Perkins 2806FA-E18TA Operation And Maintenance Manual
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Perkins 2806FA-E18TA Operation And Maintenance Manual

Perkins 2806FA-E18TA Operation And Maintenance Manual

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M0168981 (en-us)
May 2024
Operation and
Maintenance
Manual
2806FA-E18TA Engine

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Summary of Contents for Perkins 2806FA-E18TA

  • Page 1 M0168981 (en-us) May 2024 Operation and Maintenance Manual 2806FA-E18TA Engine...
  • Page 2 If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that you are authorized to perform this work, and that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.

  • Page 3: Table Of Contents

    M0168981 Table of Contents Table of Contents Engine Stopping ..........63 Maintenance Section Foreword ............4 Refill Capacities..........65 Safety Section Maintenance Recommendations ....82 Safety Messages..........6 Maintenance Interval Schedule....... 85 Additional Messages ......... 9 Warranty Section General Hazard Information......10 Warranty Information........119 Burn Prevention..........

  • Page 4: Foreword

    State of arises regarding your engine, or this manual, please California to cause cancer, birth defects, consult with your Perkins dealer or your Perkins distributor for the latest available information. and other reproductive harm. WARNING – This product can...
  • Page 5 Perkins distributor offers various options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available. Consult with your Perkins dealer or your Perkins distributor for information regarding these options.

  • Page 6: Safety Section

    Replace any safety message that is damaged or missing. If a safety message is attached to a part of the engine that is replaced, install a new safety message on the replacement part. Your Perkins distributor can provide new safety messages. Note: Certain engines have factory installed radiators.
  • Page 7 M0168981 Safety Section Safety Messages Illustration 1 g07739940 Typical example (1) Universal warning label (2) Hot surface label...
  • Page 8 M0168981 Safety Section Safety Messages Illustration 2 g07739949 Typical example (1) Universal warning label (2) Hot surface label Universal Warning (1) Illustration 3 g01370904 One safety message is on the left side of the valve mechanism cover. One safety message is on the right side of the engine gear case.

  • Page 9: Additional Messages

    Replace any message that is damaged, or missing. If a message is attached to a part that is replaced, install a message on the replacement part. Replacement labels may be obtained from Perkins distributors. Illustration 5 g03422039 Purge notice message...

  • Page 10: General Hazard Information

    M0168981 Safety Section General Hazard Information • Use all cleaning solutions with care. i08312804 General Hazard Information • Report all necessary repairs. Unless other instructions are provided, perform the maintenance under the following conditions: • The engine is stopped. Ensure that the engine cannot be started.
  • Page 11 Do not disassemble any hydraulic • Perkins recommend that you do not stand next to components or parts until pressure has been relieved an exposed running engine unless it is necessary or personal injury may occur.
  • Page 12 Perkins equipment and replacement parts comply with applicable regulations and requirements where The removal of sulfur and other compounds in ultra- originally sold. Perkins recommends the use of only low sulfur diesel fuel (ULSD fuel) decreases the genuine Perkins replacement parts.
  • Page 13 • Wear an approved respirator if there is no other good hygiene, and adhering to safe work practices way to control the dust. when handling the equipment or parts. Perkins also recommends the following: • Comply with applicable rules and regulations for the work place.

  • Page 14: Burn Prevention

    M0168981 Safety Section Burn Prevention Always use leakproof containers when you drain Cooling system conditioner contains alkali. Alkali can fluids. Do not pour waste onto the ground, down a cause personal injury. Do not allow alkali to contact drain, or into any source of water. the skin, the eyes, or the mouth.

  • Page 15: Fire Prevention And Explosion Prevention

    Ensure that If the application involves the presence of the hoses are correctly routed. The lines and hoses combustible gases, consult your Perkins dealer and/ must have adequate support and secure clamps. If or your Perkins distributor for additional information any fuel lines or fuel hoses become kinked, the fuel about suitable protection devices.
  • Page 16 M0168981 Safety Section Fire Prevention and Explosion Prevention Illustration 12 g00704059 Illustration 13 g00704135 Use caution when you are refueling an engine. Do Gases from a battery can explode. Keep any open not smoke while you are refueling an engine. Do not flames or sparks away from the top of a battery.

  • Page 17: Crushing Prevention And Cutting Prevention

    The engine and aftertreatment system have not been designed with Leaks can cause fires. Consult your Perkins dealer or mounting or dismounting locations. your Perkins distributor for replacement parts. Refer to the OEM for the location of foot and hand Replace the parts if any of the following conditions holds for your specific application.

