Perkins Engine 2800 Service Manual
TPD1516E, Issue 1
May 2004
User’s
Handbook
Perkins 2800 Series
2806A-E18
2806C-E18
This publication is written in
Perkins Approved Clear English
This publication is divided into six chapters:
1 General information
2 Engine views
3 Operation instructions
4 Preventive maintenance
5 Engine fluids
6 Fault diagnosis
The pages which follow contain a detailed table of contents
ii
2800 Series
Contents
1 General information
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1
Safety precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2
How to care for your engine .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3
Engine lift equipment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3
Welding ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3
Engine preservation . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3
Parts and service .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3
Service literature ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3
Training ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3
POWERPART recommended consumable products . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4
Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5
Engine data ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6
2 Engine views
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7
Location of engine parts . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7
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3 Operation instructions
How to start the engine . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 9
How to start a new, an overhauled engine or an engine which has been in storage .. ... ... . 9
How to start a cold engine in cold conditions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10
After the engine has started . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10
Engine emergency stop ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 11
Manual stop procedure .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 11
Engine diagnostics . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12
4 Preventive mainten anc e
Preventive maintenance periods ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15
Schedule ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16
How to check the coolant level ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 17
How to check the air cleaner service indicator ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 17
How to check the lubricating oil level ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18
How to drain the primary fuel filter . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18
Visual inspection . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19
Diagnostics check ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20
How to renew the element of the primary fuel filter .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22
How to renew the element of the secondary fuel filter . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24
How to obtain an oil sample . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 26
How to renew the engine lubricating oil ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28
How to renew the element of the lubricating oil filter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30
How to renew the air cleaner element .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31
How to check the fan drive belts . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 32
How to adjust the tension of the fan belts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 32
How to adjust the tension of the alternator belt .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33
How to renew the fan drive belts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34
How to renew the alternator belt . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34
How to inspect the crankshaft vibration damper ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34
Earth stud .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35
Hoses and hose clips . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36
How to clean the radiator .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
How to inspect the engine mountings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
How to drain the coolant system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38
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How to clean the coolant system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 38
How to fill the coolant system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 38
How to check the tappet clearances ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 39
How to check/adjust the electronic unit injectors ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 42
Engine protection devices .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 43
How to renew the thermostats of the coolant system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 44
How to clean and to calibrate the engine speed/timing sensors ... ... ... ... ... ... ... ... ... ... ... . 46
How to inspect the turbochargers ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 47
How to inspect the battery charging alternator ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 47
How to inspect the starter motor .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 48
How to inspect the coolant pump . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 48
How to eliminate air from the fuel system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 49
5 Engine fluids
Fuel specification .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 51
Coolant . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 51
Lubricating oil specification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 52
Warranty .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 52
6 Faul t dia gn o si s
Problems and possible causes . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 53
List of possible causes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 54
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2800 Series
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm. Battery
posts, terminals and related accessories contain lead
and lead compounds. Wash hands after handling.
1
General information 1
Introduction
The 2806-18 diesel engine is the latest development from Perkins Engines Company Limited, a world leader
in the design and manufacture of high performance diesel engines. More than fifty years of diesel production
experience, together with the use of the latest technology, have been used in the manufacture of your engine
to give you reliable and economic power.
To ensure that you use the relevant information for your specific engine type, refer to "Engine identification"
on page 5.
The terms "left side" and "right side" apply when the engine is seen from the rear end, the flywheel end.
Number one cylinder is at the front end of the engine
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: This indicates that there is a possible danger to the engine.
Note: Is used where the information is important, but there is not a danger.
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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.
Always refer to the text of this handbook for specific warnings and cautions.
Only use these engines in the type of application for which they have been designed.
Do not change the specification of the engine.
Do not make adjustments that you do not understand.
Do not allow the engine to stand on its sump.
Do not smoke when you put fuel in the tank.
Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training;
even then extreme caution must be used to prevent injury).
Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation.
Do not permit loose clothing or long hair near moving parts.
Warning! Keep away from moving parts during engine operation. Some moving parts cannot be seen clearly
while the engine runs.
Do not operate the engine if a safety guard has been removed.
Do not remove the filler cap or any component of the coolant system while the engine is hot and while the
coolant is under pressure, because dangerous hot coolant can be discharged.
Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the
gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially
to the e yes.
Disconnect the battery terminals before a repair is made to the electrical system. Always disconnect the
negative terminal first.
Only one person must control the engine.
