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Perkins 2800 Workshop Manual

6 cylinder turbocharged diesel engines for industrial applications
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Perkins 2800
Models 2806C-E16
WORKSHOP MANUAL
6 cylinder turbocharged diesel engines for industrial
applications
Publication TSD3450E, Issue 1
© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in April 2002 by Technical Publications,
Perkins Engines Company Limited, Shrewsbury SY1 3NX, England
i

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Summary of Contents for Perkins 2800

  • Page 1 6 cylinder turbocharged diesel engines for industrial applications Publication TSD3450E, Issue 1 © Proprietary information of Perkins Engines Company Limited, all rights reserved. The information is correct at the time of print. Published in April 2002 by Technical Publications, Perkins Engines Company Limited, Shrewsbury SY1 3NX, England...
  • Page 2 Chapters 1 General information 2 Specifications 3 Cylinder head assembly 4 Piston and connecting rod assemblies 5 Crankshaft assembly 6 Gear case and drive assembly 7 Crankcase and cylinder liners 8 Engine timing and electronic controls 9 Aspiration system 10 Lubrication system 11 Fuel system 12 Cooling system 13 Flywheel and housing...
  • Page 3 2800 Contents 1 General information Introduction ..................1 Safety precautions ................. 2 Viton seals .
  • Page 4 2800 Pistons and connecting rods ..............13 Crankshaft, main bearings and flywheel ............ 14 Crankshaft damper ...
  • Page 5 2800 Electronic injector units Operation 3-12 To remove and to fit ............51 Operation 3-13 To check and to adjust ............53 Injector sleeves Operation 3-14 To remove and to fit .
  • Page 6 2800 Timing gears Operation 6-2 To remove and to fit ............75 Operation 6-3 How to check the position of the timing gears ......78 Gear case Operation 6-4 To remove and to fit ...
  • Page 7 2800 10 Lubrication system General information ................95 Oil filter and oil filter header Operation 10-1 To remove and to fit .
  • Page 8 2800 12 Cooling system General information ................111 Cooling system Operation 12-1 To inspect ..............112 Operation 12-2 Leakage test .
  • Page 9 2800 13 Flywheel and housing General information ................129 Flywheel Operation 13-1 To remove and to fit ............130 Flywheel housing Operation 13-2 To remove and to fit .
  • Page 10 2800 Workshop Manual, TSD3450E, Issue 1...

  • Page 11: General Information

    General information Introduction The 2800 Series engines are from Perkins Engines Company Limited, a world leader in the design and manufacture of high-performance diesel engines. Perkins approved assembly and quality standards, together with the latest technology, have been applied to the manufacture of your engine to give you reliable and economic power.

  • Page 12: Safety Precautions

    2800 Safety precautions These safety precautions are important. You must refer also to the local regulations in the country of use. Some items only apply to specific applications. l Always refer to the text of this handbook for specific warnings and cautions.
  • Page 13 Some components are not waterproof and should not be washed with a high-pressure water jet or steam. l Fit only genuine Perkins parts. Workshop Manual, TSD3450E, Issue 1...

  • Page 14: Environmental Protection

    2800 Viton seals Some seals used in engines and in components fitted to engines are made from Viton (fluorocarbon). Viton is used by many manufacturers and is a safe material under normal conditions of operation. If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this burnt material to come into contact with the skin or with the eyes.
  • Page 15 2800 Engine views Workshop Manual, TSD3450E, Issue 1...

  • Page 16: Engine Identification

    2800 Engine identification If you need parts, service or information for your engine, you must give the complete engine number. The engine number is stamped on a data plate which is fastened to the right side of the engine. A typical engine number is: HGA060125U 1103H, which consists of these codes:...

  • Page 17: Specifications

    2800 Specifications Basic engine data Number of cylinders....................... 6 Cylinder arrangement ..
  • Page 18 2800 Rocker assemblies Rocker shaft diameter (A2) ..........40,000 +/- 0,010 mm (1.5748 +/- 0.0004 in) Valve rocker lever bore (A1) ..........40,065 +/- 0,015 mm (1.5774 +/- 0.0006 in) Bearing clearance between valve rocker lever and shaft ..
  • Page 19 2800 Valves Diameter of valve stem (B1) ..........9,441 +/- 0,010 mm (0.3717 +/- 0.0004 in) Permissible worn dimension ..............9,408 mm (0.3704 in) Diameter of valve head (B3): Inlet valve ...
  • Page 20 2800 Valve guides Bore of valve guide when installed ........9,487 +/- 0,025 mm (0.3735 +/- 0.010 in) Maximum permissible dimension..............9,538 mm (0.3755 in) Do not use a combination of a valve and valve guide which have a difference of 0,13 mm (0.005 in) or more.
  • Page 21 2800 Valve seat inserts Depth of bore in cylinder head for valve seat insert (D5): Inlet valve ..............14,00 +/- 0,10 mm (0.551 +/- 0.004 in) Exhaust valve ..

  • Page 22: Cylinder Head

    2800 Cylinder head Thickness of cylinder head (new) ......... . 120,00 +/- 0,15 mm (4.724 +/- 0.006 in) Minimum thickness for a used cylinder head ...........119,50 mm (4.705 in) Flatness of cylinder head: The cylinder head must be flat to within a total of 0,13 mm (0.005 in).

