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Maintenance

Interval

Schedule

When

Required

“ Battery - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 74

“ Battery or Battery Cable - Disconnect“ . . . . . . . . . 75

“ Engine - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

“ Engine Air Cleaner Element - Replace“ . . . . . . . . 83

“ Engine Oil Sample - Obtain“ . . . . . . . . . . . . . . . . . 86

“ Fuel System - Prime“ . . . . . . . . . . . . . . . . . . . . . . . 89

Daily

“ Coolant Level - Check“ . . . . . . . . . . . . . . . . . . . . . 81

“ Driven Equipment - Check“ . . . . . . . . . . . . . . . . . . 82

“ Engine Air Cleaner Service Indicator - Inspect“ . . 84

“ Engine Air Precleaner - Check/Clean“ . . . . . . . . . 84

“ Engine Oil Level - Check“ . . . . . . . . . . . . . . . . . . . 85

“ Walk-Around Inspection“ . . . . . . . . . . . . . . . . . . . . 97

Every Week

“ Hoses and Clamps - Inspect/Replace“ . . . . . . . . . 95

Every 50 Service Hours

“ Fuel Tank Water and Sediment - Drain“ . . . . . . . . 95

Every 250 Service Hours

“ Engine Oil Sample - Obtain“ . . . . . . . . . . . . . . . . . 86

Every 500 Service Hours or 1 Year

“ Battery Electrolyte Level - Check“ . . . . . . . . . . . . 74

“ Engine Air Cleaner Element - Replace“ . . . . . . . . 83

“ Engine Oil and Filter - Change“. . . . . . . . . . . . . . . 87

“ Fuel System Primary Filter (Water Separator)
Element - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 90

“ Fuel System Primary Filter/Water Separator -
Drain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

“ Fuel System Secondary Filter - Replace“. . . . . . . 93

Every 1000 Service Hours

“ Belt - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

“ Belt Tensioner - Check“ . . . . . . . . . . . . . . . . . . . . . 76

“ Water Pump - Inspect“. . . . . . . . . . . . . . . . . . . . . . 98

Every 2000 Service Hours

“ Alternator - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . 74

“ Engine Mounts - Inspect“ . . . . . . . . . . . . . . . . . . . 85

“ Starting Motor - Inspect“ . . . . . . . . . . . . . . . . . . . . 96

Every 3000 Service Hours

“ Alternator and Fan Belts - Replace“ . . . . . . . . . . . 74

Every 3000 Service Hours or 1 Year

“ Coolant (Commercial Heavy-Duty) - Change“ . . . 78

Every 3000 Service Hours or 2
Years

“ Coolant (Commercial Heavy-Duty) - Change“ . . . 76

Every 4500 Service Hours

“ Turbocharger - Inspect“ . . . . . . . . . . . . . . . . . . . . . 97

Every 6000 Service Hours or 3
Years

“ Coolant (ELC) - Change“. . . . . . . . . . . . . . . . . . . . 80

M0125147

Maintenance Section

Maintenance Interval Schedule

Содержание 904F-E28T

Страница 1: ...Operation and Maintenance Manual 904F E28T Industrial Engine FJ Engine M0125147 en us January 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: ...al System 19 Engine Electronics 20 Product Information Section General Information 22 Product Identification Information 27 Operation Section Lifting and Storage 29 Features and Controls 31 Engine Dia...

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: ...er 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 s...

Страница 7: ...example The universal warning labels are located in two positions One label is on the front over the engine the other label is on the right side of the engine Hand High Pressure Contact with high pres...

Страница 8: ...r other harsh chemicals to clean the messages Solvents gasoline or harsh chemicals could loosen the adhesive that secures the messages Loose adhesive will allow the messages to fall Replace any messag...

Страница 9: ...onnect the connectors for the unit injectors that are on the valve cover base This action will help prevent personal injury from the high voltage to the unit injectors Do not come in contact with the...

