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Summary of Contents for Perkins 1103D XK
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Page 1: Testing And Adjusting
KENR6912 January 2008 Systems Operation Testing and Adjusting 1103D Industrial Engine XK (Engine) XL (Engine) XM (Engine) This document has been printed from SPI². Not for Resale... -
Page 2: Important Safety Information
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. -
Page 3: Table Of Contents
KENR6912 Table of Contents Table of Contents Electrical System Alternator - Test ............ 44 Battery - Test ............44 Electric Starting System - Test ......45 Systems Operation Section Glow Plugs - Test ..........47 V-Belt - Test ............47 Engine Design ............ -
Page 4: Engine Design
KENR6912 Systems Operation Section Systems Operation Section The front of the engine is opposite the flywheel end of the engine. The left side of the engine and the right side of the engine are determined from the flywheel end. Number 1 cylinder is the front cylinder of the i02873613 engine. -
Page 5: Lifting The Engine
KENR6912 Systems Operation Section The oil pump is driven by an idler gear. The engine oil pump sends lubricating oil to the main oil gallery. The oil relief valve is internal to the oil pump. Coolant from the bottom of the radiator passes through the water pump. - Page 6 KENR6912 Systems Operation Section 1103D Engine Model Views g01399674 Illustration 2 Typical example (1) Fuel transfer pump (5) Dipstick (9) Water pump (2) Fuel filter (6) Oil filter (10) Fan pulley (3) Starting motor (7) Oil pan (11) Water temperature regulator housing (4) Oil filler cap (8) Crankshaft pulley This document has been printed from SPI².
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Page 7: Fuel System
KENR6912 Systems Operation Section g01403711 Illustration 3 Typical example (1) Alternator (3) Turbocharger oil supply (5) Exhaust manifold (2) Turbocharger (4) Turbocharger oil drain The fuel transfer pump draws fuel from the fuel tank i02873638 and through the water separator. When the fuel goes Fuel System through the water separator, any water in the fuel will go to the bottom of the bowl. -
Page 8: Fuel System Components
The Delphi DP210 and DP310 fuel injection pumps must be serviced by an authorized Delphi technician. For repair information, contact your Perkins distributor. High idle and low idle of the fuel injection pump are factory set. -
Page 9: Air Inlet And Exhaust System
KENR6912 Systems Operation Section i02797476 Air Inlet and Exhaust System Turbocharged Engines g01237037 Illustration 4 Air inlet and exhaust system (1) Exhaust manifold (5) Exhaust outlet (9) Inlet valve (2) Fuel injection nozzle (6) Turbocharger turbine wheel (10) Engine cylinder (3) Glow plug (7) Turbocharger compressor wheel (11) Exhaust valve... - Page 10 KENR6912 Systems Operation Section Just before the piston reaches the TC position, fuel is injected into the cylinder via the fuel injection nozzle (2). The air/fuel mixture ignites. The ignition of the gases initiates the power stroke. Both the inlet and the exhaust valves are closed and the expanding gases force the piston downward toward the bottom center (BC) position .
- Page 11 KENR6912 Systems Operation Section • Air is drawn in through the air cleaner into the air inlet Engine torque is increased. (6) of the inlet manifold (4). Air flow from the inlet • manifold to the engine cylinders (8) is controlled by Durability of the engine is improved.
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Page 12: Cylinder Head And Valves
KENR6912 Systems Operation Section The turbocharger has a wastegate. The wastegate is controlled by the boost pressure. This allows some of the exhaust to bypass the turbocharger at higher engine speeds. The wastegate is a type of valve that automatically opens at a preset level of boost pressure in order to allow exhaust gas to flow around the turbine. -
Page 13: Lubrication System
KENR6912 Systems Operation Section i02876572 Lubrication System g01399859 Illustration 7 Flow diagram of the lubrication system for the 1103D engine (1) Rocker shaft (5) Rod bearing journal (9) Oil pump (2) Camshaft journal (6) Filter head (10) Oil pump gear (3) Oil cooler (7) Oil filter (11) Lower idler gear... - Page 14 KENR6912 Systems Operation Section The lubricating oil flows from the outlet side of the oil pump (9) through a passage to the oil filter head (6). The oil then flows from the oil filter head through a passage to a oil cooler (3). The oil cooler is located on the left side of the cylinder block.
