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.
SEBU8455 Table of Contents Table of Contents Warranty Section Warranty Information ..........86 Foreword ..............4 Index Section Safety Section Index ..............87 Safety Messages ............ 5 General Hazard Information ........7 Burn Prevention ............ 10 Fire Prevention and Explosion Prevention ..... 11 Crushing Prevention and Cutting Prevention ..
They assist with developing the skills and Perkins authorized personnel. Your Perkins dealer techniques required to operate the engine more or your Perkins distributor offers a variety of options efficiently and economically. Skill and techniques regarding overhaul programs. If you experience...
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...
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SEBU8455 Safety Section Safety Messages g02428016 Illustration 2 (1) Universal warning The universal warning labels (1) are located on the rear left 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.
SEBU8455 Safety Section General Hazard Information g02835016 Illustration 3 (2) Hand (High Pressure) • The warning label for the Hand (High Pressure) Tampering with the engine installation or tampering (2) is a wrap around label that is installed on the with the OEM supplied wiring can be dangerous.
SEBU8455 Safety Section General Hazard Information • 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. • Disconnect the connector for the unit injector that is located on the valve cover base.
Illustration 7 Perkins replacement parts that are shipped from Perkins are asbestos free. Perkins recommends the use of only genuine Perkins replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris.
SEBU8455 Safety Section Burn Prevention • A vacuum cleaner that is equipped with a high Relieve all pressure in the following systems, efficiency particulate air filter (HEPA) can also be hydraulic system, lubrication system, fuel system, used. and the coolant system before the related items are disconnected.
These gases could cause the engine to overspeed. 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.
Repair any lines that are loose or damaged. Leaks 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.
SEBU8455 Safety Section Crushing Prevention and Cutting Prevention High-pressure oil within the high-pressure oil line is i02143194 used in order to create high-pressure fuel in the unit Crushing Prevention and injectors. Cutting Prevention Support the component correctly when work beneath the component is performed.
SEBU8455 Safety Section Before Starting Engine g02722895 Illustration 12 (1) High-pressure oil line (2) High-pressure oil pump • The high-pressure oil line is the line that is between Do not operate the engine with a leak. Refer to the high-pressure oil pump and the high-pressure oil Disassembly and Assembly, “High-Pressure Oil manifold within the cylinder head.
SEBU8455 Safety Section Engine Starting All protective guards and all protective covers must To ensure that the jacket water heater (if equipped) be installed if the engine must be started in order is working correctly, check the water temperature to perform service procedures. To help prevent an gauge and/or the oil temperature gauge during the accident that is caused by parts in rotation, work heater operation.
SEBU8455 Safety Section Engine Electronics Check the electrical wires daily for wires that The power supply connections and the ground are loose or frayed. Tighten all loose electrical connections for the engine electronics should always connections before the engine is started. Repair all be from the isolator to the battery.
SEBU8455 Product Information Section General Information Product Information Section General Information i04260031 Model View Illustrations 1600D Engine g02757356 Illustration 14 (1) Rear lifting eye (5) Belt tensioner (9) Oil cooler (2) Front lifting eye (6) Coolant pump (10) Oil filter (3) Alternator (7) Coolant intake connection (11) Turbocharger...
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SEBU8455 Product Information Section General Information g02430477 Illustration 15 (13) Valve mechanism cover (17) Oil filler (21) Secondary fuel filter (14) Air cleaner (18) Oil drain plug (22) Hand prime pump (15) Flywheel housing (19) Control module (23) Primary fuel filter (16) Flywheel (20) High-pressure oil pump...
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SEBU8455 Product Information Section General Information Coolant System for 1600D Engine g02430617 Illustration 16 (1) Radiator filler cap (5) Rear vent liner (9) Fan guard (2) Air to air charge cooler connection (6) Coolant drain plug (10) Fan (3) Coolant inlet connection (7) Coolant outlet connection (11) Fan guard (4) Front vent line...
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. The Perkins 1600 Series Industrial Engines has the following characteristics. • In-line Six cylinder •...
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The injectors are controlled by the engine electronic control module (ECM). Aftermarket Products and Perkins Engines Perkins does not warrant the quality or performance g02433836 Illustration 18 of non-Perkins fluids and filters. Cylinder and valve location...
