Perkin 2806 Mechanical Workshop Manuals

2306/2806 Training Course
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Warranty Period
Standby or low usage installations

24 months from delivery to first user or
36 months from date of despatch from Perkins
Whichever expires first
Up to maximum of 1000 hours in total
Coverage: Parts, labour and rotating electrics
Refer to Perkins warranty manual (wad 0001)

for full details
Warranty Period
Baseload or prime power installations

12 months from delivery to first user or
24 months from date of despatch from Perkins
Whichever expires first
There is no limit on engine operating hours
Coverage: Parts, labour and rotating electrics
Major components (castings) up to 36 months
Refer to Perkins warranty manual (wad 0001)

for full details
Service Interval/Overhaul Period
500 hours/12 months between lube oil and all filter

changes
1,000 hours between tappet and EUI injector
adjustments
Base Load Prime Standby

Top-end overhaul 10,000 7,500 1,000
Major overhaul 20,000 15,000 2,000
(B10) Engine life
40,000 30,000 4,000
expectation
Sealants/Lubricants
Sealant & Lubricants / 2800 Series

Part No. Pack size Descriptions Applications
CV60889 500g Anti-seize compound Turbo mounting studs
21820118 & 21820117 50ml & 10ml Thread lock compound Exhaust manifold – where two parts join
21820638 50ml Retaining Compound Cylinder head to crankcase dowel
CV60890 500g Anti-seize compound Big end bolts
CV60891 50ml Pipe thread sealant Plugs in cylinder block
CV60892 18ml Quick-cure Primer-N To clean outer surface of crankshaft
CV60893 50ml Retaining compound Injector sleeves
CV60894 500g Grease Fan drive hub assembly
CV60895 500g Lubricant Cylinder head bolts and washers & threads
CV60896 500g Coating Filter housing threads
CH10879 13ml req. Liquid Gasket Flywheel housing
Hydrosolv 4165 Cleaner

Hydrosolv 100 Cleaner
Engine Identification
Engine Component Changes
Crankshaft
Crankshaft damper (18” finned), adaptor and pulley
Camshaft (lobe profile different, bearing’s size the
same)
Injector (larger nozzle holes – 6 x 0.295 x 130
degrees spray angle)
Cylinder liner
Piston (one-piece steel) and piston rings
Piston cooling ‘jet’ pipe assembly
Connecting rods and big end bearing shells
Engine Component Changes
Crankcase stiffener plate

Sump (aluminium - with no isolation gasket)
Compound idler gear assembly (shot-peened
hardened)
Flywheel housing (SAE No ‘O’) with large flywheel
Coolant pump
Fan drive ratio (0.91 fan ratio)
Larger radiator and air-charge cooler for Tropical
Conditions
2306/2806 Product Features
Combined primary and Integral inlet manifold Radial seal
secondary ‘Eco’ (18 litre horizontal) air filter
Fuel filters element
Fuel transfer Unique wiring

pump harness
Timing ADEM 3 ECM

Calibration With Perkins
Probe access software
hole
2306/2806 Product Features
Single stage 16 litre
high boost Composite
turbocharger top cover
Air to air
charge
Oil cooler cooler
‘Ecoplus’ Torsional
full flow vibration
oil filtration damper
Composite oil pan
2806 -18 litre Product Features
Twin
Twin exhaust
exhaust Twin
Twin
manifolds
manifolds turbochargers
turbochargers
External
External oiloil feed
feed
to
to the
the cylinder
cylinder
head
head Large
Large output
output
coolant
coolant pump
pump
30%
30% larger
larger New
New oil
oil filler
filler
capacity
capacity oil
oil tube
tube
cooler
cooler
Aluminium
Aluminium
sump
sump
Cylinder Head
Composite EUI electrical

