Related Manuals for Perkins 1106AA-70TG1
Summary of Contents for Perkins 1106AA-70TG1
- Page 1 M0106585 (en-us) August 2019 Operation and Maintenance Manual 1106AA-70TG1, 1106AA-70TAG2 and 1106AA-70TAG3 Industrial Engines LT (Engine) LU (Engine) LV (Engine)
- Page 2 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 you are authorized to perform this work, and that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.
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Page 3: Table Of Contents
M0106585 Table of Contents Table of Contents Maintenance Interval Schedule....... 47 Warranty Section Foreword ............4 Warranty Information........78 Safety Section Reference Information Section Safety Messages..........6 Reference Materials ........79 General Hazard Information......7 Index Section Burn Prevention..........11 Index..............80 Fire Prevention and Explosion Prevention..11 Crushing Prevention and Cutting Prevention.. -
Page 4: Foreword
State of arises regarding your engine, or this manual, please California to cause cancer, birth defects, consult with your Perkins dealer or your Perkins distributor for the latest available information. and other reproductive harm. WARNING – This product can... - Page 5 Perkins distributor offers various options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available. Consult with your Perkins dealer or your Perkins distributor for information regarding these options.
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Page 6: Safety Section
Replace any warning sign that is damaged or missing. If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Your Perkins distributor can provide new warning signs. (1) Universal Warning... -
Page 7: General Hazard Information
M0106585 Safety Section General Hazard Information Illustration 2 g06431577 Typical example of label location (1) Universal warning (2) Ether warning (2) Ether The ether warning label (2) is on the cover of the inlet manifold. i07767258 General Hazard Information Do not use aerosol types of starting aids such as ether. - Page 8 If Perkins recommend that you do not stand next to an the engine is in an enclosed area, vent the engine exposed running engine unless it is necessary when exhaust to the outside.
- Page 9 M0106585 Safety Section General Hazard Information Do not remove any hydraulic components or parts Dispose of all fluids according to local regulations until pressure has been relieved or personal injury and mandates. may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved Static Electricity Hazard when or personal injury may occur.
- Page 10 Asbestos Information Perkins equipment and replacement parts that are shipped from Perkins engine company limited are asbestos free. Perkins recommends the use of only genuine Perkins replacement parts. Use the following guidelines when you handle any replacement parts Illustration 8...
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Page 11: Burn Prevention
M0106585 Safety Section Burn Prevention Always use leakproof containers when you drain Cooling system conditioner contains alkali. Alkali can fluids. Do not pour waste onto the ground, down a cause personal injury. Do not allow alkali to contact drain, or into any source of water. the skin, the eyes, or the mouth. - Page 12 Personal injury, property damage, or engine damage could result. If the application involves the presence of combustible gases, consult your Perkins dealer and/ or your Perkins distributor for additional information about suitable protection devices. Remove all flammable combustible materials or conductive materials such as fuel, oil, and debris from the engine.
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Page 13: Crushing Prevention And Cutting Prevention
Repair any lines that are loose or damaged. Leaks Do not climb on the engine. The engine has not been can cause fires. Consult your Perkins dealer or your designed with mounting or dismounting locations. Perkins distributor for repair or for replacement parts. -
Page 14: Engine Starting
M0106585 Safety Section Engine Starting Start the engine from the operator's compartment or from the engine start switch. Engine exhaust contains products of combustion Always start the engine according to the procedure which may be harmful to your health. Always that is described in the Operation and Maintenance start and operate the engine in a well ventilated Manual, “Engine Starting”... -
Page 15: Electrical System
M0106585 Safety Section Electrical System i07775771 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 “−”... -
Page 16: Product Information Section
M0106585 Product Information Section Model Views Product Information Section Model Views i07776330 Model View Illustrations 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 following illustrations. - Page 17 M0106585 Product Information Section Model View Illustrations 1106AA Engine Illustration 14 g06432571 Typical example (1) Oil filler (upper) (6) Oil filter (11) Water pump (2) Valve mechanism breather (7) Fuel injection pump (12) Damper (3) Air intake (8) Oil gauge (dipstick) (13) Front lifting eye (4) Primary fuel filter (9) Fuel priming...
- Page 18 The left and the right sides of the engine are determined from the flywheel end. The number 1 cylinder is the front cylinder. The Perkins 1106AA-70T, and 1106AA-70TA Industrial Engines have the following characteristics. • In-line 6 cylinder •...