Ensure that the engine is operated only from the control panel or from the operator's position.
If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons.
Protect your hands with gloves or a special solution to protect the skin.
Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets.
Discard used lubricating oil and coolant in accordance with local regulations to prevent contamination.
The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes.
Always use a safety cage to protect the operator when a component is to be pressure tested in a container
of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to
be pressure tested.
Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and debris away from
the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.
Some components are not waterproof and should not be washed with a high-pressure water jet or steam.
Do not wash an engine while it runs or while it is hot. If cold cleaning fluids are applied to a hot engine,
certain components on the engine could be damaged.
Fit only genuine Perkins parts.
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How to care for your engine
Warning! Read the "Safety precautions" and remember them. They are given for your protection and must be
applied at all times.
Caution: Do not clean an engine while it runs. If cold cleaning fluids are applied to a hot engine, certain
components on the engine may be damaged.
To obtain the best performance and the longest life from your engine, you must ensure that the maintenance
operations are done at the correct intervals, refer to "Preventive maintenance periods" on page 15.
Ensure that all adjustments and repairs are done by personnel who have had the correct training.
Engine lift equipment
Warning! The lifting eyes which are fitted to the engine must be used for lifting only the engine. Do not use
them to lift the engine if it is still attached to its driven unit.
Welding
Welding can cause damage to the electronic components fitted to the engine. If welding is necessary, the
precautions which follow must be undertaken before and during the welding operation.
Cautions:
Switch off the engine.
Disconnect the cable from the negative terminal of the battery. If the machine is fitted with a battery
disconnect the switch then open the switch.
If welding to the engine, remove the ECM (electronic control module).
If welding onto the machine chassis, ensure that the earth clamp is attached as close to the welding point
as possible and NOT near to the ECM.
If it is necessary to weld near to the ECM, remove the ECM from the engine.
Engine preservation
1E2566C - Lowest protection level: This process is for protection of engines for up to 30 days. The engine must
be stored inside and shipped in a closed container.
1E2566B - Intermediate protection level: This process will protect engines from functional deterioration for a
minimum of 6 months in outside storage conditions.
1E2566A - Highest protection level: This process will protect engines from functional deterioration for a
minimum of 12 months in outside storage conditions. This process is used to extend the protection given by
the intermediate level protection process.
Parts and service
If problems occur with your engine or with the components fitted to it, your authorised distributor can make the
necessary repairs and will ensure that only the correct parts are fitted and that the work is done correctly.
Service literature
Workshop manuals and other service publications are available from your authorised distributor.
Training
Courses on the service and overhaul of the 2806 engine are available at the Factory. For details apply to: The
Product Training Centre, Perkins Engines Company Limited, Peterborough, PE1 5NA, England.
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2800 Series
POWERPART rec ommended consumable product s
Perkins have made available the products recommended below in order to assist in the correct operation,
service and maintenance of your engine and your machine. The instructions for the use of each product are
given on the outside of each container. These products are available from your Perkins distributor.
POWERPART ELC (Extended Life Coolant).
ELC is pre-mixed and protects the cooling system against frost and corrosion. Part number 21820181.
POWERPART Easy flush
Cleans the cooling system. Part number 21825001.
POWERPART Gasket and flange sealant
To seal flat faces of components where no joint is used. Especially suitable for aluminium components.
Part number 21820518.
POWERPART Gasket remover
An aerosol for the removal of sealants and adhesives. Part number 21820116.
POWERPART Griptite
To improve the grip of worn tools and fasteners. Part number 21820129.
POWERPART Hydraulic threadseal
(1)
To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and pneumatic systems.
Part number 21820121.
POWERPART Industrial grade super glue
Instant adhesive designed for metals, plastics and rubbers. Part number 21820125.
POWERPART Lay-Up 1
A diesel fuel additive for protection against corrosion. Part number 1772204.
POWERPART Lay-Up 2
Protects the inside of the engine and of other closed systems. Part number 1762811.
POWERPART Lay-Up 3
Protects outside metal parts. Part number 1734115.
POWERPART Metal repair putty
Designed for external repair of metal and plastic. Part number 21820126.
POWERPART Pipe sealant and sealant primer
To retain and seal pipe connections with coarse threads. Pressure systems can be used immediately.
Part number 21820122.
POWERPART Radiator stop leak
For the repair of radiator leaks. Part number 21820127.
POWERPART Retainer (high strength)
To retain components which have an interference fit. Part number 21820638.