top cover connector
Integral inlet manifold

(18 litre horizontal)
Cylinder Head
Second oil pressure feed to

cylinder head (external)
Cylinder Head
Integral inlet manifold has a

single connection point.
Reduces potential leak paths
Cylinder Head
Four Valve Mono-Block Cylinder Head
Four
Forged valves
steel per
overhead cylinder
camshaft
Rocker Assemblies
Roller Type Rockers
Valve Assemblies
One of three oil
feed drillings
Valve Assemblies
Valve Assemblies
Four valves per cylinder
Valve/Injector Clearance
Establishing Number 1 TDC
Turning
tool
TDC locator
Valve
‘screw and
locknut’ adjuster
Injector adjuster
Injector
trim code
Button and ‘O’ ring
Tool CH11149 Checking correct

adjustment
Machine shoulder
With Number 1 Cylinder at TDC compression stroke adjust
Inlet valves 1,2,4
Exh valves 1,3,5 Injectors 3,5,6
With Number 6 Cylinder at TDC compression stroke adjust
Inlet valves 3,5,6
Exh valves 2,4,6 Injectors 1,2,4
Clearances
Inlet valves 0.38mm (0.015in)
Exh Valves 0.76mm (0.030in)
Injectors 78.0mm (3.07in) Tool N° CH11149
Injector Sleeve
A stainless steel sleeve is used in the injector
bore to seal the coolant
The sleeve is sealed using three ‘O’ rings.
However, combustion gases are sealed by the
injector seating on the metal in the cylinder
head bore.
The ‘O’ ring seal fitted on the injector nozzle
provides a combustion gas seal until a carbon
dam is formed
Injector Sleeve
Camshaft
Long Overlap Camshaft
Injector lobe Valve lobes
Drive gear
dowel
location
Camshaft
Thrust Plate and Seal
Camshaft
Front Plate Oil Seal
Camshaft
Head Gasket/Spacer Plate
Oil seal
Cylinder head gasket
Coolant bobbin
Spacer plate
Oil feed O ring
‘Shim’ gasket
Exhaust Manifold
Air gap
Thermal sleeve
Open Circuit Breather
Cylinder Block
Open Summit Cylinder Block
Cylinder Liners
Cylinder Liners
Induction Hardened Liners
Oil soaked filler band
Rubber O rings
(2806)
2306 three lower liner ‘O’ ring seals are all identical in size
Cylinder Liners
Protrusion
Note: Cylinder liner protrusion is measured from the top

of the cylinder liner to the top of the spacer plate
1. Ensure that the top face of the cylinder block is clean

2. Ensure that the cylinder liners are fitted to their original
positions (if being re-used)
3. Measure the liner protrusion at the four positions shown (B1,
B2, B3 and B4 in the workshop manual) and record the
measurements for each cylinder
4. Add the four readings for each cylinder and divide the sum of
the readings by four to obtain the average reading for each
cylinder
Cylinder Liners
Protrusion
Cylinder Liners
Protrusion
Pistons
2306 ‘Gallery Cooled’ Articulated Piston
Oil cooling spray cutaways
Oil cooling gallery
Pistons
2806-16 Articulated Piston
Cooling oil reservoir
Piston/Con-Rod Assembly
Tightening con-rod bolts
Pistons
2806-18 Piston
Compression ratio 14.5:1
Pistons
2806-18 Piston
Cooling gallery entry ports
Pistons/Con-Rod Assembly
2806-18 Piston
Big end cap secured by Oil supply to small

four bolts end bearing
Pistons/Con-Rod Assembly
Torque bolts (A) and (C) 70 Nm
Torque bolts (B) and (D) 70 Nm
Turn bolts (B) and (D) 60 deg
Torque bolts (A) and (C) 70Nm
Turn bolts (A) and (C) 60 deg
Torque piston cooling jet bolts (7) 40Nm
Lubricate bolt threads and their contact

faces before assembly
Piston Cooling Jets
Piston cooling jet

alignment tool
Part Number GE50004
Piston Cooling Jets
2806-18
2806-16 2806-18
Piston Cooling Jets
2806-18
Piston
Connecting rod
Entry to
cooling gallery
Piston cooling
jet pipe
assembly
Piston Rings
Tapered/Barrel Faced Piston Rings
Top
ring
Spring
Piston Rings
Crankshaft
Thrust washer position
Crankshaft
2806-18
Crankshaft
Grooved main bearing