  • Page 23: Pistons And Connecting Rods

    2800 Pistons and connecting rods Piston ring gaps measured with the ring fitted in a new liner with a bore size 139,66 mm (5.498 in): Top piston ring (F4) ............. 0,50 +/- 0,10 mm (0.020 +/- 0.004 in) Intermediate ring (F3) ..
  • Page 24 2800 Crankshaft, main bearings and flywheel Diameter of main bearing journal (G2)....... 120,650 +/- 0,020 mm (4.7500 +/- 0.0008 in) Journal undersize by 0,63 mm (0.025 in)......... 120,015 +/- 0,020 (4.7250 +/- 0.0008 in) Journal undersize by 1,27 mm (0.050 in)...

  • Page 25: Crankcase And Cylinder Liners

    2800 Crankcase and cylinder liners Thickness of spacer plate (H3) .......... 8,585 +/- 0,025 mm (0.3380 +/- 0.0010 in) Thickness of gasket fitted between spacer plate and crankcase ... 0,238 +/- 0,032 mm (0.0094 +/- 0.0013 in) Cylinder liner protrusion (H5) above the spacer plate .
  • Page 26 2800 Distance from top of crankcase to centre of main bearing bore (J1) ............425,45 +/- 0,15 mm (16.750 +/- 0.006 in) Minimum permissible (J1) ..
  • Page 27 2800 Lubricating oil pump Diameter of shafts (L1) ..........22,217 +/- 0,005 mm (0.8747 +/- 0.0002 in) Diameter of bores in cover for shafts........22,258 +/- 0,008 mm (0.8763 +/- 0.0003 in) Length of gears (L3) ...
  • Page 28 2800 Coolant pump Shaft diameter at the position of the coolant seal (M1)....19,10 +/- 0,01 mm (0.7520 +/- 0.0004 in) Workshop Manual, TSD3450E, Issue 1...
  • Page 29 2800 Recommended torque figures Exceptions to these torque figures are given in the Workshop Manual where necessary. Before any components are fitted to the engine, ensure that they are in a new or close to new condition. Bolts or threads must not be worn or damaged. Components must be free from rust or other corrosion. Clean with a non-corrosive cleaner if necessary.
  • Page 30 2800 Standard torque figures for imperial fasteners Imperial nuts and bolts Thread size Standard torque inches 12 +/- 3 Nm (9 +/- 2 lbf ft) 5/16 25 +/- 6 Nm (18 +/- 4 lbf ft) 47 +/- 9 Nm (35 +/- 7 lbf ft)
  • Page 31 2800 Standard torque figures for ‘O’ ring face seal fittings and 37 degree flared fittings Torque figures for ferrous straight thread ‘O’ ring fittings when connected to ferrous materials Thread size Standard Outside diameter of nominal tube Inches torque 3,18 mm...
  • Page 32 2800 ‘O’ ring face seal fittings Torque figures for ferrous straight thread ‘O’ ring fittings (B) Thread size Standards torque inches 8 +/- 3 Nm (6 +/- 2 lbf ft) 5/16 17 +/- 5 Nm (13 +/- 4 lbf ft)
  • Page 33 2800 Torque figures for flared and ‘O’ ring fittings The torque figures given in the table below and the table given on page 17 should be applied to the nut of the fittings which follow: 37 degree flared fittings (C1), 45 degree flared fittings (C3), inverted flared fittings (C2), ‘O’...
  • Page 34 2800 45 degree flared and 45 degree inverted flare fittings 45 degree flared and 45 degree inverted flare fittings Thread size Standard Outside diameter of nominal tube Inches torque 3,18 mm 5,0 +/- 1,5 Nm 5/16 (0.125 in) (4 +/- 1 lbf ft)
  • Page 35 2800 Torque figures for standard hose clamps of the worm drive band type Torque figure for initial Width of clamp installation on a new hose 7,9 mm (0.31 in) 0,9 +/- 0,2 Nm (8 +/- 2 lbf in) 13,5 mm (0.53 in) 4,5 +/- 0,5 Nm (40 +/- 4 lbf in) 15,9 mm (0.63 in)
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  • Page 37: Cooling System

    The operations to remove and to fit valve seat inserts and to remove and to fit camshaft bearings are not included as specialist equipment is required. It is recommended that operators take advantage of the Perkins service exchange scheme if these procedures become necessary.
  • Page 38 2800 Rocker cover To remove and to fit Operation 3-1 To remove 1 Disconnect the wiring harness at the socket on the rocker cover (A1). 2 Disconnect and remove the engine breather pipe (A2). 3 Loosen fully the bolts which retain the rocker cover, but do not remove the bolts from the assembly; allow them to be retained by the seal.
  • Page 39 2800 Rocker lever and rocker shaft assemblies To remove and to fit Operation 3-2 To remove 1 Remove the rocker cover, Operation 3-1. 2 The valve rocker levers (A1) and the unit injector rocker levers (A2) can move on the shaft (A6) after the four bolts (A5) have been removed.
  • Page 40 2800 To dismantle and to assemble Operation 3-3 To dismantle Note: Check the condition of all components and renew any which are worn or damaged. 1 Slide the valve rocker levers (A3) and the unit injector rocker levers (A4) from the shaft (A7).
  • Page 41 2800 To assemble 1 Install new ‘O’ ring seals in the buttons (A1). 2 Install new ‘O’ ring seals in the buttons (A6). 3 To fit the ‘O’ ring seals and buttons to the valve rocker levers, proceed as follows: a.