- Page 19 M0106585 Product Information Section Product Description The engine lubricating oil is supplied by a rotor type oil pump. The engine lubricating oil is cooled and the engine lubricating oil is filtered. The bypass valve can provide unrestricted flow of lubrication oil to the engine if the oil filter element should become plugged.
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Page 20: Product Identification Information
Product Identification Serial Number Plate (1) Information i07776213 Plate Locations and Film Locations Perkins engines are identified by an engine serial number. An example of an engine number is LU12345S000001E. Type of engine LU12345 The list number for the engine... - Page 21 M0106585 Product Information Section Emissions Certification Film The engine serial number plate is on the left side of the cylinder 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.
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Page 22: Operation Section
The engine must be stored in a water proof building. The building must be kept at a constant temperature. Engines that are filled with Perkins ELC will have coolant protection to an ambient temperature of −36° C (−32.8° F). The engine must not be subjected to extreme variations in temperature and humidity. - Page 23 Maintenance Manual, “Fluid recommendations”. 4. Remove the drive belt from the engine. Sealed Coolant System Ensure that the cooling system is filled with Perkins ELC, or an antifreeze that meets “ASTM D6210” specification. Open Cooling System Ensure that all cooling drain plugs have been opened.
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Page 24: Gauges And Indicators
Ammeter – This gauge indicates the Determine and correct the cause of any significant amount of charge or discharge in the change in the readings. Consult your Perkins dealer battery charging circuit. Operation of or your Perkins distributor for assistance. -
Page 25: Engine Starting
M0106585 Operation Section Engine Starting Engine Starting Engine exhaust contains products of combustion i07762178 which may be harmful to your health. Always start and operate the engine in a well ventilated Before Starting Engine area and, if in an enclosed area, vent the exhaust to the outside. - Page 26 M0106585 Operation Section Starting the Engine 3. When the engine starts, release the engine start i07762183 switch. Starting the Engine 4. If equipped, slowly move the throttle lever to the low idle position and allow the engine to idle. Refer to the Operation and Maintenance Manual, “After Starting Engine”...
- Page 27 M0106585 Operation Section After Starting Engine i06791278 NOTICE Ensure that a 12 VDC or 24 VDC battery source is After Starting Engine used to start the engine. Never attempt to start an en- gine from an external power source such as electric welding equipment, which has a voltage that is un- suitable for engine starting and will damage the elec- Note: In temperatures from 0°C to 60°C...
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Page 28: Engine Operation
Maintenance Manual are followed, costs can be minimized and engine service life can be maximized. The efficiency of the engine can affect the fuel economy. Perkins design and technology in The engine can be operated at the rated rpm after manufacturing provides maximum fuel efficiency in the engine reaches operating temperature. -
Page 29: Engine Stopping
M0106585 Operation Section Engine Stopping Engine Stopping i01903608 After Stopping Engine i01929389 Stopping the 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 return to the oil pan. NOTICE •... -
Page 30: Cold Weather Operation
• Install the correct specification of engine lubricant before the beginning of cold weather. Refer to this Perkins Diesel Engines can operate effectively in Operation and Maintenance Manual, “Fluid cold weather. During cold weather, the starting and Recommendations” for the recommended the operation of the diesel engine depends on the viscosity of oil. - Page 31 600W or 240 V ac 550W. The output can be 550 or other engine parts in better condition. The service life 600W. Consult your Perkins dealer or your Perkins of the engine will be extended. Lubrication will be distributor for more information.
- Page 32 Cold Weather Note: Only use grades of fuel that are recommended Fuel Tanks by Perkins. Refer to this Operation and Maintenance Manual, “Fluid Recommendations”. Condensation can form in partially filled fuel tanks. Properties of the diesel fuel can have a significant Top off the fuel tanks after you operate the engine.
- Page 33 M0106585 Operation Section Fuel Related Components in Cold Weather The micron rating and the location of a primary fuel filter is important in cold weather operation. The primary fuel filter and the fuel supply line are the most common components that are affected by cold fuel. Fuel Heaters Note: The OEM may equip the application with fuel heaters.