fitted to block
180° thrust washers

fitted to block
Crankshaft
Front face detail
2806-16 2806-18
6 Tapped holes 12 Tapped holes
Block Stiffener Plate
18 Litre
Torsional Damper
Hasse and Wrede Damper
Structure
2
1. Housing
2. Casing
3. Inertia Ring (mass)
4. Bearings
5. Silicone Fluid
Torsional Damper
Fan Belt Adjustment
Alternative method of checking belt tension, when

no spring gauge is available
The maximum twist using your fingers must only be
90 degrees, below 90 degrees is too tight. Being
able to twist beyond 90 degrees and the belt is too
loose and requires tightening
Too loose! Allows pulley drives to slip and can
damage the drive belts
Too tight can damage driven components bearings
and will also damage the driven belts
Timing Gears
Coolant pump ‘Pendulum’
drive gear camshaft gear
position
Adjustable
Compound idler gear
gear
assembly
Idler gear
Crankshaft gear
Fuel transfer
Oil pump pump
gear position
Timing Gears
Pendulum Camshaft Gear
Rotating
balance
weights
Locating
dowel
Timing Gears
Timing case
Alignment
marks
Timing gear
Timing Gears
Timing Gears
Checking Gear Backlash
Crankshaft Seals
Blue seal (rear) Green seal (front)
Crankshaft Seals
Crankshaft Seals
Crankshaft Seals
Oil Seal and Wear Sleeve
Must be fitted as an assembly

Must not be separated
Must be fitted dry
Crankshaft Seals
Seal Removal/Fitting
1. Gear case - split protection ring

2. Wear sleeve ‘crimp’ tool
Crankshaft Seals
Induction System
2809-18
Induction System
Air Filter Type Single medium duty paper element
Max Air Inlet Temp 60°C (140°F)
Initial Restriction 2.5kPa
(inlet depression new)
Maximum Inlet Depression 6.2Kpa
(with dirty filter)
Max Pressure Drop 14Kpa (2.03 psi)
(across charge cooler)
Maximum Charge Air Temp 260°C (500°F)
at high (ambient conditions)
Turbo Charger 2306 Allied Signal GT 50
2806 Borge Warner S 500
2806-18 twin Borge Warner S310
Induction System
Radial Seal Filters
Induction System
Induction System
Induction System
Induction System
Turbochargers
Single stage ‘high boost’ turbochargers

No oil priming required
Induction System
2806-18 Turbochargers
Rear turbocharger Forward turbocharger

Exhaust gas outlet
Induction System
Turbocharger
Three basic causes of premature turbocharger failure
Lack of lubricant
(cold start-up/hot shut-down/low oil pressure)
Lack of lubricant will show up first in bearing failure, leading to
wheel rub, seal damage or even shaft breakage
Ingestion of foreign objects
Foreign object ingestion damages turbine and compressor
wheel blades, causing imbalance and rotational instability, with
resulting damage to seal bores and bearings
Contamination of the lubricating oil
Contaminated lubricant will cause scored shaft journals and
bearings, block oil holes and plug seals, resulting in heavy oil
leakage
Induction System
Air Charge Cooling/Radiator
C
A O
O
I L
R A
N
T
Induction System
Air Charge Cooling/Radiator – 2806-16
Induction System
2806-18
Air charge
Coolant cooling / radiator
Turbo boost air
Boost air
Coolant
Induction System
2806C-18 Litre
Fuel System
Fuel injector MEUI
Electronic control module (ECM) ADEM 3
Injection pressure 2000 bar (30,000psi +)
Injector service Non-serviceable
Fuel transfer pump pressure 400-800Kpa
(60-125psi)
Governor type Electronic
Twin fuel filters Primary/Secondary filter
Flow Rate
1500 rpm 413 litres/hour
1800 rpm 457 litres/hour
Fuel to conform to BS2869 1998 Class A2
Fuel System
Internal Injector Harness
12PIN Connector Service

