Perkins 2000 2200 2300 2500 2800 Eagle Series Diesel Engine Workshop Repair Service Manual PDF - MPKN2000OPES.zip
A full workshop and repair guide, complete with Electrical Wiring Diagrams, covering Perkins 2000, 2200, 2300, 2500, 2800, and Eagle Series Engines — containing every technical detail needed to service, troubleshoot, fix, and overhaul these engines the way expert technicians do.
The workshop service and repair manual for Perkins 2000, 2200, 2300, 2500, 2800, and Eagle Series Engines contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
KENR6224 - Troubleshooting (2506-15 Industrial Engine).pdf
KENR6230 - Specifications (2506-15 Industrial Engine).pdf
KENR6231 - Systems Operation_Testing & Adjusting (2506-15 Industrial Engine).pdf
KENR6232 - Disassembly & Assembly (2506-15 Industrial Engine).pdf
KENR6233 - Schematic (2506-15 Industrial Engine Electrical System).pdf
KENR6905 - Specifications (2206-E13 Industrial Engine).pdf
KENR6906 - Disassembly & Assembly (2206-E13 Industrial Engine).pdf
KENR6907 - Systems Operation_Testing & Adjusting (2206-E13 Industrial Engine).pdf
KENR6908 - Troubleshooting (2206-E13 Industrial Engine).pdf
KENR6909 - Schematic (2206-13 Industrial Engine Electrical System).pdf
Perkins 2300, 2500, 2800 Series Diesel Engine Training.pdf
SEBU8313 - Operation & Maintenance Manual (2506-15 Industrial Engine).pdf
SEBU8337 - Operation & Maintenance Manual (2206-E13 Industrial Engine).pdf
TPD1516E1 - User’s Handbook (2800 Series_Model 2806C-E18 (6 cylinder turbocharged diesel engines for industrial applications)).pdf
TPD1517E1 - Workshop Manual (2800 Series_Models 2806C-E18 TAG1 TAG2 & TAG3 (6 cylinder turbocharged diesel engines for industrial, applications)).pdf
TSD3215E12 - User’s Handbook (All 2000 diesel models (Six cylinder diesel engines for industrial applications)).pdf
TSD3244E - User’s Handbook (Eagle TX & Eagle 800).pdf
TSD3245E2 - Workshop Manual (2000 Series_6 cylinder diesel engines for industrial applications).pdf
TSD3409E4 - User’s Handbook (2000 Series_Models 2006SI & 2006TSI_6 cylinder spark ignited engines for industrial applications).pdf
TSD3429E3 - User’s Handbook (Eagle TX2000).pdf
TSD3433E1 - Workshop Manual (Eagle TX & Eagle 800 & Eagle 2000_6 cylinder diesel engines for Trucks).pdf
TSD3449E2 - User’s Handbook (2800 Series_Model 2806C-E16 (6 cylinder turbocharged diesel engines for industrial applications)).pdf
TSD3450E - Workshop Manual (2800 Series_Model 2806C-E16 (6 cylinder turbocharged diesel engines for industrial applications)).pdf
TSD3453E3 - Diagnostic Manual (2800 Series_Models 2806C-E16 & 2806C-E18 (6 cylinder turbocharged diesel engine)).pdf
TSD3454E2 - User's Handbook (2300 Series_Models 2306A-E14 & 2306C-E14 (6 cylinder turbocharged diesel engines for industrial applications)).pdf
TSD3455E1 - Workshop Manual (2300 Series_Model 2306C-E14 (6 cylinder turbocharged diesel engines for industrial applications)).pdf
TSD3455E2 - Workshop Manual (2300 Series_Models 2306A-E14 & 2306C-E14 (6 cylinder turbocharged diesel engines for industrial applications)).pdf
TSD3457E2 - Diagnostic Manual (2300 Series_Models 2306A-E14 & 2306C-E14 (6 cylinder turbocharged diesel engine)).pdf
TSL4247 - Diagnostic Manual (2800 Series_Model 2806C-E16 (6 cylinder turbocharged diesel engine)).pdf
PRODUCT DETAILS:
Total Pages: 2,601 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KENR6224 - Troubleshooting (2506-15 Industrial Engine)...3
KENR6230 - Specifications (2506-15 Industrial Engine)...147
KENR6231 - Systems Operation_Testing & Adjusting (2506-15 Industrial Engine)...183
KENR6232 - Disassembly & Assembly (2506-15 Industrial Engine)...243
KENR6233 - Schematic (2506-15 Industrial Engine Electrical System)...343
KENR6905 - Specifications (2206-E13 Industrial Engine)...345
KENR6906 - Disassembly & Assembly (2206-E13 Industrial Engine)...381
KENR6907 - Systems Operation_Testing & Adjusting (2206-E13 Industrial Engine)...501
KENR6908 - Troubleshooting (2206-E13 Industrial Engine)...557
KENR6909 - Schematic (2206-13 Industrial Engine Electrical System)...701
Perkins 2300, 2500, 2800 Series Diesel Engine Training...703
