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• Engine Aftertreatment System

The Engine Monitoring package can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.

SEBU9068-03

Safety Section
Engine Electronics

Содержание SEBU9068-03

Страница 1: ...Operation and Maintenance Manual 854F E34TA Industrial Engine JU Engine SEBU9068 03 en us December 2020...

Страница 2: ...rmation that was available at the time that the publication was written The specifications torques pressures measurements adjustments illustrations and other items can change at any time These changes...

Страница 3: ...Engine Electronics 19 Product Information Section General Information 21 Product Identification Information 27 Operation Section Lifting and Storage 29 Features and Controls 32 Engine Diagnostics 47...

Страница 4: ...manual Whenever a question arises regarding your engine or this manual please consult with your Perkins dealer or your Perkins distributor for the latest available information Safety This safety sect...

Страница 5: ...the engine as a convenient reminder Perkins also recommends that a maintenance record be maintained as part of the permanent record of the engine Your authorized Perkins dealer or your Perkins distri...

Страница 6: ...replacement part Your Perkins distributor can provide new warning signs Universal Warning Do not operate or work on this equipment unless you have read and understand the instructions and warnings in...

Страница 7: ...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 8: ...tective 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 maximum...

Страница 9: ...nts 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 b...

Страница 10: ...n you handle components that contain asbestos fibers Inhaling this dust can be hazardous to your health The components that may contain asbestos fibers are brake pads brake bands lining material clutc...

Страница 11: ...d wait for 10 minutes to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines The 10 minute wait will also allow st...

Страница 12: ...ance is performed on the engine or the engine aftertreatment system Relieve all pressure in the appropriate system before any lines fittings or related items are disconnected Aftertreatment System and...

Страница 13: ...ilure to follow these inspection maintenance and service in structions may cause personal injury or death After the engine has stopped you must wait for 10 minutes to allow the fuel pressure to be pur...

Страница 14: ...n direct sunlight or in temperatures above 49 C 120 F Keep ether cylinders away from open flames or sparks Lines Tubes and Hoses Do not bend high pressure lines Do not strike high pressure lines Do no...

Страница 15: ...t system The engine and aftertreatment system have not been designed with mounting or dismounting locations Refer to the OEM for the location of foot and hand holds for your specific application i0583...

Страница 16: ...pressure fuel lines with the engine or the starting motor in operation After the engine has stopped wait for 10 minutes in order to allow the fuel pressure to be purged from the high pressure fuel li...

Страница 17: ...ments i08185623 Engine Starting Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury If a warning tag is attached to the engine start switc...

Страница 18: ...arging unit circuit or battery circuit cable from the battery when the charging unit is operating A spark can cause the combustible gases that are produced by some batteries to ignite To help prevent...

Страница 19: ...o the battery i04346349 Engine Electronics Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and or engine...

Страница 20: ...ne Monitoring package can vary for different engine models and different engine applications However the monitoring system and the engine monitoring control will be similar for all engines 20 SEBU9068...

Страница 21: ...engine may appear different from the illustrations Engine with Rear Mounted Aftertreatment Illustration 14 g03693338 Typical example 1 Front lifting eye 2 Rear lifting eyes 3 Diesel exhaust fluid inje...

Страница 22: ...ipstick 13 Oil filler cap 14 High pressure fuel pump Illustration 15 g03693780 Typical example 15 Electronic control module 16 Fan pulley 17 Breather 18 Crankshaft pulley 19 Coolant pump 20 Air intake...

Страница 23: ...t connection from turbocharger 23 Air intake from air cleaner 24 Coolant outlet connection 25 Alternator 26 Coolant intake connection 27 Coolant drain 28 Starting motor 29 Starter solenoid 30 Flex pip...

Страница 24: ...ensors for Doc and SCR 13 DEF pump module with DEF filter i05857921 Product Description The Perkins 854F E34TA industrial engine have the following characteristics In line 4 cylinder Four valves per c...

Страница 25: ...shaping Injection timing control System diagnostics Aftertreatment Regeneration For more information on electronic engine features refer to the Operation and Maintenance Manual Features and Controls...

Страница 26: ...the injected urea The mixture then enters the SCR catalyst Here the NOx in the exhaust reacts with the ammonia from the injected urea to split the gases into nitrogen and oxygen constituents The SCR c...

