Perkins Engine 854F-E34TA Service Manual

Name: Perkins Engine 854F-E34TA
Brand: Perkins Engine
SKU: 4535557
Rating: 4 (1 reviews)

4 (1)

SEBU9068

February 2015

Operation and

Maintenance

Manual

854F-E34TA Industrial Engine

JU (Engine)

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. 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 the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this product Perkins recommends using Perkins replacement parts.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

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Table of Contents

Table of Contents
Foreword.............................. .............................	4
Safety Section
Safety Messages....................... .......................	5
General Hazard Information............... ..............	5
Burn Prevention........................ ........................	9

Fire Prevention and Explosion Prevention ... .. 10

Crushing Prevention and Cutting Prevention . 12

Mounting and Dismounting............... ..............	13
High Pressure Fuel Lines ................ ...............	13
Before Starting Engine ................. ..................	14
Engine Starting........................ .......................	15
Engine Stopping ....................... ......................	15
Electrical System...................... ......................	15
Engine Electronics..................... .....................	17
Product Information Section
General Information.................... ....................	18
Product Identification Information.......... .........	24
Operation Section
Lifting and Storage..................... .....................	26
Features and Controls.................. ..................	29
Engine Diagnostics..................... ....................	45
Engine Starting........................ .......................	49
Engine Operation...................... ......................	52
Cold Weather Operation................. ................	54
Engine Stopping ....................... ......................	58

Maintenance Section
Refill Capacities....................... .......................	60
Maintenance Recommendations.......... ..........	75
Maintenance Interval Schedule........... ...........	78
Warranty Section
Warranty Information.................. ...................	110
Reference Information Section
Reference Materials ................... ...................	111
Index Section
Index............................... ...............................	114

Foreword

Literature Information

This manual contains safety, operation instructions,

lubrication and maintenance information. This manual should be stored in or near the engine area in a

literature holder or literature storage area. Read, study and keep it with the literature and engine information.

English is the primary language for all Perkins publications. The English used facilitates translation and consistency.

Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Perkins dealer or your Perkins distributor for the latest available information.

Safety

This safety section lists basic safety precautions. In addition, this section identifies hazardous, warning

situations. Read and understand the basic precautions listed in the safety section before

operating or performing lubrication, maintenance and repair on this product.

Operation

Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities.

The operation section is a reference for operators. Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information.

Maintenance

The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance

intervals. Items in the maintenance schedule are referenced to detailed instructions that follow.

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Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary.

The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.

Maintenance Intervals

Perform maintenance on items at multiples of the original requirement. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also

recommend that a maintenance record be maintained as part of the engine's permanent record.

Your authorized Perkins dealer or your Perkins distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment.

Overhaul

Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the

interval and the maintenance items in that interval. Major repairs should only be carried out by Perkins

authorized personnel. Your Perkins dealer or your Perkins distributor offers a variety of 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.

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

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Safety Section

i05835940

Safety Messages

There may be several specific warning signs on your engine. The exact location and a description of the warning signs are reviewed in this section. Please become familiar with all warning signs.

Ensure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if the

words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the

warning signs. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh

chemicals could loosen the adhesive that secures the warning signs. The warning signs that are loosened

could drop off the engine.

Replace any warning sign that is damaged or missing. If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Your Perkins distributor can provide new warning signs.

Universal Warning

Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death.

Illustration 1

g01154807

Typical example

The Universal Warning label (1) is located on the top

of the engine, on the engine interface connector cover.

Safety Section

Safety Messages

Illustration 2

g03373747

Typical example

i06078546

General Hazard Information

Illustration 3

g00104545

Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before the engine is serviced or before the engine is repaired. Attach the warning tags to the engine and to each operator control station. When appropriate, disconnect the starting controls.

Do not allow unauthorized personnel on the engine, or around the engine when the engine is being serviced.

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Safety Section

General Hazard Information

•Tampering with the engine installation or tampering with the OEM supplied wiring can be dangerous. Personal injury, death and/or engine damage could result.

•Vent the engine exhaust to the outside when the engine is operated in an enclosed area.

•If the engine is not running, do not release the secondary brake or the parking brake systems unless the vehicle is blocked or unless the vehicle is restrained.

•Wear a hard hat, protective glasses, and other protective equipment, as required.

•When work is performed around an engine that is operating, wear protective devices for ears in order to help prevent damage to hearing.

•Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine.

•Ensure that all protective guards and all covers are secured in place on the engine.

•Never put maintenance fluids into glass containers. Glass containers can break.

•Use all cleaning solutions with care.

•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.

•The protective locks or the controls are in the applied position.

•Engage the secondary brakes or parking brakes.

•Block the vehicle or restrain the vehicle before maintenance or repairs are performed.

•Disconnect the batteries when maintenance is performed or when the electrical system is serviced. Disconnect the battery ground leads. Tape the leads in order to help prevent sparks. If equipped, allow the diesel exhaust fluid to be purged before disconnecting the battery.

•If equipped, disconnect the connectors for the unit injectors that are located on the valve cover base. This action will help prevent personal injury from the high voltage to the unit injectors. Do not come in contact with the unit injector terminals while the engine is operating.

•Do not attempt any repairs or any adjustments to the engine while the engine is operating.

•Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.

•For initial start-up of a new engine or for starting an engine that has been serviced, make provisions to stop the engine if an overspeed occurs. The stopping of the engine may be accomplished by shutting off the fuel supply and/or the air supply to the engine. Ensure that only the fuel supply line is shut off. Ensure that the fuel return line is open.

