Perkins2806柴油发电机故障故障诊断

Perkins2806柴油发电机故障故障诊断

Self-diagnostics

2800 Series

Perkins electronic engines can perform a self-diagnostics test. Diagnostic codes are stored in the permanent

memory of the Electronic Control Module (ECM) and can be retrieved by use of the Perkins electronic service

tool, EST. A list of diagnostic codes is given in the table under "Diagnostic codes" on page 20.

Some installations have electronic dis plays that provide a direct reading of the engine diagnostic codes. Refer

to the manual that is provided by the OEM for more information on retrieving engine diagnostic codes.

Active codes, indic ated by a warning lamp or similar device (depending on application), represent problems

that currently  exist. These problems should be investigated first.

Logged codes repres ent:

Intermittent problems

Recorded events

Performance history

The problems may have been repaired since the code was logged. These codes do not indicate that a repair

is needed; the codes are guides or signals when a situation exists. Codes may be helpful to diagnose

problems.

When the problems have been corrected, the corresponding logged fault codes should be cleared, where

possible.

Use the Perkins service tool EST to determine the diagnostic code.

Fault logging

The system provides the capability of fault logging. When the Electronic Control Module (ECM) generates a

diagnostic c ode, the code will be logged in the memory  of the ECM. The codes that have been logged in the

memory of the ECM can be retrieved with Perkins electronic service tools. The codes that have been logged

can be cleared with Perkins electronic service tools. The codes that have been logged in the memory of the

ECM will be automatically cleared from the memory after 100 hours. If the engine is operated in protection

override mode, then low engine oil pressure and high engine coolant temperature events cannot be cleared

without a factory password.

Engine operation with active diagnostic codes

If a fault is indicated during normal engine operation, the system has identified a situation that is not within the

specification. Use Perkins electronic service tools to check the active diagnos tic codes.

The active diagnostic code should be inv estigated. The cause of the problem should be corrected as soon as

possible. If the cause of the active diagnostic code is repaired, and there was only one active diagnostic code,

the warning lamp or similar device will turn off.

Engine operation with intermittent diagnostic codes

If during normal engine operation a fault is indicated by a fault lamp or similar device and the lamp or device

then returns to normal, an intermittent fault may have occurred. If a fault has occurred, the fault will be logged

in the memory of the Electronic Control Module (ECM).

In most cases, it is not necessary to stop the engine because of an intermittent code. However, the operator

should retrieve the codes and refer to the relevant information to identify the nature of the event. The operator

should note the circumstances that are involved during the time that the lamp was on:

Engine load

Limits of the engine speed

Excessive smoke, etc.

This information can be useful to help diagnose the situation. The information can also be used for future

reference. For more information on diagnostic codes, refer to the Diagnostic Manual for this engine.

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User’s Handbook, TPD1516E, Issue 1

2800 Series

Customer specified parameters

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Customer specified parameters that will enhance the fuel efficiency and the operator's convenience can be

programmed into the Electronic Control Module (ECM). Some parameters may affect engine operation. This

may lead to complaints from the operator about power or performance. The engine related parameters  which

follow may be programmed by the customer, by use of the Perkins  electronic service tool, to influence the

operation of the engine:

Engine ratings selection, the ability to choose between the relevant torque maps

(prime/stand-by, 50/60 Hz) (where a switchable flash file has been specified)

Governor gain tuning parameters

Analogue throttle enable

Equipment identification

Droop set point

Engine acceleration rate

Enable speed selection by the use of an external switch

Enable droop/isochronous  selection by the use of an external switch

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2800 Series

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Preventive maintenance

Preventive maintenance periods

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These preventive maintenance periods apply to average conditions of operation. Chec k the periods given by

the manufacturer of the equipment in which the engine is ins talled. Use the periods which are shortes t. When

the operation of the engine must conform to the local regulations thes e periods and procedures may need to

be adapted to ensure c orrect operation of the engine.

It is good preventive maintenance to c heck for leakage and loos e fasteners at each service.

These maintenance periods apply only to engines that are operated with fuel and lubricating oil which conform

to the specifications given in this  handbook.

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Schedule

2800 Series

The maintenance operations must be applied at the interval (hours or months)which occurs first.

