . . . . . . . . . . . 76

“ Engine Crankcase Breather - Clean” . . . . . . . . . . 77

“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 79

“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . . 79

Every 500 Service Hours or 1 Year

“ Battery Electrolyte Level - Check” . . . . . . . . . . . . 65

“ Cooling System Supplemental Coolant Additive
(SCA) - Test/Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

“ Fuel System Primary Filter (Water Separator)
Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 84

“ Fuel System Secondary Filter - Replace”. . . . . . . 88

“Grounding Stud - Inspect/Clean/Tighten” . . . . . . . 91

“ Hoses and Clamps - Inspect/Replace”. . . . . . . . . 92

“ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . . 94

“ Water Pump - Inspect”. . . . . . . . . . . . . . . . . . . . . . 95

Every 2500 Service Hours

“ Coolant Temperature Regulator - Replace” . . . . . 71

“ Electronic Unit Injector - Check/Replace” . . . . . . 73

“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 78

“ Engine Protective Devices - Check” . . . . . . . . . . . 82

“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . . 82

“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . . 82

Every 3000 Service Hours or 2
Years

“ Coolant (DEAC) - Change” . . . . . . . . . . . . . . . . . . 68

Every 4000 Service Hours

“ Air Compressor - Check”. . . . . . . . . . . . . . . . . . . . 64

Every 6000 Service Hours or 3
Years

“ Coolant Extender (ELC) - Add” . . . . . . . . . . . . . . . 71

Every 760 000 L (200 770 US gal) of
Fuel or 10 000 Service Hours

“ Fan Drive Bearing - Replace” . . . . . . . . . . . . . . . . 83

“ Overhaul Considerations” . . . . . . . . . . . . . . . . . . . 93

Every 12 000 Service Hours or 6
Years

“ Coolant (ELC) - Change”. . . . . . . . . . . . . . . . . . . . 69

SEBU9074-01

Maintenance Section

Maintenance Interval Schedule

Содержание 2806C-E18TA

Страница 1: ...Operation and Maintenance Manual 2806C E18TA and 2806D E18TA Industrial Engine JG1 Engine SEBU9074 01 en us January 2017...

Страница 2: ...ing explains the hazard and can be either written or pictorially presented Operations that may cause product damage are identified by NOTICE labels on the product and in this publication Perkins canno...

Страница 3: ...ronics 15 Product Information Section General Information 16 Product Identification Information 22 Operation Section Lifting and Storage 24 Features and Controls 28 Engine Diagnostics 34 Engine Starti...

Страница 4: ...d to detailed instructions that follow Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule The actual operating environment of the en...

Страница 5: ...water and soap to clean the safety messages Do not use solvents gasoline or other harsh chemicals Solvents gasoline or harsh chemicals could loosen the adhesive that secures the safety messages The s...

Страница 6: ...2806D E18TA Safety Label Positions Illustration 2 g03856817 Illustration 3 g03857446 6 SEBU9074 01 Safety Section Safety Messages...

Страница 7: ...ctive glasses and other protective equipment as required When work is performed around an engine that is operating wear protective devices for ears in order to help prevent damage to hearing Do not we...

Страница 8: ...he cover plate or the device Before removing the last two bolts or nuts pry the cover loose in order to relieve any spring pressure or other pressure Illustration 6 g00702020 Wear a hard hat protectiv...

Страница 9: ...ing Fluid Spillage Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the product Be prepared to collect the fluid with...

Страница 10: ...ands lining material clutch plates and some gaskets The asbestos that is used in these components is usually bound in a resin or sealed in some way Normal handling is not hazardous unless airborne dus...

Страница 11: ...battery is an electrolyte Electrolyte is an acid that can cause personal injury Do not allow electrolyte to contact the skin or the eyes Do not smoke while checking the battery electrolyte levels Bat...

Страница 12: ...The filter housings must be tightened to the correct torque Refer to the Disassembly and Assembly manual for more information Illustration 11 g00704059 Use caution when you are refueling an engine Do...

Страница 13: ...ver attempt adjustments while the engine is running Stay clear of all rotating parts and of all moving parts Leave the guards in place until maintenance is performed After the maintenance is performed...

