Operation andMaintenanceManual
1106AA-70TG1, 1106AA-70TAG2 and1106AA-70TAG3 Industrial Engines
LT
(Engine)
LU
LV
M0106585 (en-us)
August 2019
Страница 1: ...Operation and Maintenance Manual 1106AA 70TG1 1106AA 70TAG2 and 1106AA 70TAG3 Industrial Engines LT Engine LU Engine LV Engine M0106585 en us August 2019...
Страница 2: ...rmation that was available at the time that the publication was written The specifications torques pressures measurements adjustments illustrations and other items can change at any time These changes...
Страница 3: ...rical System 15 Product Information Section Model Views 16 Product Identification Information 20 Operation Section Lifting and Storage 22 Gauges and Indicators 24 Engine Starting 25 Engine Operation 2...
Страница 4: ...s manual Whenever a question arises regarding your engine or this manual please consult with your Perkins dealer or your Perkins distributor for the latest available information Safety This safety sec...
Страница 5: ...ar the engine as a convenient reminder Perkins also recommends that a maintenance record be maintained as part of the permanent record of the engine Your authorized Perkins dealer or your Perkins dist...
Страница 6: ...hesive that secures the warning signs The warning signs that are loosened could drop off the engine Replace any warning sign that is damaged or missing If a warning sign is attached to a part of the e...
Страница 7: ...ether warning label 2 is on the cover of the inlet manifold i07767258 General Hazard Information Illustration 4 g00104545 Attach a Do Not Operate warning tag or a similar warning tag to the start swit...
Страница 8: ...provisions to stop the engine if an overspeed occurs The stopping of the engine may be accomplished by shutting off the fuel supply and or the air supply to the engine Ensure that only the fuel suppl...
Страница 9: ...se the tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids Only use the tools that are suitable for containing fluids and equipment that is suitable for...
Страница 10: ...rake bands lining material clutch plates and some gaskets The asbestos that is used in these components is usually bound in a resin or sealed in some way Normal handling is not hazardous unless airbor...
Страница 11: ...nough to touch with a bare hand Remove the filler cap slowly to relieve pressure Cooling system conditioner contains alkali Alkali can cause personal injury Do not allow alkali to contact the skin the...
Страница 12: ...ntain flammable fluid Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting Wiring must be kept in good condition Ensure that all electrical wires are...
Страница 13: ...wing conditions are present End fittings are damaged or leaking Outer coverings are chafed or cut Wires are exposed Outer coverings are ballooning Flexible parts of the hoses are kinked Outer covers h...
Страница 14: ...rt the engine from the operator s compartment or from the engine start switch Always start the engine according to the procedure that is described in the Operation and Maintenance Manual Engine Starti...
Страница 15: ...13 g06432268 Typical example 1 Ground to the battery 2 Ground to the engine block 3 Primary position for grounding Correct grounding for the engine electrical system is necessary for optimum engine pe...
Страница 16: ...The following model views show typical features of the engine Due to individual applications your engine may appear different from the illustrations Note Only major components are identified on the f...
Страница 17: ...lve mechanism breather 3 Air intake 4 Primary fuel filter 5 Oil sampling valve 6 Oil filter 7 Fuel injection pump 8 Oil gauge dipstick 9 Fuel priming 10 Oil filler lower 11 Water pump 12 Damper 13 Fro...
Страница 18: ...rkins 1106AA 70T and 1106AA 70TA Industrial Engines have the following characteristics In line 6 cylinder Four stroke cycle Two valves in each cylinder Engine Specifications Note The front end of the...
Страница 19: ...ine rating and the application Engine Cooling and Lubrication The cooling system consists of the following components Gear driven centrifugal water pump Water temperature regulator which regulates the...
Страница 20: ...t in India 000001 Engine Serial Number E Year of Manufacture Perkins dealers or Perkins distributors need all these numbers to determine the components that were included with the engine This informat...
Страница 21: ...block to the rear of the front engine mounting i07748311 Emissions Certification Film Illustration 18 g01156734 A typical example of a label is installed on engines that do not comply with emissions M...
Страница 22: ...at proper lifting devices are provided Consult your Perkins dealer for information regarding fixtures for proper engine lifting i04151489 Product Storage Perkins are not responsible for damage which m...
Страница 23: ...ystem Ensure that all cooling drain plugs have been opened Allow the coolant to drain Install the drain plugs Place a vapor phase inhibitor into the system The coolant system must be sealed once the v...
Страница 24: ...allowable temperature with the pressurized cooling system at 48 kPa 7 psi is 110 C 230 F Higher temperatures may occur under certain conditions The water temperature reading may vary according to loa...
Страница 25: ...in the engine In these instances prime the fuel system Refer to the Operation and Maintenance Manual Fuel System Prime for more information on priming the fuel system Engine exhaust contains products...
Страница 26: ...econds Allow the electric starting motor to cool for two mi nutes before cranking the engine again 2 Turn the engine start switch to the START position Hold the engine start switch in the START positi...