  • Page 18: Engine Starting

    M0168981 Safety Section Engine Starting Do not start an engine when the governor linkage is i09160524 disconnected. Engine Stopping Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits are also provided in order to help prevent •...

  • Page 19: Engine Electronics

    Engines that are installed without engine-to-frame Note: Many of the engine control systems and ground straps can be damaged by electrical display modules that are available for Perkins discharge. Engines will work in unison with the Engine To ensure that the engine and the engine electrical Monitoring System.

  • Page 20: Product Information Section

    M0168981 Product Information Section General Information Product Information Section General Information i10110880 Model View Illustrations The following model views show typical features of the engine. Due to individual applications, your engine may appear different from the illustrations. Engine Views Illustration 14 g07740880 Typical example (1) Electric priming pump and primary fuel...
  • Page 21 M0168981 Product Information Section Model View Illustrations Illustration 15 g07740882 Typical example (13) Rear lifting eye (19) Oil filler cap (25) Oil drain plug (14) Engine air cleaner service indicator (20) Water pump (26) Oil sample valve (15) Turbocharger (21) Alternator (27) Flywheel (16) Front lifting eye (22) Oil gauge (Dipstick)
  • Page 22 M0168981 Product Information Section Model View Illustrations Aftertreatment System The aftertreatment items are supplied loose by Perkins. Clean Emission Module Illustration 16 g07735771 Typical example (1) SCR mixing chamber (3) Diesel Exhaust Fluid (DEF) injector (6) Exhaust intake connection (2) Selective Catalytic Reduction (SCR)
  • Page 23 Illustration 17 g07740565 Product Description Typical example (1) PTU lifting eyes (2) DEF tank header The Perkins 2806FA-E18TA Industrial Engine has (3) DEF filler cap (4) DEF tank the following characteristics: (5) DEF tank drain (6) DEF pump containing filter •...
  • Page 24 Aftermarket Products and Perkins Engines • Engine speed governor • Automatic air/fuel ratio control Perkins does not warrant the quality or performance of non-Perkins fluids and filters. • Torque rise shaping When auxiliary devices, accessories, or • Injection timing control...
  • Page 25 M0168981 Product Information Section Product Description However, failures that result from the installation or use of other manufacturers devices, accessories, or consumables are NOT Perkins defects. Therefore, the defects are NOT covered under the Perkins warranty.

  • Page 26: Product Identification Information

    M0168981 Product Information Section Product Identification Information Product Identification Information i10112031 Plate Locations and Film Locations Illustration 21 g01403841 Serial number plate The following information is stamped on the serial number plate: engine serial number, engine model, and arrangement number. The engine information plate is on top of the valve cover near the middle of the engine.
  • Page 27 Perkins distributor to identify replacement part level, and configuration ID code. This information numbers. may be needed by the Perkins distributor when inquiries are being made on the CEM. i10130069 Pump Tank Unit (PTU) Emissions Certification Film Note: This information is pertinent.
  • Page 28 M0168981 Product Information Section Reference Information Total Lubrication System Capacity Total Cooling System Capacity Air Cleaner Element Drive Belt Clean Emission Module Part Number Serial Number Pump Tank Unit Part Number Serial Number...

  • Page 29: Operation Section

    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. Consult your Perkins distributor for information regarding fixtures for proper engine lifting.
  • Page 30 M0168981 Operation Section Product Lifting Engine Lifting Illustration 27 g07741479 Typical example (1) Rear engine lifting eye (2) Front engine lifting eye...
  • Page 31 (Engine and Aftertreatment) Typical example (1) CEM lifting eyes (2) CEM lifting eye Your Perkins distributor can help in preparing the engine for extended storage periods. Some applications, the engine can be equipped with delayed engine shutdown. Allow at least 2 minutes after the engine has stopped before you turn the battery disconnect switch to OFF.
  • Page 32 M0168981 Operation Section Engine and Aftertreatment Engine Open the fuel tank drain valve to drain any water and dirt from the fuel tank. Apply a spray of 1. Clean the engine of any dirt, rust, grease, and oil. calibration fluid or kerosene at the rate of Inspect the exterior.
  • Page 33 ISO 22241-1. (1) Plug 3. Ensure that all DEF lines and electrical connection 8. If an engine is stored for more than 1 year, Perkins are connected prior to prevent crystal from recommends Pre lubrication of the engine to avoid forming.
  • Page 34 36 months remove connector and install plug (1). Tighten plug 25° C (77° F) 18 months to a torque of 30 N·m (265 lb in). Perkins recommends that the procedure must be 30° C (86° F) 12 months performed in a minimum ambient temperature of 35°...