Страница 14: ...e engine in a ventilated area If the engine is started in an enclosed area vent the engine exhaust to the outside Note The engine may be equipped with a device for cold starting If the engine will be...

Страница 15: ...d or engine damage This engine has a comprehensive programmable Engine Monitoring System The Electronic Control Module ECM will monitor the engine operating conditions If any of the engine parameters...

Страница 16: ...pear different from the illustrations 2806C Illustration 13 g06095280 Typical example 1 Front lifting eye 2 Breather outlet hose 3 Rear lifting eye 4 Air cleaner 5 Electronic control module 6 Starting...

Страница 17: ...13 Alternator 14 Alternator belt 15 Fan belts 16 Damper 17 Coolant outlet 18 Oil drain plug 19 Oil gauge Dipstick 20 Oil filter 21 Oil cooler 22 Engine block heater 23 Oil filler 24 Turbochargers SEBU...

Страница 18: ...ver 5 Turbochargers 6 Engine rear lifting eye 7 Air filter 8 Electronic Control Module ECM 9 Oil drain plug 10 Breather fume outlet hose 11 Secondary fuel filter and priming pump 12 Primary fuel filte...

Страница 19: ...6D E18TAindustrial engines have the following characteristics Four stroke cycle Mechanically actuated electronically controlled fuel injection system Turbocharged Air to air charged cooled Engine Spec...

Страница 20: ...nd the pumping are done under high pressure High injection pressures help to reduce fuel consumption and emissions The use of this type of unit injector provides total electronic control of injection...

Страница 21: ...l consumption of the engine over a time Reduced hours of operation at full throttle and or operating at reduced throttle settings result in a lower average power demand Reduced hours of operation will...

Страница 22: ...injectors Illustration 19 g03857570 2 Serial number plate for the 2806D engine The engine serial number plate for the 2806D is on the right side of the engine block next to the front oil filter Illus...

Страница 23: ...bel is located on the engine oil cooler i06216646 Reference Information Information for the following items may be needed to order parts Locate the information for your engine Record the information i...

Страница 24: ...thin product lifting before any lifting is attempted Ensure that the correct set of lifting eyes for the assembly to be lifted have been selected Use a hoist to remove heavy components Use an adjustab...

Страница 25: ...o the inlet by removing the plug on the air inlet elbow on the left side of the engine The minimum application rate for the VCI oil mixture is 5 5 mL per L 3 oz per 1000 cu in of engine displacement 7...

Страница 26: ...cover is secure The cover should be loose enough to allow air to circulate around the engine in order to prevent damage from condensation 15 Attach a tag with the storage date to the engine 16 Remove...

Страница 27: ...ition of all rubber hoses Replace any worn hoses Replace any damaged hoses 10 Before start up test the cooling system for a 3 percent to a 6 percent concentration of coolant conditioner Add liquid coo...

Страница 28: ...Warning alarm will be set to a factory default in production The electronic service tool may be used to alter the trip point for a Warning within predefined limits Action Alert The Action Alert inform...

Страница 29: ...odule can be powered down by isolating the power supply to the electronic control module Note The ECM cannot be reset by using the Reset input until the engine has stopped Diagnostic If there is a fau...

Страница 30: ...Intake manifold pressure sensor 3 Fuel temperature sensor 4 Intake manifold temperature sensor 5 Electronic Control Module ECM 6 Oil pressure sensor 7 Atmospheric pressure sensor 8 Crankshaft speed t...

Страница 31: ...Illustration 26 g06095652 9 Sender for cylinder block heater 10 Coolant temperature sensor 11 Cylinder block heater if equipped SEBU9074 01 31 Operation Section Sensors and Electrical Components...

Страница 32: ...manifold pressure sensor 3 Intake manifold temperature sensor 4 Fuel temperature sensor 5 Electronic Control Module ECM 6 Oil pressure sensor 7 Atmospheric pressure sensor 8 Crankshaft speed timing se...

