Perkins 2806F Engine Catalyst (SCR) Removal Procedure Guide

This article introduces the Perkins 2806F engine Catalyst (SCR) removal procedure

Catalyst (SCR) - Remove
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Start By:

a. Remove the temperature sensor for the

catalyst inlet. Refer to Disassembly and

AssemblyTemperature Sensor (Catalyst Inlet) - Remove and Install for the correct procedure

WARNING ：

Hot engine components can cause injury from burns. Before performing maintenance on the en-
gine, allow the engine and the components to



WARNING：

Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particu-
late Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.






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1. Disconnect the Original Equipment Manufacturer (OEM) exhaust system from connection (3) on Selective Catalyst Reduction (SCR) (5). Refer to the OEM for the correct procedure.

2. Loosen clamp assembly (1) for flexible exhaust pipe (2) to allow removal to SCR catalyst (5).

3. Disconnect clamps (4) from SCR catalyst (5).

4.Attach Tooling (A) and a suitable lift equipment to SCR catalyst (5). The weight of SCR catalyst is approximately 53 kg (117 lb). Ensure that the

SCR catalyst is correctly balanced.

5. Use the suitable lift equipment to remove SCR

catalyst (5). Ensure that flexible exhaust pipe (2) is not strained as the SCR catalyst is removed.

6. Remove clamp assembly (1) from flexible exhaust pipe (2).








7. If necessary, follow Step 7.a through Step 7.c to remove flexible exhaust pipe (2).

a. Loosen clamp assembly (7) for flexible exhaust pipe (2).

b. Remove flexible exhaust pipe (2). Ensure that the flexible exhaust pipe is not strained as the flexible exhaust pipe is removed.

c. If necessary, remove cover (6) from flexible exhaust pipe (2).











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8. If necessary, follow Step 8.a through Step 8.b to remove clamps (4).
a. Make temporary marks on clamps (4) for
installation purposes.
b. Remove clips (8) from pins (9) and remove
clamps (4) from the bracket.
c. Follow Step 8.a through Step 8.bto remove remaining clamps (4).

Perkins 2806F Engine Exhaust Elbow Remove and Install Procedure

This article introduces the Perkins 2806F engine Exhaust Elbowre Remove and Install


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procedure Start By:




a. Remove the exhaust bellows. Refer to

Disassembly and Assembly, Flexible Exhaust Pipe - Remove and Install for the correct

procedure.

Removal Procedure

1. If necessary, remove the nitrogen oxide sensor
from elbow connection (3). Refer to Disassembly and Assembly, Nitrogen Oxide Sensor - Remove and Install for the correct procedure.
2. Loosen V-band clamp (2) and remove elbow connection (3) from turbocharger (1).



Installation Procedure

1. Ensure that all components of the exhaust elbow are free from wear or damage.

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2. Install a new V-band clamp (2) onto turbocharger ( 1). Ensure that the V-band clamp is correctly

orientated.

3. Install elbow connection (3) onto turbocharger (1). Loosely position V-band clamp (2) onto the elbow connection and the turbocharger.



4. Install the exhaust bellows. Refer to Disassembly and Assembly, Flexible Exhaust Pipe - Remove and Install for the correct procedure.

5. Align elbow connection (3) with the exhaust bellows.

6. Tighten V-band clamp (2) to a torque of 8.5 N·m (75 lb in).

Lightly tap the V-band clamp with a soft faced

hammer to seat the V-band clamp. Refer to

Illustration 167 . Again,tighten the V-band clamp to a torque of 8.5 N·m (75 lb in). Repeat this Step 6 until the V-band clamp are correctly seated onto the turbocharger.

7. If necessary, install the nitrogen oxide sensor to elbow connection (3). Refer to Disassembly and Assembly, Nitrogen Oxide Sensor - Remove and Install for the correct procedure.

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Perkins 2806F Engine Exhaust Manifold Installation Procedure

This article introduces the Perkins 2806F engine exhaust manifold Installation  procedure


Installation Procedure


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NOTICE


Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.


1. Ensure that all components of the exhaust

manifold are free from wear or damage. replace any component that is worn or damaged.