  • Page 42: Special Tools

    2800 How to check/adjust the tappet clearances Operation 3-4 Special requirements Special tools Tappet clearances Description Part number Inlet Exhaust Engine turning tool CH11148 0,38 mm (0.015 in) 0,76 mm (0.030 in) The tappet clearance is measured between the rocker levers and the top of the valve bridge pieces. The operation must be done with the engine cold and stopped.
  • Page 43 2800 5 Check the inlet and exhaust valves of the number 1 cylinder. If they are fully closed the piston is on its compression stroke and the rocker levers can be moved by hand. If the rocker levers can not be moved because the valves are slightly open, the piston is on its exhaust stroke.
  • Page 44 2800 Notes: l Move each valve bridge piece before the feeler gauge is inserted to reduce the effect of the oil film. l During the procedure, ensure that the feeler gauge is fully inserted 8 After each unit has been adjusted, tighten the lock nut (B2) of the adjustment screw (B1) to a torque of 30 +/ - 4 Nm (22 +/- 3 lbf ft).
  • Page 45 2800 Cylinder head assembly To remove and to fit Operation 3-5 Special requirements Special tools Consumable products Description Part number Description Part number Guide bolt, camshaft gear GE50019 Special lubricant CV60895 Socket, cylinder head bolt GE50020 Retaining compound 21820 638...
  • Page 46 2800 12 Remove the cylinder head gasket (B4). 13 Remove the ‘O’ ring seal from the oil transfer tube (B6) and remove the 24 coolant seals (B3). 14 Remove the seal (B2). 15 Remove the spacer plate (B5) and discard the spacer plate gasket.
  • Page 47 2800 To fit 1 If the oil transfer tube (B6) has been removed, apply retaining compound, 21820 638, and insert it in the crankcase. It must protrude from the top face of the crankcase by 20,0 +/- 0,5 mm (0.79 +/- 0.02 in). Remove any excess compound and ensure that the bore of the oil transfer tube is clean.
  • Page 48 2800 9 Fasten a hoist to the cylinder head, use the lifting bracket VP12712, and lower the cylinder head onto the spacer plate. 10 Apply special lubricant, CV60895, to the washers, the threads and under the heads of the bolts and fit the cylinder head bolts and washers.

  • Page 49: Valve Springs

    2800 Valve springs To remove and to fit Operation 3-6 Special requirements Special tools Description Part number Valve spring compressor GE50026 To remove Note: The valve springs can be removed with the cylinder head either fitted to or removed from the engine.
  • Page 50 2800 To fit 1 Apply clean engine oil to the relevant valve stems. 2 Fit the washer, valve spring and rotocoil to each valve. 3 Use the valve spring compressor, GE50026, to compress the valve springs. Note: The collets are tapered. When fitted, the large (thick) diameter must be uppermost.

  • Page 51: Cylinder Head

    2800 Valves To remove and to fit Operation 3-7 Special requirements Special tools Description Part number Valve spring compressor GE50026 To remove 1 Remove the cylinder head, Operation 3-5. Note: If more than one valve is to be removed, make a note of the position of the valves as they are removed from the cylinder head.
  • Page 52 2800 Valve seals To renew Operation 3-8 Special requirements Special tools Description Part number Insertion tool, valve seal GE50027 Note: The valve seals can be removed with the cylinder head either fitted to or removed from the engine. 1 Remove the relevant valve spring assembly, Operation 3-6.
  • Page 53 2800 Valve guides To remove and to fit Operation 3-9 Special requirements Special tools Description Part number Removal/installation tool GE50043 Sleeve GE50044 To remove 1 Remove the cylinder head, Operation 3-5. 2 Remove the valves, Operation 3-7. 3 Use the special tool (A1), GE50043, and a hammer to drive the valve guide (A2) from the cylinder head.
  • Page 54 2800 To fit 1 Apply clean engine oil to the outside diameter of the new valve guides. 2 Use the special tool (B1), GE50043, together with the sleeve (B2), GE50044, to install the valve guide. The guide must protrude from the cylinder head, as shown (C1), by 35,0 +/- 0,5 mm (1.38 +/- 0.02 in).
  • Page 55 2800 Camshaft To remove and to fit Operation 3-10 Special requirements Special tools Consumable products Description Part number Description Part number Engine turning tool CH11148 Thread lock compound (10 ml) 21820 117 Guide stud GE50019 Cradle tool GE50018 Camshaft guide...
  • Page 56 2800 8 Insert the engine turning tool, CH11148, into the flywheel housing through the aperture behind the cover (A2). Use a inch drive ratchet with the turning tool to rotate the engine flywheel in the normal direction of rotation (anti-clockwise when viewed on the flywheel) until the timing bolt engages with the threaded hole in the flywheel.
  • Page 57 2800 14 Remove the rear cover (C1), complete with seal (C3). 15 Fit the camshaft guide (D1), GE50017, to the gear case. Do not tighten the bolts for the guide at this stage. Note: It is necessary to install two pilots, GE50015, on the rear end of the camshaft. The second pilot will support the rear of the camshaft as it is moved from the cylinder head and into the guide, GE50017.
  • Page 58 2800 To fit 1 Fit the two pilot tools, GE50015, to the rear end of the camshaft. Ensure that the camshaft and camshaft bearings have been cleaned thoroughly. Apply clean engine oil to the lobes and journals of the camshaft. Apply a thin coat of clean engine oil to the camshaft bearings.
  • Page 59 2800 9 Remove the cradle tool and the camshaft guide. 10 Fit new ‘O’ ring seals to the camshaft front seal plate. Apply a small amount of engine lubricating oil to the ‘O’ ring seal on the outside of the plate. Fit the seal plate with the face seal against the cylinder head. Insert the adapter plate and fit the thrust plate.
  • Page 60 2800 How to set the backlash for the camshaft gear Operation 3-11 If the cylinder head or the camshaft is removed, the backlash between the camshaft gear (A1) and the adjustable idler gear (A2) must be checked and, if necessary, adjusted. The backlash between the camshaft gear and the adjustable idler gear, and also between the adjustable idler gear (A2) and the main idler gear (A3), must be 0,25 +/- 0,08 mm (0.010 +/- 0.003 in).
  • Page 61 2800 Electronic injector units To remove and to fit Operation 3-12 Special requirements Special tools Description Part number Description Part number Injector installer/removal GE50021 Brush GE50022 Vacuum pump GE50028 Brush GE50023 Tube GE50030 Brush GE50024 Bottle GE50029 To remove Warning! The electrical circuit for the fuel injector units operates on 110 volts. Do NOT work on the fuel injector units unless the power supply to the ECM has been disconnected.
  • Page 62 2800 To fit 1 Clean thoroughly the bore of the injector sleeve and cylinder head. Use the special brushes (GE50022, GE50023 and GE50024) to remove carbon or dirt. 2 Check the condition of the ‘O’ ring seals (B1 and B2); renew the seals if they are worn or damaged. Lubricate the ‘O’...
  • Page 63 2800 To check and to adjust Operation 3-13 Special requirements Special tools Description Part number Injector height gauge CH11149 This operation should be performed at the same time as the operation to check the valve tappet clearances. Warning! The electrical circuit for the fuel injector units operates on 110 volts. Do NOT work on the fuel injector units unless the power supply to the ECM has been disconnected.
  • Page 64 2800 Injector sleeves To remove and to fit Operation 3-14 Special requirements Special tools Description Part number Description Part number Injector installer/removal GE50021 Brush GE50022 Vacuum pump GE50028 Brush GE50023 Tube GE50030 Brush GE50024 Bottle GE50029 To remove 1 Remove the rocker shaft assemblies, Operation 3-2.
  • Page 65 2800 To fit Caution: Before installation ensure that the injector sleeve and its bore in the cylinder head are clean and free from oil, dirt and sealant. 1 Use the brushes, special tool numbers: GE50023, GE50024 and GE50022, to clean thoroughly the bore for the injector sleeve.
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  • Page 67: Pistons And Connecting Rod Assemblies