A   Daily                                         E   E very 3000 hour s o r 24 months

B   Every 250 hours or 12 month s                     F   E very 3000 h our s o r 36 months

C   Every 500 hours or 12 month s                     G   E very 5000 h ours

D   Every 1000 hours or 24 months

A   B	C   D	E   F	G                                 Operation
			Check the c oolant level
			Check the air cleaner service indicator
			Check the lubricating oil level
			Drain water/sediment from the pr imary fuel filter
			Visual inspec tion of the engine systems
			Drain water/sediment from the fuel tank
			Check battery electrol yte level
			Perform a diagnostics check
			Renew the element in the  primar y fuel filte r
			Renew the element in the  se condary fue l fil ter
			Renew the engine lubricating oil (1) (2)
			Renew the element in the lubricating oil filter
			Inspect/adjus t/renew the alternator and fan drive belts
			Inspect the crankshaft vibration damper
			Inspect/clean/tighten the earth stud
			Inspect/renew the coolant hoses, air hos es and hos e clips
			Inspect and, if necessary, clean the exterior of the radiator/charge cooler
			Inspect the engine mountings
			Check/adjust the tappet clearances and the electronic unit injectors (3)
			Check the engine protection devices (3)
			Renew the thermostats in the cool ant system
			Check/clean the engine speed/timing senso rs
			Inspect the tur bochargers (3)
			Drain and flush the coolant system and r enew the coolant mixture
			Inspect the battery charging alternator (3)
			Inspect the starter motor (3)
			Inspect the coolant p ump

(1) Oil sample analysis may be used to monitor the condition of the lubricating oil, but the lubricating oil must be replaced at

500 hours/12 months.

(2) If fuel with a high sulphur content is used, the lubricating oil may have to be replaced at more frequent intervals. Contact the

Applic ations Department (Stafford) at Perkins Engines Company Limited.

(3) This proc edure must be done by a person who has had the correct training.

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2800 Series

How to check the coolant level

Chec k the coolant level when the engine is s topped and cool.

Warning! On a hot engine release the filler cap c arefully as the system will be under pressure.

1  Remove the filler cap from the expansion tank slowly to relieve the pressure.

2  Maintain the coolant level at the bottom of the filler pipe.

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3  Clean the filler cap and check the condition of the filler cap gaskets. Renew the filler cap if the gaskets are

damaged. Fit the filler cap.

4  Inspect the coolant system for leaks.

How to check the air cleaner service indicator

Caution: Do not operate the engine if there is a blockage in the air filter or the air ducts. This can c ause

lubricating oil to enter the cylinders through the engine breather pipe.

The air filter is fitted with a restric tion indicator (A) whic h gives a visual warning when the filter needs a service.

When the red warning indicator is  seen through the clear panel after the engine has stopped, the air filter

element must be renewed.

After a clean element has been fitted, press the reset button on the restriction indicator.

Env ironmental conditions have an important effect on the frequency at which the air filter needs to be serviced.

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How to check the lubricating oil level

2800 Series

Warning! Hot oil and hot components  can cause personal injury. Do not allow hot oil or hot components to

contact the skin.

At the periods given in the service schedule use the dipstick to check the amount of lubricating oil in the sump.

1  Check the oil level with the engine stopped. The level must be maintained between the “L” mark and “H”

mark on the dipstick.

2  If necessary, remove the oil filler cap and add lubricating oil of the same grade and spec ification, see

"Lubricating oil spec ification" on page 52. Do not overfill.

3  Clean and fit the oil filler cap.

How to drain the primary fuel filter

At the periods given in the service schedule, the bowl of the primary fuel filter must be drained to remove water.

1  Stop the engine.

2  Open the drain; the drain is  self-ventilated. Use a suitable container to collect the water drained from the

filter housing. Dispose of the water safely.

3  Close the drain. Tighten the drain valve securely to prevent air from entering the fuel system.

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2800 Series

Visual inspection

A visual inspection should take only a few minutes and can prevent costly repairs  and accidents.

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For maximum engine life, inspect the engine compartment before the engine is started. Look for items such

as oil or coolant leaks, loose fastenings, worn belts  or loose connections. Repair as necessary .

The guards must be at the correct positions. Repair damaged guards or renew missing guards.

Wipe all caps and plugs before the engine is serviced to reduce the chance of system contamination.

For any type of leak (coolant, lubricating oil or fuel), clean away the fluid. If a leak is observed, find the

source and correct the leak. If a leak is suspected, check the fluid levels frequently until the leak is found

and repaired.

Accumulated grease and/or oil on an engine is a fire hazard. Remove it by steam cleaning or by the use of

a high pressure water jet. Avoid high pressure water on the elec tronic components.

Ensure that the coolant pipes are fitted correctly and that they are secure. Check  for leaks. Check the

condition of all pipes.

Inspect the coolant pump for leaks.

Note: The coolant pump seal is lubricated by the coolant in the coolant system. It is normal for a small amount

of leakage to occur as the engine cools and the parts contract.