2. If necessary, follow Step 2.a through Step 2.k to

assemble the assembly of exhaust manifold (3)

a. Ensure that Position (X) and Position (Y) for

rear exhaust section (8), center exhaust section (9), and front exhaust section (11) are clean and free from wear or damage.


b. Apply Tooling (A) in Position (X) and Position (Y).

c. Place center exhaust section (9) in a suitable support.

d. Install rear exhaust section (8) to center exhaust section (9).

e. Install front exhaust section (11) to center

exhaust section (9).

f. If necessary, Apply Tooling (A) to taper lock

studs (10). Install taper lock studs to center

exhaust section (9). Tighten the taper lock studs to a torque of 18 N·m (159 lb in).

g. If necessary follow Step 2.h through Step 2.k to install heat shield (14) to rear exhaust section

(8).

h. Position heat shield (14) onto rear exhaust

section (8).

i. Install, bracket (12), bracket (13), and spacers (16).

j. Install nuts and bolts (15) to bracket (12) and

bracket (13). Ensure heat shield (14) is correctly positioned onto rear exhaust section (8).

k. Tighten nuts and bolts (15) to a torque of

55 N·m (41 lbft). Ensure that heat shield (14) remains correctly positioned on rear exhaust section (8)

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3. If necessary, apply Tooling (A) to the threads of taper install taper lock studs (7). Install the lock studs to the cylinder head. Tighten the taper lock studs to a torque of 18 N·m ( 159 lb in).

4. Install new gaskets (6), sleeve assemblies (5), and new gaskets (4).

5. Install Tooling (B) in positions shown in Illustration 164 .

6. Install the assembly of exhaust manifold (3).

7. Install spacers (1). Apply Tooling (A) to the threads of new locknuts (2) and install the nuts.

8. Tighten locknuts (2) to a torque of 35 N·m (26 lbft) in the numerical sequence shown in Illustration

164 .








Exhaust manifold tightening sequences and Tooling (B) position

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End By:

a. Install the water temperature regulator housing. Refer to Disassembly and Assembly, “Water

Temperature Regulator Housing - Remove and Install” for the correct procedure.

b. Install the turbocharger. Refer to Disassembly

and Assembly, “Turbocharger - Install” for the

correct procedure.

c. Install the NOx Reduction System (NRS)

exhaust cooler. Refer to Disassembly and

Assembly, “Exhaust Cooler (NRS) - Remove

and Install” for the correct procedure.

Perkins 2806F Engine Exhaust Manifold Removal Procedure

This article introduces the Perkins 2806F engine exhaust manifold removal procedure

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Removal Procedure

Start By:

a. Remove the turbocharger. Refer to

Disassembly and Assembly, “Turbocharger -

Remove” for the correct procedure.

b. Remove the water temperature regulator

housing. Refer to Disassembly and Assembly, “Water Temperature Regulator Housing -

Remove and Install” for the correct procedure.

c. Remove the NOx Reduction System (NRS)

exhaust cooler. Refer to Disassembly and

Assembly, “Exhaust Cooler (NRS) - Remove

and Install” for the correct procedure.





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Exhaust manifold tightening sequences




g06078630

1. Loosen locknuts (2) in the reverse numerical order. Refer to Illustrating 159 . Loosening the nuts inreverse numerical order will help preventdistortion of the exhaust manifold.

2. Remove locknuts (2) and spacers (1).



3. Remove the assembly of exhaust manifold (3).

4. Remove gaskets (6), sleeve assemblies (5), and

gaskets (4).

5. If necessary, remove taper lock studs (7) from the

cylinder head.









h. Remove heat shield (14) from rear exhaust section (8).

Perkins 2806F Engine Flexible Exhaust Pipe Installation Procedure

This article mainly introduces the Perkins 2806F engine flexible exhaust pipe installation procedure


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1. Ensure that all components of the flexible exhaust pipe assembly are clean and free from wear and damage. If necessary, replace any components of the flexible exhaust pipe assembly that are worn or damaged. Refer to your Perkins distributor for further information.

2. If the flexible exhaust pipe assembly was

previously disassembled. Follow Step 2.a through Step 2.j to assemble the flexible exhaust pipe

assembly.


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a. If original bellows are to be reinstalled, place the internal area in Position (G) of the bellows on a suitable support. Use a 3 mm (0.118 inch) to

drill a pilot hole through the spot weld in Position (H) on clamp (6).