•Start the engine from the operators station (cab). Never short across the starting motor terminals or the batteries. This action could bypass the engine neutral start system and/or the electrical system could be damaged.

Engine exhaust contains products of combustion which may be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is in an enclosed area, vent the engine exhaust to the outside.

Cautiously remove the following parts. To help prevent spraying or splashing of pressurized fluids, hold a rag over the part that is being removed.

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•Filler caps

•Grease fittings

•Pressure taps

•Breathers

•Drain plugs

Use caution when cover plates are removed. Gradually loosen, but do not remove the last two bolts or nuts that are located at opposite ends of the cover plate or the device. Before removing the last two bolts or nuts, pry the cover loose in order to relieve any spring pressure or other pressure.

Illustration 4

g00702020

•Wear a hard hat, protective glasses, and other protective equipment, as required.

•When work is performed around an engine that is operating, wear protective devices for ears in order to help prevent damage to hearing.

•Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine.

•Ensure that all protective guards and all covers are secured in place on the engine.

•Never put maintenance fluids into glass containers. Glass containers can break.

•Use all cleaning solutions with care.

•Report all necessary repairs.

Unless other instructions are provided, perform the maintenance under the following conditions:

Safety Section

General Hazard Information

•The engine is stopped. Ensure that the engine cannot be started.

•Disconnect the batteries when maintenance is performed or when the electrical system is serviced. Disconnect the battery ground leads. Tape the leads in order to help prevent sparks.

•Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.

Pressurized Air and Water

Pressurized air and/or water can cause debris and/or hot water to be blown out. This action could result in personal injury.

When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield.

The maximum air pressure for cleaning purposes			.
must be below 205 kPa (	psi 30The maximum water )
pressure for cleaning purposes must be below		.
275 kPa ( psi 40	)

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve the hydraulic pressure.

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Safety Section

General Hazard Information

Illustration 5

g00687600

Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

Containing Fluid Spillage

Care must be taken to ensure that fluids are contained during performance of inspection,

maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Dispose of all fluids according to local regulations and mandates.

Static Electricity Hazard when Fueling with Ultra-low Sulfur Diesel Fuel

The removal of sulfur and other compounds in ultralow sulfur diesel fuel (ULSD fuel) decreases the conductivity of ULSD and increases the ability of ULSD to store static charge. Refineries may have treated the fuel with a static dissipating additive. Many factors can reduce the effectiveness of the additive over time. Static charges can build up in ULSD fuel while the fuel is flowing through fuel delivery systems. Static electricity discharge when combustible vapors are present could result in a fire or explosion. Ensure that the entire system used to refuel your machine (fuel supply tank, transfer pump, transfer hose, nozzle, and others) is properly grounded and bonded. Consult with your fuel or fuel system supplier to ensure that the delivery system complies with fueling standards for proper grounding and bonding.

Avoid static electricity risk when fueling. Ultra-low sulfur diesel fuel (ULSD fuel) poses a greater static ignition hazard than earlier diesel formulations with a higher sulfur contents. Avoid death or serious injury from fire or explosion. Consult with your fuel or fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

Inhalation

Illustration 6

g00702022

Exhaust

Use caution. Exhaust fumes can be hazardous to health. If you operate the equipment in an enclosed

area, adequate ventilation is necessary.

Asbestos Information

Perkins equipment and replacement parts that are shipped from Perkins engine company limited are asbestos free. Perkins recommends the use of only genuine Perkins replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous unless airborne dust that contains asbestos is generated.

If dust that may contain asbestos is present, there are several guidelines that should be followed:

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•Never use compressed air for cleaning.

•Avoid brushing materials that contain asbestos.

•Avoid grinding materials that contain asbestos.

•Use a wet method in order to clean up asbestos materials.

•A vacuum cleaner that is equipped with a high efficiency particulate air filter (HEPA) can also be used.

•Use exhaust ventilation on permanent machining jobs.

•Wear an approved respirator if there is no other way to control the dust.

•Comply with applicable rules and regulations for the work place. In the United States, use Occupational Safety and Health Administration (OSHA) requirements. These OSHA requirements can be found in “29 CFR 1910.1001”.

•Obey environmental regulations for the disposal of asbestos.

•Stay away from areas that might have asbestos particles in the air.

Dispose of Waste Properly

Illustration 7

g00706404

Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations.

Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water.

Safety Section

Burn Prevention

Diesel Exhaust Fluid

Diesel Exhaust Fluid (DEF) may cause eye irritation and can be moderately irritating to the skin. Exposure to decomposition products may cause a health

hazard. Serious effects may be delayed following exposure.

DEF is not expected to produce significant adverse

health effects when the recommended instructions for use are followed.

•Do not breathe DEF vapor or mist.

•Do not eat, drink, or smoke when using DEF.

•Avoid DEF contact with eyes, skin, and clothing.

•Wash thoroughly after handling DEF.

i06078513

Burn Prevention

Do not touch any part of an operating engine system. The engine, the exhaust, and the engine aftertreatment system can reach temperatures as high as 650° C (1202° F) under normal operating conditions.

Allow the engine system to cool before any maintenance is performed. Relieve all pressure in the air system, hydraulic system, lubrication system, fuel system, and the cooling system before the related items are disconnected.