  • Page 35: Features And Controls

    M0168981 Operation Section Features and Controls Features and Controls Intake manifold pressure – The intake manifold pressure sensor checks the rated pressure in the engine manifold. i10113606 Engine oil pressure – The engine oil pressure Alarms and Shutoffs sensor indicates when oil pressure drops below rated system pressure, at a set engine speed.
  • Page 36 Determine and correct the cause of any significant change in the readings. Consult your Perkins dealer Battery Disconnect Switch – The battery or your Perkins distributor for assistance.
  • Page 37 3. Inspect the cooling system for leaks. If necessary, consult your Perkins dealer or your Perkins distributor for assistance.
  • Page 38 M0168981 Operation Section Monitoring System The lamps will illuminate for 2 seconds to check that Emission Malfunction Indicator – This the lamps are functioning when the keyswitch is indicator will illuminate when an turned to the ON position. If any of the lamps stay emissions system related to DEF or SCR illuminated, or a lamp fails to be illuminated the has failed.
  • Page 39 M0168981 Operation Section Sensors and Electrical Components Sensor Locations for the 2806FA- E18TA Engine Illustration 32 g07741871 Typical example of the sensor and electrical component locations on the left side of the engine (1) Camshaft speed/timing sensor (5) Starter motor (9) Fuel temperature sensor (2) Boost pressure sensor (6) Engine oil pressure sensor...
  • Page 40 M0168981 Operation Section Sensors and Electrical Components Illustration 33 g07738726 Typical example of the close up views of sensor locations on the left side of the engine (1) Camshaft speed/timing sensor (4) Electronic control module (7) Fuel pressure sensor (2) Boost pressure sensor (5) Engine oil pressure sensor (8) Fuel temperature sensor (3) Inlet manifold air temperature sensor...
  • Page 41 M0168981 Operation Section Sensors and Electrical Components Illustration 34 g07741907 Typical example (10) Coolant temperature sensor (11) Alternator (12) Engine oil temperature sensor Sensor and Electrical Component Locations for the Clean Emissions Module Illustration 35 g07741980 Typical example (1) Diesel Exhaust Fluid (DEF) injector (3) Selective Catalytic Reduction (SCR) inlet (5) Diesel Oxidation Catalyst (DOC) inlet (2) Electrical connectors...
  • Page 42 M0168981 Operation Section Sensors and Electrical Components Pump Tank Unit (PTU) Illustration 36 g07742087 Typical example (1) DEF Level Sensor and DEF Temperature (2) Coolant Diverter Valve (4) Relays Sensor (3) Electrical connections...

  • Page 43: Engine Diagnostics

    The engine electronic control module (ECM) has two types of configuration parameters. The system configuration parameters and the customer specified Perkins Electronic Engines have the capability to parameters. perform a self-diagnostics test. When the system The electronic service tool is required to alter the detects an active problem, a diagnostic lamp is configuration parameters.
  • Page 44 M0168981 Operation Section Configuration Parameters Table 3 System Configuration Parameters Configuration Parameters Record Engine Serial Number Rating Full Load Setting Full Torque Setting ECM Software Release Date Customer Specified Parameters Customer specified parameters allow the engine to be configured to the exact needs of the application. The electronic service tool is required to alter the customer configuration parameters.
  • Page 45 M0168981 Operation Section Configuration Parameters (Table 4, contd) Transmission Default Torque Limit Reset Not Reset Air Filter Restriction Switch Installation Status Not Installed Air Filter Restriction Switch Configuration Normally Open Intermediate Engine Speed 1400. rpm Air Shutoff Disabled Air Intake Shutoff Detection Installation Status Not Installed Coolant Level Sensor Not Installed...
  • Page 46 M0168981 Operation Section Configuration Parameters (Table 4, contd) Engine Fan Suspend Purge Disabled Engine Fan Purge Cycle Interval 1200 sec Engine Fan Purge Cycle Duration 180.0sec Engine Fan Control Charge Air Cooler Outlet Temperature Input Enabled Enable Engine Cooling Fan Maximum Air Flow Charge Air Cooler Outlet 46.6°...