Note: Do not center punch the spot weld on

clamp (7).

b. Use a 6.5 mm (0.256 inch) to drill out spot weld in Position (H) on clamp (6). Remove the clamp

f. Position a new clamp (6) onto bellows (3). Hand tighten the clamp . Ensure that the center of the clamp is central to Slots (J) on the bellows. The clamp must be flush with the end of the bellows.

Note: Ensure that the bellows are not subjected to any undue stress.

g. If a new bellow (3) are installed, clamp (6) will be pre-installed to the bellows.

Note: Ensure that the bellows are not subjected to any undue stress.

h. Position a new clamp (8) onto adapter (9). Hand tighten the clamp . Ensure that the center of the clamp is central to Slots (J) on the adapter. The clamp must be flush with the end of the adapter.

i. If a new adapter (9) are installed, clamp (8) will be pre-installed to the adapter.

j. Install tube assembly (7), align the tube

assembly with the temporary marks on bellows (3) and adapter (9). Tighten clamp (6) and

clamp (8) hand tight.
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NOTICE

Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. If there is any difficulty in installation after the repair, discard the bellows.





1. Check the flexible exhaust pipe assembly for damage. Refer to your Perkins distributor for further information.

2. Install a new ball clamp (1) and a new ball clamp (5). Ensure that the ball clamps are correctly

orientated.



NOTICE

3 Failure to reinstall the bellows into the original posi- tion will result in a failure of the bellows and possible emissions failure.



Note: Ensure that the assembly of the flexible exhaust pipe is supported at all times.

4. Ensure that ball clamp (1) and ball clamp (5) are correctly seated onto the assembly of the flexible exhaust pipe. Hand tighten the ball clamps.

5. Tighten ball clamp (1) and ball clamp (5) to a torque of 35 N·m (26 lbft).

6. Cut cable straps from the suitable material that

was encasing the bellows (3) between Position (C) and Position (D). Remove the suitable material

from the bellows.

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Perkins 2806F Engine Flexible Exhaust Pipe Removal Procedure

This article describes the Perkins 2806F engine disassembly procedure for flexible exhaust pipes

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CAUTION:

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly Handle the bellows by the convolutions


NOTICE:

The bellows must be supported at all times when the bellows are not installed in the application. Failure to support the bellows adequately could result in the failure of the bellows. Do not use power tools in order to disassemble or assemble any part of the flexible exhaust system.

The alignment of the bellows is important. Incorrect alignment may lead to premature failure of the bel- lows. Misalignment can be identified by visually in- specting the uniformity of the spacing between the convolutions on the bellows.

Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. If there is any difficulty in installation after the repair, discard the bellows.







Typical example:

1. The lateral alignment of the bellows is critical. All the components must be assembled in the same alignment as prior todisassembly. The components that require correct lateral alignment are shown at Position (A) and Position (B).

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a. Use suitable material to encase flexible exhaust pipe (3). Encasing the flexible exhaust pipe will prevent damage of the bellows. Encase bellows for the flexible exhaust pipe between Position

(C) and Position (D). Use cablestraps to retain the suitable material.

Note: Ensure that the flexible exhaust pipe is

supported at all times.

b. Loosen ball clamp (1) from the flexible exhaust pipe assembly.

c. Loosen ball clamp (5).

d. Remove the assembly of the flexible exhaust pipe from CEM (2) and elbow connection (4).

Note: Ensure that the assembly of the flexible

exhaust pipe is supported as the ball clamps are removed.

Disassembly Procedure for the Flexible Exhaust Pipe Assembly

1. Ensure that all components of the flexible exhaust pipe assembly are clean and free from wear and damage. If necessary, replace any components of the flexible exhaust pipe assembly that are worn or damaged. Refer to your Perkins distributor for further information.


Typical example

2. Follow Steps 2.a through Step 2.d to remove the flexible exhaust as an assembly from Clean

Emission Module (CEM) (2) and elbow connection (4) on the turbocharger.

a. Use suitable material to encase flexible exhaust pipe (3). Encasing the flexible exhaust pipe will prevent damage of the bellows. Encase bellows for the flexible exhaust pipe between Position

(C) and Position (D). Use cablestraps to retain the suitable material.

Note: Ensure that the flexible exhaust pipe is

supported at all times.

b. Loosen ball clamp (1) from the flexible exhaust pipe assembly.

c. Loosen ball clamp (5).

d. Remove the assembly of the flexible exhaust pipe from CEM (2) and elbow connection (4).