SEBU8313 - Operation & Maintenance Manual (2506-15 Industrial Engine)...853
SEBU8337 - Operation & Maintenance Manual (2206-E13 Industrial Engine)...933
TPD1516E1 - User’s Handbook (2800 Series_Model 2806C-E18 (6 cylinder turbocharged diesel engines for industrial applications))...1021
TPD1517E1 - Workshop Manual (2800 Series_Models 2806C-E18 TAG1 TAG2 & TAG3 (6 cylinder turbocharged diesel engines for industrial, applications))...1083
TSD3215E12 - User’s Handbook (All 2000 diesel models (Six cylinder diesel engines for industrial applications))...1275
Perkins 2000 Series...1275
All 2000 diesel models...1275
USER’s HANDBOOK...1275
Six cylinder diesel engines for industrial applications...1275
This publication is divided into six chapters:...1276
1 General information...1276
2 Engine views...1276
3 Operation instructions...1276
4 Preventive maintenance...1276
5 Engine fluids...1276
6 Fault diagnosis...1276
Publication TSD 3215E, Issue 12...1275
© Proprietary information of Perkins Engines Company Limited, all rights reserved...1275
The information is correct at the time of print...1275
Published in May 1999 by Technical Publications...1275
Perkins Engines Company Limited, Lancaster Road,...1275
Shrewsbury, Shropshire, SY1 3NX, England...1275
Contents...1277
1 General information...1277
2 Engine views...1277
3 Operation instructions...1277
4 Preventive maintenance...1278
5 Engine fluids...1279
6 Fault diagnosis...1279
General information...1281
Introduction...1281
Safety precautions...1282
How to care for your engine...1283
Engine preservation...1284
1 Remove the thermostat from its housing and carefully clean it. Apply a silicone grease, such as...1284
2 Operate the engine until the normal temperature of operation is reached. Stop the engine and dr...1284
3 Fill the canisters of the oil filter with PX4 corrosion inhibitor and fit the canisters to the ...1284
4 Fill the sump, to the normal oil level, with PX4 corrosion inhibitor and, once again, run the e...1284
5 Stop the engine, disconnect the fuel supply pipe and connect the pipe to a supply of PX4 corros...1284
6 Disconnect the supply of PX4 corrosion inhibitor from the fuel system and seal the end of the p...1284
7 Remove the fuel injectors and put them in a container of PX4 corrosion inhibitor...1284
8 Set the fuel control lever to the NO FUEL position, remove the rocker covers and disconnect the...1285
9 Turn the engine by the use of the starter and, at the same time, spray PX4 corrosion inhibitor ...1285
10 Spray 40 cc of PX4 corrosion inhibitor into each cylinder, through the openings for the fuel i...1285
11 Spray PX4 corrosion inhibitor around the valves and around the rocker assemblies. Fit the rock...1285
12 Drain the PX4 corrosion inhibitor from the sump of the engine and from the oil filter canister...1285
13 Drain the cooling system and fill with the recommended coolant mixture (see "Coolant" on page ...1285
14 Wait for 15 minutes, then drain completely the coolant mixture. Fit a NO COOLANT label to the ...1285
15 Disconnect the exhaust pipe at the turbocharger outlet, or at the junction of the manifolds if...1285
16 Inject two grammes of VPI 260 powder into the turbocharger, if relevant...1285
17 Disconnect the air ducts between the air filter(s) and the turbocharger and inject two grammes...1285
18 Inject two grammes of VPI 260 powder into each paper element type air filter. Other types of a...1285
19 Spray Crodafluid PM47 onto areas of the engine and auxiliary equipment which are not protected...1285
20 Cover, completely, the alternator and the starter motor in mouldable wax wrapping, and seal wi...1285
21 Seal the air filter inlets, the crankcase breather and all other openings with mouldable wax w...1285
22 Remove all drive belts, apply French chalk to the belts and put them in a sealed plastic bag. ...1285
23 Fasten to the engine a label which indicates:...1285
Approved products for engine preservation...1286
Component...1286
Product...1286
Manufacturer...1286
Parts and Service...1287
Engine identification...1288
Engine data...1289
(1) Important for the protection of the turbocharger bearings...1290