POWERPART Retainer (oil tolerant)
To retain components which have an interference fit, but are in contact with oil. Part number 21820608.
POWERPART Safety cleaner
General cleaner in an aerosol container. Part number 21820128.
Continued
4 User’s Handbook, TPD1516E, Issue 1
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POWERPART Silicone adhesive
1
An RTV silicone adhesive for application where low pressure tests occur before the adhesive sets. Used for
sealing flange where oil resistance is needed and movement of the joint occurs. Part number 21826038.
(2)
POWERPART Silicone RTV sealing and jointing compound
Silicone rubber sealan t which prev ents leak age throu gh gaps . Part number 186110 8.
(2)
POWERP A RT Stud and bearing lock
To provide a heavy duty seal to components that have a light interference fit. Part number 21820119 or
21820120.
POWERPART Threadlock and nutlock
To retain small fasteners where easy removal is necessary. Part number 21820117 or 21820118.
POWERPART Universal jointing compound
Universal jointing compound which seals joints. Part number 1861117.
(1) Powerpart (ELC) is not recommended for the 1300 Ser ies.
(2) These product are not recommended for the 4006-23 engine.
(2)
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: HQD060003U2041L, which c onsists of these codes:
H Code for engine capacity
Q Engine application
D Engine type
06 Number of engine cylinders
0003 Engine specification number
U The country of manufacture
2041 Build line number
L Year of manufactur e
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2800 Series
Engine data
Number of cylinders... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 6
Cylinder arrangement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Vertical in li n e
Cycle.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Four stroke, compression ignition
Induction system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..Turbocharged, air to air charge cooling
Combustion system... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Direct injecti on
Nominal bore.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...145 mm (5.709 in)
Nominal stroke .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...183 mm (7.205 in)
Compression ratio.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 14.5:1 Nominal
Cubic capacity ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18,13 litres (1106.36 in
Firing order. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1, 5, 3, 6, 2, 4
Direction of rotation ... ... ... ... ... ... ..Anti-clockwise viewed on flywheel (cylinder 1 furthest from the flywheel)
Total weight Electropak.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... (dry) 2081 kg (4588 lb)
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...(wet) 2190 kg (4828 lb)
Lubricating oil capacity:
Total system... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...55,5 litres (97.7 UK pints)
Sump maximum. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...53,5 litres (94.1 UK pints)
Sump minimum.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...37,5 litres (66.0 UK pints)
Lubricating oil pressure:
At rated speed ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .4,2 bar
Coolant System:
3
)
Coolant capacity of engine and radiator ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 61 litres (107.3 UK pints)
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Engine views 2
Introduction
Perkins engines are built for specific applications and the views which follow do not necessarily match your
engine specification.
Location of engine parts
Fron t and left side view of engi ne (A)
1 Radiator
2 Hand priming pump
3 Rocker cover
4 Starter motor
5 Electronic Control Module (ECM)
1 2 3
6 Earth stud
7 Secondar y fuel filter
8 Primary fuel filter
9 Speed/timing sensor (crankshaft)
4
69 8 7
A
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2806/001
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Rear and right side view of engine (B)
2800 Series
1Radiator
2 Restriction indicator
3 Air cleaner
4 Turbochargers
5 Exhaus t manifold
6 Fill er cap for lubricating oil
1
7 Thermostat housing
8Dipstick
9 Sump drain plug
10 Lubricating oil filter
11 Flywheel housin g
12 Flywheel
32 4 5 6 7
B
89101112
2806/002
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Operation instructions 3
How to start the engine
Before the engine is started
Perform the required daily maintenance and other periodic maintenance before the engine is started. Refer to
"Preventive maintenance periods" on page 15.
Check the fuel supply. Drain water from the water separator. Open the fuel supply valve.
Caution: All valves in the fuel return line must be open before and during engine operation to help prevent
high fuel pressure. High fuel pressure can cause failure of the filter housing or other damage.
Note: If the engine has not been started for several weeks, fuel may have drained from the fuel system. Air
may have entered the filter housing. Also, when fuel filters have been changed, some air pockets will be
trapped in the engine. If necessary refer to "How to eliminate air from the fuel system" on page 49.
Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” label or similar
warning label attached to the start switch or to the controls.
Ensure that the areas around rotating parts are clear.
Reset all of the shutdown devices or alarm components.
Check the level of the engine lubricating oil. Maintain the oil level between the “L” and the “H” marks on the
dipstick.
