Perkins 2806F Engine Diesel Particulate Filter - Remove and Install Guide

This Article Introduces Perkins 2806F Engine Diesel Particulate Filter - Remove and Install

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Removal Procedure

1. Before removal of the Diesel Particulate Filter

(DPF), refer to Operation and Maintenance

Manual, “ Diesel Particulate Filter - Clean” 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 cool.

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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.






2. Place Identification Marks (X) on both sides of clamp assembly (6) and clamp assembly (7) for installation purposes.

3. Place Identification Mark (Y) on the diesel

particulate filter (4) for installation purposes.

Identification Mark (Y) is showing the flow of

exhaust gases through the diesel particulate filter.

4. Disconnect harness assembly (1).

5. Disconnect hose assemblies (2). Use Tooling (A) to cap the hose assemblies.

6. Loosen clamp assembly (3).

7. Disconnect temperature sensor (8) from diesel particulate filter (4).

8. Disconnect tube assemblies (9) from both ends of diesel particulate filter (4).

9. Loosen clamp assemblies (5).

10.Attach Tooling (B) and a suitable lifting device to diesel particulate filter (4). The weight of the diesel particulate filter is approximately 57 kg (126 lb).

11. Use the suitable lifting device to remove diesel particulate filter (4).

12. Discard clamp assembly (3) and clamp

assemblies (5).
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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




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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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