    General information The pistons fitted to the 2800 Series engines consist of two parts: a forged steel crown (A1) and a cast aluminium skirt (A2). The two parts are retained on the connecting rod by the gudgeon pin (A4). The pistons each have three rings fitted to grooves in the crown.
  • Page 68 2800 Pistons and connecting rod assemblies To remove and to fit Operation 4-1 Special requirements Special tools Consumable products Description Part number Description Part number Installer, piston GE50003 Anti-seize compound CV60890 To remove 1 Remove the cylinder head assembly, Operation 3-5.
  • Page 69 2800 To fit 1 Apply clean engine oil to the piston rings, the connecting rod bearings and the cylinder liners. 2 Ensure that the piston ring gaps are set at 120 degree intervals to each other. 3 Use the special tool (B1), GE50003, to install the piston and the connecting rod in the cylinder liner (B2).
  • Page 70 5 Remove carefully the piston rings (A3) from the piston crown and clean the piston ring grooves with a suitable cleaning tool. Special equipment is required to renew the small end bearing. If this operation becomes necessary, contact your Perkins dealer. Workshop Manual, TSD3450E, Issue 1...
  • Page 71 2800 To assemble 1 Check the gaps between the ends of the piston rings when the rings are inserted in a new liner. The rings can also be checked by insertion in an unworn part of a used liner. For the correct dimensions refer to Chapter 2, Specifications.
  • Page 72 2800 Piston cooling jets To remove and to fit Operation 4-3 Special requirements Special tools Description Part number Engine turning tool CH11148 Jet alignment tool GE50004 To remove 1 Remove oil pump, Operation 10-4. 2 Use the engine turning tool, CH11148, to turn the crankshaft in a clockwise direction (as seen from the front of the engine) to obtain access to the relevant piston cooling jet.

  • Page 73: Crankshaft Assembly

    Crankshaft assembly General information The crankshaft fitted to the 2800 Series engine has 13 bearing surfaces, which consists of seven main journals and six crank pins. Each crank pins holds two connecting rods. Eight counterweights are included within the crankshaft forging and a vibration damper is fitted at the front end to reduce torsional vibrations.

