Perkins Engine 1600 Service Manual
Operation and
Maintenance
Manual
SEBU8455
March 2012
1600 Series Industrial Engine
(Engine)
XGA
XGB (Engine)
XGD (Engine)
(Engine)
XGE
XGF (Engine)
XGH (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning 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 cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information 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 can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
SEBU8455 3
Table of Contents
Table of Contents
Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 5
General Hazard Information ................................... 7
Burn Prevention .................................................... 10
Fire Prevention and Explosion Prevention ............. 11
Crushing Prevention and Cutting Prevention ........ 13
Mounting and Dismounting ................................... 13
High Pressure Oil Lines ........................................ 13
Before Starting Engine .......................................... 14
Engine Starting ..................................................... 15
Engine Stopping ................................................... 15
Warranty Secti
Warranty Information ............................................ 86
on
Index Section
Index ..................................................................... 87
Electrical System ........ .......................................... 15
Engine Electronics ................................................ 16
Product Information Section
General Information .............................................. 17
Product Identification Information ........................ 22
Operation Sectio n
Lifting and Storage ................................................ 26
Features and Controls .......................................... 27
Engine Diagnostics ............................................... 38
Engine Starting ..................................................... 39
Engine Operation .................................................. 42
Cold Weather Operation ....................................... 43
Engine Stopping ................................................... 46
Maintenance Section
Refill Capacities .................................................... 47
Maintenance Recommendations .......................... 60
Maintenance Interval Schedule ............................ 63
4 SEBU8455
Foreword
Foreword
Literature Information
This manual co
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literatu
study and keep it with the literature and engine
information.
English is the primary language for all Perkins
publications. The English used facilitates translation
and consist
Some photographs or illustrations in this manual
show detai
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improveme
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises re
consult with your Perkins dealer or your Perkins
distributor for the latest available information.
Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
g situations. Read and understand the basic
warnin
precautions listed in the safety section before
operating or performing lubrication, maintenance and
on this product.
repair
ntains safety, operation instructions,
re holder or literature storage area. Read,
ency.
ls or attachments that may be different
nt and advancement of product design
garding your engine, or this manual, please
Recommended se
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine a
Schedule. Therefore, under extremely severe,
dusty, wet or freezing cold operating conditions,
more frequen
specified in the Maintenance Interval Schedule may
be necessary.
The maintenance schedule items are organized for
a preventive maintenance management program. If
the prevent
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should min
avoidances resulting from reductions in unscheduled
downtime and failures.
ive maintenance program is followed, a
imize operating costs through cost
rvice should be performed at the
lso governs the Maintenance Interval
t lubrication and maintenance than is
Maintenance Intervals
Perform maintenance on items at multiples of
the original requirement. We recommend that the
maintena
near the engine as a convenient reminder. We also
recommend that a maintenance record be maintained
as part o
Your authorized Perkins dealer or your Perkins
distrib
maintenance schedule to meet the needs of your
operating environment.
nce schedules be reproduced and displayed
f the engine's permanent record.
utor can assist you in adjusting your
Overhaul
Opera
Operating techniques outlined in this manual are
basic
techniques required to operate the engine more
efficiently and economically. Skill and techniques
deve
engine and its capabilities.
The o
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and
discussion of electronic diagnostic information.
tion
. They assist with developing the skills and
lop as the operator gains knowledge of the
peration section is a reference for operators.
stopping the engine. This section also includes a
Maintenance
e maintenance section is a guide to engine care.
Th
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
tervals. Items in the maintenance schedule are
in
referenced to detailed instructions that follow.
Major engine overhaul details are not covered in
the Operation and Maintenance Manual except
e interval and the maintenance items in that
for th
interval. Major repairs should only be carried out by
Perkins authorized personnel. Your Perkins dealer
r Perkins distributor offers a variety of options
or you
regarding overhaul programs. If you experience
a major engine failure, there are also numerous
r failure overhaul options available. Consult with
afte
your Perkins dealer or your Perkins distributor for
information regarding these options.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
th defects, and other reproductive harm. Battery
bir
posts, terminals and related accessories contain lead
and lead compounds. Wash hands after handling.
SEBU8455 5
Safety Section
Safety Messages
Safety Section
i04257112
Safety Messages
There may be
engine. The exact location and a description of the
warning signs are reviewed in this section. Please
become fam
Ensure that all of the warning signs are legible. Clean
the warnin
the words cannot be read or if the illustrations are
not visible. Use a cloth, water, and soap to clean
the warni
other harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
warning
coulddropofftheengine.