Страница 10: ...otective clothing protective shoes and eye protection Eye protection includes goggles or a protective face shield The maximum air pressure for cleaning purposes must be below 205 kPa 30 psi The maximu...

Страница 11: ...ents Avoid death or serious injury from fire or explosion Consult with your fuel or fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and...

Страница 12: ...ts is usually bound in a resin or sealed in some way Normal handling is not hazardous unless airborne dust that contains asbestos is generated If dust that may contain asbestos is present there are se...

Страница 13: ...ollow the directions for first aid that are noted on a material safety data sheet MSDS for sulfuric acid Coolant When the engine is at operating temperature the engine coolant is hot The coolant is al...

Страница 14: ...tor for additional information about suitable protection devices Remove all flammable combustible materials or conductive materials such as fuel oil and debris from the engine Do not allow any flammab...

Страница 15: ...ations with a higher sulfur content Avoid death or serious injury from fire or explosion Consult your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling stan...

Страница 16: ...port the component properly 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 rota...

Страница 17: ...e fuel lines Do not bend or strike the high pressure fuel lines Deformation or damage of the high pressure fuel lines may cause a point of weakness and potential failure Do not check the high pressure...

Страница 18: ...ust be installed if the engine must be started to perform service procedures To help prevent an accident that is caused by parts in rotation work around the parts carefully Do not bypass the automatic...

Страница 19: ...tart the engine until the problem that caused the emergency stop has been corrected Stop the engine if an overspeed condition occurs during the initial start up of a new engine or an engine that has b...

Страница 20: ...charging current of the alternator The power supply connection for the engine electronics should always be from the isolator to the battery The OEM decides which polarity the isolator is to be connect...

Страница 21: ...ons However the monitoring system and the engine monitoring control will be similar for all engines Note Many of the engine control systems and display modules that are available for Perkins engines w...

Страница 22: ...ur engine may appear different from the illustrations Illustration 17 g06522067 Typical example 1 Diesel Oxidation Catalyst DOC 2 Rear lifting eyes 3 Engine harness interface 4 NOx Reduction System NR...

Страница 23: ...ocharger 14 Turbocharger 15 Air intake from air cleaner 16 Starting motor 17 Electronic Control Module ECM location for transportation only 18 Oil filler lower 19 Alternator 20 Drive belt 21 Adjuster...

Страница 24: ...line 8 Link harness i08307810 Product Description Engine and Aftertreatment The Perkins 904F E28T industrial engine is a single turbocharged engine The engine aftertreatment system consists of a Dies...

Страница 25: ...a Stop or Warning lamp Under certain conditions the engine horsepower and the vehicle speed may be limited The electronic service tool may be used to display the diagnostic codes There are three type...

Страница 26: ...ngines Perkins does not warrant the quality or performance of non Perkins fluids and filters When auxiliary devices accessories or consumables filters additives catalysts which are made by other manuf...

Страница 27: ...bers to determine the components that were included with the engine This information permits accurate identification of replacement part numbers Illustration 22 g06298094 Typical example of serial num...

Страница 28: ...erence Record for Reference Engine Model Engine Serial number Engine Low Idle rpm Engine Full Load rpm In Line Fuel Filter Primary Fuel Filter Secondary Fuel Filter Element Lubrication Oil Filter Elem...

Страница 29: ...Alterations to the lifting eyes and or the engine make the lifting eyes and the lifting fixtures obsolete If alterations are made ensure that proper lifting devices are provided There are several diff...

Страница 30: ...and Maintenance Manual Fluid recommendations 4 Remove the drive belt from the engine Sealed Coolant System Ensure that the cooling system is filled with Perkins ELC or an antifreeze that meets ASTM D6...

Страница 31: ...d Fuel rail pressure The fuel rail pressure sensor measures the high pressure or low pressure in the fuel rail The ECM will Check the pressure Engine oil pressure The engine oil pressure switch indica...

