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Safety Section

i08233511

Safety

 

Messages

There

 

may

 

be

 

several

 

specific

 

warning

 

signs

 

on

 

your

 

engine.

 

The

 

exact

 

location

 

and

 

a

 

description

 

of

 

the

 

warning

 

signs

 

are

 

reviewed

 

in

 

this

 

section.

 

Become

 

familiar

 

with

 

all

 

warning

 

signs.

Ensure

 

that

 

all

 

the

 

warning

 

signs

 

are

 

legible.

 

Clean

 

the

 

warning

 

signs

 

or

 

replace

 

the

 

warning

 

signs

 

if

 

the

 

words

 

cannot

 

be

 

read

 

or

 

if

 

the

 

illustrations

 

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

 

secures

 

the

 

warning

 

signs.

 

The

 

warning

 

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

 

sign

 

on

 

the

 

replacement

 

part.

 

Your

 

Perkins

 

distributor

 

can

 

provide

 

new

 

warning

 

signs.

Illustration 1

g06642298

(1) Universal warning label locations
(2) Do not step label location

(3) Electrocution danger label location
(4) Hot fluid under pressure label locations

(5) Hot surface label location
(6) Ether warning label location

6

M0122761

Safety Section
Safety Messages

Содержание 5006A-E23TA

Страница 1: ...Operation and Maintenance Manual 5006A E23TA 5006C E23TA 5008A E30TA and 5008C E30TA Industrial Engines E08 Engine E06 Engine M0122761 en us May 2021...

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: ...rical System 18 Engine Electronics 19 Product Information Section Model Views 20 Product Identification Information 26 Operation Section Lifting and Storage 28 Features and Controls 31 Engine Diagnost...

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: ...other harsh chemicals Solvents gasoline or harsh chemicals could loosen the adhesive that secures the warning signs The warning signs that are loosened could drop off the engine Replace any warning si...

Страница 7: ...e 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 the warnings could res...

Страница 8: ...stand the instructions and warnings in the Operation and Maintenance Manual Failure to follow the instructions or heed the warnings will result in serious injury or death 4 Hot Fluid Under Pressure Il...

Страница 9: ...ment to protect your skin The hot surface warning labels 5 can be found in two locations The oil cooler and heat shield of the coolant rail 6 Ether Warning Illustration 8 g01372254 Do not use aerosol...

Страница 10: ...each operator control station When appropriate disconnect the starting controls Do not allow unauthorized personnel on the engine or around the engine when the engine is being serviced Tampering with...

Страница 11: ...tart the engine and operate the engine in a well ventilated area If the engine is in an enclosed area vent the engine exhaust to the outside Cautiously remove the following parts To help prevent spray...

Страница 12: ...cause severe injury If fluid is injected into your skin you must get treatment immediately Seek treatment from a doctor that is familiar with this type of injury Containing Fluid Spillage Care must b...

Страница 13: ...ces 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...

Страница 14: ...iller cap The filler cap must be cool enough to touch with a bare hand Remove the filler cap slowly to relieve pressure Refer to this Operation and Maintenance Manual Cooling System Coolant Level Chec...

Страница 15: ...le 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 the engine Store...

Страница 16: ...y open flames or sparks away from the top of a battery Do not smoke in battery charging areas Never check the battery charge by placing a metal object across the terminal posts Use a voltmeter or a hy...

Страница 17: ...njured by flying debris i05875651 Mounting and Dismounting Do not climb on the engine The engine has not been designed with mounting or dismounting locations Refer to the OEM for the location of foot...

Страница 18: ...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 been overhauled This may be accomplishe...

Страница 19: ...eed and or the engine power Many of the parameters that are monitored by the ECM can be programmed for the engine monitoring functions The following parameters can be monitored as a part of the Engine...

Страница 20: ...llowing model views show typical features of the engine Due to individual applications your engine may appear different from the illustrations Illustration 20 g06617223 Typical example of an engine vi...