Tool
Connector
Interface
Connector
Non CAT OEM Interface Connectors
Main Engine Harness

ADEM III ECM
Crank Speed/Timing
36-1 TOOTH
CRANK
GEAR Inlet Air Manifold Temperature
Cam Speed/Timing
Fuel Temperature
36+1 TOOTH
CAM GEAR
Coolant Temperature
Boost
Atmospheric Pressure Sensor
Pres Sensor
Timing Probe
Lub Oil Pressure

Sensor
Fuel System
Fuel System
Low Injection Pressure

Large Droplets
High Injection Pressure

Small Droplets – Improved Emissions
Fuel System
Checking correct
Tool CH11149
adjustment
Machine shoulder
Fuel System
EUI Location
Trim code
Fuel System
Injector Seals
O ring seals
‘Sacrificial’
compression ‘O’ ring
6 hole
injector nozzle
Do not re-use seals
Fuel System
Injector Sleeve
A stainless steel sleeve is used in

the injector bore to seal the
coolant
The sleeve is sealed using three ‘O’
rings. However, combustion gases
are sealed by the injector seating B1
on the metal in the cylinder head
The lower ‘O’ ring seal installed on
the injector provides for a
combustion gas seal until a carbon
dam is formed
B2
Fuel System
Injector Taper Seal
A line A failed seal

contact results in
seal is blow by and
attained a hot
injector
Fuel System
Low Pressure Fuel System
Priming pump
Venting points
Fuel return
Secondary filter
Transfer pump Fuel supply Primary filter
Fuel System
Fuel Cooler/Return
Flow =
413 litres/h at
1500
Flow =
457 litres/h at
1800
Return flow
dependant on
engine load
Fuel System
Fuel Transfer Pump
Fuel System
Non-return/PRV
Fuel System
Ecoplus Fuel Filtration
Supply to head
From Temp sensor
transfer
pump
Hand
To primer
transfer
pump
Hand
primer
From
By-pass
Tank
valve
Return from
head
Return to PRV Air vent

cooler
Fuel System
Fuel System
Ecoplus Fuel Filtration Identification
Oil
Fuel Secondary Fuel primary
Fuel System
Fuel System
Fuel System
Fuel System
Fuel System
Fuel System
Causes of Low Fuel Pressure
Blocked fuel filters

Debris in the PRV
Debris in the check valves for the fuel priming pump
Partially open/worn PRV
Sticking or worn PRV in the fuel transfer pump
Worn gears in the fuel transfer pump
Pinched or restricted fuel lines
Debris in the fuel tank/fuel lines
Lubrication System
Type Wet sump - full flow
system
Oil pump Gear driven - with PRV
Capacity - total system 68 litres
Sump maximum 60 litres
Sump minimum 45 litres
Lube oil temp - normal (sump) 95°C
Lube oil temp - maximum 113°C
Lube oil pressure - rated speed 2.7-6 bar (40-88psi)
Lube oil pressure - min rated speed 2 bar (30psi)
Oil pressure relief valve opening pressure 6.1 bar (88psi)
Lubrication System
Composite ‘High Capacity’ Sump
Lubrication System
Oil Pump
Lubrication System
API CG4 oils acceptable API CH4 oils preferred
Lubrication System
Ecoplus Oil Filtration
Sampling
point O/P switch
Filter by-pass Cooler by-pass

