Systems Operation

Testing and Adjusting

1600 Series Industrial Engine

XGA (Engine)

XGB (Engine)

XGD (Engine)

XGE (Engine)

XGF (Engine)

XGH (Engine)

This document is printed from SPI². Not for RESALE

Important Safety Information

Most  accidents    tha t involve  produc  t  op eration,  ma intena nc e and   repair   are  caus  ed  by  failure  to

ob serve  basic   safety   rules  or  precautions  .  An accident    can   often  be  avoided   by  recog nizing  pote ntially

ha za rdous  situations   before   an  accident    oc curs . A person    mus t be  alert   to pote ntial  ha za rds.  This

person   should   also  ha ve  the  ne cessary   training,  skills  and   tools  to perform   the se  func tions 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.

Sa fety precautions     and  warning s  are   provided   in this  ma nua l and   on  the  produc t.  If the se  ha za rd

warning s  are  not  he eded,   bod ily injury  or death   could   oc cur to  you  or to  othe r persons  .

The  ha za rds are   identified   by  the  “Safety  Alert  Symb ol”  and  followed  by  a  “Signa l  Word” suc h  as

“DANGER”, “WARNING”  or “CAUTION”.  The Sa fety  Alert  “WARNING” label  is  shown   below.

The  me aning  of  this safety   alert   symb ol is  as  follows:

Attention! Become Alert! Your Safety is  Involved.

The  me ssage   tha t appears     und er the   warning  explains    the  ha za rd and   can  be   either  written  or

pictorially   presente  d.

Op erations  tha t  ma y caus e  produc  t dama  ge  are  identified   by  “NOTICE” labels   on  the  produc  t and   in

this  pub lication.

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  informa tion, specifications   ,  and  illustrations   in  this  pub lication  are   on the  basis    of informa tion tha t

was  available    at  the  time  tha t the  pub lication   was  written.   The  specifications   , torque  s,  pressure  s,

me asure me nts , adjustme  nts , illustrations ,  and  othe r  items  can  cha  ng e at  any  time.  These  cha ng es  can

affect   the  service   tha t is given   to the  produc  t.  Ob tain the  comp  lete  and  mos t current   informa tion before

you  start any   job. Pe  rkins  dealers   or   Pe rkins  distributors     ha ve  the  mos t current   informa tion  available.

When  replacement  parts  are  required  for  this

product Perkins recommends using Perkins

 replacement  parts.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

This document is printed from SPI². Not for RESALE

KENR8772

3

Table of  Contents

Table of Contents

Crankshaft Thrust - Measure ................................ 81

Gear Group - Inspect ............................................ 82

Vibration Damper - Check ....................................  83

Systems Operation Section

Electrical System

Alternator - Test ....................................................  85

Battery - Test ......................................................... 86

Charging System - Test ........................................  86

Electric Starting System - Test .............................. 86

V-Belt - Test ..........................................................  87

General Information ................................................ 4

Glossary of Electronic Control Terms .....................  7

Electronic Control System Components ................ 11

Power Sources .....................................................  26

Fuel System  ......................................................... 28

Air Inlet and Exhaust System ...............................  37

Lubrication System  ..............................................  41

Cooling System  .................................................... 43

Basic Engine ......................................................... 46

Electrical System  .................................................  49

Index Section

Index .....................................................................  88

Testing and Adjusting Section

Fuel System

Fuel System - Inspect ........................................... 52

Air in Fuel - Test .................................................... 52

Finding Top Center Position for No. 1 Piston  ....... 53

Fuel Quality - Test ................................................. 53

Fuel System - Prime .............................................  54

Fuel System Pressure - Test ................................. 55

Gear Group (Front) - Time .................................... 56

Air Inlet and  Exhaust System

Air Inlet and Exhaust System - Inspect ................. 58

Turbocharger - Inspect .......................................... 58

Exhaust Temperature - Test .................................. 61

Exhaust Cooler (NRS) - Test (If Equipped) ........... 61

Engine Crankcase Pressure (Blowby) - Test ........ 62

Engine Valve Lash - Inspect/Adjust ......................  62

Valve Depth - Inspect ............................................ 64

Valve Guide - Inspect ............................................ 64

Lubrication System

Engine Oil Pressure - Test .................................... 65

Engine Oil Pump - Inspect .................................... 65

Excessive Bearing Wear - Inspect ........................ 66

Excessive Engine Oil Consumption - Inspect ....... 66

Increased Engine Oil Temperature - Inspect ........  67

Cooling System

Cooling System - Check (Overheating) ................  68

Cooling System - Inspect ...................................... 69

Cooling System - Test ........................................... 70

Engine Oil Cooler - Inspect ................................... 72

Water Temperature Regulator - Test ..................... 74

Water Pump - Inspect ...........................................  74

Basic Engine

Piston Ring Groove - Inspect ................................ 75

Connecting Rod - Inspect .....................................  76

Connecting Rod Bearings - Inspect ...................... 77

Main Bearings - Inspect ........................................ 77

Cylinder Block - Inspect ........................................ 77

Cylinder Head - Inspect ........................................  77

Cylinder Liner Projection - Inspect ........................ 78

Flywheel - Inspect ................................................. 79

Flywheel Housing - Inspect ................................... 80

This document is printed from SPI². Not for RESALE

4

Systems Operation  Section

KENR8772

Systems Operation Section

i04031010

General Information

The following model views show the 1600  Series

Industrial Engine features.  Due to individual

applications, your engine may appear different from

the illustrations.

g02757356

Illustration 1

Typical example of the right side  of the 1600D engine

(1) Rear lifting eye

(2) Front lifting eye

(3) Alternator

(5) Belt tensioner

(6) Coolant pump

(7) Coolant intake connection

(8) Crankcase breather

(9) Oil cooler

(10) Oil filter

(11) Turbocharger

(12) Exhaust gas cooler (NRS)