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

After the engine has stopped, wait for 10 minutes in order to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed on the engine fuel lines. The 10 minute wait will also allow static charge to dissipate from the low-pressure fuel system.

Allow the pressure to be purged in the air system, in the hydraulic system, in the lubrication system, or in the cooling system before any lines, fittings, or related items are disconnected.

Safety Section

Fire Prevention and Explosion Prevention

Induction System

Sulfuric Acid Burn Hazard may cause serious personal injury or death.

The exhaust gas cooler may contain a small

amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the

amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the en-

gine. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid.

Coolant

When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters, aftertreatment system or to the engine contain hot coolant.

Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained.

Check that the coolant level after the engine has stopped and the engine has been allowed to cool.

Ensure that the filler cap is cool before removing the filler cap. The filler cap must be cool enough to touch with a bare hand. Remove the filler cap slowly in order to relieve pressure.

Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.

Oils

Skin may be irritated following repeated or prolonged exposure to mineral and synthetic base oils. Refer to your suppliers Material Safety Data Sheets for detailed information. Hot oil and lubricating components can cause personal injury. Do not allow hot oil to contact the skin. Appropriate personal protective equipment should be used.

Diesel Fuel

Diesel may be irritating to the eyes, respiratory system, and skin. Prolonged exposure to diesel may cause various skin conditions. Appropriate personal protective equipment should be used. Refer to supplier Material safety Data sheets for detailed information.

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Batteries

Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended.

Aftertreatment System

Allow the aftertreatment to cool down before any maintenance or repair is performed.

Aftertreatment System and Diesel

Exhaust Fluid

Diesel Exhaust Fluid (DEF) temperatures can reach 65° to 70°C (149.° to 126°F) during normal engine operation. Stop the engine. Wait for 15 minutes in order to allow the DEF system to be purged and the DEF to cool before service or repair is performed.

i05670934

Fire Prevention and Explosion

Prevention

Illustration 8

g00704000

All fuels, most lubricants, and some coolant mixtures are flammable.

Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire. Fire may cause personal injury and property damage.

After the emergency stop button is operated, ensure that you allow 15 minutes, before the engine covers are removed.

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Determine whether the engine will be operated in an environment that allows combustible gases to be drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, property damage, or engine damage could result.

If the application involves the presence of combustible gases, consult your Perkins dealer and/ or your Perkins distributor for additional information about suitable protection devices.

Remove all flammable combustible materials or conductive materials such as fuel, oil, and debris from the engine. Do not allow any flammable combustible

materials or conductive materials to accumulate on the engine.

Store fuels and lubricants in correctly marked containers away from unauthorized persons. Store oily rags and any flammable materials in protective

containers. Do not smoke in areas that are used for storing flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in case of a line, a

tube, or a seal failure. Exhaust shields must be installed correctly.

Do not weld on lines or tanks that contain flammable fluids. Do not flame cut lines or tanks that contain flammable fluid. Clean any such lines or tanks

thoroughly with a nonflammable solvent prior to welding or flame cutting.

Wiring must be kept in good condition. Ensure that all electrical wires are correctly installed and securely attached. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all electrical connections.

Eliminate all wiring that is unattached or unnecessary. Do not use any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers.

Arcing or sparking could cause a fire. Secure connections, recommended wiring, and correctly maintained battery cables will help to prevent arcing or sparking.

Safety Section

Fire Prevention and Explosion Prevention

After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed on the engine fuel lines. The 10 minute wait will also allow static charge to dissipate from the low-pressure fuel system.

Ensure that the engine is stopped. Inspect all lines

and hoses for wear or for deterioration. Ensure that the hoses are correctly routed. The lines and hoses

must have adequate support and secure clamps.

Oil filters and fuel filters must be correctly installed. The filter housings must be tightened to the correct torque. Refer to the Disassembly and Assembly manual for more information.

Illustration 9

g00704059

Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open flames or sparks. Always stop the engine before refueling.

Avoid static electricity risk when fueling. Ultra-low Sulfur Diesel fuel (ULSD fuel) poses a greater static ignition hazard than earlier diesel formulations with a higher sulfur content. Avoid death or serious injury from fire or explosion. Consult your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

Safety Section

Crushing Prevention and Cutting Prevention

Illustration 10

g00704135

Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery. Do not smoke in battery charging areas.

Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer.

Incorrect jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specific instructions.

Do not charge a frozen battery. A frozen battery may cause an explosion.

The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the recommended cables, connections, and battery box covers when the engine is operated.

Fire Extinguisher

Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the instruction plate.

Ether

Ether is flammable and poisonous.

Do not smoke while you are replacing an ether cylinder or while you are using an ether spray.

Do not store ether cylinders in living areas or in the engine compartment. Do not store ether cylinders in direct sunlight or in temperatures above 49° C (120° F). Keep ether cylinders away from open flames or sparks.

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Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike highpressure lines. Do not install any lines that are damaged.

Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for replacement parts.

Replace the parts if any of the following conditions are present:

•High-pressure fuel line or lines are removed.

•End fittings are damaged or leaking.

•Outer coverings are chafed or cut.

•Wires are exposed.

•Outer coverings are ballooning.

•Flexible parts of the hoses are kinked.

•Outer covers have embedded armoring.

•End fittings are displaced.

Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, correct installation will help to prevent vibration, rubbing against other parts, and excessive heat.

i02143194

Crushing Prevention and

Cutting Prevention

Support the component correctly when work beneath the component is performed.

Unless other maintenance instructions are provided, never attempt adjustments while the engine is running.

Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, reinstall the guards.

Keep objects away from moving fan blades. The fan blades will throw objects or cut objects.

When objects are struck, wear protective glasses in order to avoid injury to the eyes.

Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure that no one will be injured by flying debris.

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Safety Section

Mounting and Dismounting

i05768982

Mounting and Dismounting

Do not climb on the engine or the engine aftertreatment system. The engine and aftertreatment system have not been designed with mounting or dismounting locations.

Refer to the OEM for the location of foot and hand holds for your specific application.

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High Pressure Fuel Lines

Illustration 11

g03691673

(1) High-pressure line	(3) High-pressure line	(5) High-pressure fuel manifold (rail)
(2) High-pressure line	(4) High-pressure line	(6) Fuel transfer line that is high pressure

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Safety Section

Before Starting Engine

The high-pressure fuel lines are the fuel lines that are between the high-pressure fuel pump and the highpressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head. These

fuel lines are different from fuel lines on other fuel systems.

These differences are because of the following items:

•The high-pressure fuel lines are constantly charged with high pressure.

•The internal pressures of the high-pressure fuel lines are higher than other types of fuel system.

•The high-pressure fuel lines are formed to shape and then strengthened by a special process.

Do not step on the high-pressure fuel lines. Do not deflect the high-pressure fuel lines. Do not bend or strike the high-pressure fuel lines. Deformation or damage of the high-pressure fuel lines may cause a point of weakness and potential failure.

Do not check the high-pressure fuel lines with the engine or the starting motor in operation. After the engine has stopped wait for 10 minutes in order to allow the fuel pressure to be purged from the highpressure fuel lines before any service or repair is performed.

Do not loosen the high-pressure fuel lines in order to remove air from the fuel system. This procedure is not required.

Visually inspect the high-pressure fuel lines before the engine is started. This inspection should be each day.

If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”.

•Inspect the high-pressure fuel lines for damage, deformation, a nick, a cut, a crease, or a dent.

•Do not operate the engine with a fuel leak. If there is a leak, do not tighten the connection in order to stop the leak. The connection must only be tightened to the recommended torque. Refer to Disassembly and Assembly, “Fuel injection lines - Remove and Fuel injection lines - Install”.

•If the high-pressure fuel lines are torqued correctly, and the high-pressure fuel lines are leaking the high-pressure fuel lines must be replaced.

•Ensure that all clips on the high-pressure fuel lines are in place. Do not operate the engine with clips that are damaged, missing, or loose.

•Do not attach any other item to the high-pressure fuel lines.

•Loosened high-pressure fuel lines must be replaced. Also removed high-pressure fuel lines must be replaced. Refer to Disassembly and Assembly, “Fuel Injection Lines - Install”.

i03560601

Before Starting Engine

NOTICE

For initial start-up of a new or rebuilt engine, and for start-up of an engine that has been serviced, make provision to shut the engine off should an overspeed occur. This may be accomplished by shutting off the air and/or fuel supply to the engine.

Engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area and, if in an enclosed area, vent the exhaust to the outside.

Inspect the engine for potential hazards.

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 to the controls.

Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel.

If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work properly, if equipped.

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Safety Section

Engine Starting

All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.

Do not bypass the automatic 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 engine damage.

See the Service Manual for repairs and for adjustments.

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Engine Starting

Note: The engine is equipped with a device for cold starting. If the engine will be operated in very cold conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with the correct type of starting aid for your region of operation.

These engines are equipped with a glow plug starting aid in each individual cylinder that heats the intake air in order to improve starting. Some Perkins engines may have a cold starting system that is controlled by

the ECM that allows a controlled flow of ether into the engine. The ECM will disconnect the glow plugs

before the ether is introduced. This system would be installed at the factory.

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Engine Stopping

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.

If a warning tag is attached to the engine start switch, or to the controls DO NOTstart the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.

Start the engine from the operators compartment or from the engine start switch.

Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Knowing that the correct procedure will help to prevent major damage to the engine components. Knowing that the procedure will also help to prevent personal injury.

To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is working correctly, check the water temperature gauge. Also, check the oil temperature gauge during the heater operation.

Engine exhaust contains products of combustion which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside.

Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine components.

Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOTstart the engine until the problem that caused the emergency stop has been corrected.

Stop the engine if an overspeed condition occurs during the initial start-up of a new engine or an engine that has been overhauled.

To stop an electronically controlled engine, cut the power to the engine and/or shutting off the air supply to the engine.

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Electrical System

Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible gases that are produced by some batteries, the negative “−” cable should be connected last from the external power source to the negative “−” terminal of the starting motor. If the starting motor is not equipped with a negative “−” terminal, connect the cable to the engine block.

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Safety Section

Electrical System

Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical connections before the engine is started. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for specific starting instructions.