Страница 32: ...or more information about the gauge package see the OEM information Gauges provide indications of engine performance Ensure that the gauges are in good working order Determine the normal operating ran...

Страница 33: ...o the side of 0 zero Fuel Level This gauge indicates the fuel level in the fuel tank The fuel level gauge operates when the START STOP switch is in the on position Service Hour Meter The gauge indicat...

Страница 34: ...amps come on for 2 seconds and the lamps will then go off The keyswitch is in the ON position but the en gine has not yet been cranked If any of the indicators will not illuminate during indicator che...

Страница 35: ...or an engine shutdown This pattern of lamps can be caused by the detection of a serious active diagnostic code Contact your Perkins distributor Flash Codes Some applications may support flash codes A...

Страница 36: ...sor pre NRS valve 4 Coolant temperature sensor 5 Fuel temperature sensor 6 Control valve for high pressure fuel pump 7 Camshaft speed timing sensor 8 Inlet Manifold Pressure Sensor 9 Inlet Manifold Te...

Страница 37: ...sure sensor 12 NRS valve 13 Injector 1 2 and injector 4 Injector 3 not shown 14 Starting motor 15 Crankshaft speed timing sensor 16 Engine oil pressure switch 17 Alternator 18 Fuel rail pressure senso...

Страница 38: ...ectrical Components Illustration 28 g06481423 Typical example 1 ECM 2 If equipped Air intake temperature sensor Air Cleaner 3 Priming pump 4 Water in fuel switch 38 M0125147 Operation Section Sensors...

Страница 39: ...mp will flash once 3 A flashing YELLOW lamp indicates a 3 digit diagnostic code for the engine The sequence of flashes represents the system diagnostic message Count the first sequence of flashes in o...

Страница 40: ...tween these active diagnostic codes and engine performance i01797063 Engine Operation with Intermittent Diagnostic Codes If a diagnostic lamp illuminates during normal engine operation and the diagnos...

Страница 41: ...ectrical loads or remove any electrical loads i08165229 Cold Weather Starting Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury The abil...

Страница 42: ...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 illuminated or fla...

Страница 43: ...ome batteries Note The engine ECM must be powered before the starting motor is operated or damage can occur 4 Start the engine in the normal operating procedure Refer to this Operation and Maintenance...

Страница 44: ...engine is operating Comparing the data over time will help to determine normal readings for each gauge Comparing data over time will also help detect abnormal operating developments Significant change...

Страница 45: ...stress on the drive train Interrupted starts also waste fuel To get the driven equipment in motion engage the clutch smoothly with no load on the equipment This method should produce a start that is...

Страница 46: ...usting V Belt Test for further information Ensure that all the connections of the hoses are tight The connections should not leak Ensure that the driven equipment is in good working order Cold engines...

Страница 47: ...t low loads until a minimum operating temperature of 80 C 176 F is achieved Achieving operating temperature will help prevent the intake valves and exhaust valves from sticking The cooling system and...

Страница 48: ...n of a light load parasitic load will help in achieving the minimum operating temperature The minimum operating temperature is 80 C 176 F Recommendations for Coolant Warm Up Warm up an engine that has...

Страница 49: ...o affect under hood temperatures Reducing air flow can increase surface temperatures during an aftertreatment regeneration and could affect component reliability If an airflow restriction device must...

Страница 50: ...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 allow water and sedi...

Страница 51: ...ne start switch key may be removed 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 una...

Страница 52: ...ading Perform the maintenance that is in the Operation and Maintenance Manual Maintenance Interval Schedule Fill the fuel tank to help prevent accumulation of moisture in the fuel Do not overfill the...

Страница 53: ...Re fer to the OEM specifications Enter the value for the capacity of the External System in this row i07911111 Fluid Recommendations General Coolant Information NOTICE Never add coolant to an overheat...

Страница 54: ...ntration of additives can cause the inhibitors to drop out of solution The deposits can enable the following problems to occur Formation of gel compounds Reduction of heat transfer Leakage of the wate...