Replace
missing.Ifawarningsignisattachedtoapartofthe
engine that is replaced, install a new warning sign on
the rep
provide new warning signs.
lacement part. Your Perkins distributor can
several specific warning signs on your
iliar with all warning signs.
g signs or replace the warning signs if
ng signs. Do not use solvents, gasoline, or
signs. The warning signs that are loosened
any warning sign that is damaged or
(1) Universal Warning
Do not operate or work on this equipment unless
ave read and understand the instructions
you h
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
the warnings could result in serious injury
heed
or death.
Illustration 1
ypical example
T
g01154807
6 SEBU8455
Safety Section
Safety Messages
Illustration 2
ersal warning
(1) Univ
The universal warning labels (1) are located on the
ft side of the valve mechanism cover and the
rear le
rear right side of the valve mechanism cover.
(2) Hand (High Pressure)
Contact with high pressure fuel may cause fluid
tration and burn hazards. High pressure fu-
pene
el spray may cause a fire hazard. Failure to follow these inspection, maintenance and service in-
ctions may cause personal injury or death.
stru
g02428016
SEBU8455 7
Safety Section
General Hazard Information
Illustration 3
(2) Hand (High Pressure)
The warning label for the Hand (High Pressure)
(2) is a wrap around label that is installed on the
high-pressure oil line.
i04257489
General Hazard Information
g02835016
Tampering with the engine installation or tampering
•
with the OEM 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, protective glasses, and other
•
protective equipment, as required.
When work is performed around an engine that is
•
operating, wear protective devices for ears in order
to help prevent damage to hearing.
Do not wear loose clothing or jewelry that can snag
•
on controls or on other parts of the engine.
Ensure that all protective guards and all covers are
•
securedinplaceontheengine.
Never put maintenance fluids into glass containers.
•
Glass containers can break.
Illustration 4
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
repaired. Attach the warning tags to the engine and
to each operator control station. When appropriate,
disconnect the starting controls.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
g00104545
Use all cleaning solutions with care.
•
Report all necessary repairs.
•
Unless other instructions are provided, perform the
maintenance under the following conditions:
The engine is stopped. Ensure that the engine
•
cannot be started.
The protective locks or the controls are in the
•
applied position.
8 SEBU8455
Safety Section
General Hazard Information
Disconnect the
•
is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads
Disconnect the connector for the unit injector that
•
is located on
prevent personal injury from the high voltage to the
unit injectors. Do not come in contact with the unit
injector te
Do not attempt any repairs or any adjustments to
•
the engine w
Do not attempt any repairs that are not understood.
•
Use the pro
is damaged or repair the equipment.
For initia
•
engine that has been serviced, make provisions to
stop the engine if an overspeed occurs. This may
be accomp
and/or the air supply to the engine.
Start the
•
Never short across the starting motor terminals or
the batteries. This could bypass the engine neutral
start sy
damaged.
l start-up of a new engine or for starting an
stem and/or the electrical system could be
batteries when maintenance
in order to help prevent sparks.
the valve cover base. This will help
rminals while the engine is operating.
hile the engine is operating.
per tools. Replace any equipment that
lished by shutting off the fuel supply
engine from the operators station (cab).
Illustration 5
Wear a hard hat, protective glasses, and other
•
protective equipment, as required.
When work is performed around an engine that is
•
operating, wear protective devices for ears in order
to help prevent damage to hearing.
Do not wear loose clothing or jewelry that can snag
•
on controls or on other parts of the engine.
Ensure that all protective guards and all covers are
•
securedinplaceontheengine.
g00702020
Engine e
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. I
engine exhaust to the outside.
Cauti
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
Filler caps
•
Grea
•
Pressure taps
•
Breathers
•
Dra
•
Use caution when cover plates are removed.
Gra
bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing the
st two bolts or nuts, pry the cover loose in order to
la
relieve any spring pressure or other pressure.
xhaust contains products of combustion
f the engine is in an enclosed area, vent the
ously remove the following parts. To help
se fittings
in plugs
dually loosen, but do not remove the last two
Never put maintenance fluids into glass containers.
•
Glass containers can break.
Use all cleaning solutions with care.