Страница 33: ...Illustration 28 g03858148 9 Coolant temperature sensor SEBU9074 01 33 Operation Section Sensors and Electrical Components...

Страница 34: ...n active diagnostic code the code will be logged in the memory of the ECM The codes that have been logged by the ECM can be identified by the electronic service tool The active codes that have been lo...

Страница 35: ...pped The operator should retrieve the logged fault codes and reference the appropriate information in order to identify the nature of the event The operator should log any observation that could have...

Страница 36: ...ent the exhaust to the outside If there is a DO NOT OPERATE warning tag or similar attached to the start switch or the controls do not start the engine or move any controls Ensure that the areas aroun...

Страница 37: ...flywheel is turning Do not start the engine under load If the engine fails to start within 30 seconds release the starter switch or button and wait two minutes to allow the starting motor to cool bef...

Страница 38: ...of battery cables from a battery may cause an explosion which may result in in jury or death The connection and the disconnec tion of other electrical equipment may also cause an explosion which may...

Страница 39: ...al Starting the Engine 5 Immediately after the engine is started disconnect the jump start cables in reverse order After jump starting the alternator may not be able to recharge batteries to full capa...

Страница 40: ...gauges and check the equipment for proper operation Check the gauges and check the equipment frequently while the engine is operating under load i06217701 Fuel Conservation Practices The efficiency o...

Страница 41: ...system when possible Keep cooling system components clean and keep cooling system components in good repair Never operate the engine without a water temperature regulator All of these items will help...

Страница 42: ...e temperature at which waxes naturally found in the diesel fuel begin to form crystals The cloud point of the fuel must be below lowest ambient temperature to prevent filters from plugging Cold Filter...

Страница 43: ...er should also help to prevent overheating of the fuel High fuel temperatures reduce engine performance and the availability of engine power Choose a fuel heater with a large heating surface The fuel...

Страница 44: ...tood Use the following general guidelines in order to stop the engine 1 Remove the load from the engine so that the engine has no more than 30 power 2 Run the engine for at least 3 minutes 3 After the...

Страница 45: ...cooling system the total cooling system capacity must be known The capacity of the total cooling system will vary The capacity will depend on the size of the radiator capacity Table 3 should be comple...

Страница 46: ...quired oil viscosity for starting a cold engine Refer to illustration 32 maximum temperature in order to select the oil viscosity for engine operation at the highest ambient temperature that is antici...

Страница 47: ...tion NOTICE Never add coolant to an overheated engine Engine damage could result Allow the engine to cool first NOTICE If the engine is to be stored in or shipped to an area with below freezing temper...

Страница 48: ...rkins recommends a 1 1 mixture of a water glycol solution Note Use a mixture that will provide protection against the lowest ambient temperature Note 100 percent pure glycol will freeze at a temperatu...

Страница 49: ...s in order 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 1 mixture The Premixed ELC...

Страница 50: ...ther 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 follow these recommenda tions can resul...

Страница 51: ...necessary Table 11 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 amount of SCA that is required Table 12 is an ex...

Страница 52: ...stated in table 13 NOTICE The footnotes are a key part of the Perkins Specifica tion for Distillate Diesel Fuel Table Read ALL of the footnotes Table 13 Perkins Specification for Distillate Diesel Fue...

Страница 53: ...ents at 40 C 104 F of either the ASTM D445 test method or the ISO 3104 test method If a fuel with a low viscosity is used cooling of the fuel may be required to maintain 1 4 cSt or greater viscosity a...

Страница 54: ...ter fuels are acceptable but these fuels will not produce the rated power Sulfur The level of sulfur is governed by emissions legislations Regional regulation national regulations or international reg...

Страница 55: ...e when used with ap propriate lubricity additive and must meet minimum requirements that are listed in table 13 The lubricity of these fuels must not exceed wear scar diameter of 0 46 mm 0 01811 inch...

Страница 56: ...es This cleaning of the fuel system can prematurely block of the fuel filters Perkins recommends that after the initial usage of B20 biodiesel blended fuel the fuel filters must be replaced at 50 hour...