Number of Cylinders i04266129 Plate Locations and Film Locations Perkins dealers and Perkins distributors require all of these numbers in order to determine the components that were included in the engine. This information Perkins engines are identified by serial numbers.
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SEBU8455 Product Information Section Product 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 filter. g02435519 Illustration 20 Typical example...
SEBU8455 Product Information Section Product Identification Information 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 the 1600A engine is installed on rear of the valve mechanism cover.
SEBU8455 Product Information Section Product Identification Information g02834955 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.
Operation Section Lifting and Storage Operation Section i04823376 Product Storage Lifting and Storage Refer to Perkins Engine Company limited, Stafford for information on engine storage. i04655490 Product Lifting There are three different levels of engine storage. Level “A, B and C”.
• Operating temperature Determine and correct the cause of any significant change in the readings. Consult your Perkins • Operating pressure distributor for assistance. •...
• Fuel pressure engine may shut down again in as little as 3 seconds. • Engine speed/timing For more information or assistance for repairs, consult your Perkins distributor or your Perkins • Fuel temperature dealer. • Atmospheric pressure (Barometric pressure) i04266532 •...
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SEBU8455 Operation Section Features and Controls g02435937 Illustration 24 (1) Valve for the NOx Reduction System (5) Engine oil temperature sensor (10) Crankshaft position sensor (NRS) (6) Injection pressure regulator (11) Coolant jacket heater (2) Manifold absolute pressure sensor (7) Engine fuel pressure sensor (12) Engine oil pressure sensor (3) Manifold air temperature sensor (8) Air inlet heater...
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SEBU8455 Operation Section Features and Controls g02731387 Illustration 25 (14) Injection control pressure sensor (15) Exhaust back pressure sensor (17) Camshaft position sensor (Internal) (16) Engine coolant temperature sensor (18) Alternator Alternator has been shown separately for clarity.
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SEBU8455 Operation Section Features and Controls g02740697 Illustration 26 (19) Connector and seal...
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SEBU8455 Operation Section Features and Controls g02732035 Illustration 27 (1) Valve for the NOx Reduction System (3) Manifold air temperature sensor (6) Injection pressure regulator (NRS) (4) Water in fuel sensor (7) Engine fuel pressure sensor (2) Manifold absolute pressure sensor (5) Engine oil temperature sensor (8) Air inlet heater...
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SEBU8455 Operation Section Features and Controls g02732036 Illustration 28 (9) Control module (B) Injection Drive Module (IDM) (D) Electronic Control Module (ECM) (A) Driver for the NRS valve (C) High current relay...
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SEBU8455 Operation Section Features and Controls g02732039 Illustration 29 (10) Crankshaft position sensor (12) Engine oil pressure sensor (E) Solenoid (11) Coolant jacket heater (13) Starting motor (F) Relay...
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SEBU8455 Operation Section Features and Controls g02732040 Illustration 30 (14) Injection control pressure sensor (16) Coolant temperature sensor (15) Exhaust back pressure sensor (17) Camshaft position sensor...
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SEBU8455 Operation Section Features and Controls g02740857 Illustration 31 Item 18 alternator not shown. (19) Connector and seal (H) Connector for injectors 1 and injector 2 (J) Connector for injectors 5 and injector 6 (G) Injection control pressure connection (I) Connector for injectors 3 and injector 4...
SEBU8455 Operation Section Features and Controls Wiring Harness g02740876 Illustration 32 (1) Coolant temperature (2) Exhaust back pressure (3) NRS (4) Injection control (5) Injectors 1 and 2 (6) Water in fuel (7) Inlet air temperature (8) Manifold absolute pressure (9) Inlet heater terminal (10) Injectors 3 and 4 (11) Injectors 5 and 6...
If a diagnostic lamp illuminates during normal engine be logged in the memory of the ECM. The Perkins operation and the diagnostic lamp shuts OFF, an electronic service tool can retrieve codes that have intermittent fault may have occurred.
Reset all of the shutoffs or alarm components (if equipped). 3. If the engine fails to start, investigate the problem. Use the Perkins electronic service tool. A system • Ensure that any equipment that is driven by the fault may be indicated after the engine is started. If engine has been disengaged from the engine.