Check the level of the coolant. Maintain the level of coolant within 13 mm (0.5 inch) of the bottom of the
filler pipe. If the engine is fitted with a sight glass, maintain the coolant level in the sight glass.
Check the service indicator for the air cleaner. When the red warning indicator is seen through the clear
panel after the engine has stopped, the air filter element must be renewed.
Ensure that any driven equipment has been disengaged. Remov e any electrical loads.
How to start a new, an overhauled engine or an engine which has been in storage
Prime the turbocharger. This can be achieved by operating the engine briefly with the injection disable switch
on.
When a new engine, or an engine which has been serviced, is first started, prepare to stop the engine if an
overspeed condition occurs. Use the quickest method available, for example: Emergency Stop button.
Start proced ur e
This start procedure may be used for all engines which are not fitted with an air inlet heater.
Refer to the Owner's Manual of the OEM for your type of controls. Use this procedure to start the engine:
1 Mov e the ignition switch to the ON position. If a system fault is indicated by, for example a panel light,
investigate the cause. If necessary use the Perkins Electronic Service Tool, EST.
2 Push the start button or turn the ignition switch to the START position to operate the engine.
3 If the engine fails to start within 30 seconds, release the start button or ignition switch. Wait for 30 seconds
to allow the starter motor to cool before attempting to start the engine again.
Note: A system fault may be indicated after the engine is started. If this occurs the ECM has detected a
problem with the system. Investigate the cause, if necessary use the Perkins service tool EST.
Caution: Oil pressure should rise within 15 seconds after the engine starts. The electronic engine controls
monitor the oil pressur e and w ill stop the engine if the oil pressure is below norm a l.
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4 If possible, allow the engine to run at no load for approximately three minutes. Run the engine at no load
until the water temperature gauge has started to rise. Check all gauges during the warm-up period.
2800 Series
How to start a cold engine in cold conditions
Refer to the Owner's Manual of the OEM for your type of controls. Use the procedure which follows to start the
engine.
Warning! Ether type fuels must not be used in the 2806-18 six cylinder engine.
The engine will start without aids down to a temperature of -10 °C (14 °F), but the ability to start at temperatures
below 10 °C (50 °F) will improve by the use of a cylinder block coolant heater or a device which heats the
crankcase oil. This will help to reduce white smoke and misfires when the engine is started in cold weather.
Note: If the engine has not been run for several weeks, fuel may have drained. Air may have moved into the
filter housing. Also, when fuel filters have been changed, some air will be left in the filter housing. Refer to "How
to eliminate air from the fuel system" on page 49.
1 Move the ignition switch to the ON position. If a system fault is indicated by, for example a panel light,
investigate the cause. If necessary use the Perkins Electronic Service Tool, EST.
2 Push the start button or turn the ignition switch to the START position to crank the engine.
3 If the engine fails to start within 30 seconds, release the start button or ignition switch. Wait for 30 seconds
to allow the starter motor to cool before attempting to start the engine again. Repeat for a maximum of three
times; if the engine fails to start investigate the cause,
4 A system fault may be i ndi ca te d a fte r th e e ngin e is st arted. If this occurs th e ECM ha s detected a problem
with the system. Investigate the cause, if necessary use the Perkins s ervice tool E ST. Refer to the Diagnostic
Manual for more information on engine diagnostics.
Note: Oil pressure should rise within 15 seconds after the engine starts. The electronic engine controls monitor
the oil pressure and will stop the engine if the oil pressure is below normal.
5 If possible, allow the engine to run at no load for approximately three minutes. Run the engine at no load
until the coolant temperature gauge starts to rise. Check all gauges during the warm-up period.
Caution: The oil pressures and fuel pressures should be in the normal range on the instrument panel. Do not
apply a load to the engine until the oil pressure gauge indicates at least normal pressure. Inspect the engine
for leaks and/or unusual noises.
Important notes
The cold sta rt s tra t eg y w ill be ac ti v a ted when the c oo lan t tem p er a t ur e is be lo w 17 °C ( 63 °F ) . The c o ld s tart
strategy will continue until the coolant temperature reaches 28 °C (82 °F), or until the engine has been running
for 14 minutes. A timer will disable the cold start strategy after a maximum time of 14 minutes.
If the cold start strategy is active and if the ECM measures engine speed, the engine power that is available is
reduced.
After the ECM has completed the cold mode (or the cold mode is disabled), it cannot be enabled again until
the ECM is switched OFF.
If an engine has been stopped, for example after a fault has been indicated, do not attempt to restart the engine
until it has fully stopped.