  • Page 74: Crankshaft Front Seal And Wear Sleeve

    2800 Crankshaft To remove and to fit Operation 5-1 Special requirements Consumable products Description Part number Anti-seize compound CV60890 To remove 1 Remove the gear case cover, Operation 6-1. 2 Remove the flywheel housing, Operation 13-2. 3 Remove the pistons and connecting rod assemblies, Operation 4-1.
  • Page 75 2800 To fit 1 Clean the crankcase and the main bearing caps thoroughly. Apply clean engine oil to the main bearings and fit the upper halves of the main bearings into the crankcase. 2 Install one of the bolts from the front pulley in each end of the crankshaft, fasten a suitable hoist and fit the crankshaft into the crankcase.
  • Page 76 2800 Crankshaft front seal and wear sleeve To renew Operation 5-2 Special requirements Special tools Consumable products Description Part number Description Part number Locator assembly GE50008 Bolt GE50009 Quick cure primer CV60892 Distorter protection ring GE50010 Distorter tool GE50011 Installer...
  • Page 77 2800 To fit Note: Before the new seal and wear sleeve are installed, read carefully the special instruction which is supplied with each seal and wear sleeve. 1 Clean and the wear sleeve inside diameter and crankshaft outside diameter with quick cure primer, CV60892.
  • Page 78 2800 Crankshaft rear seal and wear sleeve To renew Operation 5-3 Special requirements Special tools Consumable products Description Part number Description Part number Locator assembly GE50008 Bolt GE50009 Quick cure primer CV60892 Distorter protection ring GE50010 Distorter tool GE50011 Installer...
  • Page 79 2800 To fit Note: Before the new seal and wear sleeve are installed, read carefully the special instruction which is supplied with each seal and wear sleeve. 1 Clean and the wear sleeve inside diameter and crankshaft outside diameter with quick cure primer, CV60892.
  • Page 80 2800 Crankshaft vibration damper To remove and to fit Operation 5-4 To remove 1 Remove the fan guards. 2 Slacken the tension on the fan drive belts, then remove the belts from the crankshaft pulley (A1). 3 Attach a strap and a suitable lifting device to the vibration damper (A2). Remove the six bolts and washers which retain the vibration damper and the adapter (A3) to the crankshaft.
  • Page 81 2800 To fit 1 Attach a strap and a suitable lifting device to the vibration damper (A2). Use a 5/8 -18 x 6 in (152 mm) long guide stud, and fit the vibration damper (A2) and adapter (A3) to the crankshaft. The weight of the vibration damper is approximately 25 kg (55 lb).
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  • Page 83 2800 Gear case and drive assembly General information The cast iron gear case contains the timing gears for the engine and the gears which drive the coolant pump, the lubricating oil pump and the fuel transfer pump (A8). Both helical and spur gears are used. The crankshaft gear (A2), the large gear of the compound idler (A3), the coolant pump gear (A4) and the lubricating oil pump gear (A1) are helical.
  • Page 84 2800 Gear case cover To remove and to fit Operation 6-1 To remove 1 Remove the radiator, Operation 12-4. 2 Remove the fan, Operation 12-5. 3 Loosen the bolts which retain the gear case cover. Do not remove the bolts from the assembly, allow them to be retained by the seal.

  • Page 85: Timing Gears

    2800 Timing gears To remove and to fit Operation 6-2 Special requirements Special tools Consumable products Description Part number Description Part number Engine turning tool CH11148 Thread lock compound (10 ml) 21820 117 Guide stud GE50019 To remove 1 Remove the gear case cover, Operation 6-1, and set the engine to the correct timing position for number...
  • Page 86 2800 5 Remove the rocker lever and rocker shaft assemblies, Operation 3-2. If the camshaft gear (C2) is to be removed, slacken the six retaining bolts before the removal of the rocker lever and rocker shaft assemblies. 6 Remove the camshaft gear (C2), if relevant. Use the guide stud, GE50019. If the gear case is to be removed, the camshaft gear should be removed at this stage.
  • Page 87 2800 To fit 1 Fit the assembly of the compound idler to its shaft, ensure that the "V" timing mark on the crankshaft is aligned with the marks on the large gear of the compound idler. Fit the thrust plate and fit new bolts. Tighten the bolts to a torque of 28 +/- 7 Nm (21 +/- 5 lbf ft).

  • Page 88: Gear Case

    2800 How to check the position of the timing gears Operation 6-3 Fuel injection timing and the operation of the rocker valves depends on the correct alignment of the timing gears. When the timing mark on the camshaft gear (A1) is aligned with the mark on the gear case, the ‘V’ on the crankshaft must also be aligned exactly with the line (A2) on the idler gear.
  • Page 89 2800 Gear case To remove and to fit Operation 6-4 Special requirements Consumable products Description Part number Thread lock compound (10 ml) 21820 117 To remove 1 Remove the gear case cover, Operation 6-1. 2 Disconnect the lead and remove camshaft timing sensor from behind the top of the gear case.
  • Page 90 2800 To fit 1 Clean thoroughly the contact surfaces of the crankcase and gear case. 2 Fit the two dowels, if they have been removed, and ensure that they protrude from the crankcase by 19,1 +/ - 0,5 mm (0.75 +/- 0.02 in).
  • Page 91 2800 Crankcase and cylinder liners General information The crankcase is a single unit casting made from high quality cast iron and comprises the crank chamber and the cylinder block. The crank chamber extends below the centre of the crankshaft to ensure rigidity. The crankshaft is supported in seven bearings secured by removable caps and fitted with thrust washers at the centre bearing.
  • Page 92 2800 Front engine support To remove and to fit Operation 7-1 To remove 1 Remove the radiator, Operation 12-4. 2 Use a suitable hoist, attached to the front lifting bracket, to support the engine and remove the bolts (A2). which retain the front mounting support (A3) to the base frame.
  • Page 93 2800 Cylinder liners To remove and to fit Operation 7-2 Special requirements Special tools Consumable products Description Part number Description Part number Cylinder liner remover GE50001 Anti-seize compound CV60890 Cylinder liner installer GE50000 Anti-seize compound CV60890 To remove 1 Remove the pistons and connecting rod assemblies, Operation 4-1.
  • Page 94 2800 To check and to adjust the protrusion of the cylinder liners Operation 7-3 Special requirements Special tools Description Part number Description Part number Clamp bolt GE50005 Fibre washer GE50007 Clamp washer GE50006 Cylinder liner projection tool GE50002 Note: Cylinder liner protrusion is measured from the top of the cylinder liner to the top of the spacer plate.
  • Page 95 6 If the liner protrusions are all below the specifications or low in the range, 0,025 mm (0.001 in) or 0,051 mm (0.002 in), try a thinner spacer plate, available from your Perkins dealer. These plates are 0,076 mm (0.003 in) thinner than the original plate and will increase the liner protrusion.
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  • Page 97 Diagnostic Manual, TSD3453. The ECM communicates with the service tool through the Perkins Data Link (PDL); a connector is normally fitted to the wiring harness to enable the service tool to be connected. A J1939 data link is also available in addition to the Perkins Data Link.
  • Page 98 2800 Electronic control module To remove and to fit Operation 8-1 To remove 1 Switch off the engine and disconnect the electrical power supply. 2 Loosen fully the Allen screws from the J1 and J2 connectors (A1 and A4). 3 Remove the two nuts which retain the bar (A6) and the control module (A3), release the ground strap and withdraw the bar and connectors from the control module.