•
Report all necessary repairs.
•
Unless other instructions are provided, perform
the maintenance under the following conditions:
The engine is stopped. Ensure that the engine
•
cannot be started.
Disconnect the batteries when maintenance
•
is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
Do not attempt any repairs that are not understood.
•
Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
Pressurized Air and Water
Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
personal injury.
SEBU8455 9
Safety Section
General Hazard Information
When pressuriz
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a pr
The maximum air pressure for cleaning purposes
must be below
water pressure for cleaning purposes must be below
275kPa(40psi).
ed air and/or pressurized water is
otective face shield.
205 kPa (30 psi). The maximum
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydra
escape rapidly if the pressure is not relieved correctly.
Do not remo
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
componen
or personal injury may occur. Refer to the OEM
information for any procedures that are required to
relieve t
ulic fluid or items such as pipe plugs to
ve any hydraulic components or parts
ts or parts until pressure has been relieved
he hydraulic pressure.
Containing Fluid Spillage
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Asbestos Information
Illustration 6
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
g00687600
tration 7
Illus
Perkins replacement parts that are shipped from
ns are asbestos free. Perkins recommends
Perki
the use of only genuine Perkins replacement parts.
Use the following guidelines when you handle any
acement parts that contain asbestos or when you
repl
handle asbestos debris.
aution. Avoid inhaling dust that might be
Use c
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
our health. The components that may contain
to y
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
estos that is used in these components is usually
asb
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
ntains asbestos is generated.
co
If dust that may contain asbestos is present, there
e several guidelines that should be followed:
ar
Never use compressed air for cleaning.
•
Avoid brushing materials that contain asbestos.
•
g00702022
void grinding materials that contain asbestos.
A
•
Useawetmethodinordertocleanupasbestos
•
materials.
10 SEBU8455
Safety Section
Burn Prevention
A vacuum cleane
•
efficiency particulate air filter (HEPA) can also be
used.
Use exhaust ventilation on permanent machining
•
jobs.
Wear an approved respirator if there is no other
•
way to control the dust.
Comply with applicable rules and regulations
•
for the work place. In the United States, use
Occupation
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
Obey environmental regulations for the disposal
•
of asbestos.
Stay away from areas that might have asbestos
•
particles in the air.
r that is equipped with a high
al Safety and Health Administration
Dispose of Waste Properly
Relieve all pre
hydraulic system, lubrication system, fuel system,
and the coolant system before the related items are
disconnected
After the engine has stopped, you must wait for 10
minutes in or
from the high-pressure lines before any service or
repair is performed 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 cooli
related items are disconnected.
ssureinthefollowingsystems,
.
der to allow the pressure to be purged
ng system before any lines, fi ttings, or
Induction System
Sulfuric Acid Burn Hazard may cause serious personal inj
The exhaust gas cooler may contain a small
amount o
fur levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid
may spil
engine. The sulfuric acid will burn the eyes, skin
and clothing on contact. Always wear the appropriate
is noted on a material safety data sheet (MSDS)
for sulfuric acid. Always follow the directions for
first ai
sheet (MSDS) for sulfuric acid.
ury or death.
f sulfuric acid. The use of fuel with sul-
l from the cooler during service of the
personal protective equipment (PPE) that
d that are noted on a material safety data
Illustration 8
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
g00706404
4259330
i0
Burn Prevention
o not touch any part of an operating engine
D
system. Allow the engine system to cool before any
maintenance is performed.
Coolant
the engine is at operating temperature, the
When
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
e engine contain hot coolant.
to th
Any contact with hot coolant or with steam can cause
re burns. Allow cooling system components to
seve
cool before the cooling system is drained.
ck that the coolant level after the engine has
Che
stopped and the engine has been allowed to cool.
sure that the filler cap is cool before removing the
En
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
der to relieve pressure.
or
Cooling system conditioner contains alkali. Alkali can
use personal injury. Do not allow alkali to contact
ca
the skin, the eyes, or the mouth.
SEBU8455 11
Safety Section
Fire Prevention and Explosion Prevention
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.
Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.
i0425938
Fire Preve ntio n and Exp losion
Preventi
on
Remove all flamm
conductive materials such as fuel, oil, and debris from
the engine. Do not allow any flammable combustible
materials or c
the engine.
Store fuels a
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers
storing flammable materials.