Страница 21: ...nator 4 Oil filler 5 Coolant pump 6 Module for twin primary fuel filters 7 Electric priming pump 8 Oil gauge Dipstick 9 Twin secondary fuel filters 10 Oil filters 11 Starting motor 12 Rear lifting eye...

Страница 22: ...g06643111 Typical example 14 Thermostat housing 15 Breather 16 Turbochargers 17 Oil drain plug 18 Crankshaft damper 19 Fan belts 20 Front lifting eye 22 M0122761 Product Information Section Model Vie...

Страница 23: ...olant vent i08229531 Engine Description The Perkins 5006A E23TA 5006C E23TA 5008A E30TA and 5008C E30TA Industrial Engines have the following characteristics Four stroke cycle Mechanically actuated el...

Страница 24: ...s Table 2 Engine Specifications Engine 5008A E30TA and 5008C E30TA Arrangement and cylinders In line 8 cylinder Bore 160 mm 6 30 inch Stroke 190 mm 7 48 inch Displacement 30 56 L 1864 89 cubic inch Co...

Страница 25: ...ings result in a lower average power demand Reduced hours of operation will increase the length of operating time before an engine overhaul is required For more information refer to the Operation and...

Страница 26: ...mber plate and engine ratings labels location Illustration 27 g06649090 Typical example of engine serial number plate Illustration 28 g06651739 Typical example of ratings label Your Perkins distributo...

Страница 27: ...Illustration 29 g06646849 Typical example of Emissions label M0122761 27 Product Information Section Plate Locations and Film Locations...

Страница 28: ...normal conditions of storage from 15 to 55 C 5 to 99 F and 90 relative humidity Protection is for a maximum of 2 years Level C This level is additional to level B Level C will give protection for 5 ye...

Страница 29: ...ple 1 5008 engine Rear lifting eye 2 5008 engine Rear lifting eye 3 5006 engine Rear lifting eye 4 5006 engine Rear lifting eye 5 5006 engine Front lifting eye 6 5008 engine Front lifting eye M0122761...

Страница 30: ...Radiator Only Illustration 31 g06649667 Typical example of a 5008 radiator 1 Radiator lifting eyes 30 M0122761 Operation Section Product Lifting...

Страница 31: ...gged in the memory of the ECM An event code will be transmitted over the Perkins Data link and the hard wired Warning output will be energized If the engine is in the Warning condition the event code...

Страница 32: ...he engine After an engine shutdown operate the reset input of the ECM or power down the controller Powering down the electronic control module can be achieved by the operation of the keyswitch into sl...

Страница 33: ...nsor Views Illustration 32 g06595481 Typical example 1 Coolant temperature sensor 2 Air inlet temperature sensor 3 Oil pressure sensor 4 Camshaft speed timing sensor M0122761 33 Operation Section Sens...

Страница 34: ...l pressure sensor after primary fuel filters 8 Water In Fuel WIF sensor 9 Fuel pressure sensor after secondary fuel filter 10 Fuel pressure sensor before secondary fuel filter 11 Fuel temperature sens...

Страница 35: ...5502 Wiring harness removed for clarity 12 Barometric pressure sensor i08233020 Sensors and Electrical Components Electrical Components The engine view shown is a typical examples only M0122761 35 Ope...

Страница 36: ...xample 1 Injector wiring harness 2 Alternator 3 Fuel priming pump with remote switch 4 Electric Priming Pump EPP relay 5 Starter relay 6 Starting motor 7 Electronic Control Module ECM 36 M0122761 Oper...

Страница 37: ...erature i01797063 Engine Operation with Intermittent Diagnostic Codes If a diagnostic lamp illuminates during normal engine operation and the diagnostic lamp shuts off an intermittent fault may have o...

Страница 38: ...be reached After three times of cranking the engine and the engine oil pressure fail to reach 30 kPa 4 35 psi a failed to start alarm will be indicated on the EST A fault reset will be required Refer...