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Page 34: Maintenance Section
M0106585 Maintenance Section Refill Capacities i07755383 Maintenance Section Fluid Recommendations Refill Capacities General Coolant Information i07766346 NOTICE Never add coolant to an overheated engine. Engine Refill Capacities damage could result. Allow the engine to cool first. NOTICE Lubrication System If the engine is to be stored in, or shipped to an area with below freezing temperatures, the cooling system The refill capacities for the engine crankcase reflect must be either protected to the lowest outside tem-... - Page 35 Table 4 • Cavitation of the water pump Table 4 Acceptable Water For optimum performance, Perkins recommends a 50 percent by volume of glycol in the finished coolant Property Maximum Limit (also referred to as 1:1 mixture).
- Page 36 NOTICE Do not use a commercial coolant/antifreeze that only agents with low amounts of nitrite. Perkins ELC has meets the ASTM D3306 specification. This type of been formulated with the correct amount of these...
- Page 37 Containers of several sizes are available. Consult your Perkins distributor for the part numbers. Changing to Perkins ELC ELC Cooling System Maintenance To change from heavy-duty antifreeze to the Perkins ELC, perform the following steps: Correct additions to the Extended Life NOTICE...
- Page 38 8. Repeat Steps 6 and repeat steps 7 until the checking the glycol concentration. Do not use a system is completely clean. hydrometer. 9. Fill the cooling system with the Perkins Premixed NOTICE ELC. Do not mix types and specifications of coolant.
- Page 39 Example of the Equation for Adding the SCA to the Commer- or a cooling system cleaner to clean deposits. cial Heavy-Duty Coolant for Maintenance Consult your Perkins dealer for suitable product. Total Volume of the Multiplication Amount of SCA 4.
- Page 40 “SAE J754”. Some classifications follow “SAE J183” abbreviations, and some classifications follow the “EMA 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 in this publication, “Fluid Recommendations/...
- Page 41 • The Oil Condition Analysis determines the loss of the oils lubricating properties. An infrared analysis Perkins does not recommend the use of aftermarket is used to compare the properties of new oil to the additives in oil. It is not necessary to use aftermarket properties of the used oil sample.
- Page 42 M0106585 Maintenance Section Fuel Recommendations NOTICE The footnotes are a key part of Perkins specification requirements for China distillate diesel fuel. Read ALL of the footnotes. Table 13 Specification for China Distillate Diesel Fuel Property UNITS Requirements “ASTM Test” “ISO Test”...
- Page 43 NOTICE fuel. The common reference is to kinematic viscosity. Operating with fuels that do not meet the Perkins rec- Kinematic viscosity is the quotient of the dynamic ommendations can cause the following effects: Start- viscosity that is divided by the density.
- Page 44 80 hours. lubricity up to 0.46 mm (0.01811 inch) wear scar di- Perkins fuel cleaner can be used on an on-going ameter as tested by “ISO 12156-1”. Fuel with higher basis with no adverse impact on engine or fuel wear scar diameter than 0.46 mm (0.01811 inch) will...
- Page 45 200 ppm water or less. • Perkins recommends the use of bulk fuel filter / coalescer units which clean the fuel of both particulate contamination and water in a single pass.
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Page 46: Maintenance Recommendations
• Failure to use recommended fuel, lubricants, and coolant/antifreeze Refer to the standards for the engine or consult your Perkins dealer or your Perkins distributor in order to determine if the engine is operating within the defined parameters. Severe service operation can accelerate component wear. -
Page 47: Maintenance Interval Schedule
M0106585 Maintenance Section Maintenance Interval Schedule “ Fuel System Primary Filter (Water Separator) i07757779 Element - Replace” ......70 Maintenance Interval Schedule Every 300 Service Hours When Required... - Page 48 M0106585 Maintenance Section Maintenance Interval Schedule “ Turbocharger - Inspect” ..... 75 Every 3000 Service Hours “ Fuel Injector - Test/Change” ....66 Every 3000 Service Hours or 2 Years “...
- Page 49 M0106585 Maintenance Section Aftercooler Core - Clean/Test i02322260 Aftercooler Core - Clean/Test Personal injury can result from air pressure. Personal injury can result without following prop- er procedure. When using pressure air, wear a 1. Remove the core. Refer to the OEM information for protective face shield and protective clothing.
- Page 50 Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps and seals. Make repairs, if necessary. i02322311 Alternator - Inspect Perkins recommends a scheduled inspection of the Illustration 22 g06420392 alternator. Inspect the alternator for loose Typical example connections and correct battery charging.