Excessive coolant leakage may indicate the need to renew the coolant pump s eal. For the removal of the

coolant pump and the installation of the coolant pump and/or coolant pump seals, refer to the Workshop

Manual.

Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the sump, the

oil filter and the rocker cover. If many oil leaks are present, particularly on an old engine, there could be a

blockage of the engine breather.

Inspect the fuel system for leaks. Check for loose fuel line clamps or for loose ties on the fuel lines.

Inspect the ducts for the air inlet system and the elbows for cracks. Check also for loose clamps and check

the condition of mounting rubbers. Ensure that hoses and tubes are not in contact with other hoses, tubes,

wiring harnesses , etc.

Inspect the fan belts and the alternator belt for cracks, breaks or other damage. Where more than one belt

is used between two pulleys, all of the belts must be renewed together. Maximum belt life will only be

obtained if the belts are maintained at the correct tension.

Drain the water and sediment from fuel tank s on a daily basis to ensure that only clean fuel enters the fuel

sys tem.

Inspect the wiring and the wiring harnesses for loose connections and for worn or frayed wires.

Inspect the earth strap for a good connection and for good condition.

Inspect the ECM-to-cylinder head earth strap for a good connection and for good condition.

Disconnect any battery chargers which are not protec ted against the current drain of the starter motor.

Check the condition and the electrolyte level of the batteries, unless the engine is fitted with a maintenance

free battery.

Check the condition of the gauges. Renew any gauges that are cracked. Renew any gauge that cannot be

calibrated.

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Diagnostics check

2800 Series

At the periods specified in the service schedule, use the Perkins Electronic Service Tool to retrieve the

diagnostic codes. A key to the codes is given below. Refer to the relevant Diagnostic Manual for further details.

Diagnostic codes

CID-FMI

1-11

2-11

3-11

4-11

5-11

6-11

Injector cylinder No. 1 fault

Injector cylinder No. 2 fault

Injector cylinder No. 3 fault

Injector cylinder No. 4 fault

Injector cylinder No. 5 fault

Injector cylinder No. 6 fault

Diagnostic code description

4 1-03

4 1-04

9 1-08

100-03

100-04

110-03

110-04

168-02

172-03

172-04

174-03

174-04

190-02

190-09

190-11, 12

248-09

253-02

254-12

261-13

262-03

262-04

268-02

273-03

273-04

274-03

274-04

281-03

281-04

281-05

282-03

282-04

285-03

285-04

286-03

286-04

286-05

323-03

323-04

323-05

8 volt Sensor power supply open/short to B+

8 volt Sensor power supply short to ground

PWM Speed control abnormal

Engine oil pressure sensor open/short to B+

Engine oil pressure sensor short to ground

Engine coolant temp sensor open/short to B+

Engine coolant temp sensor short to ground

Intermittent battery power to the ECM

Intake manifold temperature sensor open/short to B+

Intake manifold temperature sensor short to ground

Fuel temperature sensor open/short to B+

Fuel temperature sensor short to ground

Engine speed sensor data intermittent

Engine speed sensor abnormal update

Engine speed sensor mechanical fault

Per kins data link communications abnormal

Check customer or system parameters

ECM Fault

Engine timing calibration required

5 volt Sensor power supply open/short to B+

5 volt Sensor power supply short to ground

Check programmable parameters

Turbo outlet pressure sensor open/short to B+

Turbo outlet pressure sensor short to ground

Atmospheric pressure sensor open/short to B+

Atmospheric pressure sensor short to ground

Action alert lamp open/short to B+

Action alert lamp short to ground

Action alert lamp open circuit

Engine overspeed lamp open/short to B+

Engine overspeed lamp short to ground

Engine coolant temperature lamp open/short to B+

Engine coolant temperature lamp short to ground

Engine lubrica ting oil pressure lamp open/short to B+

Engine lubricating oil pressure lamp short to ground

Engine lubricating oil pressure lamp open circuit

Engine shutdown lamp open/short to B+

Engine shutdown lamp short to ground

Engine shutdown  lamp open circuit

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User’s Handbook, TPD1516E, Issue 1

2800 Series

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CID-FMI

324- 03

324- 04

324- 05

342 -02

342-11, 12

443- 03

799- 12

1266-03

1266-04

169 0-8

Diagnostic code description

Engine warning lamp open/short to B+

Engine warning lamp short to ground

Engine warning lamp open circuit

Engine speed sensor No. 2 data intermittent

Engine speed sensor No. 2 mechanical fault

Crank terminate relay open/short to B+

Service tool fault

Diagnostic lamp open/short to B+

Diagnostic lamp short to ground

Analogue throttle signal abnormal

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