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Table of Contents

Foreword ........................................................... 4

Safety Section

Safety Messages............................................... 6

General Hazard Information.............................. 7

Burn Prevention................................................11

Fire Prevention and Explosion Prevention.......11

Crushing Prevention and Cutting Prevention.. 13

Mounting and Dismounting ............................. 13

Before Starting Engine .................................... 14

Engine Starting................................................ 14

Engine Stopping .............................................. 14

Electrical System............................................. 15

Product Information Section

Model Views .................................................... 16

Product Identification Information ................... 19

Operation Section

Lifting and Storage .......................................... 21

Gauges and Indicators .................................... 23

Features and Controls..................................... 24

Engine Starting................................................ 25

Engine Operation ............................................ 28

Engine Stopping .............................................. 29

Cold Weather Operation ................................. 30

Maintenance Section

Refill Capacities............................................... 34

Maintenance Interval Schedule....................... 46

Warranty Section

Warranty Information....................................... 72

Index Section

Index................................................................ 73

SEBU8352-02

Table of Contents

Содержание 1103D Series

Страница 1: ...Operation and Maintenance Manual 1103D Industrial Engine XK Engine XL Engine XM Engine SEBU8352 02 en us January 2021...

Страница 2: ...rmation 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...

Страница 3: ...14 Engine Stopping 14 Electrical System 15 Product Information Section Model Views 16 Product Identification Information 19 Operation Section Lifting and Storage 21 Gauges and Indicators 23 Features...

Страница 4: ...manual Whenever a question arises regarding your engine or this manual please consult with your Perkins dealer or your Perkins distributor for the latest available information Safety This safety sect...

Страница 5: ...the engine as a convenient reminder Perkins also recommends that a maintenance record be maintained as part of the permanent record of the engine Your authorized Perkins dealer or your Perkins distri...

Страница 6: ...the warning signs The warning signs that are loosened could drop off of the engine Replace any warning sign that is damaged or missing If a warning sign is attached to a part of the engine that is re...

Страница 7: ...09 Typical example The ether warning label 1 is located on the front end of the inlet manifold cover Refer to illustration 2 i08312758 General Hazard Information Illustration 4 g00104545 Attach a Do N...

Страница 8: ...across the starting motor terminals or the batteries This action could bypass the engine neutral start system and or the electrical system could be damaged Engine exhaust contains products of combusti...

Страница 9: ...ductivity of ULSD and increases the ability of ULSD to store static charge Refineries may have treated the fuel with a static dissipating additive Many factors can reduce the effectiveness of the addi...

Страница 10: ...rials that may contain or have come into contact with hexavalent chromium Stay away from areas that might have hexavalent chromium particles in the air Asbestos Information Perkins equipment and repla...

Страница 11: ...Ensure that the filler cap is cool before removing the filler cap The filler cap must be cool enough to touch with a bare hand Remove the filler cap slowly to relieve pressure Cooling system conditio...

Страница 12: ...ain flammable fluid Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting Wiring must be kept in good condition Ensure that all electrical wires are co...

Страница 13: ...the hoses are kinked Outer covers have embedded armoring End fittings are displaced Make sure that all clamps guards and heat shields are installed correctly During engine operation correct installati...

Страница 14: ...controls DO NOTstart the engine or move 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 installe...

Страница 15: ...engine block Check the electrical wires daily for wires that are loose or frayed Tighten all loose electrical wires before the engine is started Repair all frayed electrical wires before the engine is...

Страница 16: ...on 12 g01439632 Typical example 1 Front lifting eye 2 Water temperature regulator housing horizontal outlet 3 Fuel priming pump 4 Fuel filter 5 Breather tube 6 Water pump 7 Starting motor 8 Oil filter...

Страница 17: ...Engines are designed for the following applications machine and industrial mobile equipment The engines are available in the following types of aspiration Turbocharged aftercooled Turbocharged Natural...

Страница 18: ...engine parts if the oil cooler should become plugged or if the oil filter element should become plugged Engine efficiency efficiency of emission controls and engine performance depend on adherence to...

Страница 19: ...nents that were included with the engine This permits accurate identification of replacement part numbers i02875212 Serial Number Plate The Serial Number Plate is located on the upper left side of the...

Страница 20: ...Engine Serial number Engine Low Idle rpm Engine Full Load rpm Primary Fuel Filter Water Separator Element Secondary Fuel Filter Element Lubrication Oil Filter Element Auxiliary Oil Filter Element Tot...

Страница 21: ...n an engine is in storage after a period in service Your Perkins dealer or your Perkins distributor can assist in preparing the engine for extended storage periods Condition for Storage The engine mus...

Страница 22: ...nhibitor has been introduced The effect of the vapor phase inhibitor will be lost if the cooling system is open to the atmosphere For maintenance procedures refer to this Operation and Maintenance Man...