Страница 27: ...Serial Number location Illustration 19 g03733236 Typical example of a non stressed cylinder block The engine serial number can be installed in three different positions All engines will have the seri...

Страница 28: ...he information for your engine Record the information in the appropriate space Make a copy of this list for a record Keep the information for future reference Record for Reference Engine Model Engine...

Страница 29: ...porting members chains and cables should be parallel to each other The chains and cables should be perpendicular to the top of the object that is being lifted Some removals require lifting the fixture...

Страница 30: ...Drain any water from the primary filter water separator Ensure that the fuel tank is full 3 The engine oil will not need to be drained in order to store the engine Provided the correct specification o...

Страница 31: ...th DEF that meet ISO 22241 1 2 Replace the DEF filter refer to this Operation and Maintenance Manual Diesel Exhaust Fluid Filter Clean Replace 3 Ensure that the drive belt is correctly installed Ensur...

Страница 32: ...in the fuel rail The ECM will Check the pressure Engine oil pressure The engine oil pressure sensor indicates when oil pressure drops below rated system pressure at a set engine speed Engine overspee...

Страница 33: ...all connect with the engine ECM If the ECM determines that any of the signals are out of the specified range an alarm will be triggered Testing Turning the keyswitch to the ON position will check the...

Страница 34: ...be locked in de rate at low idle only Override Option The key switch can be cycled in order to give emergency power for 30 minutes Turn on key switch for a minimum 5 seconds to a maximum of 15 seconds...

Страница 35: ...Ten Percent Full Power Level 1 Indica tors Active ON Flashing Slowly OFF On Solid ON Flashing Slowly Less than Five Percent Engine will Start to be Derated Derate Timer Starts A Level 2 In ducement is...

Страница 36: ...Range Level 1 Inducement is Active Stop Engine and Check DEF Quality Refer to Sys tems Operation Testing and Ad justing Diesel Exhaust fluid Quality Test for More Information ON Flashing Slowly OFF O...

Страница 37: ...evel 1 Induce ment is Active Contact your Per kins dealer or your Perkins distributor If a Code has been Activated Provide this Information to Your Dealer ON Flashing Slowly OFF ON Flashing Slowly Der...

Страница 38: ...For 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 ra...

Страница 39: ...cator should be to 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...

Страница 40: ...he lamps will illu minate for 2 seconds and the lamps will then go off During indicator check the after treatment indicators will also be checked The keyswitch is in the ON position but the engine has...

Страница 41: ...e time the warning indicator is activated Depending on the application special precautions should be taken to avoid personal injury The engine can be re started following shutdown for emergency ma neu...

Страница 42: ...may still exist The engine may shut down again in as little as 20 seconds If there is a signal for high coolant temperature there will be a 2 second delay in order to verify the condition If there is...

Страница 43: ...nlet metering valve 2 10 pin engine interface connector 3 Intake throttle valve 4 62 pin engine interface connector 5 Fuel temperature sensor 6 Fuel rail pressure sensor 7 Oil pressure switch 8 Water...

Страница 44: ...ir pressure and temperature sensor 12 Exhaust temperature sensor connector 13 Exhaust gas pressure sensor 14 Coolant temperature sensor 15 Wastegate regulator 16 Secondary speed timing sensor camshaft...

Страница 45: ...rtreatment Illustration 28 g03700027 Typical example 18 Engine out NOx sensor 19 Diesel Exhaust Fluid DEF injector 20 DOC inlet temperature sensor SEBU9068 03 45 Operation Section Sensors and Electric...

Страница 46: ...ater Control Unit HCU 24 Glow plug Control Unit GCU 25 Coolant diverter valve 26 DEF tank header unit 27 Heated DEF line 28 Tailpipe out NOx sensor 29 Ammonia sensor 30 Control unit for the ammonia se...

Страница 47: ...y of Fault Logging 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 identif...

Страница 48: ...ters and the customer specified parameters The electronic service tool is required in order to alter the configuration parameters System Configuration Parameters System configuration parameters affect...

Страница 49: ...n Rate Engine Location High Exhaust System Temperature Indicator Installation Status Oil Pressure Lamp Installation Status Wait to Start Lamp Installation Status Warning Lamp Installation Status Shutd...