valve valve
Lubrication System
Oil Sampling Kit
Lubrication System
2806-18
Oil cooler
assembly
Re-positioned
oil filler
tube
Re-designed
Oil filter
head
Cooling System
Capacity of engine 20.8 Litres
Capacity of complete system 50 Litres
Pressure cap setting 70kPa (0.7 Bar) (10psi)
Thermostat operating range Starts 88°C. Fully open 98°C
Coolant pump Gear driven, centrifugal type
Radiator Aluminium core, composite tanks
Fan Plastic, 8 blade, belt driven,
pusher type,1016 mm diameter
Maximum temperature - top tank 103°C
Coolant immersion heater capacity 1500W
Recommended coolant for initial fill 50% extended life coolant,
and top up 50% de-ionised clean water
(distilled)
Coolant Life 3,000 hours or six years - max
Cooling System
Air Charge Cooling/Radiator
Composite top and bottom radiator tanks
ELC coolant to be used at all times
Cooling System
Gear Driven Coolant Pump
Cooling System
Thermostat and Housing
Coolant
Air vents
Cooling System
Thermostat Housing
Thermostat
Flow to radiator
Thermostat seal
By-pass
return to
coolant pump
Cooling System
Bypass to
coolant
pump
Oil cooler
If you need Technical advice contact our dedicated Engineers
Use the Request Form
on the Perkins Secured Internet
http://www.perkins.com/perkins/cda/technicalSupportRequest/1,4077,,00.html
Or
Send an email to
technical_help@perkins.com
For URGENT queries only, telephone +44 (0)1733 582858

Perkin 2806 Mechanical Workshop Manuals

Caricato da

Informazioni sul documento

Descrizione originale:

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Perkin 2806 Mechanical Workshop Manuals

Caricato da

Copyright:

Formati disponibili

2306/2806 Training Course

Standby or low usage installations

 36 months from date of despatch from Perkins

 Whichever expires first

 Up to maximum of 1000 hours in total

 Coverage: Parts, labour and rotating electrics

 Refer to Perkins warranty manual (wad 0001)

Baseload or prime power installations

 24 months from date of despatch from Perkins

 Whichever expires first

 There is no limit on engine operating hours

 Coverage: Parts, labour and rotating electrics

 Major components (castings) up to 36 months

 Refer to Perkins warranty manual (wad 0001)

 500 hours/12 months between lube oil and all filter

Base Load Prime Standby

Sealant & Lubricants / 2800 Series

Hydrosolv 4165 Cleaner

 Crankcase stiffener plate

Fuel transfer Unique wiring

Timing ADEM 3 ECM

Composite oil pan

Composite EUI electrical

Integral inlet manifold

Second oil pressure feed to

Integral inlet manifold has a

Button and ‘O’ ring

Tool CH11149 Checking correct

Injector lobe Valve lobes

Cylinder head gasket

Oil feed O ring

Oil soaked filler band

Note: Cylinder liner protrusion is measured from the top

1. Ensure that the top face of the cylinder block is clean

Oil cooling spray cutaways

Oil cooling gallery

Cooling oil reservoir

Tightening con-rod bolts

Compression ratio 14.5:1

Cooling gallery entry ports

Big end cap secured by Oil supply to small

Lubricate bolt threads and their contact

Piston cooling jet

Grooved main bearing

180° thrust washers

 Alternative method of checking belt tension, when

Blue seal (rear) Green seal (front)

 Must be fitted as an assembly

1. Gear case - split protection ring

Single stage ‘high boost’ turbochargers

Rear turbocharger Forward turbocharger

Fuel to conform to BS2869 1998 Class A2

12PIN Connector Service

Non CAT OEM Interface Connectors

Main Engine Harness

Lub Oil Pressure

Low Injection Pressure

High Injection Pressure

Do not re-use seals

 A stainless steel sleeve is used in

A line A failed seal

Return to PRV Air vent

36 months from date of despatch from Perkins

Whichever expires first

Up to maximum of 1000 hours in total

Coverage: Parts, labour and rotating electrics

Refer to Perkins warranty manual (wad 0001)

24 months from date of despatch from Perkins

Whichever expires first

There is no limit on engine operating hours

Coverage: Parts, labour and rotating electrics

Major components (castings) up to 36 months

Refer to Perkins warranty manual (wad 0001)

500 hours/12 months between lube oil and all filter

Crankcase stiffener plate

Alternative method of checking belt tension, when

Must be fitted as an assembly

A stainless steel sleeve is used in

Blocked fuel filters