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Illustration 25

g06049705

Typical example of the close up views of sensor locations on the left side of the engine

(1) Camshaft speed/timing sensor
(2) Boost pressure sensor
(3) Inlet air temperature sensor
(4) NRS inlet temperature sensor

(5) NOx Reduction System (NRS)

differential pressure sensor

(6) NRS inlet pressure sensor
(7) Engine Electronic Control Module (ECM)
(8) Engine oil pressure sensor

(9) Atmospheric pressure sensor
(10) Fuel pressure sensor
(11) Fuel temperature sensor
(12) Crankshaft speed/timing sensor

M0109073

33

Operation Section

Sensors and Electrical Components

Содержание 2806J-E18TTA

Страница 1: ...Operation and Maintenance Manual 2806J E18TTA Industrial Engine PP8 Engine M0109073 en us July 2019...

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: ...m 16 Engine Electronics 16 Product Information Section Model Views 18 Product Identification Information 23 Operation Section Lifting and Storage 24 Features and Controls 28 Engine Diagnostics 35 Engi...

Страница 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...

Страница 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...

Страница 6: ...icals could loosen the adhesive that secures the safety messages The safety messages that are loosened could drop off the engine Replace any safety message that is damaged or missing If a safety messa...

Страница 7: ...terial safety data sheet MSDS for sulfuric acid Always follow the directions for first aid that are noted on a material safety data sheet MSDS for sulfuric acid i07833369 Additional Messages There are...

Страница 8: ...her 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 cleani...

Страница 9: ...tenance 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 controls or on...

Страница 10: ...id 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...

Страница 11: ...rake bands 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 airbor...

Страница 12: ...ts for detailed information Batteries The liquid in a 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 sm...

Страница 13: ...wiring that is unattached or unnecessary Do not use any wires or cables that are smaller than the recommended gauge Do not bypass any fuses and or circuit breakers Arcing or sparking could cause a fi...

Страница 14: ...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 dealer or your Perkins distributor for replacemen...

Страница 15: ...provided in order to help prevent personal injury The circuits are also provided in order to help prevent engine damage i07828827 Engine Starting Do not use aerosol types of starting aids such as eth...

Страница 16: ...ths Uncontrolled electrical circuit paths can result in damage to main bearings to crankshaft bearing journal surfaces and to aluminum components Engines that are installed without engine to frame gro...

Страница 17: ...r Perkins Engines will work in unison with the Engine Monitoring System Together the two controls will provide the engine monitoring function for the specific engine application Refer to the Troublesh...

Страница 18: ...Model Views 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 18 M0109073 Pr...

Страница 19: ...nkcase breathers 5 Exhaust gas valve NRS 6 Electronic Control Module ECM 7 Electric starting motor 8 Air intake elbow 9 Oil gauge Dipstick 10 Twin secondary fuel filters 11 Fuel transfer pump 12 Alter...

Страница 20: ...ocharger 20 Water temperature regulator housing 21 Precooler 22 Water pump 23 Oil cooler 24 Oil drain plug 25 Oil filters 26 Oil sample valve 27 Exhaust gas cooler NRS 28 Flywheel housing 29 Flywheel...

Страница 21: ...em The Clean Emissions Module CEM consists of Diesel Oxidation Catalyst DOC Engine Specifications Note The front end of the engine is opposite the flywheel end of the engine The left and the right sid...

Страница 22: ...c codes are logged and stored in the ECM For additional information refer to the Operation and Maintenance Manual Engine Diagnostictopic Operation Section Engine Service Life Engine efficiency and max...

Страница 23: ...top of the valve cover near the middle of the engine The engine information plate may contain the following information engine serial number engine model engine arrangement number maximum altitude of...

Страница 24: ...Use an adjustable lifting beam to lift the engine All supporting members chains and cables should be parallel to each other The chains and cables should be perpendicular to the top of the object that...

Страница 25: ...tions the engine can be equipped with delayed engine shutdown Allow at least 2 minutes after the engine has stopped before you turn the battery disconnect switch to OFF During the 2 minutes the engine...

Страница 26: ...covers to prevent evaporation of the vapors from the VCI oil 11 Apply a heavy amount of Multipurpose Grease to all outside parts that move such as rod threads ball joints linkage Note Install all cov...