Страница 50: ...ne Operation Mode 2 High Idle Droop Percentage Engine Operation Mode 2 Throttle 1 Droop Percentage Engine Operation Mode 2 Throttle 2 Droop Percentage Engine Operation Mode 2 TSC1 Droop Percentage Eng...

Страница 51: ...ctrical loads or remove any electrical loads i05365825 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 abili...

Страница 52: ...tor lamps will be illuminated for 2 seconds in order to check lamp operation If any of the lamps do not illuminate check the bulb If the fault remains refer to Troubleshooting Indicator Lamp Circuit T...

Страница 53: ...of the jump start cable to the negative cable terminal of the electrical source Connect the other negative end of the jump start cable to the engine block or to the chassis ground This procedure helps...

Страница 54: ...eed with no load for 2 minutes Note Gauge readings should be observed and the data should be recorded frequently while the engine is operating Comparing the data over time will help to determine norma...

Страница 55: ...f any input from the operator During the time of elevated fuel pressure the operator may notice a change in the tone of the engine The ECM will operate the check at low idle for approximately 5 minute...

Страница 56: ...res to attain optimum performance for the life of the engine Avoid spilling fuel Fuel expands when it is warmed up The fuel may overflow from the fuel tank Inspect fuel lines for leaks Repair the fuel...

Страница 57: ...y to start readily Install the correct specification of engine lubricant before the beginning of cold weather Check all rubber parts hoses fan drive belts weekly Check all electrical wiring and connec...

Страница 58: ...es become stuck Pushrods may become bent Other damage to valve train components can result For this reason when the engine is started the engine must be operated until the coolant temperature is 80 C...

Страница 59: ...d Weather Note Only use grades of fuel that are recommended by Perkins Refer to this Operation and Maintenance Manual Fluid Recommendations Properties of the diesel fuel can have a significant effect...

Страница 60: ...er to the Operation and Maintenance Manual in the Maintenance Section for more information on priming the fuel system The micron rating and the location of a primary fuel filter is important in cold w...

Страница 61: ...peration are secured after the engine is stopped Emergency Stop Button Illustration 30 g00104303 Typical emergency stop button The emergency stop button is in the OUT position for normal engine operat...

Страница 62: ...Only use antifreeze coolant mixtures recommended in this Operation and Maintenance Manual Refill Capacities and Recommendations topic or in this Operation and Maintenance Manual Fluid Recom mendations...

Страница 63: ...case oil sump aluminum which includes the standard factory installed oil filters Engines with auxiliary oil filters will require additional oil Refer to the OEM specifications for the capacity of the...

Страница 64: ...o change with out notice Contact your local Perkins distributor for the most up to date recommendations Diesel Fuel Requirements Perkins is not in a position to continuously evaluate and monitor all w...

Страница 65: ...ication includes the requirements for Ultra Low Sulfur Diesel ULSD ULSD fuel will have 15 ppm 0 0015 sulfur Refer to ASTM D5453 ASTM D2622 or ISO 20846 ISO 20884 test methods 2 A fuel with a higher ce...

Страница 66: ...fuel injectors signifi cantly reduce service life of the fuel system deposits in the combustion chamber and reduced service life of the engine NOTICE The Perkins 854 industrial engine must be operated...

Страница 67: ...he viscosity of the fuel is significant because fuel serves as a lubricant for the fuel system components Fuel must have sufficient viscosity in order to lubricate the fuel system in both extremely co...

Страница 68: ...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 that are manufactured toda...

Страница 69: ...ion refer to Perkins Diesel Fuel System Cleaner and Perkins Biodiesel fuel contains metal contaminants sodium potassium calcium and or magnesium that form ash products upon combustion in the diesel en...

Страница 70: ...of biodiesel and biodiesel blends These deposits can create a loss of power and engine performance Once the fuel cleaner has been added to the fuel the deposits within the fuel system are removed aft...

Страница 71: ...commendations for Direct Injection DI Diesel Engines The correct SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start up and the maximum ambient tempera...

Страница 72: ...by water glycol or fuel The Oil Condition Analysis determines the loss of the oils lubricating properties An infrared analysis is used to compare the properties of new oil to the properties of the use...

Страница 73: ...can enable the following problems to occur Formation of gel compounds Reduction of heat transfer Leakage of the water pump seal Plugging of radiators coolers and small passages Glycol Glycol in the co...

Страница 74: ...e glycol base coolant However ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite Perkins ELC has been formulated with the correct amount of these additives to pr...