Страница 39: ...If no leaks are present proceed to step 5 b If leaks are present repair the leaks Repeat Step 3 to Step 4 5 Start the engine Operate the engine for 1 minute Monitor the engine oil pressure Continue t...

Страница 40: ...ot outside the canopy or enclosure Fully charged batteries of the correct capacity Electrical cables that meet the recommended specification Contact your Perkins distributor or Perkins dealer for more...

Страница 41: ...al operating developments Significant changes in the readings should be investigated i02415226 Fuel Conservation Practices The efficiency of the engine can affect the fuel economy Perkins design and t...

Страница 42: ...equipped with a service hour meter note the reading Perform the maintenance that is in the Operation and Maintenance Manual Maintenance Interval Schedule Check the crankcase oil level Maintain the oil...

Страница 43: ...fuel are available in the countries and territories with severe winters For more information refer to the Operation and Maintenance Manual Fuel For Cold Weather Operation Another important fuel prope...

Страница 44: ...re regulator can heat the fuel in excess of 65 C 149 F The maximum fuel temperature at the lift pump inlet is 58 C 136 4 F Note Heat exchanger type fuel heaters should have a bypass provision to preve...

Страница 45: ...US gal Table 6 5008 30 Engine and Engine with Radiator Engine Only 48 L 12 7 US gal Engine and Radiator 140 L 37 0 US gal Fuel System Refer to the OEM specifications for additional information on the...

Страница 46: ...ny Agricultural agent Independent laboratory Periodic analysis of water that is used to add to the coolant is recommended Water quality can be affected by various factors including malfunctioning puri...

Страница 47: ...tions ELC Extended 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 Su...

Страница 48: ...enance Manual that is provided by the OEM for capacities of the fuel system i08364472 Fluid Recommendations Engine Oil Specification General Lubricant Information Because of government regulations reg...

Страница 49: ...nding on the parasitic load and other factors Cold soaked starts occur when the engine has not been operated for a period of time This interval will allow the oil to become more viscous due to cooler...

Страница 50: ...wear metal and type of wear metal that is in the oil is analyzed The increase in the rate of engine wear metal in the oil is as important as the quantity of engine wear metal in the oil For more info...

Страница 51: ...t incorrect operating procedures and incorrect maintenance procedures can be factors which contribute to a severe service application Environmental Factors Ambient temperatures The engine may be expos...

Страница 52: ...lyte Level Check 55 Belts Inspect Adjust Replace 56 Belts Inspect Adjust Replace 57 Belts Inspect Adjust Replace 59 Cooling System Coolant Change 64 Cooling System Coolant Level Check 67 Crankshaft Vi...

Страница 53: ...or 89 Every 6000 Service Hours or 3 Years Cooling System Coolant ELC Change 61 Every 5 Years Alternator Inspect 54 Fuel Injector Replace 78 Fuel Transfer Pump Lift Pump Inspect 82 Starting Motor Inspe...

Страница 54: ...e engine When the engine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge A battery with a low charge will freeze more easily than a bat...

Страница 55: ...rged the ammeter reading should be very near zero when the engine is in operation All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and prote...

Страница 56: ...t accidental starting 7 Proceed with necessary system repairs 8 To connect the battery connect the positive connection before the negative connection i07212767 Belts Inspect Adjust Replace Alternator...

Страница 57: ...0 to allow more moment 3 Remove belt 13 and discard Install new belt and ensure that the belt is located over pulley 12 and pulley 14 Ensure that new toothed belt is located into the pulley 12 and pul...

Страница 58: ...the middle point between the two pulleys New belt tension should be set to 49 N 11 lb Belt tension range should be from 31 N to 49 N 6 9 lb to 11 lb Belt deflection should be 4 2 mm 0 165 inch Illustr...