Note: Ensure that the assembly of the flexible

exhaust pipe is supported as the ball clamps are removed.

Disassembly Procedure for the Flexible Exhaust Pipe Assembly

1. Ensure that all components of the flexible exhaust pipe assembly are clean and free from wear and damage. If necessary, replace any components of the flexible exhaust pipe assembly that are worn or damaged. Refer to your Perkins distributor for further information.






2. If necessary, follow Step 2.a through Step 2.d to disassemble the flexible exhaust pipe assembly.

a. Make temporary marks in Position (F) on all components of the bellows (3) and tube

assembly (7) to show correct orientation and alignment.

Note: Do not scribe the components to mark the position of the flexible exhaust pipe

assembly.

b. Loosen clamp (6) and remove tube assembly (8) from bellows (3).

c. Remove bellows (3) from tube assembly (7).

d. Remove tube assembly (7) from adapter (9).

Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress.
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Perkins 2806F Engine Relay (ARD Nozzle Heater) Removal Instructions

This article introduces the Perkins 2806F engine relay (ARD nozzle heater) removal instructions

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1. Turn the battery disconnect switch to the OFF position.












2. Cut cablestraps (3) from harness assembly (4)

Note: Note position of cable straps. Ensure that all

cablestraps are removed for the harness

assemblies.

3. Slide the locking tab for the harness assembly (4) into the unlocked position.

4. Disconnect harness assembly (4) from harness assembly connection (5) for the clean emission module.

5. Remove bolts ( 1) and spacers.

Note: Note position and orientation of any brackets that are attached to the relay assembly.

6. Remove relay assembly (2) from the bracket for the clean emission module.

7. If necessary, follow Step 7.a through Step 7.b to remove relay assembly (2) from bracket (6).

a. Remove bolts (7) from relay assembly (2) and remove bracket (6).

Note: Note the orientation of the bracket for

installation purposes.

b. Remove relay (2) from bracket (6).

Installation Procedure

1. Ensure that all components are clean and free

from wear and damage. If necessary, replace any components that are worn or damaged.




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Typical example

2. If necessary, follow Step 2.a through Step 2.b to install relay assembly (2) to bracket (6).

a. Position relay assembly (2) onto bracket (6).

Note: Ensure the correct orientation of the relay assembly on the bracket.

b. Install bolts (7) to relay assembly (2) and tighten the bolts to a torque of 9 N·m (80 lb in).

3. Position brackets onto relay assembly (2) and install bolts (1) and spacers.

Note: Ensure correct position and orientation of the brackets.

4. Position relay assembly (2) onto the bracket for the clean emission module.

Note: Ensure that the relay assembly is correctly oriented on the clean emission module bracket.

5. Tighten the bolts to a torque of 12 N·m ( 142 lb in).

6. Connect harness assembly (4) to harness

assembly connection (5) for the clean emission module.

7. Install cablestraps (3) to harness assembly (4).

Note: Ensure that cablestraps meet the Original Equipment Manufacturer (OEM) specification.

8. Turn the battery disconnect switch to the ON

position.
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Perkins 2806F Engine Combustion Head Installation Procedure Guide

This article introduces the Perkins 2806F engine combustion head Installation procedure

Installation Procedure

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1. Ensure that all components are free from wear or damage.

2. Clean the combustion head. Refer to Systems Operation Testing and Adjusting, Swirl Plate (ARD Combustion)-Inspect/Clean for the correct procedure.

3. If necessary, follow Step 3.a through Step 3.d to assemble combustion head (21).

a. Install combustion head (21) into a suitable support.

b. Install a new O-ring seal (25) (not shown) and new O-ring seal (27) (not shown) to adapter (24)
and adapter (26).

c. Install adapter (24) and adapter (26) to combustion head (21). Tighten the adapters to a torque of 30 N-m (266 lb in).

d. Install adapter (22) and adapter (23) to combustion head (21). Tighten the adapters to a torque of 60 N-m (44 Ibft).

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4. If necessary, install studs (18). Tighten the studs to a torque of 17 N-m (150 Ib in).