Страница 23: ...allowable temperature with the pressurized cooling system at 48 kPa 7 psi is 110 C 230 F Higher temperatures may occur under certain conditions The water temperature reading may vary according to load...

Страница 24: ...id is located on the fuel injection pump When the fuel shutoff solenoid is activated the solenoid moves to the Open position When the fuel shutoff solenoid is deactivated the solenoid moves to the Clo...

Страница 25: ...area and if in an enclosed area vent the exhaust to the outside Do not start the engine or move any of the controls if there is a DO NOT OPERATE warning tag or similar warning tag attached to the sta...

Страница 26: ...HEAT position for 6 seconds until the glow plug indicator light illuminates This action will activate the glow plugs and aid in the starting of the engine NOTICE Do not crank the engine for more than...

Страница 27: ...re produced by some batteries 4 Start the engine 5 Immediately after the stalled engine is started disconnect the jump start cables in reverse order After jump starting the alternator may not be able...

Страница 28: ...ed Engine 1 Run the engine for 3 to 5 minutes More time may be necessary when the temperature is below 18 C 0 F 2 Check all of the gauges during the warm up period 3 Perform a walk around inspection C...

Страница 29: ...or the external system that support the engine operation are secured after the engine is stopped i02818879 After Stopping Engine Note Before you check the engine oil do not operate the engine for at l...

Страница 30: ...Cold Weather Operation If the engine will start operate the engine until a minimum operating temperature of 81 C 177 8 F is achieved Achieving operating temperature will help prevent the intake valve...

Страница 31: ...ations for Coolant Warm Up Warm up an engine that has cooled below normal operating temperatures due to inactivity The warm up should be performed before the engine is returned to full operation Durin...

Страница 32: ...y insulating the engine compartment i05927268 Fuel and the Effect from Cold Weather Note Only use grades of fuel that are recommended by Perkins Refer to this Operation and Maintenance Manual Fluid Re...

Страница 33: ...l filter is installed between the fuel tank and the engine fuel inlet After you change the fuel filter always prime the fuel system in order to remove air bubbles from the fuel system Refer to the Ope...

Страница 34: ...e Only 4 21 4 External cooling system capacity OEM recommendation 1 Total Cooling System 2 1 The external cooling system includes a radiator or an expan sion tank with the following components heat ex...

Страница 35: ...lowing oils are recommended API CH 4 API CG 4 and API CF 4 DHD 1 oils are intended to provide superior performance in comparison to API CG 4 and API CF 4 DHD 1 oils will meet the needs of high perform...

Страница 36: ...vice life due to deposits and or excessive wear Total Base Number TBN and Fuel Sulfur Levels for Direct Injection DI Diesel Engines The Total Base Number TBN for an oil depends on the fuel sulfur leve...

Страница 37: ...efined base stock oil should adequately remove all wear metals that are in the used oil and all the additives that are in the used oil The process that is used to make re refined base stock oil genera...

Страница 38: ...ed The increase in the rate of engine wear metal in the oil is as important as the quantity of engine wear metal in the oil Tests are conducted in order to detect contamination of the oil by water gly...

Страница 39: ...e lubricity of 650 micrometers wear scar and the reliability of the fuel pump and fuel injectors will be reduced The fuel injection pump is not covered by a warranty even when the additives are includ...

Страница 40: ...in order to bring down the vis cosity to a 20 cSt viscosity 3 Follow the test conditions and procedures for gasoline motor 4 The lubricity of a fuel is a concern with low sulfur fuel To deter mine th...

Страница 41: ...re regulators in the cooling system Water temperature regulators help to maintain the engine coolant at the proper operating temperature Cooling system prob lems can develop without water temperature...

Страница 42: ...l Protection 50 Percent 29 C 20 F 106 C 223 F To check the concentration of glycol in the coolant measure the specific gravity of the coolant Coolant Recommendations The following two coolants are use...

Страница 43: ...TICE Use only Perkins products for pre mixed or concen trated coolants Mixing Extended Life Coolant with other products re duces the Extended Life Coolant service life Failure to follow the recommenda...

Страница 44: ...ces the effective ness of the ELC and shortens the ELC service life Use only Perkins Products for premixed or concen trate coolants Failure to follow these recommenda tions can result in shortened coo...

Страница 45: ...of SCA For the interval refer to the Operation and Maintenance Manual Maintenance Interval Schedule Maintenance Section Test the concentration of SCA Additions of SCA are based on the results of the...

Страница 46: ...ngine Air Cleaner Element Dual Element Clean Replace 55 Engine Air Cleaner Element Single Element Inspect Replace 57 Engine Oil and Filter Change 60 Fuel System Primary Filter Water Separator Element...

Страница 47: ...can result without following prop er procedure When using pressure air wear a protective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cl...