(4) Drive belt

This document is printed from SPI². Not for RESALE

KENR8772

5

Systems Operation  Section

g02430477

Illustration 2

Typical example of the left  side of the 1600D engine

(13) Valve mechanism cover

(14) Air cleaner

(17) Oil filler and oil gauge

(18) Oil drain plug

(21) Secondary fuel filter

(22) Hand priming pump

(15) Flywheel housing

(16) Flywheel

(19) Electronic Control Module (ECM)

(20) High-pressure oil pump

(23) Primary fuel filter

This document is printed from SPI². Not for RESALE

6

Systems Operation  Section

KENR8772

g02794993

Illustration 3

Typical example of the 1600A  engine

The 1600 Series diesel  engine is electronically

controlled. The 1600  Series engine uses an

Electronic Control Module (ECM)  that receives

signals from the engine sensors in order to control

the electronic unit injectors.

The steel pistons  have a specially designed

combustion chamber in the top of the piston in order

to achieve clean exhaust emissions.

The pistons have two compression rings and an oil

control ring.

The fuel system is electro-hydraulic. The  system

includes an under-valve-cover  high-pressure

oil manifold, electronic  unit injectors, and  a

high-pressure oil pump. The electronic unit injectors

are installed in  the cylinder head, under  the

high-pressure oil manifold.

A piston and a  connecting rod are matched to

each cylinder. The piston height  is controlled by

the distance between the center of  the large end

bearing and the center of the small end bearing of

the connecting rod.

The six cylinders are arranged in-line. The cylinder

head assembly has two inlet valves and two exhaust

valves for each cylinder. The ports for the exhaust

valves are on the right side of the cylinder head. The

ports for the inlet valves are on the left side  of the

cylinder head. Each cylinder valve has a single valve

spring.

The crankshaft has seven main bearing journals. End

play is controlled by thrust washers which are located

on both sides of the number 7 upper main bearing.

Each cylinder has a piston cooling jet that is installed

in the cylinder block. The piston cooling jet sprays

engine oil onto the gallery of the piston in order to

cool the piston.

This document is printed from SPI². Not for RESALE

KENR8772

7

Systems Operation  Section

The timing case is made of aluminum. The timing

gears are stamped with timing marks  in order to

ensure the correct assembly of the  gears. When

the number 1 piston is at the top center position of

the compression stroke, the marked teeth on  the

idler gears will align with the marks that are on the

camshaft gear, and the gear on the crankshaft. There

are no timing marks on the rear face of  the timing

case.

i04201673

Glossary of Electronic Control

Terms

Active Diagnostic Code  – An active diagnostic

code alerts the operator or the service technician that

an electronic system malfunction is currently present.

Refer to the term “Diagnostic Trouble Code” in this

glossary.

The crankshaft gear turns the lower idler gear which

then turns the following gears:

•  the upper idler gear

Air-To-Air Aftercooler – An air-to-air aftercooler is a

device that is used on turbocharged engines in order

to cool inlet air that has undergone compression. The

inlet air is cooled after the inlet air passes through

the turbocharger. The inlet air is passed through an

aftercooler (heat exchanger) that uses ambient air for

cooling. The inlet air that has been cooled advances

to the inlet manifold.

•  the camshaft gear

•  the spline gear for the engine oil pump

•  the gear for the high-pressure oil pump

•  the accessory drive gear

Adaptive Trim  – This is a software process that

is performed in the  ECM that optimizes engine

performance by automatically compensating for

degradation of injector components.

The camshaft runs at half the rpm of the crankshaft.

The high-pressure oil pump runs at half the rpm as

the crankshaft.

The high-pressure oil pump that is installed on the left

side of the engine is gear-driven from the timing case.

The low-pressure fuel transfer pump is mounted on

the high-pressure oil pump.

Alternating Current (AC)  – Alternating current is an

electric current that reverses direction at a regular

interval that is reoccurring.

Before Top Center (BTC)  – BTC is the 180 degrees

of crankshaft rotation before the piston reaches the

top center position in the normal direction of rotation.

The low-pressure fuel transfer pump draws fuel from

the fuel tank across a suction strainer to the primary

fuel filter.

Inlet Manifold Pressure  – The difference between

the turbocharger outlet pressure and atmospheric

pressure is commonly referred to as inlet manifold

pressure. The sensor for  the inlet manifold air

pressure measures the amount of boost.

The fuel flows from the primary  fuel filter into the

fuel rail. The fuel rail is an integral part of  the inlet

manifold. The fuel flows  into six cylinder head

passages to each electronic unit injector.

When the electronic unit injectors are activated, fuel

flows from the fuel passages through the inlet ports

of the electronic unit injector and inside the electronic

unit injectors.

Breakout Harness  – The breakout harness is a

test harness that is designed to  connect into the

engine harness. This connection allows a normal

circuit operation and the connection simultaneously

provides a Breakout T  in order to measure the

signals.

The high-pressure oil pump is not serviceable. The

engine uses speed sensors  and the Electronic

Control Module to control the engine speed.

Bypass Circuit  – A bypass circuit is a circuit that is

used as a substitute circuit for an existing circuit. A

bypass circuit is typically used as a test circuit.

For the specifications for the 1600 Series  engine,

refer to Specifications, “Engine Design”.

CAN Data Link  – The CAN Data Link is used for

communication with other microprocessor-based

devices.

Code  – Refer to “Diagnostic Code” or “Event Code”.

Cold Mode  – Cold mode is a mode for cold starting

and for cold engine operation. This mode is used for

engine protection, reduced smoke emissions and

faster warm-up time.

This document is printed from SPI². Not for RESALE