Engine views...1291
Introduction...1291
Location of engine parts...1291
1 Thermostat housing...1291
2 Alternator...1291
3 Belt tensioner...1291
4 Canisters of the lubricating oil filter...1291
5 Oil cooler...1291
6 Breather pipe...1291
7 Starter motor...1291
8 Air charge cooler/inlet manifold...1291
9 Rocker cover...1291
1 Coolant pipe...1292
2 Fuel filter canister...1292
3 Turbocharger...1292
4 Dipstick and tube...1292
5 Filler cap for the engine lubricating oil...1292
6 Fuel lift pump...1292
7 Relief valve for the fuel...1292
8 Exhaust manifold...1292
9 Fuel injector...1292
Operation instructions...1293
How to prepare a new or an overhauled engine...1293
1 Check that all protection covers and blanking plugs have been removed...1293
2 Fit all components which were removed for storage or for transport...1293
3 Ensure that the drain plugs for the coolant and for the lubricating oil are securely fitted...1293
4 Where necessary, connect the remote control linkages, the pressure gauge pipes, the air inlet p...1293
5 Connect the fuel pipes...1293
6 Connect the exhaust pipes...1293
7 Fill the fuel tank/s with the correct grade of fuel (see "Diesel fuel" on page 53)...1293
8 Fill the cooling system with the approved coolant mixture (see "Coolant mixture" on page 53)...1293
9 Fill the sump to the ‘H’ mark on the dipstick with the correct grade of lubricating oil (see "L...1293
10 Remove the plug from the right side of the fuel injection pump and fill the fuel injection pum...1293
11 Add oil to the turbocharger, or to the two turbochargers if relevant, as follows: Clean the ar...1293
12 Eliminate air from the fuel system (see page 41)...1293
13 Lubricate all of the control linkages and check the linkages for free movement...1293
14 Ensure that the stop control is in the STOP position and that the lever of the speed control i...1293
Normal start procedures...1294
1 Check that the level of the coolant is just at the bottom of the filler extension in the radiat...1294
2 Check the engine oil level. With the engine stopped the oil level must be at the ‘H’ mark on th...1294
3 Check the level in the fuel tank. Open the fuel valve, if one is fitted...1294
How to start the engine...1295
1 Move the speed control lever to the maximum speed position...1295
2 Press the start switch and release it when the engine starts...1295
3 Move the speed control lever to the idle position...1295
1 ‘ER’ system. Remove the cap (A1) of the capsule chamber and pull the plunger (A2) fully out. In...1295
2 After a short delay, when the capsule is empty, repeat the operation with two or three more cap...1295
3 ‘Viso-F’ system. Use the canister to fill the reservoir to the MAX mark. Then operate the pump ...1295
4 Move the lever for the speed control away from the IDLE position and operate the start switch. ...1295
5 When the engine starts and runs, release the start switch and continue to operate the pump unti...1295
1 Move the lever for the speed control away from the IDLE position and operate the start switch...1296
2 When the engine turns, pull the control knob to operate the priming valve for two seconds and t...1296
3 According to the adverse ambient temperature, repeat the operation of the priming valve until t...1296
4 Do not turn the engine continuously at cranking speed for more than 20 seconds. If the engine d...1296
How to run the engine...1296
1 Do not operate the engine at high speeds and loads until the coolant has reached a minimum temp...1296
2 Do not allow the engine to run at idle speed, or without load, for prolonged periods...1296
3 Do not exceed the maximum rated speed of the engine...1296
4 Never allow an engine to continue to run if the oil pressure is below 207 kN/m2 (30 lbf/in2) at...1296
5 Fill the fuel tank/s at the end of each day to prevent condensation and to allow sediment to fa...1296
How to stop the engine...1296
1 Operate the engine for 3 minutes at idle speed with no load to allow the turbocharger to reduce...1296
2 Move the switches for the engine protection devices to their OFF positions...1296
3 Move the stop control or switch to the STOP position and release it after the engine has stopped...1296