Страница 59: ...or more information 5 The belt tension must be checked at position A Use a suitable spring balance and a suitable straight edge to check the belt tension 6 The belt tension should be 62 N 14 lb with a...

Страница 60: ...Remove the belts 1 Procedure to Apply the Grease to Fan Drive Assembly and Jockey Pulley 1 Use Shell Alvania RL3 or Shell Gadus S2 V100 3 and apply 8 to 10 grams of grease to the bearings Note Each gr...

Страница 61: ...e for the correct procedure 7 Stop the engine Refer to Operation and Maintenance Manual Stopping the Engine for the correct procedure 8 Isolate the electrical supply to the engine Remove the guards 9...

Страница 62: ...rical supply to the engine Loosen the cooling system filler cap 1 slowly to relieve any pressure Remove the cooling system filler cap 2 Clean the cooling system filler cap 1 and inspect the seal 2 If...

Страница 63: ...the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 3 Fill the cooling system with clean water Install the cooling system...

Страница 64: ...artment or disassem bling any component containing fluids Dispose of all fluids according to Local regulations and mandates NOTICE Keep all parts clean from contaminants Contaminants may cause rapid w...

Страница 65: ...ller cap If the seal is not damaged use a suitable pressurizing pump to pressure test the filler cap The correct pressure is stamped on the face of the filler cap If the filler cap does not retain the...

Страница 66: ...rain cock or remove the drain plug 5 in the oil cooler Allow the water to drain Flush the cooling system with clean water Fill 1 Close the drain cock or install the drain plug 3 on the radiator Close...

Страница 67: ...to pressure test the filler cap The correct pressure is stamped on the face of the filler cap If the filler cap does not retain the correct pressure replace the filler cap Install the cooling system f...

Страница 68: ...cables into the rear of the connectors Avoid electrical components such as the alternator the starting motors and the ECU Ensure that care is taken that the safety labels emission label and any infor...

Страница 69: ...filter element is in a serviceable condition the center section of the service indicator 1 is clear Illustration 62 g01242332 When the air filter element requires replacement the center section of the...

Страница 70: ...g seal 3 onto cover 1 and install cover to breather body 5 6 Install bolts 1 and tighten bolts to a torque of 50 N m 36 lb ft Install power to the engine i02978569 Engine Crankcase Breather Clean Repl...

Страница 71: ...bolts for the isolators are tightened to the correct torque Replace any isolator that shows deterioration For more information see the literature that is provided by the OEM of the isolators i08238446...

Страница 72: ...p i08397579 Engine Oil Pump Inspect A failed engine oil pump may result in a seizure of the crankshaft A failed engine oil pump may result in contaminating the engine lubricating system Visually inspe...

Страница 73: ...the sample is clearly labeled To ensure that the sample is representative of the oil in the crankcase obtain a warm well mixed oil sample To avoid contamination of the oil samples the tools and the su...

Страница 74: ...rque of 68 N m 50 lb ft Replace the Oil Filter Table 11 Required Tools Tool Part Number Part Name Qty A Strap Wrench 1 Note Ensure that all 3 oil filters are changed as a set 1 Use Tooling A to remove...

Страница 75: ...d As the engine lubricating oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with draining cold oil Drain the oil pan with the engine stopped...

Страница 76: ...lters have been replaced fill the oil pan Fill the Oil Pan Refer to Operation and Maintenance Manual Fluid Recommendations for information on suitable oils 1 Remove the oil filler cap 2 2 Fill the oil...

Страница 77: ...ng and components that are loose broken or damaged Damaged wiring or components should be repaired or replaced immediately i03783789 Engine Valve Lash Inspect Adjust Valves and Valve Bridges NOTICE On...

Страница 78: ...ystem Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over any disconnected fuel system components NOTICE If a fuel injector is suspected of ope...

Страница 79: ...Step 5 The fuel system can also be primed by using the key switch Turn the key to the ON position for 2 minutes After 2 minutes the fuel system should be primed If necessary by cycling the key switch...