SEBU8455 Operation Section Engine Starting 4. Operate the engine at no load until all the coolant i04268176 temperature starts to rise. Check the gauges Starting the Engine during the warm-up period. Note: The oil pressures and fuel pressures should be in the normal range on the instrument panel. Do Note: Do not adjust the engine speed control during not apply a load to the engine until the oil pressure start-up.
SEBU8455 Operation Section Engine Starting i02428473 Starting with Jump Start Cables Do not use jump start cables in order to start the engine. Charge the batteries or replace the batteries. Refer to Operation and Maintenance Manual, “Battery - Replace”. i01646248 After Starting Engine Note: In temperatures from 0 to 60°C (32 to 140°F), the warm-up time is approximately three minutes.
Fuel Conservation Practices i02578030 Engine Operation The efficiency of the engine can affect the fuel economy. Perkins design and technology in manufacturing provides maximum fuel efficiency in all applications. Follow the recommended procedures Correct operation and maintenance are key factors...
Alcohol or starting fluids are highly flammable and toxic and if improperly stored could result in injury or property damage. Perkins Diesel Engines can operate effectively in cold weather. During cold weather, the starting and the operation of the diesel engine is dependent on...
Fuel and the Effect from Cold Note: Group 3 fuels reduce the life of the engine. The Weather use of Group 3 fuels is not covered by the Perkins warranty. Group 3 fuels include Low Temperature Fuels and Aviation Kerosene Fuels.
SEBU8455 Operation Section Cold Weather Operation i04268370 Fuel Related Components in Cold Weather Fuel Tanks Condensation can form in partially filled fuel tanks. Top off the fuel tanks after you operate the engine. Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks.
SEBU8455 Operation Section Engine Stopping Engine Stopping i02583411 After Stopping Engine i04268255 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 •...
Total Cooling System. Diesel Fuel Requirements Table 6 Engine Perkins is not in a position to continuously evaluate Refill Capacities and monitor all worldwide distillate diesel fuel Compartment or System specifications that are published by governments and technological societies.
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SEBU8455 Maintenance Section Refill Capacities NOTICE The footnotes are a key part of the Perkins Specifica- tion for Distillate Diesel Fuel Table. Read ALL of the footnotes. Table 7 Perkins Specification for Distillate Diesel Fuel Property UNITS Requirements “ASTM”Test “ISO”Test...
However, a cetane NOTICE number of 40 may be experienced in some territories. Operating with fuels that do not meet the Perkins rec- The United States of America is one of the territories ommendations can cause the following effects: Start- that can have a low cetane value.
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0.46 mm (0.01811 inch). The fuel lubricity test must be performed on an HFRR, operated at Perkins recommends a value of density of 841 kg/m3 60 °C (140 °F). Refer to “ISO 12156-1 ”. in order to obtain the correct power output. Lighter fuels are acceptable but these fuels will not produce the rated power.
Perkins recommends Protection Agency (EPA) and European Certification that a fuel sample is taken to determine the cetane fuels. Perkins does not certify engines on any other number. fuel. The user of the engine has the responsibility of using the correct fuel that is recommended by Note: Fuels must have minimum viscosity of 1.4...
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Biodiesel blends are denoted as “BXX” with “XX” • representing the content of neat biodiesel contained Perkins recommends the use of oil analysis in order in the blend with mineral diesel fuel (for example B5, to check the quality of the engine oil if biodiesel B10, B20).
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(filters, additives) which are made by other manufac- and if necessary, drain the water separator. turers are used on Perkins products, the Perkins war- ranty is not affected simply because of such use. Materials such as brass, bronze, copper, led, tin, and...
“SAE J754”. Some classifications follow “SAE J183” 80 hours. Perkins fuel cleaner can be used on an abbreviations, and some classifications follow the on-going basis with no adverse impact on engine or “EMA Recommended Guideline on Diesel Engine...
This analysis allows technicians to determine the amount of Perkins does not recommend the use of aftermarket deterioration of the oil during use. This analysis additives in oil. It is not necessary to use aftermarket...
Society for Testing and Materials contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite. Perkins ELC The following two coolants are used in Perkins diesel has been formulated with the correct amount of engines: these additives in order to provide superior corrosion protection for all metals in engine cooling systems.
This lowering will lower the ability of 4. Use an approved Perkins cleaner to clean the the coolant to protect the system from pitting, from system. Follow the instruction on the label.