Grounding Practices

			Illustration 13		g02315900
			Typical example
			(	Ground5 to battery)
			(	Ground6 to engine) block
			(	Primary7 position) for grounding
			Correct grounding for the engine electrical system is
			necessary for optimum engine performance and
Illustration 12		g02315896	reliability. Incorrect grounding will result in
Illustration 12		g02315896	uncontrolled electrical circuit paths and in unreliable
Typical example			electrical circuit paths.
(	Ground1 to battery)		Uncontrolled electrical circuit paths can result in
(	Primary2 position) for grounding		Uncontrolled electrical circuit paths can result in
(	Ground3 to engine) block		damage to engine components.
(	Ground4 to starting) motor		Engines that are installed without engine-to-frame
			Engines that are installed without engine-to-frame
			ground straps can be damaged by electrical
			discharge.
			To ensure the engine and the engine electrical
			systems function correctly, an engine-to-frame
			ground strap with a direct path to the battery must be
			used. This path may be provided by way of a direct
			engine ground to the frame.
			The connections for the grounds should be tight and
			free of corrosion. The engine alternator must be
			grounded to the negative “ batteryterminal”		with a
			wire adequate to handle the full charging current of
			the alternator.

The power supply connections and the ground connections for the engine electronics should always be from the isolator to the battery.

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Engine Electronics

Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/or engine damage.

Electrical Shock Hazard. The electronic unit injectors use DC voltage. The ECM sends this voltage to the electronic unit injectors. Do not come in contact with the harness connector for the electronic unit injectors while the engine is operating. Failure to follow this instruction could result in personal injury or death.

This engine has a comprehensive, programmable Engine Monitoring System. The Electronic Control Module (ECM) has the ability to monitor the engine operating conditions. If any of the engine parameters extend outside an allowable range, the ECM will initiate an immediate action.

The following actions are available for engine monitoring control:

•Warning

•Derate

•Shutdown

The following monitored engine operating conditions and components have the ability to limit engine speed and/or the engine power :

•Engine Coolant Temperature

•Engine Oil Pressure

•Engine Speed

•Intake Manifold Air Temperature

•Engine Intake Throttle Valve Fault

•Wastegate Regulator

•Supply Voltage to Sensors

•Fuel Pressure in Manifold (Rail)

•NOxReduction System

•Engine Aftertreatment System

Safety Section

Engine Electronics

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

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Product Information Section

Model View Illustrations

Product Information

Section

General Information

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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 with Rear Mounted Aftertreatment

Illustration 14		g03693338
Typical example
(1) Front lifting eye	(6) Primary fuel filter	(11) Spin-on oil filter
(2) Rear lifting eyes	(7) Water in fuel switch	(12) Oil gauge (Dipstick)
(3) Diesel exhaust fluid injector	(8) Secondary fuel filter	(13) Oil filler cap
(4) Rear mounted aftertreatment	(9) Flywheel	(14) High-pressure fuel pump
(5) Priming pump	(10) Flywheel housing

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General Information

Model View Illustrations

Illustration 15								g03693780
Typical example
(	Electronic15 control module)		(	Breather17	)	(	Coolant19 pump	)
(	Fan16 pulley	)	(	Crankshaft18 pulley	)	(	Air20intake	)

Perkins Engine 854F-E34TA Service Manual

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General Information

Model View Illustrations

Illustration 16								g03693786
Typical example
(	Turbocharger21	)	(	Alternator25	)	(	Starter29 solenoid	)
(	Air22outlet connection from) turbocharger		(	Coolant26 intake connection)		(	Flex30 pipe	)
(	Air23intake from air cleaner)		(	Coolant27 drain	)
(	Coolant24 outlet connection)		(	Starting28 motor	)

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General Information

Product Description

Off Engine Components

Illustration 17		g03694456
Typical example
(1) Inlet air temperature sensor	(6) Selective Catalytic Reduction (SCR)	(11) Ammonia sensor and controller
(2) Breather heater	(7) SCR Outlet manifold	(12) Temperature sensors for Doc and SCR
(3) Heater line controller	(8) Diesel Exhaust Fluid (DEF) tank	(13) DEF pump module with DEF filter
(4) Glow plug control unit	(9) DEF Heated line
(5) Coolant diverter valve	(10) NOx Sensor

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Product Description

The Perkins 854F-E34TA industrial engine have the following characteristics

•In-line 4 cylinder

•Four valves per cylinder

•Four stroke cycle

•Turbocharged charge cooled

•Aftertreatment system

Engine Specifications

Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right sides of the engine are determined from the flywheel end. The number 1 cylinder is the front cylinder.

General Information

Product Description

Illustration 18				g03692044
Cylinder and valve location
(	ExhaustA valves)
(	InletB valves )
Table 1
	854F-E34TA Engine Specifications
Operating Range (rpm)		800 to 2750(1)
Number of Cylinders		4 In-Line
Bore		99 mm	(	3.89763inch
Stroke		110 mm (		4.33070inch
Power		Turbocharged Charge Cooled
		63 to 90 kW
		(	84to.48120.69 hp
Aspiration		Turbocharged charge cooled
Compression Ratio			17: 1
Displacement		3.4 L (	207cubic.48 inch
Firing Order			1-3-4-2
Rotation (flywheel end)		Counterclockwise

(1)The operating rpm is dependent on the engine rating, the application, and the configuration of the throttle.

Electronic Engine Features

The engine operating conditions are monitored. The Electronic Control Module (ECM) controls the response of the engine to these conditions and to the demands of the operator. These conditions and operator demands determine the precise control of fuel injection by the ECM. The electronic engine control system provides the following features:

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•Engine monitoring

•Engine speed governing

•Control of the injection pressure

•Cold start strategy

•Automatic air/fuel ratio control

•Torque rise shaping

•Injection timing control

•System diagnostics

•Aftertreatment Regeneration

For more information on electronic engine features, refer to the Operation and Maintenance Manual

“FeaturesndControls topic (Operation Section).