Do not expos
Exhaust shields (if equipped) protect hot exhaust
component
9
a tube, or a seal failure. Exhaust shields must be
installed correctly.
Do not weld on lines or tanks that contain flammable
fluids. D o not flame cut lines or tanks that contain
flammable
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. All electrical
wires must be correctly routed and securely attached.
Check al
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all elec
.Donotsmokeinareasthatareusedfor
s from oil or fuel spray in case of a line,
fluid. Clean any such lines or tanks
l electrical wires daily. Repair any wires
trical connections.
able combustible materials or
onductive materials to accumulate on
nd lubricants in correctly marked
etheenginetoanyflame.
stration 9
Illu
All fuels, most lubricants, and some coolant mixtures
ammable.
are fl
Flammable fluids that are leaking or spilled onto hot
faces or onto electrical components can cause
sur
a fire. Fire may cause personal injury and property
damage.
A flash fire may result if the covers for the engine
crankcase are removed within 15 minutes after an
ergency shutdown.
em
Determine whether the engine will be operated in an
vironment that allows combustible gases to be
en
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
roperty damage, or engine damage could result.
p
If the application involves the presence of combustible
ases, consult your Perkins dealer and/or your
g
Perkins distributor for additional information about
suitable protection devices.
g00704000
Eliminate all wiring that is unattached or unnecessary .
Do not u
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and correctly
maint
or sparking.
Insp
deterioration. The hoses must be correctly routed.
The lines and hoses must have adequate support
and s
recommended torque. Leaks can cause fires.
Oil
The filt
torque.
se any wires or cables that are smaller than
ained battery cables will help to prevent arcing
ect all lines and hoses for wear or for
ecure clamps. Tighten all connections to the
filters and fuel filters must be correctly installed.
er housings must be tightened to the correct
12 SEBU8455
Safety Section
Fire Prevention and Explosion Prevention
Illustration 10
Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not
refuel an engine near open flames or sparks. Always
stop the engine before refueling.
g00704059
Incorrect jump
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions
Do not charge a frozen battery. This may cause an
explosion.
The batteries must be kept clean. The covers
(if equippe
recommended cables, connections, and battery box
covers when the engine is operated.
er cable connections can cause
.
d) must be kept on the cells. Use the
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect th
extinguisher regularly. Obey the recommendations
on the instruction plate.
e fire extinguisher and service the fire
Lines, Tubes, and Hoses
Do not bend high-pressure lines. Do not strike
high-pressure lines. Do not install any lines that are
bent or d
high-pressure lines.
amaged. Do not clip any other items to the
Illustration 11
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
ahydrometer.
g00704135
Repair a
can cause fires. Consult your Perkins dealer or your
Perkins distributor for repair or for replacement parts.
Check lines, tubes, and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardb
to the recommended torque.
Repla
are present:
•
•
•
•
•
•
•
Make sure that all clamps, guards, and heat shields
ar
will help to prevent vibration, rubbing against other
parts, and excessive heat.
ny lines that are loose or damaged. Leaks
oard to check for leaks. Tighten all connections
ce the parts if any of the following conditions
tings are damaged or leaking.
End fit
Outer coverings are chafed or cut.
Wires are exposed.
r coverings are ballooning.
Oute
Flexible parts of the hoses are kinked.
Outer covers have embedded armoring.
fittings are displaced.
End
e installed correctly. During engine operation, this
SEBU8455 13
Safety Section
Crushing Prevention and Cutting Prevention
i02143194
Crushing Prevention and
Cutting Preve
Support the component correctly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Lea
is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective 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
ve the guards in place until maintenance
be injured by flying debris.
ntion
High-pressure
used in order to create high-pressure fuel in the unit
injectors.
oil within the high-pressure oil line is
i04016709
Mounting and Dismoun ting
Do not climb on the engine or the engine
aftertreatment. The engine and aftertreatment have
not been designed with mounting or dismounting
locations.
Refer to the OEM for the location of foot and hand
holds for your specific application.
i04553464
h Pressure Oil Lines
Hig
Personal injury can result from oil under high
pressure.
DO NOT allow high pressure oil to contact skin.
Wear appropriate protective equipment while
working with high pressure oil systems.