Running-in after a repair...1297
1 Run the engine without a load until the normal temperature is reached...1297
2 During a period of three to four hours, increase gradually the load on the engine until the fin...1297
Preventive maintenance...1299
Preventive maintenance periods...1299
Schedule for engines in normal use...1300
A...1300
B...1300
C...1300
D...1300
E...1300
Operation...1300
(1) By a person who has had the correct training...1300
Schedule for engines in intermittent use...1301
A...1301
B...1301
C...1301
Operation...1301
(1) By a person who has had the correct training...1301
How to check the coolant level...1302
How to check the lubricating oil level...1302
Air filter...1303
1 Loosen the clamp ring and remove the assembly of the dust bowl and the baffle plate...1303
2 Remove the wing nut and separate the dust bowl and the baffle plate...1303
3 Remove the debris from the dust bowl; clean and assemble the two components...1303
4 Remove the wing nut which retains the filter element and withdraw carefully the filter element...1303
5 Use compressed air at a maximum pressure of 700 kN/m2 (100 lbf/in2) to clean the inner side of ...1303
6 Put a light inside the element and inspect the material of the element for damage. Thin areas o...1303
7 Clean the body of the air filter, fit the element and the assembly of the dust bowl and the baf...1303
8 Press the reset button (B1) on the restriction indicator...1303
How to check the drive belts...1304
How to adjust the tension of the fan belts...1305
How to adjust the tension of the alternator belt...1306
How to renew the engine lubricating oil...1307
1 Operate the engine until it is warm...1307
2 Stop the engine, remove the sump drain plug (A1, B1, C1, C2 or D1) and drain the lubricating oi...1307
3 Fit the drain plug and a new sealing washer and, according to the type of thread, proceed as fo...1307
4 Renew both of the oil filter canisters, see "How to renew the canisters of the oil filter" on p...1308
5 Clean the area around the oil filler cap and remove the cap. Fill the sump to the H mark on the...1308
6 Operate the engine and check for leakage from the filter canisters. When the engine has cooled,...1308
How to renew the canisters of the oil filter...1309
1 Put a tray under the canisters and use a strap wrench, 21825 825, to remove each canister...1309
2 Check that the sealing rings (A1) are correctly fitted to the new canisters and clean the conta...1309
3 Fill the two new canisters with new engine lubricating oil of the correct grade and lubricate t...1309
4 To install the new canisters use this procedure: Tighten the canisters, on their adaptors, unti...1309
How to renew the rotor of the by-pass filter for the lubricating oil...1310
1 Clean the area around the by-pass filter. Remove the filter bowl (A2), remove and discard the r...1310
2 Remove the seal (A4) from the filter bowl and clean all the components, especially the recess f...1310
3 Fit a new seal to the recess in the filter bowl and lubricate the face of the seal with clean e...1310
4 Fit a new rotor to the spindle and ensure that it can rotate freely. Fit the filter bowl and ti...1310
5 When the engine is operated, check for leakage from the by-pass filter...1310
How to renew the canister of the main fuel filter...1311
1 Clean the area around the filter and remove the fuel filter canister. If necessary, use a strap...1311
2 Check that the sealing ring (A1) is fitted correctly to the new canister and clean the contact ...1311
3 Fill the new canister with clean fuel oil of the correct specification, lubricate the top of th...1311
4 To install the new canister use this procedure: Tighten the canister on its adaptor, until the ...1311
How to drain and clean the primary fuel filter...1312
1 Remove the drain plug (A5) from the base of the filter bowl and allow all water and sediment to...1312
2 Fit the drain plug and tighten it securely...1312
1 Remove the three bolts and remove the sediment bowl...1312
2 Clean all of the components with paraffin and dry them with compressed air...1312