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Use the equation that is in Table 10 to determine the antifreeze or SCA. If the contamination exceeds 10 amount of Perkins SCA that is required when the percent of the total system capacity, perform ONE of cooling system is initially filled.
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× 0.014 0.2 L (7 oz) Cleaning the System of Heavy-Duty Antifreeze Perkins cooling system cleaners are designed to clean the cooling system of harmful scale and corrosion. Perkins cooling system cleaners dissolve mineral scale, corrosion products, light oil contamination, and sludge.
Consult the OEM of the ous burn. To open cap, stop engine, wait until ra- equipment or your Perkins dealer regarding welding diator is cool. Then loosen cap slowly to relieve on a chassis frame or rail.
(5) Disconnected battery cables Refer to the standards for the engine or consult your (6) Battery Perkins dealer or your Perkins distributor in order to (7) Electrical/Electronic component determine if the engine is operating within the defined (8) Minimum distance between the component that is being welded parameters.
Due to individual applications, it is not possible to identify all of the factors which can contribute to severe service operation. Consult your Perkins dealer or your Perkins distributor for the unique maintenance that is necessary for the engine. The operating environment, incorrect operating...
SEBU8455 Maintenance Section Maintenance Interval Schedule Every 2000 Service Hours i04268574 Maintenance Interval Schedule Engine Mounts - Inspect ........74 Starting Motor - Inspect ........83 Turbocharger - Inspect .......... 83 Note: The oil and filter change period for the Every 3000 Service Hours 1606A engine is different to the 1606D engine.
Aftercooler Core - Alternator - Inspect Inspect/Clean/Test Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose Note: Adjust the frequency of cleaning according to connections and correct battery charging. Check the the effects of the operating environment.
SEBU8455 Maintenance Section Alternator and Fan Belts - Replace i04766049 i01878164 Alternator and Fan Belts - Battery - Replace Replace Batteries give off combustible gases which can explode. A spark can cause the combustible gas- es to ignite. This can result in severe personal in- jury or death.
SEBU8455 Maintenance Section Battery Electrolyte Level - Check 8. Connect the cable from the NEGATIVE “-” terminal i02857256 on the starter motor to the NEGATIVE “-” battery Battery or Battery Cable - terminal. Disconnect i02563861 Battery Electrolyte Level - Check The battery cables or the batteries should not be removed with the battery cover in place.
SEBU8455 Maintenance Section Belt Tensioner - Check i04633290 Belt Tensioner - Check g02865556 Illustration 38 Typical example 5. Install a suitable tool into the half inch square hole (7). Rotate the tensioner between the point (A) and g02778118 Illustration 37 point (B).
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The full distillation coolant system. procedure is the only method acceptable by Perkins to reclaim the coolant. Drain For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or your Perkins distributor.
SEBU8455 Maintenance Section Coolant (ELC) - Change 5. Stop the engine and allow the engine to cool. 5. Clean the cooling system filler cap and inspect the Loosen the cooling system filler cap slowly in gasket. If the gasket is damaged, discard the old order to relieve any pressure.
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filling. If necessary, repeat step 3. for reuse in engine cooling systems. The full distillation Maintain the coolant level in the expansion bottle procedure is the only method acceptable by Perkins to (if equipped) at the correct level. reclaim the coolant.
SEBU8455 Maintenance Section Coolant Level - Check 3. Clean the cooling system filler cap and check the i04272912 condition of the filler cap gaskets. Replace the Coolant Level - Check cooling system filler cap if the filler cap gaskets are damaged.
SEBU8455 Maintenance Section Crankshaft Vibration Damper - Inspect i04751069 Crankshaft Vibration Damper Pressurized System: Hot coolant can cause seri- - Inspect ous burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pres- sure.
SEBU8455 Maintenance Section Engine - Clean • Adjustment i04633632 Engine Air Cleaner • Lubrication Element (Single Element) - • Other maintenance recommendations Inspect/Clean/Replace Perform any maintenance for the driven equipment which is recommended by the OEM. i02568158 Engine - Clean Personal injury or death can result from high volt- age.
Indicator - Inspect (If Equipped) Note: The engine mounts may not have been supplied by Perkins. Refer to the OEM information for further information on the engine mounts and the correct bolt torque. Some engines may be equipped with a different service indicator.
