Perkins XGA 1600 Series Operation And Maintenance Manual Download Page 17

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SEBU8455

Product Information Section

General Information

Product Information

Section

General Information

i04260031

Model View Illustrations

1600D Engine

g02757356

Illustration 14

(1) Rear lifting eye
(2) Front lifting eye
(3) Alternator
(4) Drive belt

(5) Belt tensioner
(6) Coolant pump
(7) Coolant intake connection
(8) Crankcase breather

(9) Oil cooler
(10) Oil

lter

(11) Turbocharger
(12) NOx Reduction cooler

Summary of Contents for XGA 1600 Series

Page 1: ...SEBU8455 March 2012 Operation and Maintenance Manual 1600 Series Industrial Engine XGA Engine XGB Engine XGD Engine XGE Engine XGF Engine XGH Engine...

Page 2: ...ing explains the hazard and can be either written or pictorially presented Operations that may cause product damage are identified by NOTICE labels on the product and in this publication Perkins canno...

Page 3: ...Engine Starting 15 Engine Stopping 15 Electrical System 15 Engine Electronics 16 Product Information Section General Information 17 Product Identification Information 22 Operation Section Lifting and...

Page 4: ...schedule are referenced to detailed instructions that follow Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule The actual operating...

Page 5: ...soline or other harsh chemicals Solvents gasoline or harsh chemicals could loosen the adhesive that secures the warning signs The warning signs that are loosened could drop off the engine Replace any...

Page 6: ...t side of the valve mechanism cover and the rear right side of the valve mechanism cover 2 Hand High Pressure Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure...

Page 7: ...M supplied wiring can be dangerous Personal injury death and or engine damage could result Vent the engine exhaust to the outside when the engine is operated in an enclosed area Wear a hard hat protec...

Page 8: ...elp prevent spraying or splashing of pressurized fluids hold a rag over the part that is being removed Filler caps Grease fittings Pressure taps Breathers Drain plugs Use caution when cover plates are...

Page 9: ...r that is familiar with this type of injury Containing Fluid Spillage NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and...

Page 10: ...on the engine lines Allow the pressure to be purged in the air system in the hydraulic system in the lubrication system or in the cooling system before any lines fittings or related items are disconn...

Page 11: ...ustible materials or conductive materials to accumulate on the engine Store fuels and lubricants in correctly marked containers away from unauthorized persons Store oily rags and any flammable materia...

Page 12: ...er is available Be familiar with the operation of the fire extinguisher Inspect the fire extinguisher and service the fire extinguisher regularly Obey the recommendations on the instruction plate Line...

Page 13: ...ve glasses in order to avoid injury to the eyes Chips or other debris may fly off objects when objects are struck Before objects are struck ensure that no one will be injured by flying debris i0401670...

Page 14: ...nspect the engine in operation always use the proper inspection procedure in order to avoid a fluid penetration hazard Refer to Operation and Maintenance Manual General hazard Information Inspect the...

Page 15: ...ctly check the water temperature gauge and or the oil temperature gauge during the heater operation Engine exhaust contains products of combustion which can be harmful to your health Always start the...

Page 16: ...of corrosion The engine alternator must be grounded to the negative battery terminal with a wire that is adequate to handle the full charging current of the alternator The power supply connections an...

Page 17: ...nformation i04260031 Model View Illustrations 1600D Engine g02757356 Illustration 14 1 Rear lifting eye 2 Front lifting eye 3 Alternator 4 Drive belt 5 Belt tensioner 6 Coolant pump 7 Coolant intake c...

Page 18: ...formation g02430477 Illustration 15 13 Valve mechanism cover 14 Air cleaner 15 Flywheel housing 16 Flywheel 17 Oil filler 18 Oil drain plug 19 Control module 20 High pressure oil pump 21 Secondary fue...

Page 19: ...600D Engine g02430617 Illustration 16 1 Radiator filler cap 2 Air to air charge cooler connection 3 Coolant inlet connection 4 Front vent line 5 Rear vent liner 6 Coolant drain plug 7 Coolant outlet c...

Page 20: ...Turbocharged charge cooled The 1600 series engines can be divided into two different engine groups The 1606A LBSFC unregulated engine and the 1606D EU stage 3A compliant engine The 1606D engines will...