Страница 48: ...iods the batteries may not fully charge A battery with a low charge will freeze more easily than a battery with a full charge i02883869 Alternator and Fan Belts Inspect Adjust Replace Inspection To ma...

Страница 49: ...battery terminal Note Always recycle a battery Never discard a battery Dispose of used batteries to an appropriate recycling facility 5 Remove the used battery 6 Install the new battery Note Before t...

Страница 50: ...05901701 Cooling System Coolant Commercial Heavy Duty Change NOTICE Care must be taken to ensure that fluids are con tained during performance of inspection mainte nance testing adjusting and repair o...

Страница 51: ...5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain cock or remove the drain...

Страница 52: ...mmended maintenance interval if the following conditions exist The engine overheats frequently Foaming is observed The oil has entered the cooling system and the coolant is contaminated The fuel has e...

Страница 53: ...from the cavities of the engine block Stop the engine 4 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level in...

Страница 54: ...will be forced into the coolant recovery tank during engine operation When the engine is stopped and cool the coolant will return to the engine Engines Without a Coolant Recovery Tank Check the coola...

Страница 55: ...he junction of cables Avoid electrical components such as the alternator and the starter motor Protect the fuel injection pump from fluids when washing the engine i01915869 Engine Air Cleaner Element...

Страница 56: ...y air cleaner element Install a primary air cleaner element that is new or cleaned 6 Install the air cleaner cover 7 Reset the air cleaner service indicator Cleaning the Primary Air Cleaner Elements N...

Страница 57: ...Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air cleaner element Rotate the primary air cleaner element Inspect the primary air cleaner element...

Страница 58: ...eset in less than three pushes Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch approximately at the greatest vacuum that is...

Страница 59: ...der to regularly sample the engine lubricating oil The oil sampling valve is positioned on the oil filter head or the oil sampling valve is positioned on the cylinder block Perkins recommends using a...

Страница 60: ...ottom oil drain plugs from both ends of the oil pan After the oil has drained the oil drain plugs should be cleaned and installed If necessary renew the O ring seal on the drain plug Some types of oil...

Страница 61: ...r cap Refer to the Operation and Maintenance Manual for more information on lubricant specifications Fill the crankcase with the proper amount of oil Refer to the Operation and Maintenance Manual for...

Страница 62: ...use burns Allow additional time for the engine to cool before measuring adjusting valve lash clearance Ensure that the engine is stopped before measuring the valve lash The engine valve lash can be in...

Страница 63: ...with high pressure fuel obtain medical assistence immediately Operate the engine at a fast idle speed in order to identify the faulty fuel injector Individually loosen and tighten the union nut for t...

Страница 64: ...Water Separator Drain 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...

Страница 65: ...and remove the screw 1 Remove the element and the glass bowl 3 from the base Discard the old element 6 Clean the glass bowl 4 Clean the bottom cover 6 7 Install the new O ring seal Install the bottom...

Страница 66: ...Ensure that the fuel drain 3 on the new spin on filter is closed Illustration 41 g01440510 Typical example 4 Lubricate the sealing ring 4 with clean fuel oil 5 Install the spin on filter 2 into the t...

Страница 67: ...n for further information on the coolant system and the hoses for the coolant system Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and w...

Страница 68: ...tandards for the following engine parameters Performance such as power range speed range and fuel consumption Fuel quality Operational Altitude Maintenance intervals Oil selection and maintenance Cool...

Страница 69: ...akage of oil into a turbocharger under ex tended low idle operation should not cause problems as long as a turbocharger bearing failure has not occured When a turbocharger bearing failure is accompani...

Страница 70: ...ce the water pump seal For the removal of the water pump and the installation of water pump and or seal refer to the Disassembly and Assembly Manual Water Pump Remove and Install for more information...

Страница 71: ...gine cools down and parts contract Visually inspect the water pump for leaks Renew the water pump seal or the water pump if there is an excessive leakage of coolant Refer to the Disassembly and Assemb...

Страница 72: ...eous emission standards that are prescribed by the law at the time of manufacture This engine may be covered by an Emissions Warranty Consult your authorized Perkins dealer or distributor to determine...

Страница 73: ...and Cutting Prevention 13 D Driven Equipment Check 55 E Electrical System 15 Grounding Practices 15 Emergency Stopping 29 Emissions Certification Film 20 Emissions Warranty Information 72 Engine Clea...

Страница 74: ...Fueling with Ultra low Sulfur Diesel Fuel 9 H Hoses and Clamps Inspect Replace 66 Replace the Hoses and the Clamps 67 I Important Safety Information 2 L Lifting and Storage 21 M Maintenance Interval...

Страница 75: ...les 26 Stopping the Engine 29 T Table of Contents 3 Turbocharger Inspect If Equipped 69 Inspecting 69 Removal and Installation 69 W Walk Around Inspection 70 Inspect the Engine for Leaks and for Loose...

Страница 76: ......

Страница 77: ...aintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Inf...

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