  • Page 47: Engine Starting

    M0168981 Operation Section Engine Starting Engine Starting • Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or i02109067 to the controls. Before Starting Engine •...
  • Page 48 M0168981 Operation Section Starting the Engine Note: If the engine has not been run for several During the key on, all warning lamps will illuminate weeks, fuel may have drained. Air may have moved for a few seconds, in order to test the circuits. If into the filter housing.
  • Page 49 1000 to 1200 rpm in order to raise 3. Start the engine. If the engine does not start, check engine temperature. Do not exceed the for a diagnostic code and consult your Perkins recommended rpm in order to increase the speed of distributor.
  • Page 50 M0168981 Operation Section After Starting Engine i07749904 NOTICE Using a battery source with the same voltage as the After Starting Engine electric starting motor. Use ONLY equal voltage for jump starting. The use of higher voltage will damage the electrical system. Note: In temperatures from 0 to 60°C (32 to 140°F), Do not reverse the battery cables.

  • Page 51: Engine Operation

    SCR reducing the NOx in the exhaust emissions. The efficiency of the engine can affect the fuel economy. Perkins design and technology in manufacturing provides maximum fuel efficiency in all applications. Follow the recommended procedures to attain optimum performance for the life of the engine.
  • Page 52 M0168981 Operation Section Fuel Conservation Practices Fuel expands when it is warmed up. The fuel may overflow from the fuel tank. Inspect fuel lines for leaks. Repair the fuel lines, as needed. • Be aware of the properties of different fuels. Use only the recommended fuels.

  • Page 53: Aftertreatment Operation

    M0168981 Operation Section Aftertreatment Operation Aftertreatment Operation inducement categories. DEF level inducements are based on the DEF level, the other inducement categories are based on escalating time. The escalating time inducements will always have an i10113667 associated fault code along with the inducement fault Selective Catalytic Reduction code.
  • Page 54 M0168981 Operation Section Selective Catalytic Reduction Warning System Illustration 38 g03676102 Illustration 40 g03676111 DEF Level Normal If the DEF level falls below 13.5%, a level 1 inducement event will occur. The check engine lamp Inducement Strategy for DEF Level and the emissions malfunction indicator lamp will illuminate.
  • Page 55 M0168981 Operation Section Selective Catalytic Reduction Warning System The check engine and emissions malfunction indicator lamp will illuminate for any inducement- related fault. There are two inducement categories. If the inducement is a result of a category 1 fault, then a level 1 inducement will occur for a duration of 36 hours.
  • Page 56 Operation Section Selective Catalytic Reduction Warning System If a fault condition exists for the entire duration of Note: Contact your Perkins dealer for repairs if a fault inducement level 1, the strategy advances to occurs. inducement level 2. The check engine lamp and the...
  • Page 57 M0168981 Operation Section Selective Catalytic Reduction Warning System Note: Turn the key to the OFF and add DEF to the DEF tank to reset the DEF level inducement. Inducement Strategy for Escalating Time Inducement Faults (Worldwide) Illustration 48 g03676174 If the DEF level is below 7.5%, a level 2 inducement Illustration 50 g03676215 event will occur.
  • Page 58 For repeat occurrence, a category 3 level 2 inducement fault will occur for a duration of 5 hours. Note: Contact your Perkins dealer for repairs if a fault occurs. Reduced Time If a fault condition exists for the entire duration of inducement level 1, the strategy advances to inducement level 2.

  • Page 59: Cold Weather Operation

    Cold Weather Operation • Check all rubber parts (hoses, fan drive belts) weekly. Perkins Diesel Engines can operate effectively in • Check all electrical wiring and connections for any cold weather. During cold weather, the starting and fraying or damaged insulation.
  • Page 60 For these reasons, when the engine is started, the engine is stopped. A block heater can be 110 V dc or engine must be operated until the coolant 240 V dc. Consult your Perkins distributor for more temperature is 80° C (176° F) minimum. Carbon information.
  • Page 61 M0168981 Operation Section Fuel and the Effect from Cold Weather Perkins recommends a warning device for the inlet Winter and arctic grades of diesel fuel are available in manifold temperature and/or the installation of an the countries and territories with severe winters. For more information refer to the Operation and inlet air temperature gauge.
  • Page 62 Note: Heat exchanger type fuel heaters should have a bypass provision in order to prevent overheating of the fuel in warm-weather operation. For further information on fuel heaters, consult your Perkins distributor . i08811356 Diesel Exhaust Fluid in Cold Weather...