Страница 75: ...LC Cooling System Contamination NOTICE Mixing ELC with other products reduces the effective ness of the ELC and shortens the ELC service life Use only Perkins Products for premixed or concen trate coo...

Страница 76: ...Table 21 Example Of The Equation For Adding The SCA To The Heavy Duty Coolant For Maintenance Total Volume of the Cooling System V Multiplication Factor Amount of SCA that is Required X 15 L 4 US gal...

Страница 77: ...e should be taken when dispensing DEF Spills should be cleaned immediately Machine or engine surfaces should be wiped clean and rinsed with water Caution should be used when dispensing DEF near an eng...

Страница 78: ...e high pressure fuel lines are higher than other types of fuel system Before any service or repair is performed on the engine fuel lines perform the following tasks 1 Stop the engine 2 Wait for 10 min...

Страница 79: ...itch in the OFF position 4 Battery disconnect switch in the open position 5 Disconnected battery cables 6 Battery 7 Electrical Electronic component 8 Minimum distance between the component that is bei...

Страница 80: ...F Frequent operation in ambient temperatures which are below 0 C 32 F Severe Operating Conditions Frequent operation with inlet air which has a corrosive content Operation with inlet air which has a...

Страница 81: ...place 109 Every 50 Service Hours or Weekly Fuel Tank Water and Sediment Drain 109 Every 500 Service Hours Fan Clearance Check 103 Every 500 Service Hours or 1 Year Battery Electrolyte Level Check 85 E...

Страница 82: ...Hours Aftercooler Core Clean Test 83 Every 6000 Service Hours or 3 Years Coolant Extender ELC Add 90 Every 10 000 Service Hours DEF Manifold Filters Replace 92 Every 12 000 Service Hours or 6 Years C...

Страница 83: ...opened with a comb Note If parts of the aftercooler system are repaired or replaced a leak test is highly recommended Inspect these items for good condition Welds mounting brackets air lines connectio...

Страница 84: ...ll the guard refer to OEM for more information i03559623 Battery Replace Batteries give off combustible gases which can explode A spark can cause the combustible gases to ignite This can result in sev...

Страница 85: ...n the battery case with one of the following cleaning solutions Use a solution of 0 1 kg 0 2 lb baking soda and 1 L 1 qt of clean water Use a solution of ammonium hydroxide Thoroughly rinse the batter...

Страница 86: ...s contaminated Note When the cooling system is cleaned only clean water is needed NOTICE When any servicing or repair of the engine cooling system is performed the procedure must be per formed with th...

Страница 87: ...slowly in order to relieve any pressure Remove the cooling system filler cap Remove the drain plug on the engine Open the drain cock or remove the drain plug on the radiator Allow the water to drain F...

Страница 88: ...ditions exist The engine overheats frequently Foaming of the coolant is observed The oil has entered the cooling system and the coolant is contaminated The fuel has entered the cooling system and the...

Страница 89: ...and run the engine at low idle until the temperature reaches 49 to 66 C 120 to 150 F 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any...

Страница 90: ...lant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to reli...

Страница 91: ...order to relieve any pressure Remove the filler cap 2 Maintain the coolant level at the maximum mark that is correct for your application If the engine is equipped with a sight glass maintain the cool...

Страница 92: ...n dispensing DEF Spills should be cleaned immediately All surfaces should be wiped clean and rinsed with water DEF that has been split will crystallize when the water within the liquid evaporates Spli...

Страница 93: ...ing the DEF tank Note At key on the DEF level gauge will show the last known DEF level and will transition to the new DEF level value 6 Install the DEF cap Check visually the DEF tank for leakage i059...

Страница 94: ...ion The key switch must be OFF to allow the DEF pump to purge ensuring the system is free of pressurized distilled water Note In certain circumstances allow for a maximum of 15 minutes after turning t...

Страница 95: ...Cleaner Element Dual Element Inspect Clean Replace NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner...

Страница 96: ...e air cleaner service indicator Cleaning the Primary Air Cleaner Elements Refer to the OEM information in order to determine the number of times that the primary filter element can be cleaned When the...

Страница 97: ...dusty environment Cleaning from the clean side inside with pressurized air is recommended prior to vacuum cleaning the dirty side outside of a primary air cleaner element Note Refer to Inspecting the...

Страница 98: ...ntial gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cl...