Страница 27: ...ons for more information After the engine internal surfaces have been lubricated remove connector and install plug 1 Tighten plug to a torque of 30 N m 265 lb in Perkins recommends that the procedure...

Страница 28: ...e 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 info...

Страница 29: ...module 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 fa...

Страница 30: ...Note Some items have been removed from engine for clarity 30 M0109073 Operation Section Sensors and Electrical Components...

Страница 31: ...Engine Illustration 24 g06445644 Typical example 1 Camshaft speed timing sensor 2 Boost pressure sensor 3 Inlet air temperature sensor M0109073 31 Operation Section Sensors and Electrical Components...

Страница 32: ...sensor 6 NRS inlet pressure sensor 7 Engine Electronic Control Module ECM 8 Engine oil pressure sensor 9 Atmospheric pressure sensor 10 Fuel pressure sensor 11 Fuel temperature sensor 12 Crankshaft sp...

Страница 33: ...temperature sensor 4 NRS inlet temperature sensor 5 NOx Reduction System NRS differential pressure sensor 6 NRS inlet pressure sensor 7 Engine Electronic Control Module ECM 8 Engine oil pressure sens...

Страница 34: ...Primary Fuel Filter Illustration 28 g06450466 Typical example The fuel priming pump and primary fuel filter 1 provides filtered fuel to the engine and is electrically operated Diesel Oxidation Cataly...

Страница 35: ...When the Electronic Control Module ECM generates an 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 electro...

Страница 36: ...e Speed Decelerating Ramp Rate 2000rpm s Ether Start Aid Configuration Not Installed Crankcase Pressure Sensor Installation Status Not Installed Ambient Air Temperature Sensor Installation Status Not...

Страница 37: ...Percent Throttle Failure Mode Latch Enable Status Enabled Throttle 1 Engine Speed Droop 5 Percent Throttle 2 Engine Speed Droop 5 Percent Data Link Engine Speed Droop 5 Percent Droop No Load Fuel Offs...

Страница 38: ...Engine Cooling Fan Control Auxiliary 1 Temperature Input Enable Status Disabled Engine Cooling Fan Control Auxiliary 2 Temperature Input Enable Status Disabled Maintenance Indicator Mode Off PM1 Inte...

Страница 39: ...e engine in a well ventilated area and if in an enclosed area vent the exhaust to the outside Do not start the engine or move any of the controls if there is a DO NOT OPERATE warning tag or similar wa...

Страница 40: ...If oil pressure is not indicated on the gauge within 15 seconds DO NOT operate the engine STOP the engine investi gate and correct the cause 5 Allow the engine to idle for approximately 3 minutes Idl...

Страница 41: ...n and Maintenance Manual Fuel System Prime Maintenance Section for more information on priming the fuel system Ether Injection System If Equipped The ether injection system is controlled by the ECM Th...

Страница 42: ...he 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 sparks from igniting the combustible...

Страница 43: ...0 C 32 F for extended periods The purpose of the automatic speed change is threefold to maintain the desired operation of the NOx reduction system to maintain the desired operation of the regeneration...

Страница 44: ...ance of the emis sions control system The exhaust gases and hydrocarbon particles from the engine first pass through the Diesel Oxidation Catalyst DOC Some of the gases and hydrocarbon particles are o...

Страница 45: ...allowing the engine to idle for long periods of time Observe the service indicator frequently Keep the air cleaner elements clean Ensure that the turbocharger is operating correctly For more informat...

Страница 46: ...code will become active Note There may be regulations that define the requirements for the operator and or support personnel to be present when the engine is running Leaving the machine unattended wh...

Страница 47: ...ng Engine Note Before you check the engine oil do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan Check the crankcase oil level Maintain the oi...

Страница 48: ...nance Manual Fluid Recommendations for the recommended viscosity of oil Check all rubber parts hoses fan drive belts weekly Check all electrical wiring and connections for any fraying or damaged insul...

Страница 49: ...ngine operating temperatures When starting and stopping an engine many times without being operated to warm up completely the carbon deposits become thicker This starting and stopping can cause the fo...

Страница 50: ...d from the fuel storage tank and into the engine fuel tank Fuel Heaters Fuel heaters help to prevent fuel filters from plugging in cold weather due to waxing A fuel heater should be installed in order...