  • Page 63: Engine Stopping

    M0168981 Operation Section Engine Stopping Engine Stopping Leaving the machine unattended when the engine i05798719 is running may result in personal injury or death. Before leaving the machine operator station, neu- Stopping the Engine tralize the travel controls, lower the work tools to the ground and deactivate all work tools, and place the lever for the hydraulic lockout control in the LOCKED position.
  • Page 64 M0168981 Operation Section Manual Stop Procedure i01465494 After Stopping Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan. •...

  • Page 65: Maintenance Section

    The capacity of the total cooling system will vary. The capacity will depend on the size of the radiator, which is not provided by Perkins for this engine. Table 6 should be completed by the customer for the maintenance of the cooling system.
  • Page 66 To meet the “EMA Recommended Guideline on Diesel Engine designed life of the product, the use of the Oil”. In addition to Perkins definitions, there are other definitions that will be of assistance in purchasing appropriate engine oil is essential. The oil lubricants.
  • Page 67 Aftermarket Oil Additives properties of the used oil sample. This analysis allows technicians to determine the amount of Perkins does not recommend the use of aftermarket deterioration of the oil during use. This analysis additives in oil. Aftermarket additives are not...
  • Page 68 These additives must be replaced periodically. Water, additives, and glycol. Additives must be added at the correct concentration. Refer to Perkins Diesel Engines Fluids Over concentration of additives can cause the Recommendations, M0113102 for additional inhibitors to drop out-of-solution. The deposits can information that relates to coolant.
  • Page 69 NOTICE NOTICE Do not use propylene glycol in concentrations that The Perkins industrial engines with a NOx reduc- exceed 50 percent glycol because of the reduced tion system must be operated with a minimum heat transfer capability of propylene glycol. Use ethyl-...
  • Page 70 Note: If the cooling system is already using ELC, agents with low amounts of nitrite. Perkins ELC has cleaning agents are not required to be used at the been formulated with the correct amount of these specified coolant change interval.
  • Page 71 An SCA that is liquid may be needed at 500-hour Perkins. intervals. NOTICE 6. Fill the cooling system with the Perkins Premixed Do not mix types and brands of coolant. ELC. Operate the engine. Ensure that all coolant valves open then stop the engine. When cool Do not mix brands and types of SCAs.
  • Page 72 Use a non-foaming detergent to clean Example Of The Equation For Adding The SCA To The Heavy- Duty Coolant At The Initial Fill oil contamination, consult your Perkins dealer for suitable product. Total Volume of the Multiplication...
  • Page 73 Spilling DEF onto hot components will cause harmful vapors. DEF that is used in Perkins engines must meet the ISO specification 22241-1 for quality. The ISO Storage specification 22241-1 requirements are met by many brands of DEF, including the ones that carry the Do not store DEF in direct sunlight.
  • Page 74 Fluid Recommendations Diesel Fuel Requirements (General Fuel Information) Perkins is not in a position to continuously evaluate and monitor all worldwide distillate diesel fuel specifications that are published by governments and technological societies. • Glossary The Perkins “Specification for Distillate Diesel Fuel”...
  • Page 75 M0168981 Maintenance Section General Fuel Information Table 17 "Perkins Specification for Distillate Diesel Fuel" Property UNITS Requirements “ASTM”Test “ISO/Other”Test Aromatics %Volume 35% maximum “D1319” “ISO 3837” %Weight 0.01% maximum “D482” “ISO 6245” Carbon Residue on 10% %Weight 0.20% maximum “D524”...
  • Page 76 EPA and other appropriate regulatory agencies. NOTICE Operating with fuels that do not meet the Perkins rec- ommendations can cause the following effects: Start- ing difficulty, reduced fuel filter service life, poor combustion, deposits in the fuel injectors, signifi- cantly reduce service life of the fuel system.
  • Page 77 “EU Off-Road Diesel fuel. Acceptable from 2011 MUST have less than 10 PPM sulfur level” All the fuels must comply with the specification in the table for the Perkins Specification Distillate Diesel Fuel. Diesel Fuel Characteristics Perkins recommends kinematic viscosities of 1.4 and 4.5 mm2/sec that is delivered to the fuel injection...
  • Page 78 Protection Agency (EPA) and European Certification wear scar diameter than 0.52 mm (0.0205 inch) will fuels. Perkins does not certify engines on any other lead to reduced service life and premature failure of fuel. The user of the engine has the responsibility of the fuel system.
  • Page 79 • Perkins recommend the use of oil analysis to check the quality of the engine oil if biodiesel fuel Perkins strongly recommends that seasonally is used. Ensure that the level of biodiesel in the...
  • Page 80 If biodiesel or biodiesel blends of fuel are to be used, Fuel for Cold-Weather Operation Perkins require the use of Perkins fuel cleaner. The use of the fuel is to remove deposits within the fuel system that is created with the use of biodiesel. For The European standard “EN590”...
  • Page 81 Maintenance Section General Fuel Information Detailed instructions on the rate of which the fuel • Perkins recommends the use of bulk fuel filter / cleaner must be used are on the container. coalescer units which clean the fuel of both...