Страница 27: ...nance Manual Starting the Engine 5 Immediately after the engine is started disconnect the jump start cables in reverse order After jump starting the alternator may not be able to recharge fully batter...
Страница 28: ...peed Engine 1 Run the engine for 3 to 5 minutes More time may be necessary when the temperature is below 18 C 0 F 2 Check all of the gauges during the warm up period 3 Perform a walk around inspection...
Страница 29: ...n emergency stop button For more information about the emergency stop button refer to the OEM information Ensure that any components for the external system that support the engine operation are secur...
Страница 30: ...brication system for the engine do not lose heat immediately upon shutdown This means that an engine can be shut down for aperiodof timeand the retained heat within the engine will allow the engine to...
Страница 31: ...posits to form on the valve stems Generally the deposits do not cause problems and the deposits are burned off during operation at normal engine operating temperatures When starting and stopping an en...
Страница 32: ...Problems can result due to changes in temperature Before troubleshooting for low power or for poor performance in the winter check the fuel for waxing The following components can provide a means of m...
Страница 33: ...If this is the case disconnect an electric type of fuel heater in warm weather in order to prevent overheating of the fuel If the type of fuel heater is a heat exchanger the OEM should have included...
Страница 34: ...e Only 9 L 2 38 US gal Engine and radiator i07755383 Fluid Recommendations General Coolant Information NOTICE Never add coolant to an overheated engine Engine damage could result Allow the engine to c...
Страница 35: ...the correct concentration Over concentration of additives can cause the inhibitors to drop out of solution The deposits can enable the following problems to occur Formation of gel compounds Reduction...
Страница 36: ...plications NOTICE A commercial heavy duty antifreeze that meets ASTM D4985 specification requires a treatment with an SCA at the initial fill Read the label or the in structions that are provided by t...
Страница 37: ...ed must be set to the HOT position Refer to the OEM to set the heater control After the cooling system is drained and the cooling system is refilled operate the engine until the coolant level reaches...
Страница 38: ...s part of the corrosion protection system must not be used NOTICE Never operate an engine without water temperature regulators in the cooling system Water temperature regulators help to maintain the e...
Страница 39: ...ed water NOTICE Most commercial cooling system cleaning agents are corrosive and their use is not recommended by Per kins If these cleaning agents have to be used to clean heavy deposits then they sho...
Страница 40: ...on for the required service interval for operating with Biodiesel Engines Operating on High Sulfur Fuel Refer to this Manual Fluid Recommendations Fuel Specification for the required service interval...
Страница 41: ...identified and measured by using oil analysis The oil analysis includes the following tests The Wear Rate Analysis monitors the wear of the engines metals The amount of wear metal and type of wear met...
Страница 42: ...or GB T 1885 Flash Point Pensky Martens C Legal limit D93 ISO 2719 GB T 261 Thermal Stability Minimum of 80 re flectance after aging for 180 minutes at 150 C 302 F D6468 No equivalent test Sulfur mg k...
Страница 43: ...ed as acceptable to use Table 14 Acceptable Fuel Specification for 1100AA Genset Engines Fuel Specification Description GB 19147 Automobile diesel fuel GB 252 General diesel fuels Diesel Fuel Characte...
Страница 44: ...ith higher wear scar diameter than 0 46 mm 0 01811 inch will lead to reduced service life and premature failure of the fuel system If fuels do not meet specified lubricity requirement appropriate lubr...
Страница 45: ...bsolute filter Beta 4 75 up to 200 to reach the recommended cleanliness level This filtration should be at the device that dispenses the fuel to the fuel tank In addition filtration at the dispensing...
Страница 46: ...perating environment incorrect operating procedures and incorrect maintenance procedures can be factors which contribute to a severe service application Environmental Factors Ambient temperatures The...
Страница 47: ...64 Every 250 Service Hours Engine Oil and Filter Change 61 Fuel Inlet Screen Clean Inspect Replace 67 Fuel System Primary Filter Water Separator Element Replace 70 Every 300 Service Hours Fuel Contro...
Страница 48: ...ours or 2 Years Cooling System Coolant Commercial Heavy Duty Change 52 Every 4000 Service Hours Aftercooler Core Clean Test 49 Every 6000 Service Hours or 3 Years Cooling System Coolant ELC Change 54...
Страница 49: ...y can result without following prop er procedure When using pressure air wear a protective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for c...
Страница 50: ...rt periods the batteries may not fully charge A battery with a low charge will freeze more easily than a battery with a full charge i07766388 Alternator and Fan Belts Inspect Adjust Replace Inspection...
Страница 51: ...ote After the engine has stopped allow 2 minutes in order for the diesel exhaust fluid lines to be purged before disconnecting the power 2 Turn off any battery chargers Disconnect any battery chargers...
Страница 52: ...all disconnected connection and battery terminals 5 Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove mate...
Страница 53: ...r and a suitable cleaning agent to remove any debris Refer to your Perkins dealer or distributor for suitable cleaning agents 2 Clean the drain plugs Install the drain plugs Tighten drain plug securel...