- Page 51 M0106585 Maintenance Section Battery - Replace The battery cables or the batteries should not be removed with the battery cover in place. The bat- tery cover should be removed before any servic- ing is attempted. Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.
- Page 52 M0106585 Maintenance Section Battery or Battery Cable - Disconnect 4. Clean all disconnected connection and battery terminals. All lead-acid batteries contain sulfuric acid which 5. Use a fine grade of sandpaper to clean the can burn the skin and clothing. Always wear a terminals and the cable clamps.
- Page 53 Loosen the cooling system filler cap slowly to suitable cleaning agent to remove any debris. relieve any pressure. Remove the cooling system Refer to your Perkins dealer or distributor for filler cap. suitable cleaning agents. Note: Refer to Operation and Maintenance Manual, 2.
- Page 54 M0106585 Maintenance Section Cooling System Coolant (ELC) - Change 6. Install the drain plugs and tighten securely. Note: Use non-foaming detergent to clean oil or fuel contamination. Fill Note: When the cooling system is cleaned, only clean water is needed when the ELC is drained and NOTICE replaced.
- Page 55 (ELC). Refer to this Operation and Maintenance For information regarding the disposal and the Manual, “Refill Capacities” topic (Maintenance recycling of used coolant, consult your Perkins dealer Section) for more information on cooling system or Perkins distributor. specifications. Do not install the cooling system filler cap.
- Page 56 - Check Engines With a Coolant Recovery Tank Note: The cooling system may not have been provided by Perkins. The procedure that follows is for typical cooling systems. Refer to the OEM information for the correct procedures. Illustration 27 g02590196...
- Page 57 M0106585 Maintenance Section Driven Equipment - Check • Other 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. Illustration 28 g00285520 Moisture create paths...
- Page 58 Servicing the Air Cleaner Elements Note: The air filter system may not have been provided by Perkins. The procedure that follows is for a typical air filter system. Refer to the OEM information for the correct procedure.
- Page 59 M0106585 Maintenance Section Engine Air Cleaner Service Indicator - Inspect 6. Install end cover (4) to air cleaner body (2) and • Check the movement of the yellow core when the engine is accelerated to the engine rated speed. secure end cover. If necessary, reset the air The yellow core should latch at the greatest service indicator, refer to this Operation and vacuum that is attained.
- Page 60 M0106585 Maintenance Section Engine Mounts - Inspect Perkins use the starter motor in order to ground the engine. Check the connection on the starter motor at every oil change. Ground wires and straps should be combined at engine grounds. All grounds should be tight and free of corrosion.
- Page 61 Do not allow hot oil or hot components to valve is positioned on the cylinder block. contact the skin. Perkins recommends using a sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when a sampling valve is...
- Page 62 Perkins oil filters are manufactured to Perkins specifi- cations. Use of an oil filter that is not recommended by Perkins could result in severe damage to the en- 3. Clean sealing surface of the oil filter base (2). gine bearings, or crankshaft, as a result of the larger waste particles from unfiltered oil entering the engine 4.
- Page 63 If equipped with an auxiliary oil filter system or a re- maintenance. Refer to the Service Manual or your au- mote filter system, follow the OEM or the filter manu- thorized Perkins dealer or your Perkins distributor for facture's recommendations. Under filling or over the complete valve lash adjustment procedure.
- Page 64 Typical example Adjustment of the cover will change the clearance Perkins recommends a scheduled inspection of the (gap) between the edge of the cover and the tip of fuel control linkage for the fuel injection pump for the fan blade. Ensure that the cover is centralized to loose components and free movement of the linkage the fan.
- Page 65 M0106585 Maintenance Section Fuel Control Linkage - Check/Lubricate Check 6. Check that the solenoid attachment bracket (3) is not damaged and is securely tightened to the engine block. Lubricate with Grease Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery ter- minal.
- Page 66 M0106585 Maintenance Section Fuel Injector - Test/Change Lubricate the solenoid ball joint plunger (4) and plunger seal with clean engine oil at a service interval of every 6 months. i07754449 Fuel Injector - Test/Change Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire.
- Page 67 There will be little effect on the engine speed when the union nut to the faulty fuel injection nozzle is loosened. Refer to the Disassembly and Assembly Manual for more information. Consult your authorized Perkins dealer or your Perkins distributor for assistance. i07777086 Fuel Inlet Screen - Clean/...