  • Page 82: Maintenance Recommendations

    Consult the OEM of the equip- To relieve the pressure from the coolant system, turn ment or your Perkins dealer regarding welding on a off the engine. Allow the cooling system pressure cap chassis frame or rail.
  • Page 83 (2) Welding electrode Refer to the standards for the engine or consult your (3) Keyswitch in the OFF position Perkins distributor to determine if the engine is (4) Battery disconnect switch in the open position operating within the defined parameters.
  • Page 84 Severe Service Application Due to individual applications, identification is not possible for all the factors which can contribute to severe service operation. Consult your Perkins distributor for the unique maintenance that is necessary for the engine. The operating environment, incorrect operating...

  • Page 85: Maintenance Interval Schedule

    M0168981 Maintenance Section Maintenance Interval Schedule “ Engine Oil and Filter - Change“....108 i10116230 Maintenance Interval Schedule “ Fuel System Primary Filter (Water Separator) Element - Replace“ ......111 “...
  • Page 86 M0168981 Maintenance Section Maintenance Interval Schedule “ Diesel Exhaust Fluid Injector (Emission Related Component) - Replace“ ..... 101 Every 6000 Service Hours or 3 Years “...
  • Page 87 Aftercooler Core - Clean/Test Alternator - Inspect (Air-To-Air Aftercooler) Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose The air-to-air aftercooler is OEM installed in many connections and correct battery charging. Check the applications. Please refer to the OEM specifications ammeter (if equipped) during engine operation in for information that is related to the aftercooler.
  • Page 88 M0168981 Maintenance Section Battery Electrolyte Level - Check The battery cables or the batteries should not be All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a removed with the battery cover in place. The bat- face shield and protective clothing when working tery cover should be removed before any servic- on or near batteries.
  • Page 89 M0168981 Maintenance Section Belt Tensioner - Check 2. Disconnect the negative battery terminal. Ensure i10114636 that the cable cannot contact the terminal. When Belt Tensioner - Check four 12 V batteries are involved, 2 negative connections must be disconnected. 3. Remove the positive connection. 4.
  • Page 90 M0168981 Maintenance Section Belts - Inspect/Adjust/Replace i10114633 Belts - Inspect/Adjust/Replace Illustration 60 g06302436 Typical example (A) Tensioner stop (3) Tensioner body stop (B) Tensioner stop 3. Ensure that the tensioner has full movement of travel from stop (A) the other stop (B). Using a constant force the tensioner should move smoothly between the tensioner stop and the tensioner body stop.
  • Page 91 Disassembly and Assembly, Alternator Belt - Remove and Install. i07748139 Compression Brake - Inspect/ Adjust/Replace (If Equipped) Contact your Perkins distributor or dealer for the correct procedure. Illustration 62 g02351659 i10114677 The cooling system drain valve is towards the bottom of the radiator.
  • Page 92 4. Drain the cooling system. NOTICE 5. Fill the cooling system with clean water and Perkins ELC must be using with an extender in order operate the engine until the engine is warmed to to achieve 12000 hours operation. For more informa- tion on a suitable extender contact your Perkins 82 °C (180 °F).
  • Page 93 M0168981 Maintenance Section Cooling System Coolant (ELC) - Change NOTICE Fill the cooling system no faster than 19 L (5 US gal) per minute to avoid air locks. 3. Fill the cooling system with clean water. Install the cooling system filler cap. 4.
  • Page 94 M0168981 Maintenance Section Cooling System Coolant Level - Check 5. Start the engine and Inspect the cooling system for leaks and for proper operating temperature. i06606851 Cooling System Coolant Level - Check Check the coolant level when the engine is stopped and cool.
  • Page 95 M0168981 Maintenance Section DEF Filler Screen (Emission Related Component) - Clean Use a Coolant Conditioner Test Kit in order to check 4. Clean the cooling system filler cap and inspect the the concentration of the SCA. gasket. If the gasket is damaged, discard the old filler cap and install a new filler cap.
  • Page 96 M0168981 Maintenance Section DEF Manifold Filters - Replace 2. Using a suitable tool, press the tabs (2) in order to release the tabs. With the tabs released remove the filter screen (3) from DEF tank neck adapter (4). 3. The filter screen can be cleaned in clean water and dried using compressed air.
  • Page 97 M0168981 Maintenance Section DEF Manifold Filters - Replace 7. Install the manifold, refer to Disassembly and Assembly, “Manifold (DEF Heater) - Remove and Install” for the correct procedure. Type 2 Manifold To remove the DEF manifold and the hoses connections from the DEF tank, refer to Disassembly and Assembly, Manifold (DEF Heater) - Remove and Install.
  • Page 98 M0168981 Maintenance Section DEF Manifold Filters - Replace 5. Install new filter (5) onto pickup tube (4). 6. Install the retaining plate (6) and install screws (7). Tighten screws (7) to a torque of 1.1 N·m (9.8 lb in). 7. Install new outer filter (3) onto DEF tank header (1).
  • Page 99 M0168981 Maintenance Section Diesel Exhaust Fluid (Emission Related Component) - Fill 6. Install the manifold, refer to Disassembly and Assembly, “Manifold (DEF Heater) - Remove and Install” for the correct procedure. i10116321 Diesel Exhaust Fluid (Emission Related Component) - Fill Illustration 74 g07722287 Illustration 76...