Страница 57: ...ecommends that seasonally operated engines have the fuel systems including fuel tanks flashed with conventional diesel fuel before prolonged shutdown periods An example of an application that should s...

Страница 58: ...basis with no adverse impact on engine or fuel system durability Detailed instructions on the rate of which the fuel cleaner must be use are on the container Perkins Diesel Fuel Conditioner Perkins D...

Страница 59: ...commended cleanliness level Install desiccant type breathers of 4 m or less absolute efficiency with the ability to remove water on bulk storage tanks Follow proper practices of fuel transportation Fi...

Страница 60: ...pressure from the lubricating system turn off the engine i06221218 Welding on Engines with Electronic Controls NOTICE Because the strength of the frame may decrease some manufacturers do not recommen...

Страница 61: ...are located between the welder ground and the weld current flow from the welder could severely damage the component 6 Protect the wiring harness from welding debris and spatter 7 Use standard welding...

Страница 62: ...uipment is cleaned regularly Mud dirt and dust can encase components Maintenance can be very difficult The buildup can contain corrosive chemicals Buildup Compounds elements corrosive chemicals and sa...

Страница 63: ...ngine Oil Sample Obtain 79 Engine Oil and Filter Change 79 Every 500 Service Hours or 1 Year Battery Electrolyte Level Check 65 Cooling System Supplemental Coolant Additive SCA Test Add 72 Fuel System...

Страница 64: ...air compressor exhausts all personnel should be at a safe distance away from the air compressor All personnel should also stay clear of the air compressor when the engine is operating and the air comp...

Страница 65: ...used battery 6 Install the new battery Note Before the cables are connected ensure that the engine start switch is OFF 7 Connect the cable from the starting motor to the POSITIVE battery terminal 8 C...

Страница 66: ...ceed with necessary system repairs 8 In order to connect the battery connect the positive connection before the negative connector i06757654 Belts Inspect Adjust Replace Inspection To maximize the eng...

Страница 67: ...m 34 lb ft Tighten nut and bolt 3 to a torque of 70 N m 51 lb ft Alternator Belt Adjustment 2806D Illustration 36 g06109400 2806D engine view 1 Remove the belt guard refer to OEM for the correct proc...

Страница 68: ...system and flush the cooling system before the recommended maintenance interval if the following conditions exist The engine overheats frequently Foaming is observed The oil has entered the cooling sy...

Страница 69: ...ant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level within 13 mm 0 5 inch to the proper level on the sight glass 4 Clean the...

Страница 70: ...e water to drain Flush the cooling system with clean water Close the drain valve Fill NOTICE Fill the cooling system no faster than 19 L 5 US gal per minute to avoid air locks 1 Fill the cooling syste...

Страница 71: ...the cooling system filler cap and check the condition of the filler cap gaskets Replace the cooling system filler cap if the filler cap gaskets are damaged Reinstall the cooling system filler cap 4 In...

Страница 72: ...e a Coolant Conditioner Test Kit in order to check the concentration of the SCA Add the SCA If Necessary NOTICE Do not exceed the recommended amount of supple mental coolant additive concentration Exc...

Страница 73: ...with an electronic unit injector which is improperly adjusted may reduce engine efficiency This reduced efficiency may result in excessive fuel usage and or shortened engine component life Note Only...

Страница 74: ...irt and debris as needed Operating in dirty conditions may require more frequent service of the air cleaner element The air cleaner element should be replaced at least one time per year This replaceme...

Страница 75: ...the outer cover Discard any damaged air cleaner element Two methods may be used in order to clean the primary air cleaner element pressurized air Vacuum cleaning Pressurized Air Personal injury can re...

Страница 76: ...and Maintenance Manual Engine Air Precleaner Check Clean procedure if equipped before performing the following procedure NOTICE Never run the engine without an air cleaner element installed Never run...

Страница 77: ...movement of the service indicator core when the engine is run at full load speed The core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset ea...

Страница 78: ...gine Mounts Inspect Note The engine mounts may not have been supplied by Perkins Refer to the OEM information for further information on the engine mounts and the correct bolt torque Inspect the engin...