14 SEBU8455
Safety Section
Before Starting Engine
Illustration 12
(1) High-pressure oil line (2) High-pressure oil pump
The high-pressure oil line is the line that is between
the high-pressure oil pump and the high-pressure oil
manifold within the cylinder head. This high-pressure
line is different from fuel lines on other fuel systems.
These differences are because of the following items:
The high-pressure oil line is constantly charged
•
with high pressure.
The internal pressure of the high-pressure oil line
•
is higher than other types of fuel systems.
Do not step on the high-pressure oil line. Do not
deflect the high-pressure oil line. Do not bend or
strike the high-pressure oil line. Deformation or
damage of the high-pressure oil line may cause a
point of weakness and potential failure.
Do not check the high-pressure oil line with the
engine or the starting motor in operation. After the
engine has stopped, wait 10 minutes in order to allow
the pressure to be purged from the high-pressure oil
line, before any service or repair is performed.
Visually inspect the high-pressure oil line before the
engine is started. This inspection should be each day.
g02722895
Do not operate the engine with a leak. Refer to
•
Disassembly and Assembly, “High-Pressure Oil
Line- Remove and Install”.
If the high-pressure oil line is torqued correctly,
•
and the high-pressure oil line is leaking the
high-pressure oil line must be replaced.
Do not attach any other item to the high-pressure
•
oil line.
i02813489
Before Starting Engine
Before the initial start-up of an engine that is new,
serviced or repaired, make provision to shut the
engine off, in order to stop an overspeed. This may
be accomplished by shutting off the air and/or fuel
supply to the engine.
Overspeed shutdown should occur automatically for
engines that are controlled electronically. If automatic
shutdown does not occur, press the emergency stop
button in order to cut the fuel and/or air to the engine.
If you inspect 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 high-pressure oil line for damage,
•
deformation, a nick, a cut, a crease, or a dent.
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights work correctly, if equipped.
SEBU8455 15
Safety Section
Engine Starting
All protective
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that
around the parts carefully.
Do not bypass
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits ar
engine damage.
See the Serv
adjustments.
guards and all protective covers must
is caused by parts in rotation, work
the automatic shutoff circuits. Do not
e also provided in order to help prevent
ice Manual for repairs and for
i02583384
Engine Starting
To ensure that t
is working correctly, check the water temperature
gauge and/or the oil temperature gauge during the
heater operat
Engine exhaust contains products of combustion
which can be h
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the eng
Note: Theenginemaybeequippedwithadevicefor
cold starti
cold conditions, then an extra cold starting aid may
be required. Normally, the engine will be equipped
with the co
of operation.
Engine St
Stop the engine according to the procedure in
the Operation and Maintenance Manual, “Engine
Stoppin
overheating of the engine and accelerated wear of
the engine components.
g (Operation Section)” in order to avoid
he jacket water heater (if equipped)
ion.
armful to your health. Always start the
ine exhaust to the outside.
ng. If the engine will be operated in very
rrect type of starting aid for your region
i02234873
opping
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
nal injury.
perso
If a warning tag is attached to the engine start switch
the controls DO NOT start the engine or move
or to
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started in order
erform service procedures. To help prevent an
to p
accident that is caused by parts in rotation, work
around the parts carefully.
Start 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
nual, “Engine Starting” topic in the Operation
Ma
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
nowing the procedure will also help to prevent
K
personal injury.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the Emergency
Stop Bu
emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
corre
Stop the engine if an overspeed condition occurs
duri
that has been overhauled.
To s t
power to the engine and/or shutting off the air supply
to the engine.
tton for normal engine stopping. After an
cted.
ng the initial start-up of a new engine or an engine
op an electronically controlled engine, cut the
i04259711
Electrical System
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” cable should be connected last from
the external power source to the primary position for
grounding.
16 SEBU8455
Safety Section
Engine Electronics
Check the elect
are loose or frayed. Tighten all loose electrical
connections before the engine is started. Repair all
frayed electr
See the Operation and Maintenance Manual for
specific starting instructions.
rical wires daily for wires that
ical wires before the engine is started.
Grounding Practices
The power suppl
connections for the engine electronics should always
be from the isolator to the battery.
y connections and the ground
i04259752
Engine Electronics
Tampering with the electronic system installation
or the OEM wiring installation can be dangerous
andcouldr
engine damage.
This engi
Engine Monitoring System. The Engine Control
Module (ECM) has the ability to monitor the engine
operati
extend outside an allowable range, the ECM will
initiate an immediate action.