Страница 55: ...mixture of distilled or de ionized water and glycol This concentration al lows the NOx reduction system to operate correctly at high ambient temperatures NOTICE Do not use a commercial coolant antifre...

Страница 56: ...ilter from the system to prevent ELC contamination and filter corrosion and leaks ELC Cooling System Cleaning Note If the cooling system is already using ELC cleaning agents are not required to be use...

Страница 57: ...ercent of the total system capacity perform ONE of the following procedures Drain the cooling system into a suitable container Dispose of the coolant according to local regulations Flush the system wi...

Страница 58: ...ions Clean the cooling system after used coolant is drained or before the cooling system is filled with new coolant Clean the cooling system whenever the coolant is contaminated or whenever the coolan...

Страница 59: ...recommendations are subject to change with out notice Contact your local Perkins distributor for the most up to date recommendations Refer to Perkins Diesel Engines Fluids Recommendations M0113102 fo...

Страница 60: ...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 61: ...s 8 Examples of trace metals include but not limited to Cu Fe Mn Na P Pb Si and Zn Use of metal based additives is not allowed 9 Additional limit for fuel containing FAME Fuel containing more than 2 v...

Страница 62: ...ificant because fuel serves as a lubricant for the fuel system components Fuel must have sufficient viscosity to lubricate the fuel system in both extremely cold temperatures and extremely hot tempera...

Страница 63: ...any concentration 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 en...

Страница 64: ...Cleaner 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 life and per...

Страница 65: ...try There are five classes that are given to arctic climates and severe winter climates 0 1 2 3 and 4 Fuel that complies with EN590 CLASS 4 can be used at temperatures as low as 44 C 47 2 F Refer to E...

Страница 66: ...rs To reduce downtime due to contamination follow these fuel maintenance guidelines Use high quality fuels per recommended and required specifications Fill fuel tanks with fuels of ISO 18 16 13 cleanl...

Страница 67: ...nce Section Refer to Perkins Diesel Engines Fluids Recommendations M0113102 for additional information that relates to oil Engine Oil Commercial Oils Perkins recommends use of Perkins Diesel Engine Oi...

Страница 68: ...ure 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 te...

Страница 69: ...he 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 70: ...of 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...

Страница 71: ...e 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...

Страница 72: ...cedures 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...

Страница 73: ...trolyte Level Check 74 Engine Air Cleaner Element Replace 83 Engine Oil and Filter Change 87 Fuel System Primary Filter Water Separator Element Replace 90 Fuel System Primary Filter Water Separator Dr...

Страница 74: ...ables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with t...

Страница 75: ...he start switch to the OFF position Turn the ignition switch if equipped to the OFF position and remove the key and all electrical loads Note After the engine has stopped allow 2 minutes for the stori...

Страница 76: ...me engines have an idler pulley 2 Ensure that the idler pulley is securely installed Visually inspect the idler pulley for damage Ensure that the idler pulley can rotate freely and that the bearing is...

Страница 77: ...essure Remove the cooling system filler cap Note Refer to Operation and Maintenance Manual General Hazard Information for information on Containing Fluid Spillage Illustration 36 g06302798 Typical exa...

Страница 78: ...ged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged perform a pressure test If the cooling s...

Страница 79: ...ooling system can result in damage to copper and other metal components To avoid damage to the cooling system make sure to completely flush the cooling system with clear water Continue to flush the sy...

Страница 80: ...e cooling system has been drained Replace the water pump the water temperature regulator and the hoses if necessary NOTICE Service or repair of the engine cooling system must be performed on level gro...

Страница 81: ...ximum mark that is correct for your application 4 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap...

Страница 82: ...T OPERATE NOTICE Accumulated grease and oil on an engine is a fire hazard Keep the engine clean Remove debris and fluid spills whenever a significant quantity accumu lates on the engine Periodic clean...

Страница 83: ...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 Replace the dirty air cleaner elements...

