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SEBU8455

Maintenance Section

ll Capacities

NOTICE

Frequently check the speci

c gravity of the coolant for

proper freeze protection or for anti-boil protection.

Clean the cooling system for the following reasons:

•

Contamination of the cooling system

•

Overheating of the engine

•

Foaming of the coolant

NOTICE

Never operate an engine without water temperature

regulators in the cooling system. Water temperature

regulators help to maintain the engine coolant at the

proper operating temperature. Cooling system prob-

lems can develop without water temperature regula-

tors.

Many engine failures are related to the cooling

system. The following problems are related to cooling

system failures: Overheating, leakage of the water

pump, and plugged radiators or heat exchangers.

These failures can be avoided with correct cooling

system maintenance. Cooling system maintenance is

as important as maintenance of the fuel system and

the lubrication system. Quality of the coolant is as

important as the quality of the fuel and the lubricating

oil.

Coolant Recommendations

•

ELC

____________________________

Extended Life Coolant

•

SCA

___________________

Supplement Coolant Additive

•

ASTM

__________________________________________

American

Society for Testing and Materials

The following two coolants are used in Perkins diesel

engines:

Preferred –

Perkins ELC

Acceptable –

A commercial heavy-duty antifreeze

that meets “ASTM D6210 ” speci

cations

NOTICE

The 1600 series industrial engines must be oper-

ated with a 1:1 mixture of water and glycol. This

concentration allows the NOx reduction system to

operate correctly at high ambient temperatures.

NOTICE

Do not use a commercial coolant/antifreeze that on-

ly meets the ASTM D3306 speci

cation. This type of

coolant/antifreeze is made for light automotive appli-

cations.

Perkins recommends a 1:1 mixture of water and

glycol. This mixture of water and glycol will provide

optimum heavy-duty performance as an antifreeze.

This ratio may be increased to 1:2 water to glycol if

extra freezing protection is required.

Table 9

Coolant Service Life

Coolant Type

Service Life

(1)

Perkins ELC

6,000 Service Hours or

Three Years

(2)

Commercial Heavy-Duty

Antifreeze that meets

“ASTM D6210”

3000 Service Hours or

Two Year

(1)

Use the interval that occurs

rst. The cooling system must

also be

ushed out at this time.

(2)

ELC can be extender to 12000 hours by using an approved

extender.

ELC

Perkins provides ELC for use in the following

applications:

•

Heavy-duty spark ignited gas engines

•

Heavy-duty diesel engines

•

Automotive applications

The anti-corrosion package for ELC is different from

the anti-corrosion package for other coolants. ELC

is an ethylene glycol base coolant. However, ELC

contains organic corrosion inhibitors and antifoam

agents with low amounts of nitrite. Perkins ELC

has been formulated with the correct amount of

these additives in order to provide superior corrosion

protection for all metals in engine cooling systems.

ELC is available in a premixed cooling solution with

distilled water. ELC is a 1:1 mixture. The Premixed

ELC provides freeze protection to

−

36 °C (

−

33 °F).

The Premixed ELC is recommended for the initial

ll of the cooling system. The Premixed ELC is also

recommended for topping off the cooling system.

Containers of several sizes are available. Consult

your Perkins distributor for the part numbers.

Содержание XGA 1600 Series

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 90: ...90 SEBU8455 Index Section...

Страница 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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