SEBU8455 Maintenance Section Engine Oil and Filter - Change Note: After the engine has been switched OFF , wait i04272814 for 10 minutes in order to allow the engine oil to drain Engine Oil and Filter - Change to the oil pan before checking the oil level. (1606A Engine ) 1.
SEBU8455 Maintenance Section Engine Oil and Filter - Change Use a suitable container in order to catch the oil that will drain from the filter. Ensure that the filter assembly is clean and free from dirt. 1. Using a suitable tool remove the oil filter (2). Note: Ensure that the sealing faces is clean.
SEBU8455 Maintenance Section Engine Valve Lash - Check i04272831 Engine Valve Lash - Check Table 14 Table 1 Valve Lash Schedule Schedule Type Hours Standby Power Every 500 Prime Power Initial 500 Every 1000 g02793297 Illustration 51 Typical example Remove the valve mechanism cover. Refer to Disassembly and Assembly, “Valve Mechanism Cover-Remove and Install”...
SEBU8455 Maintenance Section Fan Clearance - Check Ensure that the engine is stopped. Ensure that the battery disconnect switch is in the OFF position. Ensure that the cooling system is full. The clearance between the cover (2) and the fan (1) will require checking.
SEBU8455 Maintenance Section Fuel System Primary Filter - Clean/Inspect/Replace 3. When fuel free from air comes from the schrader valve, stop depressing the priming pump. Remove the tool and install the dust cap. 4. Depress the priming pump for a short time in order to pressurize the system.
SEBU8455 Maintenance Section Fuel System Secondary Filter - Replace 3. Ensure that the assembly is clean and free from i04654710 dirt. Remove the element (6) from cap (2). Ensure Fuel System Secondary Filter - that the element housing is clean and free from Replace dirt.
SEBU8455 Maintenance Section Fuel System Water Separator - Check/Drain 6. Tighten the cap to 25 N·m (18 lb ft). Clean any 2. Install a suitable tube onto drain (3). Loosen the split fluid and remove the container. Depose of cap (1) in order to allow atmospheric pressure to all fluids in accordance with local regulations.
SEBU8455 Maintenance Section Hoses and Clamps - Inspect/Replace Check the fuel daily. Allow five minutes after the fuel tank has been filled before draining water and NOTICE sediment from the fuel tank. Do not bend or strike high pressure lines. Do not in- stall bent or damaged lines, tubes or hoses.
If the starting motor fails, the engine procedure for the radiator. For information on may not start in an emergency situation. equipment that is not supplied by Perkins, refer to the OEM. Check the starting motor for proper operation. Check...
7. Fasten the air inlet piping and the exhaust outlet piping to the turbocharger housing. For options regarding the removal, installation, repair, and replacement, consult your Perkins distributor. Refer to the Service Manual for this engine for the i02568213 procedure and specifications.
Note: Refer to the Service Manual or consult your • Inspect the piping for the air inlet system and the Perkins distributor if any repair is needed or any elbows for cracks and for loose clamps. Ensure replacement is needed.
Emissions Warranty. Consult your authorized Perkins dealer or your authorized Perkins distributor in order to determine if your engine is emissions certified and if your engine is subject to an Emissions Warranty.
SEBU8455 Index Section Index Electrical System ........... 15 After Starting Engine ..........41 After Stopping Engine..........46 Grounding Practices .......... 16 Aftercooler Core - Inspect/Clean/Test....64 Emergency Stopping ..........46 Alarms and Shutoffs ..........27 Emissions Certification Film ........24 Engine Alarms............
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Fuel Tank Water and Sediment - Drain ....81 Serial Number Plate (1) ........23 Drain the Water and the Sediment..... 81 Product Description ..........20 Aftermarket Products and Perkins Engines ..21 Fuel Storage Tanks ..........82 Engine Specifications......... 20 Fuel Tank ............81 Product Identification Information ......
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SEBU8455 Index Section Turbocharger - Inspect .......... 83 Cleaning and Inspecting ........84 Removal and Installation........84 Walk-Around Inspection ........84 Inspect the Engine for Leaks and for Loose Connections ............. 84 Warranty Information ..........86 Warranty Section ........... 86 Water Pump - Inspect..........
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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:...
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