  • Page 99: Engine Timing

    2800 Engine timing To check Operation 8-2 Special requirements Special tools Description Part number Engine turning tool CH11148 If it becomes necessary to check the valve/ignition timing position of the engine, use this procedure: 1 With the engine switched off and electrically isolated, remove the rocker cover, Operation 3-1.
  • Page 100 2800 When the number one piston is at TDC on its compression stroke, the valves of number one cylinder will be fully closed, if not, remove the timing bolt, rotate the engine by a further 360 degrees and insert again the timing bolt.

  • Page 101: Aspiration System

    2800 Aspiration system General information The induction system of the engine is supplied with air under pressure by a turbocharger. The turbocharger is driven by the energy of the exhaust gas. Special thermal sleeves manufactured from stainless steel are fitted to the exhaust ports. These reduce the amount of heat transferred to the cooling system and direct the thermal energy to the turbocharger.

  • Page 102: Exhaust Manifold

    2800 Exhaust manifold To remove and to fit Operation 9-1 Special requirements Special tools Consumable products Description Part number Description Part number Pressurizing pump GE50031 Anti-seize compound CV60889 To remove 1 Remove the turbocharger, Operation 9-2. 2 Remove the thermostat housing, Operation 12-10.
  • Page 103 2800 Turbocharger To remove and to fit Operation 9-2 To remove 1 Disconnect the exhaust pipe from the turbocharger. 2 Remove the air duct from between the turbocharger and the air cleaner. 3 Disconnect the air duct from between the turbocharger and the charge air cooler.
  • Page 104 2800 To dismantle and to assemble Operation 9-3 To dismantle 1 Remove turbocharger, Operation 9-2. 2 Add temporary alignment marks between the bearing housing and both the compressor housing and the turbine housing to ensure that the parts can be correctly aligned during the assembly operation.

  • Page 105: Lubrication System

    2800 Lubrication system General information A wet sump type of lubrication system is used on the engine. The engine is fitted with a lubricating oil pump, of the spur gear type, which is driven by a helical gear. The helical gear is driven by a gear on the front of the crankshaft. The oil pump draws oil from the sump through a suction strainer.

  • Page 106: Oil Filter Header

    2800 Oil filter and oil filter header To remove and to fit Operation 10-1 To remove 1 Remove the plug (A5) and drain the oil from the oil filter housing. 2 Remove the oil filter housing (A3), and remove the oil filter element.
  • Page 107 6 Fit a new element into the filter housing, ensure that it engages fully with the guide in the base of the housing. Fit a new ‘O’ ring seal around the top of the housing. Caution: It is important that only genuine Perkins parts are used. The use of incorrect parts could damage the engine.
  • Page 108 2800 Oil filter header To dismantle and to assemble Operation 10-2 To dismantle 1 Remove the two plugs (A5 and A6) which retain the by-pass valves in the oil filter header (A1). 2 Remove the spring (A3) and the plunger (A2) for the oil cooler by-pass valve. Remove the spring (A8) and plunger (A9) for the oil filter by-pass valve.
  • Page 109 2800 Sump To remove and to fit Operation 10-3 Special requirements Consumable products Description Part number RTV silicone sealant CV60888 To remove Warning! Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin.
  • Page 110 2800 To fit 1 Examine the sump seal and renew if necessary. Ensure that the machined surface of the sump is clean before a new seal is fitted. 2 Clean the bottom face of the crankcase and also the bottom faces of the flywheel housing and the gear case.

  • Page 111: Oil Pump

    2800 Oil pump To remove and to fit Operation 10-4 To remove 1 Remove the sump, Operation 10-3. 2 Remove the oil supply tube (A4) and the strainer and tube (A2). 3 Remove the bolts and remove the oil pump (A5).
  • Page 112 2800 To dismantle and to assemble Operation 10-5 To dismantle 1 Remove the bolt and washer which retain the gear on the shaft. 2 Use a suitable gear puller to remove drive gear (A1) from the shaft. Remove the key from the shaft.

  • Page 113: Fuel System

    2800 Fuel system General information The fuel supply circuit used on the 2806 engine is a conventional design for engines fitted with unit injectors. A fuel transfer pump, driven by the timing gears of the engine, is fitted behind the gear case on the left side of the engine.
  • Page 114 2800 Fuel priming pump To remove and to fit Operation 11-1 To remove‘ 1 Remove two bolts (A2) and remove fuel priming pump (A1). To fit 1 Inspect the gasket of the fuel priming pump; fit a new gasket if necessary.
  • Page 115 2800 Fuel transfer pump To remove and to fit Operation 11-2 To remove 1 Disconnect the fuel pipes from the fuel transfer pump (A2). 2 Use plugs or caps to seal temporarily all openings to prevent contamination of the fuel system.
  • Page 116 2800 To test Operation 11-3 Use a suitable test rig and diesel fuel to test the fuel transfer pump. 1 Run the pump at 2940 rev/min. The flow at 650 kPa (94 lb/in ) must be 4,5 litres/min (1.0 UK gall/min).
  • Page 117 2800 Drive for the fuel transfer pump To remove and to fit Operation 11-4 To remove 1 Remove the fuel transfer pump (A2), Operation 11-2. 2 Remove four bolts and washers (A1) and withdraw the assembly of the pump drive and housing (A3) from the gear case.
  • Page 118 2800 Fuel filter header To remove and to fit Operation 11-5 To remove 1 Remove the fuel priming pump (A2), Operation 11-1. 2 Disconnect the fuel pipes (A1, A3, A4 and A5). Fit plugs or caps to all openings to prevent contamination of the fuel system.
  • Page 119 2800 Low pressure fuel system How to eliminate air from the fuel system Operation 11-6 This procedure is used normally when the engine runs out of fuel. 1 Loosen the union of the fuel return pipe (A1). Unlock and operate the hand priming pump (A2) until fuel, free from air, flows from the union;...
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  • Page 121: Cooling System