Страница 51: ...ion Fluid Recommendations Engine Oil topic Maintenance Section Engine Oil Commercial Oils Perkins recommends use of Perkins Diesel Engine Oil for all Perkins engines Perkins unique oil formulations ha...

Страница 52: ...ature 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...

Страница 53: ...elow freezing temperatures the cooling system must be either protected to the lowest outside tem perature or drained completely to prevent damage NOTICE Frequently check the specific gravity of the co...

Страница 54: ...col provide similar protection against freezing and boiling Refer to Table 6 and refer to table 7 Table 6 Ethylene Glycol Concentration Freeze Protection 50 Percent 36 C 33 F 60 Percent 51 C 60 F NOTI...

Страница 55: ...ins recommends a 6 percent to 8 percent concentration of SCA in those cooling systems Distilled water or deionized water is preferred Table 8 Coolant Service Life Coolant Type Service Life 1 Perkins E...

Страница 56: ...coolant into a suitable container 2 Dispose of the coolant according to local regulations 3 Fill the cooling system with a 33 percent solution of Perkins ELC and operate the engine ensure that the the...

Страница 57: ...he Heavy Duty Coolant At The Initial Fill Total Volume of the Cooling System V Multiplication Factor Amount of SCA that is Required X 15 L 4 US gal 0 07 1 05 L 35 5 oz Adding The SCA to The Heavy Duty...

Страница 58: ...iesel Particulate Filter v v volume of solute volume of solution CFPP Cold Filter Plugging Point BTL Biomass to liquid GTL Gas to liquid CTL Coal to liquid HVO Hydrotreated Vegetable Oil General Infor...

Страница 59: ...um of 80 reflec tance after aging for 180 mi nutes at 150 C 302 F D6468 No equivalent test Pour Point C 6 C 42 8 F minimum be low ambient temperature D97 ISO 3016 Sulfur 3 mass 0 0010 Stage V Europe a...

Страница 60: ...for fuel as dispensed into machine or engine fuel tank is ISO 18 16 13 or cleaner as per ISO 4406 Refer to the Contamination Control Recommendations for Fuels 8 Examples of trace metals include but no...

Страница 61: ...must have sufficient viscosity to lubricate the fuel system in both extremely cold temperatures and extremely hot temperatures If the kinematic viscosity of the fuel is lower than 1 4 cSt at the fuel...

Страница 62: ...oncentration in compression engines Without esterification these oils solidify in the crankcase and the fuel tank These fuels may not be compatible with many of the elastomers that are used in engines...

Страница 63: ...Cleaner and Perkins Biodiesel fuel contains metal contaminants sodium potassium calcium and or magnesium that form ash products upon combustion in the diesel engine The ash can have an impact on the...

Страница 64: ...hysical properties of the fuel The diesel fuel ASTM D975 1 D used in the United States of America may be used in very cold temperatures that are below 18 C 0 4 F Aftermarket Fuel Additives NOTICE Perk...

Страница 65: ...el tanks with fuels of ISO 18 16 13 cleanliness 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 f...

Страница 66: ...proximate capacities for the crankcase oil sump which include the standard oil filters that are installed at the factory Engines with auxiliary oil filters will require extra oil Refer to the OEM spec...

Страница 67: ...elieve pressure from the lubricating system turn off the engine i07677878 Welding on Engines with Electronic Controls NOTICE Because the strength of the frame may decrease some manufacturers do not re...

Страница 68: ...components are used as a ground for the welder or electrical electronic components are located between the welder ground and the weld current flow from the welder could severely damage the component 6...

Страница 69: ...uality of the air The engine may be exposed to extended operation in an environment that is dirty or dusty unless the equipment is cleaned regularly Mud dirt and dust can encase components Maintenance...

Страница 70: ...Coolant Additive SCA Test Add 76 Engine Oil and Filter Change 82 Hoses and Clamps Inspect Replace 89 Every 500 Service Hours or 3 Months Belts Inspect Adjust Replace 72 Every 500 Service Hours or 1 Y...

Страница 71: ...te Always recycle a battery Never discard a battery Return used batteries to an appropriate recycling facility 5 Remove the used battery 6 Install the new battery Note Before the cables are connected...

Страница 72: ...connection and battery terminals 5 Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively E...

Страница 73: ...oaming 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 contaminated Note Inspect the water pump and the wa...