Страница 79: ...nclude an oil sampling valve as an option The oil sampling valve if equipped is included in order to regularly sample the engine lubricating oil The oil sampling valve is positioned on the oil filter...

Страница 80: ...s equipped with a drain valve turn the drain valve knob counterclockwise to drain the oil After the oil has drained turn the drain valve knob clockwise to close the drain valve If the engine is not eq...

Страница 81: ...nd could be contaminated Contaminated oil can cause accelerated wear to en gine components 4 Install the new oil filters 3 Spin on the oil filter until the O rings contacts the sealing surfaces 2 Then...

Страница 82: ...order to help provide maximum engine life NOTICE Only qualified service personel should perform this maintenance Refer to the Service Manual or your au thorized Perkins dealer or your Perkins distribu...

Страница 83: ...759816 Fuel System Prime Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire To help prevent possible injury turn the start switch off when changing fuel filters or wat...

Страница 84: ...riming pump handle several times until strong pressure is felt 5 When strong pressure can be felt press in the fuel priming pump handle 1 and lock the handle into the fuel pump body 2 To lock the hand...

Страница 85: ...econdary fuel filter The element should be changed regularly If a vacuum gauge is installed the primary filter water separator should be changed at 50 to 70 kPa 15 to 20 inches Hg Illustration 55 g061...

Страница 86: ...onto the fuel filter base 1 and tighten to a torque of 80 N m 59 lb ft Inspect the O ring seal Not Shown on drain plug 3 for wear or damage replace if necessary Install drain plug 3 into filter housi...

Страница 87: ...ry Filter Replace 10 Dispose of the fluid and old filter in accordance with local regulations i06761567 Fuel System Primary Filter Water Separator Drain Fuel leaked or spilled onto hot surfaces or ele...

Страница 88: ...spilled onto hot surfaces or electri cal components can cause a fire To help prevent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spil...

Страница 89: ...alve 3 3 Remove filter housing assembly 2 from filter base 1 Illustration 65 g06110975 Typical example 4 Remove filter element 4 from filter housing 2 and discard the old filter element Remove O ring...

Страница 90: ...fore the fuel filter is removed After the engine has stopped wait for 1 to 5 minutes until the fuel pressure has lowered Use a suitable container to collect any fuel that may spill 2 Turn the fuel sup...

Страница 91: ...iment from the fuel tank Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel...

Страница 92: ...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 leaking Outer covering that is chafe...

Страница 93: ...d 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 Consideration...

Страница 94: ...2 Starting Motor 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 pro...

Страница 95: ...and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Inspect the ECM to the cylinder head ground strap for a good connection and for good condition...

Страница 96: ...New non road diesel engines including Tier 1 and Tier 2 marine propulsion engines 37 kW and Tier 1 through Tier 4 marine auxiliary engines 37 kW but excluding locomotive and other marine engines opera...

Страница 97: ...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 98: ...intenance Log Table 15 Engine Model Customer Identifier Serial Number Arrangement Number Service Hours Quantity Of Fuel Service Item Date Authorization 98 SEBU9074 01 Reference Information Section Mai...

Страница 99: ...vel of protection for your Perkins Engine Coverage can be extended to 2 years 1 000 hours right up to 10 year 40 000 You can buy an ESC at any time during standard warranty even the last day Each Perk...

Страница 100: ...iagnostic Lamp 34 Driven Equipment Check 73 E Electrical System 14 Grounding Practices 15 Electronic Unit Injector Check Replace 73 Emissions Certification Film 23 Emissions Warranty Information 96 En...

Страница 101: ...806D Water Separator Drain 88 Fuel System Secondary Filter Replace 88 2806C Secondary Fuel Filter 89 2806D Secondary Fuel Filter 90 Fuel Tank Water and Sediment Drain 91 Drain the Water and the Sedime...

Страница 102: ...45 Coolant Refill Capacity 45 Lubricant Refill Capacity 45 S Safety Messages 5 2806C E18TA Safety Label Positions 5 2806D E18TA Safety Label Positions 6 Universal Warning 1 7 Safety Section 5 Self Di...

Страница 103: ...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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