    2800 Cooling system General information A pressurised coolant system is used on the engine. This allows the system to operate at a temperature higher than the boiling point of water and prevents cavitation in the coolant pump. In normal operation, the coolant pump directs most of the coolant through the oil cooler and into the cylinder block.
  • Page 122 2800 Cooling system To inspect Operation 12-1 Inspect visually the cooling system before any tests are performed. Notes: l Inspect the coolant pump seals. A small amount of leakage of coolant across the surface of the face seal in the water pump is normal. Its purpose is to provide lubrication for the seal.
  • Page 123 2800 Leakage test Operation 12-2 Special requirements Special tools Description Part number Pressurizing pump GE50031 Use the procedure which follows to check for leakage of the cooling system. Warning! On a hot engine release the filler cap carefully as the system will be under pressure. Cooling system conditioner contains alkali.

  • Page 124: Radiator

    2800 Coolant filler cap To test Operation 12-3 Special requirements Special tools Description Part number Pressurizing pump GE50031 Use the procedure which follows to check the operation of the coolant filler cap. Warning! On a hot engine release the filler cap carefully as the system will be under pressure. Cooling system conditioner contains alkali.
  • Page 125 2800 Radiator To remove and to fit Operation 12-4 To remove 1 Drain the coolant into a suitable container. 2 Remove the air duct from between the charge air cooler and the air inlet elbow. 3 Remove the coolant pipe from between the thermostat housing and the top of the radiator.
  • Page 126 2800 To remove and to fit Operation 12-5 To remove 1 Switch off the engine and disconnect the electrical power supply. 2 Remove the fan guards. Caution: Take care during the removal of the fan; ensure that the radiator does not become damaged.

  • Page 127: Fan Drive Belts

    2800 Fan drive assembly To remove and to fit Operation 12-6 To remove 1 Remove the fan, Operation 12-5. 2 Remove the hub (A1). 3 Loosen the adjustment bolts to release the tension on the alternator belt. Remove the belt and the alternator (A3).
  • Page 128 2800 Fan drive belts To check and to adjust the tension Operation 12-7 1 Remove the fan guards. 2 Use a Borroughs belt tension gauge to check the tension at the position shown (A1). It should be 800 N, which is equivalent to 4,0 mm of movement when a force of 33 N is applied. To adjust the tension, proceed as...
  • Page 129 2800 To renew Operation 12-8 1 Remove the fan, Operation 12-5. 2 Loosen the belt tensioner and remove the old belts. Ensure that the grooves of the pulley are free from grease and dirt and fit a new set of belts.

  • Page 130: Engine Oil Cooler

    2800 Engine oil cooler To remove and to fit Operation 12-9 To remove 1 Drain the coolant from the engine. 2 Use a tray to collect any oil which may spill from the oil cooler during its removal. 3 Make temporary marks on the coolant duct (A2) and the oil cooler (A1) for correct alignment during assembly.
  • Page 131 2800 Thermostats and thermostat housing To remove and to fit Operation 12-10 To remove 1 Drain the coolant until the level is below the thermostat housing (A1). 2 Disconnect the cable (A3) from the coolant temperature sensor. 3 Release the hose clips (A2) and disconnect the pipe and hose from the top of the unit.
  • Page 132 2800 To fit Note: If the thermostat housing has not been dismantled, continue from step 3. 1 Clean thoroughly both parts of the assembly and check the condition of the lip-type seals. Renew the seals if they are worn or damaged.
  • Page 133 2800 To test the thermostats Operation 12-11 1 Remove the thermostats from the engine. Warning! Use care during this operation to avoid serious injury from the hot water. 2 Heat water in a suitable container until the temperature is 98 °C (208 °F). Stir the water to ensure that the temperature is consistent within the container.

  • Page 134: Coolant Temperature Sensor

    2800 Coolant temperature sensor To test Operation 12-12 Special requirements Special tools Description Part number Thermometer GE50032 Check the accuracy of the coolant temperature sensor (A2) if one of these conditions exist: The engine runs at a temperature that is too hot, but a normal temperature is indicated. A loss of coolant is found.
  • Page 135 2800 Coolant pump To remove and to fit Operation 12-13 To remove 1 Drain the coolant from the engine into a suitable container for storage or disposal. 2 Remove the thermostat housing, Operation 12-10. 3 Remove the oil cooler, Operation 12-9.
  • Page 136 Service exchange coolant pumps can be obtained from your Perkins dealer. To dismantle 1 Remove the bolt (A15) and washer (A14). Use a suitable puller to remove the impeller (A11) from the shaft (A16).
  • Page 137 2800 To assemble 1 Ensure that the shaft and the seal counter bore in the pump housing are clean. 2 Fit the bearing (A1), the spacer if relevant, and the second bearing (A2) to the shaft (A16). 3 Fit the retainer (A7) and gear (A8) to the shaft assembly. Fit the second retainer (A3) and the bolt (A4).
  • Page 138 2800 To test the pressure of the coolant pump Operation 12-15 Special requirements Special tools Description Part number Pressure gauge GE50033 1 To check that the coolant pump is operating correctly, the outlet pressure can be measured. 2 Remove the plug (A1) from the coolant manifold and connect the pressure gauge, GE50033, to the port.