Страница 74: ...gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old filler cap and install a new filler cap If the gasket that is on the c...

Страница 75: ...h 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 system with Extended Life...

Страница 76: ...ine is equipped with a sight glass maintain the coolant level to the proper level in the sight glass Illustration 43 g00103639 Typical filler cap gaskets 3 Clean the cooling system filler cap and chec...

Страница 77: ...in some coolant from the cooling system into a suitable container in order to allow space for the extra SCA 3 Add the correct amount of SCA Refer to the Operation and Maintenance Manual Refill Capacit...

Страница 78: ...t During the engine cleaning process ensure that water or cleaning fluids cannot enter the aftertreatment system If cleaning fluids enters the aftertreatment system damage could occur i07003542 Engine...

Страница 79: ...r element not shown from air cleaner body 1 Ensure that the inner body of the air cleaner is clean and free from dirt Ensure that the inner of the air cleaner cover 3 is clean and free from dirt 4 Ins...

Страница 80: ...dicator to a torque of 2 N m 18 lb in i07819538 Engine Mounts Inspect Note The engine mounts may not have been supplied by Perkins Refer to the Original Equipment Manufacturer OEM information for furt...

Страница 81: ...tion helps to provide the most accurate oil analysis i01907674 Engine Oil Sample Obtain The condition of the engine lubricating oil may be checked at regular intervals as part of a preventive maintena...

Страница 82: ...f all fluids according to local regulations and mandates NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life Do not drain the engine lubricatin...

Страница 83: ...e started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for...

Страница 84: ...imed If necessary by cycling the key switch the system will prime again for 2 minutes i06614133 Fuel System Primary Filter Water Separator Element Replace Fuel leaked or spilled onto hot surfaces or e...

Страница 85: ...nd old filter in accordance with local regulations i06616051 Fuel System Primary Filter Water Separator Drain Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire To hel...

Страница 86: ...el filters Illustration 52 g06042986 Typical example Note The fuel system has two secondary filters both must be replaced 3 The residual fuel pressure in the fuel system may need relieving Wait from 1...

Страница 87: ...he tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel...

Страница 88: ...8 If necessary install hose clamp 2 to the hose 1 Install hose 1 to the cap 4 Tighten hose clamp 2 to a torque of 6 N m 53 lb in i03965989 Grounding Stud Inspect Clean Tighten Illustration 55 g013761...

Страница 89: ...gs Replace the Hoses and the Clamps Refer to the OEM information for further information on removing and replacing fuel hoses if equipped The following text describes a typical method of replacing coo...

Страница 90: ...bulb behind the core in order 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 conditio...

Страница 91: ...other hoses tubes and wiring harnesses Inspect the alternator belt and the accessory drive belts for cracks breaks or other damage Belts for multiple groove pulleys must be replaced as matched sets I...

Страница 92: ...equipped 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...

Страница 93: ...cate your nearest Perkins Distributor by visiting www perkins com NOTICE Dependant upon engine type and application i06103116 Decommissioning and Disposal When the product is removed from service loca...

Страница 94: ...warranty Also keep these types of documents as proof of repair for warranty Dealer work orders and itemized bills Owners repair costs Owners receipts Maintenance log i05204675 Maintenance Log Table 17...

Страница 95: ...Table 17 contd M0109073 95 Reference Information Section Maintenance Log...

Страница 96: ...ELC Change 74 Drain 75 Fill 75 Flush 75 Cooling System Coolant Level Check 76 Cooling System Supplemental Coolant Additive SCA Test Add 76 Add the SCA If Necessary 77 Test for SCA Concentration 76 Cru...

Страница 97: ...Replace 87 G General Hazard Information 8 Containing Fluid Spillage 10 Dispose of Waste Properly 11 Fluid Penetration 9 Inhalation 11 Pressurized Air and Water 9 Static Electricity Hazard when Fueling...

Страница 98: ...apacities 66 S Safety Messages 6 Sulfuric Acid Burn 2 7 Universal Warning 1 6 Safety Section 6 Self Diagnostics 35 Sensors and Electrical Components 29 Diesel Oxidation Catalyst DOC 34 Engine 31 Engin...

Страница 99: ...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 100: ...M0109073 2019 Perkins Engines Company Limited All Rights Reserved 100 July 2019...

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