After the engine has started
1 Check all of the gauges during the warm-up period.
2 Perform another walk-around inspection. Check the engine for fluid leaks and air leaks.
Note: Gauge readings should be observed and the data should be recorded frequently while the engine runs.
A comparison of the data over time will help to determine normal readings for each gauge, it will also help to
detect abnormal conditions of operation. Significant changes in the readings should be investigated.
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Engine emergency stop
Caution: Emergency shut-off controls are for emergency use only. Do not use emergency shut-off devices or
controls for the normal stop procedure.
Ensure that any components for the external system that support the engine operation are secured after the
engine is stopped.
Manual stop procedure
Individual applications will have different control systems. Ensure that the engine shut-down procedures are
understood. To stop the engine, use the general guidelines which follow:
1 Run the engine with no load for five minutes to allow it to cool.
2 After the cool-down period, turn the start switch to the OFF position.
User’s Handbook, TPD1516E, Issue 1 11
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2800 Series
Engine diagnostics
Self-diagnostics
Perkins electronic engines can perform a self-diagnostics test. Diagnostic codes are stored in the permanent
memory of the Electronic Control Module (ECM) and can be retrieved by use of the Perkins electronic service
tool, EST. A list of diagnostic codes is given in the table under "Diagnostic codes" on page 20.
Some installations have electronic displays that provide a direct reading of the engine diagnostic codes. Refer
to the manual that is provided by the OEM for more information on retrieving engine diagnostic codes.
Active codes, indicated by a warning lamp or similar device (depending on application), represent problems
that currently exist. These problems should be investigated first.
Logged codes represent:
Intermittent problems
Recorded events
Performance history
The problems may have been repaired since the code was logged. These codes do not indicate that a repair
is needed; the codes are guides or signals when a situation exists. Codes may be helpful to diagnose
problems.
When the problems have been corrected, the corresponding logged fault codes shoul d be cleared, where
possible.
Use the Perkins service tool EST to determine the diagnostic code.
Fault l oggin g
The system provides the capability of fault logging. When the Electronic Control Module (ECM) generates a
diagnostic code, the code will be logged in the memory of the ECM. The codes that have been logged in the
memory of the ECM can be retrieved with Perkins electronic service tools. The codes that have been logged
can be cleared with Perkins electronic service tools. The codes that have been logged in the memory of the
ECM will be automatically cleared from the memory after 100 hours. If the engine is operated in protection
override mode, then low engine oil pressure and high engine coolant temperature events cannot be cleared
without a factory password.
Engine operation with active diagnostic codes
If a fault is indicated during normal engine operation, the system has identified a situation that is not within the
specification. Use Perkins electronic service tools to check the active diagnostic codes.
The active diagnostic code should be investigated. The cause of the problem should be corrected as soon as
possible. If the cause of the active diagnostic code is repaired, and there was only one active diagnostic code,
the warning lamp or similar device will turn off.
Engine opera t ion wit h intermit t ent dia gnostic code s
If during normal engine operation a fault is indicated by a fault lamp or similar device and the lamp or device
then returns to normal, an intermittent fault may have occurred. If a fault has occurred, the fault will be logged
in the memory of the Electronic Control Module (ECM).
In most cases, it is not necessary to stop the engine because of an intermittent code. However, the operator
should retrieve the codes and refer to the relevant information to identify the nature of the event. The operator
should note the circumstances that are involved during the time that the lamp was on:
Engine load
Limits of the engine speed
Excessive smoke, etc.
This information can be useful to help diagnose the situation. The information can also be used for future
reference. For more information on diagnostic codes, refer to the Diagnostic Manual for this engine.
12 User’s Handbook, TPD1516E, Issue 1
2800 Series
Customer specified parameters
Customer specified parameters that will enhance the fuel efficiency and the operator's convenience can be
programmed into the Electronic Control Module (ECM). Some parameters may affect engine operation. This
may lead to complaints from the operator about power or performance. The engine related parameters which
follow may be programmed by the customer, by use of the Perkins electronic service tool, to influence the
operation of the engine:
Engine ratings selection, the ability to choose between the relevant torque maps
(prime/stand-by, 50/60 Hz) (where a switchable flash file has been specified)
Governor gain tuning parameters
Analogue throttle enable
Equipment identification
Droop set point
Engine acceleration rate
Enable speed selection by the use of an external switch
Enable droop/isochronous selection by the use of an external switch
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User’s Handbook, TPD1516E, Issue 1 13
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