Page 21: ...valves and two exhaust valves The engine lubricating oil is supplied by a gerotor oil pump The engine has an oil cooler and a spin on oil filter The diesel fuel is drawn from the fuel tank into a stra...

Page 22: ...__________________________Made in Stafford G _________ ___________________________Application Table 2 E _________ _______________________Type of engine Table 3 F _________ ________________Number of cy...

Page 23: ...duct Identification Information Serial Number Plate 1 g02435523 Illustration 19 Typical example The engine serial number plate is located on right side of the cylinder block above the engine oil filte...

Page 24: ...mation i04266330 Emissions Certification Film The emission label for the 1600D engine is installed on rear of the valve mechanism cover g02435679 Illustration 21 Typical example The emission label for...

Page 25: ..._____________ Engine Serial number _________ ____________________________ Engine rpm _________ _________________________________________ Fuel Strainer _________ _______________________________________...

Page 26: ...Lifting eyes are designed and installed for specific engine arrangements Alterations to the lifting eyes and or the engine make the lifting eyes and the lifting fixtures obsolete If alterations are ma...

Page 27: ...all of the gauges that are described For more information about the gauge package see the OEM information Gauges provide indications of engine performance Ensure that the gauges are in good working o...

Page 28: ...g on the application special precautions should be taken to avoid personal injury The engine can be programmed to the following modes Warning The orange Warning lamp will turn ON and the warning signa...

Page 29: ...anifold absolute pressure sensor 3 Manifold air temperature sensor 4 Water in fuel sensor 5 Engine oil temperature sensor 6 Injection pressure regulator 7 Engine fuel pressure sensor 8 Air inlet heate...

Page 30: ...Controls g02731387 Illustration 25 14 Injection control pressure sensor Internal 15 Exhaust back pressure sensor 16 Engine coolant temperature sensor 17 Camshaft position sensor 18 Alternator Alterna...

Page 31: ...SEBU8455 31 Operation Section Features and Controls g02740697 Illustration 26 19 Connector and seal...

Page 32: ...Illustration 27 1 Valve for the NOx Reduction System NRS 2 Manifold absolute pressure sensor 3 Manifold air temperature sensor 4 Water in fuel sensor 5 Engine oil temperature sensor 6 Injection pressu...

Page 33: ...BU8455 33 Operation Section Features and Controls g02732036 Illustration 28 9 Control module A Driver for the NRS valve B Injection Drive Module IDM C High current relay D Electronic Control Module EC...

Page 34: ...34 SEBU8455 Operation Section Features and Controls g02732039 Illustration 29 10 Crankshaft position sensor 11 Coolant jacket heater 12 Engine oil pressure sensor 13 Starting motor E Solenoid F Relay...

Page 35: ...BU8455 35 Operation Section Features and Controls g02732040 Illustration 30 14 Injection control pressure sensor 15 Exhaust back pressure sensor 16 Coolant temperature sensor 17 Camshaft position sens...

Page 36: ...ls g02740857 Illustration 31 Item 18 alternator not shown 19 Connector and seal G Injection control pressure connection H Connector for injectors 1 and injector 2 I Connector for injectors 3 and injec...

Page 37: ...ater in fuel 7 Inlet air temperature 8 Manifold absolute pressure 9 Inlet heater terminal 10 Injectors 3 and 4 11 Injectors 5 and 6 12 Plug for inlet heater 13 Relay 14 Crankshaft position 15 Injector...

Page 38: ...agnostic codes The active diagnostic code should be investigated The cause of the problem should be corrected as soon as possible If the cause of the active diagnostic code is repaired and there is on...

Page 39: ...ther Starting Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury The engine will start at a temperature of 10 C 14 F The ability to start...

Page 40: ...or the wait to stat lamp to go off Note The air inlet heat will be required in low ambient temperatures The ECM will decide if the air heater element will be required to warn the intake air in order t...

Page 41: ...operating the engine under load When the engine idles during warm up observe the following conditions Check for any fluid or for any air leaks at idle rpm and at one half full rpm no load on the engin...

Page 42: ...formance for the life of the engine Avoid spilling fuel Fuel expands when the fuel is warmed up The fuel may overflow from the fuel tank Inspect fuel lines for leaks Repair the fuel lines as needed Be...

Page 43: ...trical wiring and connections for any fraying or damaged insulation Keep all batteries fully charged and warm Check the air cleaners and the air intake daily Personal injury or property damage can res...