Engine Diagnostics

The engine has built-in diagnostics in order to ensure
that the engine systems are functioning correctly. The
operator will be alerted to the condition by a	“	orStop	”
Warning lamp. Under certain conditions, the engine			”
horsepower and the vehicle speed may be limited.
)
The electronic service tool may be used to display the
diagnostic)codes.
There are three types of diagnostic codes: active,
logged and event.
)
Most of the diagnostic codes are logged and stored in
the ECM. For additional information, refer to the
Operation and Maintenance Manual “	Engine
Diagnostics topic (Operation Section).

)

The ECM provides an electronic governor that controls the injector output in order to maintain the desired engine rpm.

Engine Cooling and Lubrication

The cooling system and lubrication system consists of the following components:

•Belt driven centrifugal water pump

•Water temperature regulator which regulates the engine coolant temperature

•Gear-driven rotor type oil pump

•Multi plate oil cooler

The engine lubricating oil is cooled and the engine lubricating oil is filtered.

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Engine Service Life

Engine efficiency and maximum utilization of engine performance depend on the adherence to proper operation and maintenance recommendations. In

addition, use recommended fuels, coolants, and lubricants. Use the Operation and Maintenance

Manual as a guide for required engine maintenance.

AftertreatmentSystem

The aftertreatment system is approved for use by Perkins . In order to be emission-compliant only the approved Perkins aftertreatment system must be used on a Perkins engine.

The aftertreatment system is Diesel Oxidation Catalyst (DOC) and Selective Catalytic Reduction (SCR), with Diesel Exhaust Fluid (DEF) injection.

The engine is connected by a flexible pipe to the aftertreatment. The exhaust gases pass through the DOC and then the mixer where the gases are mixed with the injected urea. The mixture then enters the SCR catalyst. Here the NOx in the exhaust reacts with the ammonia from the injected urea to split the gases into nitrogen and oxygen constituents. The SCR catalyst includes an ammonia oxidation section to clean up any remaining ammonia before the gases exit the system.

AftertreatmentConfiguration

The engine can be configured with a top mounted

aftertreatment or an aftertreatment mounted across the rear of the engine.

Aftermarket Products and Perkins

Engines

Perkins does not warrant the quality or performance of non-Perkins fluids and filters.

When auxiliary devices, accessories, or consumables (filters, additives, catalysts,) which are made by other manufacturers are used on Perkins products, the Perkins warranty is not affected simply because of such use.

However, failures that result from the installation or use of other manufacturers devices, accessories, or consumables are NOT Perkins defects. Therefore, the defects are NOTcovered under the Perkins warranty.

General Information

Product Description

Product Identification Information

Plate Locations and Film Locations

Product Identification

Information

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Plate Locations and Film

Locations

(Aftertreatment)

Ensure that all numbers on the aftertreatment are recorded

Your Perkins distributor or your dealer will require all the numbers in order to identify the components for your aftertreatment

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Plate Locations and Film

Locations

Perkins engines are identified by an engine serial number.

An example of an engine number is

JU*****L000001V.

*****	The list number for the engine
JU	The type of engine
L	Built in the Italy
000001	Engine Serial Number
V	Year of Manufacture

Perkins dealers or Perkins distributors need all of these numbers in order to determine the components

that were included with the engine. This information permits accurate identification of replacement part numbers.

The numbers for fuel setting information for electronic engines are stored within the flash file. These numbers can be read by using the electronic service tool.

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Serial Number location

Illustration 19

g03733236

Typical example of a non-stressed cylinder block

The engine serial number can be installed in three different positions.

All engines will have the serial number install in location (1) on the front face of the engine.

On a non-stressed cylinder block the serial number is located in position (2). On the left-hand side on the cylinder block.

Illustration 20

g02826736

Typical example

On a stressed cylinder block the serial number is located in position (3).

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Product Identification Information

Emissions Certification Film

The engine serial number is stamped on the emissions plate.

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Emissions Certification Film

The emission label will be installed on the left side of the non-stressed cylinder block. The emission label

will be installed on the left side of the engine oil pan for stressed cylinder blocks

Illustration 21

Typical example

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Reference Information

Information for the following items may be needed to order parts. Locate the information for your engine. Record the information in the appropriate space. Make a copy of this list for a record. Keep the information for future reference.

Record for Reference

Engine Model Engine Serial number

Engine Low Idle rpm

Engine Full Load rpm Primary Fuel Filter

Secondary Fuel Filter Element

Lubrication Oil Filter Element

g03708641

Auxiliary Oil Filter Element

Total Lubrication System Capacity

Total Cooling System Capacity

Air Cleaner Element

Drive Belt

Aftertreatment System

Part Number

Serial Number

Operation Section

Product Lifting

Operation Section

Lifting and Storage

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Product Lifting

Illustration 22

g03779921

Typical example

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Illustration 23

g03796087

Typical example of lifting eyes with top mounted aftertreatment

(1)Front lifting eye

(2)Rear lifting eyes

NOTICE

Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees.

Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted.

Some removals require lifting the fixtures in order to obtain correct balance and safety.

The lifting eyes should be used to lift only the engine as supplied by Perkins , including engine mounted aftertreatment equipment.