The following actions are available for engine
monitoring control: WARNING, ACTION ALERT, and
SHUTDO
esult in personal injury or death and/or
ne has a comprehensive, programmable
ng conditions. If any of the engine parameters
WN.
Illustration 13
Typical exam p le
(1) Ground to battery
(2) Primary position for grounding
(3) Ground to engine block
(4) Ground to stating motor
Correct grounding for the engine electrical system
is necessary for optimum engine performance
and reliability. Incorrect grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to the crankshaft bearing journal surfaces
and to aluminum components.
Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
discharge.
To ensure that the engine and the engine electrical
systems function correctly, an engine-to-frame
ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct
engine ground to the frame.
The connections for the grounds should be tight and
free 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.
g02430157
Many of the parameters that are monitored by the
ECM can
functions. The following parameters can be monitored
as a part of the Engine Monitoring System:
Intake Manifold Air Pressure
•
Intak
•
Coolant Temperature
•
Engine Oil Pressure
•
Engi
•
Crankshaft Position
•
Camshaft Position
•
Fue
•
System Voltage
•
The Engine Monitoring package can vary for different
engine models and different engine applications.
wever, the monitoring system and the engine
Ho
monitoring control will be similar for all engines.
be programmed for the engine monitoring
eManifoldTemperature
ne Oil Temperature
lPressure
SEBU8455 17
Product Information Section
General Information
Product Information
Section
General Infor mation
i04260031
Model View Illustrations
1600D Engine
Illustration 14
(1) Rear lifting eye
(2) Front lifting ey e
(3) Alternator
(4) Drive belt
(5) Belt tensioner
(6) Coolant pump
(7) Coolant intake connection
(8) Crankcase breather
g02757356
(9) Oil co oler
(10) Oil filter
(11) Turbocharger
(12) NOx Reduction cooler
18 SEBU8455
Product Information Section
General Information
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
g02430477
(21) Secondary fuel filter
(22) Hand prime pump
(23) Primary fuel filter
SEBU8455 19
Product Information Section
General Information
Coolant System for 1600D Engine
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 connection
(8) Air to air charge cooler connection
g02430617
(9) Fan guard
(10) Fan
(11) Fan guard
20 SEBU8455
Product Information Section
General Information
1600A Engine
Illustration 17
Typical example
i04261592
Product Description
The Perkins 1600 Series Industrial Engines has the
following characteristics.
In-line Six cylinder
•
Four stroke cycle
•
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 have NOx Reduction System
(NRS) installed.
g02794993
Engine Specifications
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right
sides of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder.
SEBU8455 21
Product Information Section
General Information
Illustration 18
Cylinder and valve location
(A) I nlet valves
(B) Ex haust valves
Table 1
1600 Series Engine Specifications
Operating Range (rpm)
Number of Cylinders 6 In-Line
Bore 116.6mmsleevediameter
Stroke 146
Power 298 to 315 kW
Aspiration Turbocharged charge
Compression Ratio
Displacement 9.3 L
Firing Order 1-5-3-6-2-4
Rotation (flywheel end) Counterclockwise
(1)
Depending upon application.
(2)
Gross power
1500 to 1800
(400 to 422 hp )
cooled
17.2 to 1
g02433836
(1)
(2)
The diesel fuel
is drawn from the fuel tank into a
strainer and into a fuel pump. The fuel pump sends
the fuel into the main fuel filter. From the main fuel
filter the fuel
is sent internally to the fuel injectors by
means of an internal fuel manifold. The fuel injectors
use engine lubricating oil from a high-pressure
pump in order
to increase the injection pressure.
The injectors are controlled by the engine electronic
control module (ECM).
Aftermarket Products and P erkins
Engines
Perkins doe
of non-Perkins fluids and filters.
When auxil
(filters, additives, catalysts,) which are made by other
manufacturers are used on Perkins products, the
Perkins w
such use.
However,
or use of other manufacturers devices,
accessories, or consumables are NOT Perkins
defects
under the Perkins warranty.
s not warrant the quality or performance
iary devices, accessories, or consumables
arranty is not affected simply because of
failures that result from the installation
. Therefore, the defects are NOT covered
The crankshaft has a seven main bearing journals, a
fractured split connecting rods is connected to each
crankshaft journal. The pistons have an off set axis
and made from a one piece steel construction. The
cylinder block has wet liners with a single seal. Four
bushing support the camshaft, and the camshaft is
driven by a drive gear. The camshaft operates the
over head valves. Each cylinder has two inlet 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.