  • Page 100 M0168981 Maintenance Section Diesel Exhaust Fluid Filter (Emission Related Component) - Replace Caution should be used when dispensing DEF near an engine that has recently been running. Spilling DEF onto hot components may cause the release of ammonia vapors. Do not breathe ammonia vapors. Do not clean up any spills with bleach.
  • Page 101 M0168981 Maintenance Section Diesel Exhaust Fluid Injector (Emission Related Component) - Replace i07508568 Diesel Exhaust Fluid Injector (Emission Related Component) - Replace Illustration 78 g03332637 Typical Example 3. Insert the DEF filter removal tool (4) into the DEF filter (1) and remove the DEF filter (1). Note: Avoid twisting the DEF filter (1) upon removal.
  • Page 102 M0168981 Maintenance Section Diesel Exhaust Fluid Tank - Flush i10116333 Diesel Exhaust Fluid Tank - Flush Required Tools Table 19 Required Tools Part Description Tool Part Number Plugs Flushing Procedure 1. Turn the key switch to the OFF position. The key switch must be OFF to allow the DEF pump to purge, ensuring the system is free of pressurized DEF.
  • Page 103 11. Reconnect all lines to the DEF pump and to the The operation of Perkins engines with improper manifold (DEF heater). Refer to Disassembly and adjustments of the electronic unit injector can reduce Assembly for the correct procedures.
  • Page 104 A clean engine provides the following Note: The air filter system may not have been benefits: provided by Perkins. The procedure that follows, is for a typical air filter system. Refer to the OEM • Easy detection of fluid leaks information for the correct procedure.
  • Page 105 M0168981 Maintenance Section Engine Air Cleaner Service Indicator - Inspect Replace the dirty air cleaner elements with new air cleaner elements. Before installation, the air cleaner elements should be thoroughly checked for tears and/or holes in the filter material. Inspect the gasket or the seal of the air cleaner element for damage.
  • Page 106 • The yellow diaphragm enters the red zone. recommended torques. • The red piston locks in the visible position. When the engine mounts are supplied by Perkins the maintenance procedure will be supplied in the • The air restriction reaches 6 kPa Disassembly and Assembly manual for your engine.
  • Page 107 The condition of the engine lubricating oil may be checked at regular intervals as part of a preventive maintenance program. Perkins include an oil sampling valve as an option. The oil sampling valve (if equipped) is included, toregularly sample the engine lubricating oil.
  • Page 108 • The date of the sample If the engine is operated in severe service conditions, • Engine model Perkins recommends the use of engine oil sampling. Refer to this Operation and Maintenance Manual, • Engine number Engine Oil sample - Obtain for more information.
  • Page 109 Use of an oil filter that is not recommended Note: Ensure that the vessel that will be used is large by Perkins could result in severe damage to the en- enough to collect the waste oil. gine bearings, and crankshaft. As a result of the larg-...
  • Page 110 Only qualified service personel should perform this Typical example maintenance. Refer to the Service Manual or your au- thorized Perkins dealer or your Perkins distributor for 2. Clean sealing surface (1). the complete valve lash adjustment procedure. 3. Apply clean engine oil to O ring seal (2) of the new Operation of Perkins engines with incorrect valve oil filter (3).
  • Page 111 M0168981 Maintenance Section Fuel System - Prime The fuel system can also be primed by using the key i06827467 switch. Turn the key to the ON position for 2 minutes. Fuel System - Prime After 2 minutes the fuel system should be primed. If necessary, by cycling the key switch the system will prime again for 2 minutes.
  • Page 112 M0168981 Maintenance Section Fuel System Primary Filter/Water Separator - Drain i06616051 Fuel System Primary Filter/ Water Separator - Drain Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.
  • Page 113 M0168981 Maintenance Section Fuel System Secondary Filter - Replace i06605835 Fuel System Secondary Filter - Replace Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.
  • Page 114 M0168981 Maintenance Section Fuel Tank Water and Sediment - Drain Some fuel tanks use supply pipes that allow water i02348492 and sediment to settle below the end of the fuel Fuel Tank Water and Sediment supply pipe. Some fuel tanks use supply lines that take fuel directly from the bottom of the tank.
  • Page 115 M0168981 Maintenance Section Hoses and Clamps - Inspect/Replace The grounding stud must have a wire ground to the A constant torque hose clamp can be used in place battery. Tighten the grounding stud at every oil of any standard hose clamp. Ensure that the constant change.
  • Page 116 Overhaul Considerations clamps, and seals. Make repairs, if necessary. i02568202 For an overhaul solution, contact your Perkins Starting Motor - Inspect distributor. i09670468 Perkins recommends a scheduled inspection of the Radiator - Clean starting motor.
  • Page 117 M0168981 Maintenance Section Walk-Around Inspection 4. Check for obvious heat discoloration of the NOTICE turbocharger (1). Check for any loose bolts or any Turbocharger bearing failures can cause large quan- missing bolts. Check for damage to the oil supply tities of oil to enter the air intake and exhaust sys- tems.
  • Page 118 Service Manual for the engine or consult your Perkins distributor . • Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters, and the valve cover.