Страница 80: ...O ring seal 9 contacts the sealing surface 8 rotate the primary fuel filter 3 4 of a turn 9 Repeat Step 6 through Step 8 for the remaining fuel filter 10 Install new O ring seal 5 to the WIF sensor 11...

Страница 81: ...ressure of the fuel that is entering the engine The electronic service tool EST can be used to monitor the fuel pressure Contact Perkins distributor for more information Illustration 79 g06309402 Typi...

Страница 82: ...e 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 tanks use su...

Страница 83: ...tem are not always supplied by Perkins The following text describes a typical method of replacing coolant hoses Refer to the OEM information for further information on the coolant system and the hoses...

Страница 84: ...ngine Inspect the cooling system for leaks Clamps and V Band Locations For 6 Cylinder Engines Illustration 80 g06642391 1 Clamp torque 7 N m 62 lb in 84 M0122761 Maintenance Section Hoses and Clamps I...

Страница 85: ...Illustration 81 g06329566 1 Clamp torque 7 N m 62 lb in 2 Clamp torque 9 N m 79 lb in M0122761 85 Maintenance Section Hoses and Clamps Inspect Replace...

Страница 86: ...Illustration 82 g06329596 1 Clamp torque 7 N m 62 lb in 86 M0122761 Maintenance Section Hoses and Clamps Inspect Replace...

Страница 87: ...Clamps and V Band Locations For 8 Cylinder Engines Illustration 83 g06620523 1 Clamp torque 7 N m 62 lb in M0122761 87 Maintenance Section Hoses and Clamps Inspect Replace...

Страница 88: ...Illustration 84 g06620538 1 Clamp torque 7 N m 62 lb in 2 Clamp torque 9 N m 79 lb in 88 M0122761 Maintenance Section Hoses and Clamps Inspect Replace...

Страница 89: ...starting should have jacket water heaters Check the operation of the jacket water heater Check the operation of the circulation pump if equipped For an ambient temperature of 0 C 32 F the heater shoul...

Страница 90: ...08304220 Overhaul Top End Scheduling a Top End Overhaul Top end overhauls should be scheduled according to the recession of the valve stems This measurement provides an accurate indication of the rate...

Страница 91: ...leaning purposes Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction to the fans air flow Hold the nozzle approximately 6 mm 0 25 inch away from...

Страница 92: ...rect Operating Procedures Frequent hot shutdowns Operating at excessive loads Operating at excessive speeds Operating outside the intended application Incorrect Maintenance Procedures Extending the ma...

Страница 93: ...wiring harnesses and so forth Ensure that the areas around the rotating parts are clear Inspect the alternator belt and fan drive belts for cracks breaks or other damage Check that the fan and belts...

Страница 94: ...aseous emission standards that are prescribed by the law at the time of manufacture This engine may be covered by an Emissions Warranty Consult your authorized Perkins dealer or distributor to determi...

Страница 95: ...ng Prevention 17 D Driven Equipment Check 67 E Electrical System 18 Grounding Practices 18 Emergency Stopping 42 Emissions Warranty Information 94 Engine Clean 68 Engine Air Cleaner Element Replace 68...

Страница 96: ...Secondary Filter Replace 81 Fuel Tank Water and Sediment Drain 82 Drain the Water and the Sediment 82 Fuel Storage Tanks 82 Fuel Tank 82 Fuel Transfer Pump Lift Pump Inspect 82 G General Hazard Infor...

Страница 97: ...fety Messages 6 1 Universal Warning 7 2 Do Not Step 7 3 Electrocution 8 4 Hot Fluid Under Pressure 8 5 Hot Surface 9 6 Ether Warning 9 7 Rotating Shaft Hand Crush Hazard 9 Safety Section 6 Self Diagno...

Страница 98: ......

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: ...M0122761 2021 Perkins Engines Company Limited All Rights Reserved 100 May 2021...

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