Page 44: ...re three major differences between Group 1 fuels and Group 2 fuels Group 1 fuels have the following different characteristics to Group 2 fuels A lower cloud point A lower pour point A lower energy per...

Page 45: ...tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Drain the water and sediment from any fuel storage tank at the following intervals weekly oil...

Page 46: ...on are secured after the engine is stopped i02583411 After Stopping Engine Note Before you check the engine oil do not operate the engine for at least 10 minutes in order to allow the engine oil to re...

Page 47: ...ine Only 13 2 L 2 9 Imp gal 1600D Total System 32 3 L 7 1 Imp gal i04268521 Fluid Recommendations Glossary ISO International Standards Organization ASTM American Society for Testing and Materials HFRR...

Page 48: ...F 2 Kg M 3 801 minimum and 876 maximum No equivalent test ISO 3675 ISO 12185 Distillation C 10 at 282 C 539 6 F maximum 90 at 360 C 680 F maximum D86 ISO 3405 Flash Point C legal limit D93 ISO 2719 Th...

Page 49: ...the fuel in jectors reduced service life of the fuel system de posits in the combustion chamber and reduced ser vice life of the engine Engines that are manufactured by Perkins are certified with the...

Page 50: ...high alkaline lubricating oil is used or reduce the oil change interval Refer to Operation and Maintenance Manual Fluid Recommendations Lubricant Information for information on sulfur in fuel Lubricit...

Page 51: ...esel Fuel Biodiesel is a fuel that can be defined as mono alkyl esters of fatty acids Biodiesel is a fuel that can be made from various feedstock The most commonly available biodiesel in Europe is Rap...

Page 52: ...kcase oil fuel dilution can be higher when biodiesel or biodiesel blends are used This increased level of fuel dilution when using biodiesel or biodiesel blends is related to the typically lower volat...

Page 53: ...order to dilute diesel fuel Failure to follow this instruction may result in death or personal in jury There are many other diesel fuel specifications that are published by governments and by technol...

Page 54: ...Recommended Guideline on Diesel Engine Oil In addition to Perkins definitions there are other definitions that will be of assistance in purchasing lubricants Recommended oil viscosities can be found...

Page 55: ...l viscosity grade for your engine At the specified interval service the engine Use new oil and install a new oil filter Perform maintenance at the intervals that are specified in the Operation and Mai...

Page 56: ...stem to operate correctly at high ambient temperatures NOTICE Do not use a commercial coolant antifreeze that on ly meets the ASTM D3306 specification This type of coolant antifreeze is made for light...

Page 57: ...coolant level reaches the normal operating temperature and until the coolant level stabilizes As needed add the coolant mixture in order to fill the system to the specified level Changing to Perkins...

Page 58: ...n order to ensure adequate protection against boiling or freezing Perkins recommends the use of a refractometer for checking the glycol concentration A hydrometer should not be used Perkins engine coo...

Page 59: ...al Volume of the Cooling System V Multiplication Factor Amount of SCA that is Required X 15 L 4 US gal 0 014 0 2 L 7 oz Cleaning the System of Heavy Duty Antifreeze Perkins cooling system cleaners are...

Page 60: ...he engine i04268569 Welding on Engines with Electronic Controls NOTICE Because the strength of the frame may decrease some manufacturers do not recommend welding onto a chassis frame or rail Consult t...

Page 61: ...ic components electrical components and ground straps Note If electrical electronic components are used as a ground for the welder or electrical electronic components are located between the welder gr...

Page 62: ...cold temperatures Hot intake air reduces engine performance Quality of the air The engine may be exposed to extended operation in an environment that is dirty or dusty unless the equipment is cleaned...

Page 63: ...evel Check 66 Fuel Tank Water and Sediment Drain 81 Every 400 Service Hours Engine Oil and Filter Change 76 Every 500 Service Hours Belt Inspect 67 Engine Air Cleaner Element Single Element Inspect Cl...

Page 64: ...steam for removal of oil and grease Wash the core with detergent and hot water Thoroughly rinse the core with clean water After cleaning start the engine Run the engine for 2 minutes Operating the en...

Page 65: ...r ventilation for batteries that are in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced The ba...

Page 66: ...soda and 1 L 1 qt of clean water A mixture of 0 1 L 0 11 qt of ammonia and 1 L 1 qt of clean water Thoroughly rinse the battery case with clean water Use a fine grade of sandpaper to clean the termin...