22 SEBU8455
Product Information Section
Product Identification Information
Product Identification
Information
i04266129
Plate Locations and Film
Locations
Perkins engines are identified by serial numbers.
These numbers are shown on the engine serial
number plate. Perkins distributors need these
numbers in order to determine the components that
were included with the engine. This information
permits accurate identification of replacement part
numbers.
Engine Identification
Perkins engines are identified by an engine serial
number.
A typical example of an engine serial number is
XGE F**** U00001W.
Table 4
Number of Cylinders
F 6
H 8
M 12
R 16
Perkins dealers and Perkins distributors require all of
these numbers in order to determine the components
that were included in the engine. This information
permits accurate identification of replacement part
numbers.
X
___________________________________ ______Made in Stafford
____________________________________ Application (Table 2)
G
________________________________ Type of engine (Table 3)
E
_________________________ Number of cylinders (Table 4)
F
__________________________________Fixed build number
*****
__________________________________________ Built in t he USA
N
00001
W
Table 2
Table 3
____________________________________Engine Number
____________________________________ Year of Manufacture
Application
G Genset
Type of engine (Diesel)
A TAG1
B TAG2
D TAG3
E
F
H
AG4
T
TAG 5
TAG 6
SEBU8455 23
Product Information Section
Product Identification Information
Serial Number Plate (1)
Illustration 19
Typical example
The engine serial number plate is located on right
side of the cylinder block above the engine oil filter.
g02435523
Illustration 20
Typical example
g02435519
24 SEBU8455
Product Information Section
Product Identification Information
i04266330
Emissions Certification Film
The emission l
abel for the 1600D engine is installed
on rear of the valve mechanism cover.
Illustration 21
Typical example
The emission label for the 1600A engine is installed
on rear of the valve mechanism cover.
g02435679
SEBU8455 25
Product Information Section
Product Identification Information
Illustration 22
i04266250
Reference Information
Information for the following items may be needed to
order parts. Locate the information for your engine.
Record the information in the appropriate space.
Make a copy of this list for a record. Keep the
information for future reference.
Record for Reference
Engine Model _______ ________________________________________
Engine Serial number _____________________________________
Engine rpm __________________________________________________
Fuel Strainer ________________________________________________
Fuel Filter Element ________________________________________
g02834955
Lubrication Oil Filter _ ______________________________________
Total Lubrication System Capacity _____________________
Total Cooling System Capacity _________________________
Air Cleaner Element _______________________________________
Drive Belt ____________________________________________________
_________________________________________________________________
26 SEBU8455
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage
i04655490
Product Lifting
219
Illustration 23
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle
between the supporting members and the object becomes less than 90 degrees.
g00103
i04823376
Product Storage
Refer to Perki
for information on engine storage.
There are thr
Level “A, B and C”.
Level “A ”
Level “A” wi
engines and 12 month protection for gas engines.
This level is for engines that are transported by a
container
of items that are within the United kingdom and within
Europe.
Level “B ”
This level is additional to level “A”. Level “B ” will
give protection under normal storage condition
from −15
humidity for 2 year. Level “B” is for the transportation
of items overseas.
Level “C ”
In order to protect the product to Level “C”, contact
Perkins Engines Company Limited Stafford.
ns Engine Company limited, Stafford
ee different levels of engine storage.
ll give protection for 12 month for diesel
or a truck. Level “A” is for the transportation
° to +55°C (5° to 99°F) and “90%” relative
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
Use a hoist to remove heavy components. Use
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
Some removals require lifting the fixtures in order to
obtain proper balance and safety.
ToremovetheengineONLY,usetheliftingeyesthat
are on the engine.
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 made, ensure
that proper lifting devices are provided. Consult your
Perkins dealer for information regarding fixtures for
proper engine lifting.
SEBU8455 27
Operation Section
Features and Controls
Features and Controls
i04266770
Alarms and Shutoffs
Engine Shutoffs
The shutoffs are electrically operated or mechanically
operated. The electrically operated shutoffs are
controlled by the ECM.
Shutoffs are set at critical levels for the following
items:
Operating temperature
•
Operating pressure
•
Operating level
•
The particular shutoff may need to be reset before
the engine will start.
i04266369
Gauges and Indicato rs
Your engine ma
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 order.