- Page 68 M0106585 Maintenance Section Fuel Inlet Screen - Clean/Inspect/Replace 7. If the accumulation of particles found in the aluminum bowl is found to be acceptable, the screen can be cleaned. The screen and aluminum can be cleaned with diesel fuel / air from inside out.
- Page 69 M0106585 Maintenance Section Fuel System - Prime 5. Swing the tension bracket (4) into position so that the knurled nut (1) is central to the aluminum bowl (2). Tighten the knurled nut (1) until the aluminum bowl (2) is securely in place. 6.
- Page 70 M0106585 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace i07756290 Fuel System Primary Filter (Water Separator) Element - Replace Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.
- Page 71 M0106585 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace Illustration 47 g06423641 Typical example 4. Support filter canister (2) and rotate the clamp ring (1) to the left. 5. Remove the filter canister (2) from the fuel filter base (4) by a direct pull downwards.
- Page 72 M0106585 Maintenance Section Fuel System Primary Filter/Water Separator - Drain Illustration 48 g06423641 Typical example 1. Install new O ring seal (5) onto new filter canister 6. Remove the container below the filter assembly (2). and dispose any diesel fuel spillages in accordance with local regulations.
- Page 73 M0106585 Maintenance Section Fuel Tank Water and Sediment - Drain i02348492 NOTICE The water separator is under suction during normal Fuel Tank Water and Sediment engine operation. Ensure that the drain valve is tight- ened securely to help prevent air from entering the - Drain fuel system.
- Page 74 The coolant system and the hoses for the coolant Contact with high pressure fuel may cause fluid system are not usually supplied by Perkins. The penetration and burn hazards. High pressure fuel following text describes a typical method of replacing spray may cause a fire hazard.
- Page 75 Radiator - Clean i02177969 Starting Motor - Inspect The radiator is not usually supplied by Perkins. The following text describes a typical cleaning procedure for the radiator. Refer to the OEM information for Perkins recommends a scheduled inspection of the further information on cleaning the radiator.
- Page 76 Loose Connections For options regarding the removal, installation, and A walk-around inspection should only take a few replacement, consult your Perkins dealer or your minutes. When the time is taken to perform these Perkins distributor. Refer to the Disassembly and checks, costly repairs and accidents can be avoided.
- Page 77 A failed water pump may cause severe engine “Water Pump - Remove and Install” for more overheating problems that could result in the information or consult your Perkins dealer or your following conditions: Perkins distributor. • Cracks in the cylinder head •...
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Page 78: Warranty Section
This engine may be covered by an Emissions Warranty. Consult your authorized Perkins dealer or distributor to determine if your engine is emissions certified and if your engine is subject to an Emissions... -
Page 79: Reference Information Section
Why buy an Extended Service Contract? 1. No surprises - total protection from unexpected repair cost (parts, labor, and travel). 2. Enjoy longer lasting product support from Perkins global network. 3. Genuine Perkins parts ensure continued engine performance. 4. Highly trained technicians carry out all repairs. -
Page 80: Index
M0106585 Index Section Index After Starting Engine ........27 Driven Equipment - Check ......57 After Stopping Engine ........29 Aftercooler Core - Clean/Test......49 Aftercooler Core - Inspect ....... 49 Electrical System..........15 Alternator - Inspect .......... 50 Grounding Practices ........15 Alternator and Fan Belts - Inspect/Adjust/ Emergency Stopping........ - Page 81 M0106585 Index Section Fluid Recommendations (Fuel Recommendations) ........41 Hoses and Clamps - Inspect/Replace..... 74 Contamination Control Recommendations for Replace the Hoses and the Clamps .... 74 Fuels ............45 Diesel Fuel Characteristics......43 Diesel Fuel Requirements ......41 General Information........41 Important Safety Information......
- Page 82 M0106585 Index Section Product Information Section......16 Product Lifting ..........22 Product Storage ..........22 Condition for Storage........22 Radiator - Clean ..........75 Reference Information Section ....... 79 Reference Materials ........79 Refill Capacities..........34 Cooling System..........34 Lubrication System ........34 Safety Messages..........
- Page 83 Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number:...
- Page 84 M0106585 ©2019 Perkins Engines Company Limited All Rights Reserved August 2019...