5. Install a new gasket (20). Install tube assembly
(19) and a new gasket (17).

6. Apply Tooling (A) onto the threads of studs (18).

 

7. Install combustion head (21). Install nuts (16).
Tighten nuts (16) in a crisscross pattern to a torque of 23 N-m (204 Ib in).
Tighten the nuts again in a crisscross pattern to a torque of 23 N-m (204 Ib in).
Tighten the nuts again in a crisscross pattern to a torque of 23 N-m (204 Ib in).

8. Install ARD spark plug (15) to combustion head
(21). Refer toDisassembly and Assembly, ARD Spark Plug -Remove and Install for the correct procedure.

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9. Install flame detection temperature sensor (11) and flame detect (12). Refer to Disassembly and Assembly, Temperature Sensor (DPF Inlet, Flame Detect)-Remove and Install for the correct procedure.

10. Remove caps from adapters and plugs from hose assembly (6), hose assembly (7), hose assembly
(9), and hose assembly (10).

11. Install hose assembly (6), hose assembly (7), hose assembly (10), and tube assembly (9).
Ensure that the hose assemblies and tube assembly are installed into the correct positions.

12. Tighten the tube nuts for the hose assembly (6)
and hose assembly (7) to a torque of 13 N-m
(115 lb in). Ensure that the hose assemblies are not strained as the tube nuts are tightened.

13. Tighten the tube nuts for tube assembly (9) and hose assembly (10) to a torque of 25 N-m
(221 lb in). Ensure that the hose assemblies and the tube assembly are not strained as the tube nuts are tightened.

14. Connect high tension lead (8) to the spark plug.

15. Position ground strap (14) onto the combustion head. Install bolt (13) to the ground strap. Tighten the bolt to a torque of 12 N-m (106 Ib in).

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16. Install tube assembly (3) to hose assembly (2).

17. Install a new gasket (5) (not shown) between tube assembly (3) and the combustion head. Ensure that the gasket is correctly orientated.

18. Apply Tooling (A) onto the threads of bolts (4). Install the bolts to tube assembly (3). Tighten the bolts to a torque of 28 N-m (248 Ib in).

19. Tighten hose clamp (1) to a torque of 11 N-m
(97 lb in).

20. Turn the fuel supply to the ON position.

21. Turn the battery disconnect switch to the ON position.

22. Perform the ARD ignition test. Refer to Troubleshooting Manual, "ARD Ignition -Test"for the correct procedure.

Perkins 2806F Engine Combustion Head Removal Procedure Guide

This article introduces the Perkins 2806F engine combustion head removal procedure


a. Remove the Exhaust Elbow.

WARNING

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent

possible injury, turn the start switch off when

changing fuel filters or water separator elements.

Clean up fuel spills immediately.

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NOTICE:

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.



WARNING


Hot engine components can cause injury from burns. Before performing maintenance on the en- gine, allow the engine and the components to cool.

1. Turn the fuel supply to the OFF position.

2. Turn the battery disconnect switch to the OFF

Start By:

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3. Loosen hose clamp (1) on hose assembly (2).
4. Remove bolts (4) and remove tube assembly (3).
Remove gasket (5) (not shown).

5. Disconnect hose assembly (6), hose assembly (7), hose assembly (10), and tube assembly (9). Cap the adapters and plug the hose assemblies.
6. Remove bolt (13) from ground strap (14).
7. Disconnect high tension lead (8) from the sparkplug. Position the high tension lead away from the combustion head.

8. Remove flame detection temperature sensor (11)
Assembly, Temperature Sensor (DPF Inlet, Flame Detect) -Remove and Install for the correct and flame detect (12). Refer toDisassembly and procedure.

9. Remove Aftertreatment Regeneration DeviceRefer to Disassembly and Assembly, ARD Spark Plug-Remove and Install for the correct procedure.
(ARD) spark plug (15) from combustion head (21).
10. Remove nuts (16) from combustion head (21).
Remove the combustion head.
11. Remove gasket (20), tube assembly (19), and gasket (17).
12. If necessary, remove studs (18).

 

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13. If necessary, follow Step 13.a through Step 13.d to disassemble combustion head (21).
a. Install combustion head (21) into a suitable support.
b. Remove adapter (22) and adapter (23) from combustion head (21).
c. Remove adapter (24) and adapter (26) from combustion head (21).
d. Remove O-ring seal (25) (not shown) and O-
ring seal (27) (not shown).