Determine t
the gauges over a period of time.
Noticeabl
potential gauge or engine problems. Problems may
also be indicated by gauge readings that change
even if the
Determine and correct the cause of any significant
change in the readings. Consult your Perkins
distribu
If no oil pressure is indicated, STOP the engine. If
maximum coolant temperature is exceeded, STOP
the engi
tor for assistance.
ne. Engine damage can result.
y not have the same gauges or all of
he normal operating range by observing
e changes in gauge readings indicate
readings are within specifications.
NOTICE
NOTICE
Always determine the cause of the engine shutdown.
Make necessary repairs before attempting to restart
the engine.
Be familiar with the following items:
Types and locations of the shutoff
•
Conditions which cause each shutoff to function
•
The resetting procedure that is required to restart
•
the engine
Engine Alarms
The alarms are electrically operated. The operation
of the alarms is controlled by the ECM.
The alarm is operated by a sensor or by a switch.
When the sensor or the switch is activated, a signal
is sent to the ECM. An event code is created by
theECM.TheECMwillsendasignalinorderto
illuminate the lamp.
Your engine may be equipped with the following
sensors or switches:
Engine oil temperature sensor
•
Engine oil pressure sensor
•
Engine Oil Pressure – Theengineoil
pressu
The 160
•
between 340 to 360 kPa (49 to 52 psi)
The 16
•
370kPa(53psi)
temp
The water temperature reading may vary according
to load. The reading should never exceed 109° C
(228
1. A high water temperature switch is installed in the
indicator should be to the right side of “0” (zero).
00D oil pressure at full load operates at
Jacke
Typical water temperature into the engine
is 88° to 109°C (190° to 228°F). Higher
eratures may occur under certain conditions.
°F).
cooling system.
Tachometer – This gauge indicates engine
speed (rpm).
Ammeter – This gauge indicates the
amount of charge or discharge in the
battery charging circuit. Operation of the
re at idle is 103 kPa (15 psi).
0A oil pressure at full load can range
t Water Coolant Temperature –
Engine coolant temperature sensor
•
28 SEBU8455
Operation Section
Features and Controls
Programmable Options and
Service Hour Meter – The gauge indicates
operating hours of the engine.
Systems Operation
i04266490
Monitoring S
If the Shutdown mode has been selected and the
warning indicator activates, engine shutdown may
take as little as 20 seconds from the time the warning indicator is activated. Depending on the application, special precautions should be taken to
avoid personal injury. The engine can be restarted
following shutdown for e mergency maneuvers, if
necessary.
The Engine Monitoring System is not a guarantee
against catastrophic failures. Programmed delays
and dera
alarms and provide time for the operator to stop the
engine.
The following parameters are monitored:
•
•
•
te schedules are designed to minimize false
Coolan
Intake manifold air temperature
Intake manifold air pressure
ttemperature
ystem
NOTICE
If the Warning/Derate/Shutdown mode has been
selected and the warning indicator activates,
bring the engine to a stop whenever possible. Depending 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 signal is activated continuously in order to
alert the operator that one or more of the engine
parameters is not within normal operating range.
“Derate”
The engine will be derated if the engine exceeds
preset operational limits. The engine derate is
achieved by restricting the amount of fuel that is
available for each injection. The amount of this
reduction of fuel is dependent on the severity of the
fault that has caused the engine derate, typically up
to a limit of 50%. This reduction in fuel results in a
predetermined reduction in engine power.
“Shutdown”
The orange warning will turn “ON” and the red
shutdown lamp will also turn “ON”.
essure
Oil pr
•
Oil temperature
•
Fuel pressure
•
ne speed/timing
Engi
•
Fuel temperature
•
Atmospheric pressure (Barometric pressure)
•
ection control pressure
Inj
•
Water in fuel switch
•
A shutdown of the engine may occur in as little as
3 seconds. The engine can be restarted after a
shutdown for use in an emergency. However, the
cause of the initial shutdown may still exist. The
engine may shut down again in as little as 3 seconds.
For more information or assistance for repairs,
consult your Perkins distributor or your Perkins
dealer.
i04266532
Sensors and Electrical
Components
The illustrations within the section show the typical
location of the sensors. Specific engines may appear
different from the illustration due to differences in
applications.
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