Page 67: ...on 38 Typical example 5 Install a suitable tool into the half inch square hole 7 Rotate the tensioner between the point A and point B Ensure that there is an even resistance when rotating between the...

Page 68: ...omponents are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order t...

Page 69: ...e gasket If the gasket is damaged discard the old filler cap and install a new filler cap If the gasket is not damaged use a suitable pressurizing pump in order to pressure test the filler cap The cor...

Page 70: ...top the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain cock or remove the drain pl...

Page 71: ...lemental Coolant Additive SCA Test Add Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and the eyes Do not drink cooling system coolant addi...

Page 72: ...ance Manual Refill Capacities and Recommendations for more information on SCA requirements 4 Clean the cooling system filler cap and inspect the gasket If the gasket is damaged discard the old filler...

Page 73: ...and grease A clean engine provides the following benefits Easy detection of fluid leaks Maximum heat transfer characteristics Ease of maintenance Note Caution must be used in order to prevent electri...

Page 74: ...lement should be replaced when the following condition occurs The red piston locks in the visible position i04654709 Engine Air Precleaner Check Clean If equipped the precleaner should be check daily...

Page 75: ...ained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembli...

Page 76: ...ill the Oil Pan 1 Remove the oil filler cap Refer to this Operation and Maintenance Manual Fluid Recommendations for more information on suitable oils Fill the oil pan with the correct amount of new e...

Page 77: ...and Install Rotate crankshaft in order to get number one piston at top dead center position with both valves on number six cylinder on overlap Set the valve lash use table 2 valve lash The inlet valv...

Page 78: ...between the cover and the edge of the fan blade Ensure that the cover is centralized to the fan The clearance A must be 21 2 mm 0 82677 0 07874 inch i04272833 Fuel System Prime Ensure that all adjust...

Page 79: ...tool and install the dust cap 4 Depress the priming pump for a short time in order to pressurize the system Check the low pressure system for leaks 5 Priming the fuel filter from empty should take app...

Page 80: ...ght spill Clean up any spilled fluid Ensure that the outer body of the filter assembly is clean and free from dirt 2 Install a suitable tube onto drain valve 4 Loosen the cap 1 in order to allow atmos...

Page 81: ...drain valve and tighten the vent cap to 30 N m 22 lb ft 4 Remove the drain tube and depose of the drain fluid in accordance with local regulations i02568194 Fuel Tank Water and Sediment Drain NOTICE...

Page 82: ...wing conditions Cracking Softness Loose clamps Replace hoses that are cracked or soft Tighten any loose clamps NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tu...

Page 83: ...imately 6 mm 0 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes Pressurized water may also be used...

Page 84: ...rder to prevent dirt from entering during reassembly 2 Turn the compressor wheel and the turbine wheel by hand The assembly should turn freely Inspect the compressor wheel and the turbine wheel for co...

Page 85: ...or leaks Look for loose fuel line clamps or for loose fuel line tie wraps Inspect the piping for the air inlet system and the elbows for cracks and for loose clamps Ensure that hoses and tubes are not...

Page 86: ...ith exhaust emission standards and gaseous emission standards that are prescribed by the law at the time of manufacture and this engine may be covered by an Emissions Warranty Consult your authorized...

Page 87: ...tification Film 24 Emissions Warranty Information 86 Engine Clean 73 Engine Air Cleaner Element Single Element Inspect Clean Replace 73 Engine Air Cleaner Service Indicator Inspect If Equipped 74 Engi...

Page 88: ...olant System for 1600D Engine 19 Monitoring System 28 Programmable Options and Systems Operation 28 Mounting and Dismounting 13 O Operation Section 26 P Plate Locations and Film Locations 22 Engine Id...

Page 89: ...eaning and Inspecting 84 Removal and Installation 84 W Walk Around Inspection 84 Inspect the Engine for Leaks and for Loose Connections 84 Warranty Information 86 Warranty Section 86 Water Pump Inspec...

Page 90: ...90 SEBU8455 Index Section...

Page 91: ...aintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Inf...

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Summary of Contents for XGA 1600 Series

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Perkins XGA 1600 Series, Operation And Maintenance Manual, Page: 17 / 92

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Summary of Contents for XGA 1600 Series

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