  • Page 119: Warranty Section

    1 through Tier 4 marine auxiliary engines < 37 kW, Warranty supplement - Emission warranty parts but excluding locomotive and other marine available at the Perkins engines website. Consult engines) operated and serviced in the state of your authorized Perkins distributor to determine if...

  • Page 120: Reference Information Section

    Maintenance records are a key element of a maintenance program that is correctly managed. Accurate maintenance records can help your Perkins dealer to fine-tune the recommended maintenance intervals in order to meet the specific operating situation. This should result in a lower engine operating cost.
  • Page 121 M0168981 Reference Information Section Maintenance Log i05204675 Maintenance Log Table 20 Engine Model Customer Identifier Arrangement Number Serial Number Service Quantity Of Service Item Date Authorization Hours Fuel...
  • Page 122 Why buy an Extended Service Contract? 1. No surprises - total protection from unexpected repair cost (parts, labor, and travel). 2. Enjoy longer lasting product support from Perkins global network. 3. Genuine Perkins parts ensure continued engine performance. 4. Highly trained technicians carry out all repairs.

  • Page 123: Index

    M0168981 Index Section Index Compression Brake - Inspect/Adjust/Replace (If Equipped) ............91 Additional Messages ......... 9 Configuration Parameters ....... 43 After Starting Engine ........50 Customer Specified Parameters ....44 Extended Idle at Cold Ambient System Configuration Parameters ....43 Temperature..........
  • Page 124 M0168981 Index Section Engaging the Driven Equipment ..... 51 Maintenance ..........4 Engine - Clean..........104 Maintenance Intervals ........5 Aftertreatment..........104 Operation ............4 Engine Air Cleaner Element - Replace ..104 Overhaul ............5 Replacing the Air Cleaner......105 Safety.............
  • Page 125 Sensor and Electrical Component Locations Electronic Engine Features ......24 for the Clean Emissions Module ....41 Engine Diagnostics........24 Sensor Locations for the 2806FA-E18TA Engine Service Life........24 Engine............39 Engine Specifications ........23 Severe Service Application ......83 Product Identification Information ....
  • Page 126 M0168981 Index Section Starting Motor - Inspect ........116 Starting the Engine.......... 48 Problems with the Wiring Harness ....49 Starting Problems ........49 Starting the Engine ........48 Starting with Jump Start Cables (Do Not Use This Procedure in Hazardous Locations that have Explosive Atmospheres) ..........
  • Page 127 Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number:...
  • Page 128 M0168981 ©2024 Perkins Engines Company Limited All Rights Reserved May 2024...

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