Страница 84: ...ator Observe the service indicator The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur The yellow diaphragm enters the re...

Страница 85: ...t the engine is in the normal operating position to obtain a true level indication NOTICE Do not overfill the crankcase Engine damage can result Before Operating the Engine Illustration 43 g06525971 T...

Страница 86: ...of a preventive maintenance program Perkins include 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 s...

Страница 87: ...Intervals The standard engine oil and oil filter change period is 500 hours or 1 year There are several other factors that can alter the standard engine oil and filter change of 500 hours or 1 year I...

Страница 88: ...Typical example 1 Top mounted fill cap 2 Side mounted filler cap 1 Refer to this Operation and Maintenance Manual Fluid Recommendations for more information on suitable oils 2 Fill the oil pan with th...

Страница 89: ...m is free of air DO NOT loosen the high pressure fuel lines to purge air from the fuel system This procedure is not required After the engine has stopped you must wait for 10 minutes to allow the fuel...

Страница 90: ...ss of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system NOTICE Ensure that the engine is stopped before any servi...

Страница 91: ...il there is no visible gap between the element and the filter bowl and the assembly 4 Remove the container and dispose of the fuel in a safe place 5 Install the wiring harness to connection 3 6 The se...

Страница 92: ...Note If a strap wrench is required to loosen the filter bowl 5 ensure that the strap is positioned in the middle of the ribbed section To avoid damage or mechanical failure do not position the strap a...

Страница 93: ...TICE Ensure that the engine is stopped before any servic ing or repair is performed NOTICE The water separator is under suction during normal engine operation Ensure that the drain valve is tight ened...

Страница 94: ...alve 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 Remo...

Страница 95: ...e drain valve Check the fuel daily Allow five minutes after the fuel tank has been filled before draining water and sediment from the fuel tank Fill the fuel tank after operating the engine in order t...

Страница 96: ...nd wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pressure 1 Stop the engine Allow the engine to cool 2 Loosen the cooling syst...

Страница 97: ...urbocharger Check for any loose bolts or any missing bolts Check for damage to the oil supply line and the oil drain line Check for cracks in the housing of the turbocharger Ensure that the compressor...

Страница 98: ...may cause personal injury or death After the engine has stopped wait 10 minutes to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed The...

Страница 99: ...t the water pump for leaks between water pump pulley 1 and water pump body 2 The water pump is not a serviceable item To install a new water pump refer to Disassembly and Assembly Water Pump Remove an...

Страница 100: ...at are prescribed by the law at the time of manufacture This engine may be covered by an Emissions Warranty For a full warranty statement contact your Perkins dealer or your Perkins distributor For cu...

Страница 101: ...erence Materials Maintenance Log Table 16 Engine Model Customer Identifier Serial Number Arrangement Number Service Hours Quantity Of Fuel Service Item Date Authorization continued M0125147 101 Refere...

Страница 102: ...Highly trained technicians carry out all repairs 5 Transferable coverage should you sell your machine Flexible coverage provides the right level of protection for your Perkins Engine Coverage can be e...

Страница 103: ...e Retrieval 39 Diagnostic Lamp 39 Driven Equipment Check 82 E Electrical System 19 Grounding Practices 19 Emergency Stopping 51 Emissions Certification Film 27 Emissions Warranty Information 100 Engag...

Страница 104: ...ce 93 Install the Element 94 Remove the Element 94 Fuel Tank Water and Sediment Drain 95 Drain the Water and the Sediment 95 Fuel Storage Tanks 95 Fuel Tank 95 G Gauges and Indicators 32 Aftertreatmen...

Страница 105: ...Messages 6 Ether Warning 8 Hand High Pressure 7 Universal Warning 7 Safety Section 6 Self Diagnostics 39 Sensors and Electrical Components 35 Off Engine Sensors and Electrical Components 38 Severe Ser...

Страница 106: ......

Страница 107: ...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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