Other Original Equipment Manufacturer (OEM) equipment, including transmissions, should be removed from the engine prior to lifting. For more information, refer to the OEM.

Lifting eyes are designed and installed for specific engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting

fixtures obsolete. If alterations are made, ensure that correct lifting devices are provided. Consult your

Perkins distributor for information regarding fixtures for correct engine lifting.

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Note: The engine is equipped with three lifting eyes. All the lifting eyes must be used in order to lift the engine and the aftertreatment.

The aftertreatment system has not been designed with lifting eyes for removal from the engine or application. In order to remove aftertreatment, the aftertreatment must be lifted using two lifting slings. When installing the aftertreatment, use two lifting slings in order to install the aftertreatment.

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Product Storage

(Engine and Aftertreatment)

Perkins are not responsible for damage which may occur when an engine is in storage after a period in service.

Your Perkins dealer or your Perkins distributor can assist in preparing the engine for extended storage periods.

Condition for Storage

The engine must be stored in a water proof building. The building must be kept at a constant temperature. Engines that are filled with Perkins ELC will have coolant protection to an ambient temperature of −36° C (−32.8° F). The engine must not be subjected to extreme variations in temperature and humidity.

Storage Period

An engine can be stored for up to 6 months provided all the recommendation are adhered to.

Storage Procedure

Keep a record of the procedure that has been completed on the engine.

Note: Do not store an engine that has biodiesel in the fuel system.

1.Ensure that the engine is clean and dry.

a.If the engine has been operated using biodiesel, the system must be drained and new filters installed. The fuel tank will require flushing.

b.Fill the fuel system with an ultra low sulfur fuel. For more information on acceptable fuels refer to this Operation and Maintenance Manual, “Fluid recommendations”. Operate the engine for 15 minutes in order to remove all biodiesel from the system.

Lifting and Storage

Product Storage

2.Drain any water from the primary filter water separator. Ensure that the fuel tank is full.

3.The engine oil will not need to be drained in order to store the engine. Provided the correct specification of engine oil is used the engine can be stored for up to 6 months. For the correct specification of engine oil refer to this Operation and Maintenance Manual, “Fluid recommendations”.

4.Remove the drive belt from the engine.

Sealed Coolant System

Ensure that the cooling system is filled with Perkins

ELC, or an antifreeze that meets “ASTM D6210” specification.

Open Cooling System

Ensure that all cooling drain plugs have been opened. Allow the coolant to drain. Install the drain plugs. Place a vapor phase inhibitor into the system. The coolant system must be sealed once the vapor phase inhibitor has been introduced. The effect of the vapor phase inhibitor will be lost if the cooling system is open to the atmosphere.

For maintenance procedures ref to this Operation and Maintenance Manual.

Monthly Checks

The crankshaft must be rotated in order to change the spring loading on the valve train. Rotate the crankshaft more than 180 degrees. Visibly check for damage or corrosion to the engine and aftertreatment.

Ensure that the engine and aftertreatment are covered completely before storage. Log the procedure in the record for the engine.

Aftertreatment

The engine must be allowed to perform a DEF purge before the battery disconnect switch is turned off. Allow 2 minutes after the engine has stopped before disconnecting the battery disconnect switch.

The exhaust outlet of the aftertreatment must be capped. In order to prevent damage to the exhaust

outlet connection during storage.

DEF Tank Storage

1.Ensure normal engine shutdown, allow the DEF to be purged. Do not disconnect the battery disconnect switch, allow 2 minutes after key off before disconnection.

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Lifting and Storage

Product Storage

2.Fill the tank with DEF that meet all the requirement defined in ISO 22241-1.

3.Ensure that all DEF lines and electrical connection are connected prior to prevent crystal from forming.

4.Ensure that the DEF filler cap is correctly installed.

Removal from Storage

DEF has a limited life, refer to table 2 for the time and temperature range. DEF that is outside this range

MUST be replaced.

On removal from storage the DEF quality in the tank

must be tested with a refractometer. The DEF in the tank must meet the requirements defined in ISO

22241-1 and comply with table 2 .

1.If necessary, drain the tank and fill with DEF that meet ISO 22241-1.

2.Replace the DEF filter, refer to this Operation and

Maintenance Manual “	DieselExhaust Fluid Filter-		,
Clean/Replace		”	.

3.Ensure that the drive belt is correctly installed. Ensure that all engine coolant and engine oil has the correct specification and grade. Ensure that the coolant and the engine oil are at the correct level. Start the engine. If a fault becomes active turn off the engine, allow 2 minutes for the DEF system to purge, then restart the engine.

4.If the fault continues to stay active, refer to Troubleshooting for more information.

Table 2
	Temperature		Duration
10° C (	F50°	)	36 months
25° C (	F77°	)	18 months
30° C (	F86°	)	12 months
35° C (	(1)	)	6 months
35° C (	F95°	)	6 months

(1)At 35° C, significant degradation can occur. Check every batch before use.

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Features and Controls

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Alarms and Shutoffs

Shutoffs

The shutoffs are electrically operated or mechanically operated. The electrically operated shutoffs are controlled by the Electronic Control Module (ECM).

Shutoffs are set at critical levels for the following items:

•Operating temperature

•Operating pressure

•Operating level

•Operating rpm

•Hydrocarbon build-up

The particular shutoff may need to be reset before the engine will start.

NOTICE

Always determine the cause of the engine shutdown. Make necessary repairs before attempting to restart the engine.