Страница 99: ...case breather is a very important component in order to keep your engine emissions compliant The filter element within the crankcase breather must be serviced at the prescribed service interval The co...

Страница 100: ...er 4 Install the guard refer to OEM i07819538 Engine Mounts Inspect Note The engine mounts may not have been supplied by Perkins Refer to the Original Equipment Manufacturer OEM information for furthe...

Страница 101: ...location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation Obtain the Sample and the Analysis Hot oil and hot components can cause personal...

Страница 102: ...valve turn the drain valve knob counterclockwise in order to drain the oil After the oil has drained turn the drain valve knob clockwise in order to close the drain valve If the engine is not equippe...

Страница 103: ...the crankcase with oil can cause engine damage 2 Start the engine and run the engine at LOW IDLE for 2 minutes Perform this procedure in order to ensure that the lubrication system has oil and that t...

Страница 104: ...and repairs are performed by authorized personnel that have had the correct training NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minu...

Страница 105: ...Operation and Maintenance Manual General hazard Information If the engine will not start refer to Troubleshooting Engine Cranks but will not Start i05326388 Fuel System Primary Filter Water Separator...

Страница 106: ...all the Element Illustration 65 g03374224 Typical example 1 Locate the thread in the filter element 8 onto the threads 9 Spin on the element Do not tighten 2 Lubricate the O ring seal 7 with clean eng...

Страница 107: ...ed fluid 2 Ensure that the outer body of the filter assembly is clean and free from dirt Illustration 66 g03374226 Typical example 3 Install a suitable tube onto drain 3 Open the drain valve 2 Rotate...

Страница 108: ...wise Two full turns are required Loosen vent screw 1 Note Two complete rotations of the valve will release the valve from the filter element 4 Allow the fuel to drain into the container Remove the tub...

Страница 109: ...the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Check the fuel daily Allow five minutes after the fuel tank has been filled before dra...

Страница 110: ...seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pressur...

Страница 111: ...items for good condition Welds mounting brackets air lines connections clamps and seals Make repairs if necessary i07888480 Starting Motor Inspect Perkins recommends a scheduled inspection of the star...

Страница 112: ...ildup Make repairs as needed The guards must be in the correct place Repair damaged guards or replace missing guards Wipe all caps and plugs before the engine is serviced in order to reduce the chance...

Страница 113: ...he high pressure fuel lines are in place and that the clips are not loose Inspect the rest of the fuel system for leaks Look for loose fuel line clamps Drain the water and the sediment from the fuel t...

Страница 114: ...he engine oil filter must be replaced Draining will remove any contaminate and will prevent any irregular oil samples In order to install a new water pump refer to the Disassembly and Assembly Manual...

Страница 115: ...quipped so as to conform at the time of sale to all applicable regulations adopted by the California Air Resources Board ARB b Free from defects in materials and workmanship which cause the failure of...

Страница 116: ...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 117: ...ntenance Log Table 23 Engine Model Customer Identifier Serial Number Arrangement Number Service Hours Quantity Of Fuel Service Item Date Authorization SEBU9068 03 117 Reference Information Section Mai...

Страница 118: ...ained technicians carry out all repairs 5 Transferable coverage should you sell your machine Flexible coverage provides the right level of protection for your Perkins Engine Coverage can be extended t...

Страница 119: ...Radiator Installed by OEM 91 Engine with Radiator Installed by the Engine Manufacturer 90 Crushing Prevention and Cutting Prevention 14 D DEF Filler Screen Clean 91 DEF Manifold Filters Replace 92 Di...

Страница 120: ...ctices 56 Fuel Related Components in Cold Weather 60 Fuel Filters 60 Fuel Heaters 60 Fuel Tanks 60 Fuel System Prime 104 Fuel System Primary Filter Water Separator Element Replace 105 Install the Elem...

Страница 121: ...formation 27 Product Information Section 21 Product Lifting 29 Product Storage Engine and Aftertreatment 30 Aftertreatment 30 Condition for Storage 30 R Radiator Clean 110 Radiator Restrictions 59 Ref...

Страница 122: ...System 113 High Pressure Fuel Lines 113 Inspect the Engine for Leaks and for Loose Connections 112 Warranty Information 115 Warranty Section 115 Water Pump Inspect 113 Welding on Engines with Electron...

Страница 123: ...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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