  • Page 139: Flywheel And Housing

    2800 Flywheel and housing General information The steel flywheel is fitted with a hardened starter ring. The flywheel is fastened securely to the rear face of the crankshaft by a clamp ring and 12 bolts. A dowel ensures that, when the flywheel is fitted, the timing marks on the flywheel are in the correct relationship to the crankshaft.
  • Page 140 2800 Flywheel To remove and to fit Operation 13-1 To remove 1 Remove two of the flywheel bolts from horizontally opposite sides of the flywheel and insert two suitable guide studs. 2 Remove the bolts which remain and withdraw the flywheel from the crankshaft. Fit a suitable sling through the centre of the flywheel and support the weight with a hoist.
  • Page 141 2800 Flywheel housing To remove and to fit Operation 13-2 Special requirements Consumable products Description Part number Liquid gasket CH10879 To remove 1 Remove the flywheel, Operation 13-1. 2 Remove the crankshaft rear seal and wear sleeve, Operation 5-3. 3 Remove the starter motor, Operation 14-1.
  • Page 142 2800 To fit 1 Clean thoroughly the contact surfaces of the crankcase and flywheel housing. 2 Fit the two dowels (B2 and B3) if they have been removed from the crankcase. They must protrude from the crankcase by 19,1 +/- 0,5 mm (0.75 +/- 0.02 in).

  • Page 143: Electrical Equipment

    2800 Electrical equipment General information This section includes the components which form part of the battery charging circuit and the engine starting circuit: the alternator and starter motor. A brush-type alternator is fitted at the front of the engine. The alternator unit is driven by a single belt from the fan pulley.

  • Page 144: Starter Motor

    2800 Starter motor To remove and to fit Operation 14-1 To remove Note: To assist with the assembly operation, identify and mark the positions of all wiring before it is disconnected. 1 Disconnect the batteries before any service work is attempted.
  • Page 145 2800 Alternator To remove and to fit Operation 14-2 To remove Note: To assist with the assembly operation, identify and mark the positions of all wiring before it is disconnected. 1 Disconnect the batteries before any service work is attempted.
  • Page 146 2800 To check and to adjust the tension of the alternator belt Operation 14-3 1 Remove the access panel in the fan guard and proceed as follows. 2 Use a Borroughs belt tension gauge to check the tension at the position shown (A5). It should be 267 N, which is equivalent to 2,5 mm of movement when a force of 11,3 N is applied.
  • Page 147 2800 To renew the alternator belt Operation 14-4 1 Remove the fan, Operation 12-5. 2 Loosen the adjustment bolts to release the tension on the alternator belt and remove the old belt. Check that the pulley grooves are clean and fit a new belt.
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  • Page 149: Auxiliary Equipment

    2800 Auxiliary equipment General information Details about auxiliary equipment are not available at time of print. Workshop Manual, TSD3450E, Issue 1...
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  • Page 151: Special Tools

    2800 Special tools List of special tools Tool number Description Illustration CH11148 Engine turning tool CH11149 Setting gauge, fuel injector GE50000 Installer, cylinder liner GE50001 Remover, cylinder liner GE50002 Height tool, cylinder liner projection Workshop Manual, TSD3450E, Issue 1...
  • Page 152 2800 Tool number Description Illustration GE50003 Piston ring compressor Alignment tool, piston cooling jet GE50004 (illustration not available at time of print) GE50005 Clamp bolt, cylinder liner (26 required) GE50006 Washer (26 required) GE50007 Fibre washer (26 required) GE50008 Locator, crankshaft seal...
  • Page 153 2800 Tool number Description Illustration Bolt, crankshaft seal installer GE50009 (use with GE50008) Distorter protection ring GE50010 (use with GE50008) Distorter tool GE50011 (use with GE50008) Installer, front crankshaft seal GE50012 (use with GE50008) Installer, rear crankshaft seal GE50013 (use with GE50008)
  • Page 154 2800 Tool number Description Illustration GE50015 Pilot, camshaft guide GE50016 Alignment sleeve, camshaft guide GE50017 Guide, camshaft GE50018 Cradle, camshaft GE50019 Guide stud, camshaft gear GE50020 Impact socket Workshop Manual, TSD3450E, Issue 1...
  • Page 155 2800 Tool number Description Illustration GE50021 Remover/installer, injector sleeve GE50022 Brush, large bore GE50023 Brush, small tapered GE50024 Brush, small bore GE50025 Lifting hook, camshaft GE50026 Compressor, valve spring Workshop Manual, TSD3450E, Issue 1...
  • Page 156 2800 Tool number Description Illustration GE50027 Installer, valve guide seal GE50028 Vacuum pump GE50029 Vacuum pump bottle GE50030 Vacuum pump tube GE50031 Pressurising pump, coolant system GE50032 Thermometer, coolant temperature Workshop Manual, TSD3450E, Issue 1...
  • Page 157 2800 Tool number Description Illustration GE50033 Pressure gauge GE50043 Remover/installer, valve guide GE50044 Sleeve, valve guide VP12712 Lift bracket, cylinder head Workshop Manual, TSD3450E, Issue 1...
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