Be familiar with the following items:

•Types and locations of shutoff

•Conditions which cause each shutoff to function

•The resetting procedure that is required to restart the engine

Alarms

The alarms are electrically operated. The operations of the alarms are controlled by the ECM.

The alarm is operated by a sensor or by a switch. When the sensor or the switch is activated, a signal is sent to the ECM. An event code is created by the ECM. The ECM will send a signal in order to illuminate the lamp.

Your engine may be equipped with the following sensors or switches:

Intake manifold air temperature – The intake manifold air temperature sensor indicates high intake air temperature.

Features and Controls

Alarms and Shutoffs

Intake manifold pressure – The intake manifold pressure sensor checks the rated pressure in the

engine manifold.

Fuel rail pressure – The fuel rail pressure sensor measures the high pressure or low pressure in the fuel rail. The ECM will Check the pressure.

Engine oil pressure – The engine oil pressure sensor indicates when oil pressure drops below rated system pressure, at a set engine speed.

Engine overspeed – If, the engine rpm exceeds the overspeed setting the alarm will be activated.

Air filter restriction – The switch checks the air filter when the engine is operating.

User-defined switch – This switch can shut down the engine remotely. There will be no alarm or

warning lamp to show that the switch has been operated.

Water in fuel switch – This switch checks for water in the primary fuel filter when the engine is operating.

Fuel temperature – The fuel temperature sensor

monitors the pressurized fuel in the high-pressure fuel pump.

Coolant temperature – The coolant temperature sensor indicates high jacket water coolant temperature.

Note: The sensing element of the coolant temperature sensor must be submerged in coolant in order to operate.

Engines may be equipped with alarms in order to alert the operator when undesirable operating conditions occur.

NOTICE

When an alarm is activated, corrective measures must be taken before the situation becomes an emergency in order to avoid possible engine damage.

If corrective measures are not taken within a reasonable time, engine damage could result. The

alarm will continue until the condition is corrected. The alarm may need to be reset.

Aftertreatment System

•Temperature Sensor before DOC

•Two NOx Sensors

•Two SCR Temperature Sensors

•Ammonia Sensor

Temperature Sensor before DOC – This sensor monitors the gas temperature that is entering the

DOC

Features and Controls

Selective Catalytic Reduction Warning System

NOx Sensor – Two NOx sensors monitor the NOx concentration within the exhaust gas. One sensor

before the DOC and one after the SCR module.

SCR Temperature Sensors – The sensor monitors the gas temperature entering the SCR. Also, a second temperature sensor is located down stream of the SCR. This sensor checks the temperature of the gas that is leaving the SCR.

Ammonia Sensor – The sensor monitors the concentration of ammonia within the exhaust system

after the CEM.

Quality Sensor – The quality sensor provides the

ECM with confirmation that the correct concentration of DEF is present in the tank. If the tank is filled with a

different fluid which is not DEF, such as water or fuel the sensor will detect this change in quality and raise

a fault. This fault will lead to an inducement and engine derate.

The temperature sensor before DOC, NOx sensor, SCR temperature sensors, and ammonia sensor all connect with the engine ECM. If the signal from these sensors is out of the set range, the ECM will trigger an alarm for the operator.

Diesel Exhaust Fluid (DEF) System

Control

DEF Level Sensor – The DEF level sensor signals the ECM. The ECM determines the signal in order to give a level reading of the volume of fluid in the tank.

DEF Temperature Sensor – The sensor signals the ECM. The ECM will determine the temperature of the DEF within the tank from the signals sent. The temperature of the DEF is important in order to keep the DEF injector operation correctly.

Dosing Control Unit (DCU) – The DCU controls the injection of the DEF and will signal the ECM if the injection has been interrupted.

The DEF level sensor, DEF temperature sensor, and the Dosing control unit all connect with the engine ECM. If the ECM determines that any of the signals are out of the specified range, an alarm will be triggered.

Testing

Turning the keyswitch to the ON position will check the indicator lights on the control panel. All the indicator lights will be illuminated for 2 seconds after the keyswitch is operated. Replace suspect bulbs immediately.

Refer to Troubleshooting for more information.

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Selective Catalytic Reduction

Warning System

The Selective Catalytic Reduction (SCR) system is a system used to reduce NOx emissions from the engine. Diesel Exhaust Fluid (DEF) is pumped from the DEF tank and is sprayed into the exhaust stream. The DEF reacts with the SCR catalyst to reduce NOx and leaves a nitrogen and water vapor.

NOTICE

Stopping the engine immediately after the engine has been working under load can result in overheating of DEF system components.

Refer to the Operation and Maintenance Manual, “Engine Stopping” procedure to allow the engine to cool and to prevent excessive temperatures in the turbocharger housing and the DEF injector.

NOTICE

Allow at least 2 minutes after the engine has stopped before you turn the battery disconnect switch to OFF. Disconnecting the battery power too soon will prevent purging of the DEF lines after the engine is shut down.

Warning Strategy

The engine ECM will have software enabled in order to warn, derate, and only operate a low idle. This software is in order to keep the engine emissions complaint.

Warning Indicators

The warning indicators consist of a level gauge for the DEF, a low-level lamp for the DEF, an emission malfunction lamp, a warning lamp, a DEF quality lamp, and the application stop lamp.

The DEF level gauge will only give an accurate reading with the application on level ground.

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