Страница 54: ...tem for leaks and for the correct operating temperature i07766761 Cooling System Coolant ELC Change Clean the cooling system and flush the cooling system before the recommended maintenance interval if...
Страница 55: ...e reaches 50 to 70 C 122 to 158 F 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly to relieve any pressure Remove the cooling system filler cap Remove the con...
Страница 56: ...isk of introducing an air lock into the coolant system 1 Observe the coolant level in the coolant recovery tank Maintain the coolant level to COLD FULL mark on the coolant recovery tank Pressurized Sy...
Страница 57: ...er maintenance recommendations Perform any maintenance for the driven equipment which is recommended by the OEM i07766787 Engine Clean Personal injury or death can result from high voltage Moisture ca...
Страница 58: ...dirty air cleaner elements with clean air cleaner elements Before installation the new air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gask...
Страница 59: ...e yellow diaphragm enters the red zone The red piston locks in the visible position Test the Service Indicator Service indicators are important instruments Check for ease of resetting The service indi...
Страница 60: ...recommended torques When the engine mounts are supplied by Perkins the maintenance procedure will be supplied in the Disassembly and Assembly manual for your engine i05909059 Engine Oil Level Check Ho...
Страница 61: ...the supplies that are used for obtaining oil samples must be clean The sample can be checked for the following the quality of the oil the existence of any coolant in the oil the existence of any ferr...
Страница 62: ...ble tool Note The following actions can be carried out as part of the preventive maintenance program 2 Cut the oil filter open with a suitable tool Break apart the pleats and inspect the oil filter fo...
Страница 63: ...Perkins as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life NOTICE Only qualified service personel should perform this maintenance Refer to the S...
Страница 64: ...he safety section in this Operation and Maintenance Manual for more information Perkins recommends a scheduled inspection of the fuel control linkage for the fuel injection pump for loose components a...
Страница 65: ...3 Check the solenoid ball joint stud 2 is securely attached to the stop lever 1 on the fuel injection pump 4 Check that the nut 5 is secure If necessary hand tighten the nut 5 Check that the solenoid...
Страница 66: ...tor should be taken to an authorised agent for inspection Illustration 40 g06421506 Typical example of a fuel Injector The fuel injector will need to be removed and the injector will need to be checke...
Страница 67: ...itch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system compon...
Страница 68: ...be acceptable the screen can be cleaned The screen and aluminum can be cleaned with diesel fuel air from inside out Clean the screen 5 and aluminum bowl 2 ensuring the diesel fuel used is of the corr...
Страница 69: ...re the engine can be started Air can enter the fuel system when the following events occur The fuel tank is empty or the fuel tank has been partially drained The engine has been in storage The low pre...
Страница 70: ...ine This procedure will remove any air that could be trapped within the fuel system Check for leaks in the fuel system Refer to Operation and Maintenance Manual Starting the Engine for more informatio...
Страница 71: ...rd 7 Unscrew the bowl 3 from the filter canister 2 Remove O ring 6 and discard 8 Discard the filter canister 2 in accordance with local regulations 9 Ensure that the bowl 3 is clean and free from dirt...
Страница 72: ...ilter 6 Remove the container below the filter assembly and dispose any diesel fuel spillages in accordance with local regulations i07756868 Fuel System Primary Filter Water Separator Drain Fuel leaked...
Страница 73: ...es Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system Water can be introduced into the fuel tank...
Страница 74: ...damaged or leaking Outer covering that is chafed or cut Exposed wire that is used for reinforcement Outer covering that is ballooning locally Flexible part of the hose that is kinked or crushed Armori...
Страница 75: ...r may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degr...
Страница 76: ...oil is leaking from the back side of the compressor wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The pr...
Страница 77: ...stretched The additional load on the new belt could cause the belt to break Drain the water and the sediment from the fuel tank on a daily basis in order to ensure that only clean fuel enters the fuel...
Страница 78: ...aseous emission standards that are prescribed by the law at the time of manufacture This engine may be covered by an Emissions Warranty Consult your authorized Perkins dealer or distributor to determi...
Страница 79: ...gine performance 4 Highly trained technicians carry out all repairs 5 Transferable coverage should you sell your machine Flexible coverage provides the right level of protection for your Perkins Engin...
Страница 80: ...Equipment Check 57 E Electrical System 15 Grounding Practices 15 Emergency Stopping 29 Emissions Certification Film 21 Emissions Warranty Information 78 Engine Clean 57 Engine Air Cleaner Element Repl...
Страница 81: ...24 General Hazard Information 7 Containing Fluid Spillage 9 Fluid Penetration 8 Inhalation 10 Pressurized Air and Water 8 Static Electricity Hazard when Fueling with Ultra low Sulfur Diesel Fuel 9 H H...
Страница 82: ...ntal Factors 46 Incorrect Maintenance Procedures 46 Incorrect Operating Procedures 46 Starting Motor Inspect 75 Starting the Engine 26 Starting with Jump Start Cables Do Not Use This Procedure in Haza...
Страница 83: ...aintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Inf...
Страница 84: ...M0106585 2019 Perkins Engines Company Limited All Rights Reserved 84 August 2019...