3 Fit the sediment bowl to the filter head, together with a new sealing ring (A3). Align the clam...1312
How to check the specific gravity of the coolant...1313
1 Put a hydrometer, and a reliable thermometer, into the antifreeze mixture and check the reading...1313
2 Compare the readings obtained with the chart and adjust the strength of the mixture as necessary...1313
1 Open the cover of the refractometer, check that the clear panel is clean and use a small syring...1313
2 Spread the coolant over the full area of the clear panel and close the cover. Hold the refracto...1313
3 Compare the reading with the chart in the instructions; adjust the strength of the mixture as n...1313
Antifreeze/water...1313
(% by volume)...1313
Protection down to...1313
(C)...1313
How to check the pH value of the coolant...1314
Fuel injector fault...1315
How to remove a fuel injector...1315
1 Clean the area around the fuel injector...1315
2 Disconnect and remove the leak-off pipe from the fuel injector...1315
3 Disconnect and remove the high pressure pipe. If necessary, release the pipe clip. Do not bend ...1315
4 Remove the bolts and the clamp which retains the fuel injector and withdraw the fuel injector. ...1315
5 To remove a tight fuel injector, use the slide hammer, 21825 849 (A1) and the relevant adaptor ...1315
Fuel injector sleeves...1316
How to correct a fuel injector sleeve...1316
1 To retain carbon and metal particles, grease must be applied to both of the cutters of the tool...1316
2 When a fuel injector is removed, if the copper sealing washer remains in the fuel injector slee...1316
How to fit a fuel injector...1317
1 Ensure that the fuel injector sleeve is clean and is free from carbon deposits...1317
2 Fit a new rubber seal (A1) onto the body of the fuel injector and a new copper sealing washer (...1317
3 Apply evenly anti-seize compound (‘Morris K72’ or equivalent) to the body of the fuel injector ...1317
4 Fit the fuel injector into the fuel injector sleeve. Apply an even layer of anti-seize compound...1317
5 Fit the high-pressure fuel pipe. Ensure that there is no tension on the connections and that th...1318
6 Fit and tighten all clamps which may have been removed...1318
7 Fit the leak-off pipe, complete with new washers, and eliminate air from the fuel system, see "...1318
8 Run the engine and check for leakage...1318
How to eliminate air from the fuel system...1319
1 Ensure that there is fuel in the fuel tank and that the source of any leakage has been eliminated...1319
2 Loosen the union at the outlet pipe of the lift pump. Operate the hand priming pump (A1) to all...1319
3 Continue to operate the hand priming pump and loosen the union on the outlet side of the fuel f...1319
4 Continue to operate the hand priming pump and loosen, one at a time, each union where the high ...1320
5 When all the unions are tightened fully, continue to operate the hand priming pump until the re...1320
How to check the tappet clearances...1321
Valves set on cylinder No...1321
Check tappets on cylinder No...1321
1 Remove the rocker covers...1321
2 Turn the crankshaft in the normal direction of rotation until the inlet valve of number 6 cylin...1321
3 Check the clearances of the valves of number 1 cylinder and adjust them if it is necessary (A)...1321
4 Continue to turn the engine and adjust the remainder of the tappets in the sequence given above...1321
5 Fit the rocker covers...1321
Alternator...1322
1 Check the condition and the tension of the drive belt, and adjust or renew as necessary...1322
2 Disconnect the two wires of the regulator (B1) from the terminals on the holder (B2) of the car...1322
3 Remove the screws which retain the holder of the carbon brushes, disconnect the wires and lift ...1322
4 Check the carbon brushes for damage and ensure that they are suitable for use. The minimum poss...1322
5 Remove the four screws which retain the housing of the carbon brushes, withdraw the housing and...1322
6 Clean the components and remove all of the dirt. Use a soft clean rag which is damp with gasoli...1322
Starter motor...1323
1 Clean the outside of the starter motor and remove the commutator cover. Use dry compressed air ...1323