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Page 15: Cooling System
KENR6912 Systems Operation Section i02873641 Cooling System g01016432 Illustration 8 Flow diagram of the cooling system for the 1103D engine The coolant flows from the bottom of the radiator to From the rear of the cylinder block, some of the the centrifugal water pump. -
Page 16: Electrical System
KENR6912 Systems Operation Section Crankshaft The cylinder block for the 1103D engine has four main bearings which support the crankshaft. Thrust washers on both sides of the number three main The crankshaft changes the linear energy of the bearing control the end play of the crankshaft. pistons and connecting rods into rotary torque in order to power external equipment. -
Page 17: Starting Motor
KENR6912 Systems Operation Section Starting Motor Alternator g00303424 g01216877 Illustration 10 Illustration 9 (1) Typical view of a shaft for mounting the pulley Typical view of a 12 Volt Starting Motor (1) Terminal for connection of the ground cable The alternator produces the following electrical (2) Terminal 30 for connection of the battery cable output: (3) Terminal 50 for connection of the ignition switch... -
Page 18: Testing And Adjusting Section
KENR6912 Testing and Adjusting Section Testing and Adjusting 2. Install a suitable sight gauge in the fuel return line. When possible, install the sight gauge in a straight Section section of the fuel line that is at least 304.8 mm (12 inches) long. -
Page 19: Finding Top Center Position For No. 1 Piston
KENR6912 Testing and Adjusting Section 3. If excessive air is seen in the sight gauge in the i02873757 fuel return line, install a second sight gauge at the Finding Top Center Position inlet to the fuel transfer pump. If a second sight for No. -
Page 20: Fuel Injection Pump Timing - Check
Disassembly and Assembly, “Front Cover - technician. For repair information, contact your Remove and Install”. Perkins distributor. The internal adjustment for the pump timing is tamper proof. High idle and low idle 8. Install the glow plugs. Refer to Disassembly and are factory set. -
Page 21: Fuel System - Prime
KENR6912 Testing and Adjusting Section Refer to Operation and Maintenance Manual, i02797519 “Fuel Recommendations” for more information. Fuel System Pressure - Test 3. If fuel quality is still suspected as a possible cause to problems regarding engine performance, disconnect the fuel inlet line, and temporarily operate the engine from a separate source of fuel that is known to be good. - Page 22 KENR6912 Testing and Adjusting Section 4. Use a suitable tool in order to measure the combined flow of both outlets with a stopwatch. Fuel flow should be a minimum of 2 L/min (0.53 US gpm). 5. If the combined flow is less than 2 L/min (0.53 US gpm), replace the pump.
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Page 23: Air Inlet And Exhaust System
KENR6912 Testing and Adjusting Section Air Inlet and Exhaust System Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to i02797521 cool. Air Inlet and Exhaust System - Inspect NOTICE Keep all parts clean from contaminants. -
Page 24: Exhaust Temperature - Test
4. For more information on installing a new at gaskets and seals that would not normally have turbocharger, contact a Perkins dealer. leakage. Blowby can also be caused by worn valve guides or by a failed turbocharger seal. -
Page 25: Engine Valve Lash - Inspect/Adjust
KENR6912 Testing and Adjusting Section • The battery is in good condition. Not enough valve lash can be the cause of rapid wear of the camshaft and valve lifters. Not enough • The battery is fully charged. valve lash can indicate that the seats for the valves are worn. - Page 26 KENR6912 Testing and Adjusting Section 2. Rotate the crankshaft in a clockwise direction that is viewed from the front of the engine. When the inlet valve of the No 1 cylinder has opened and the exhaust valve of the No 1 cylinder has not completely closed measure the valve lash of the inlet valve of No 2 cylinder and the exhaust valve of No 3 cylinder.
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Page 27: Valve Depth - Inspect
KENR6912 Testing and Adjusting Section 2. Position gauge body (2) and dial indicator (1) in i02875207 order to measure the valve depth. Measure the Valve Depth - Inspect depth of the inlet valve and the exhaust valve before the valve springs are removed. Refer to Specifications, “Cylinder Head Valves”... - Page 28 KENR6912 Testing and Adjusting Section Refer to Specifications, “Cylinder Head Valves” for the maximum clearance of the valve in the valve guide. g01235205 Illustration 19 (A) Dial gauge (1) Valve head (2) Valve guide (3) Radial movement of the valve in the valve guide (4) Valve stem 1.
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Page 29: Lubrication System
KENR6912 Testing and Adjusting Section Lubrication System i02875224 Engine Oil Pump - Inspect i02875215 Engine Oil Pressure - Test Table 8 Required Tools Tool Part Number Part Description Low Oil Pressure CVT0014 Feeler gauge The following conditions will cause low oil pressure. If any part of the oil pump is worn enough in order to •... -
Page 30: Excessive Bearing Wear - Inspect
KENR6912 Testing and Adjusting Section 6. Clean the top face of the oil pump and the bottom face of the cover. Install the cover on the oil pump. Install the oil pump on the engine. Refer to Disassembly and Assembly, “Engine Oil Pump - Install”. -
Page 31: Increased Engine Oil Temperature - Inspect
KENR6912 Testing and Adjusting Section • Worn components or damaged components (pistons, piston rings, or dirty return holes for the engine oil) • Incorrect installation of the compression ring and/or the intermediate ring • Leaks past the seal rings in the turbocharger shaft •... -
Page 32: Cooling System
KENR6912 Testing and Adjusting Section Cooling System 6. Check the filler cap. A pressure drop in the cooling system can cause the boiling point to be lower. This can cause the cooling system to boil. Refer to Systems Operation, Testing and Adjusting, i02801080 “Cooling System - Test”. -
Page 33: Cooling System - Inspect
KENR6912 Testing and Adjusting Section 14. When a load that is applied to the engine is too 4. Inspect the drive belt for the fan. large, the engine rpm does not increase with an increase of fuel. This lower engine rpm causes 5. - Page 34 KENR6912 Testing and Adjusting Section Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand.
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Page 35: Engine Oil Cooler - Inspect
KENR6912 Testing and Adjusting Section 5. Compare the pressure to the pressure rating that i02480718 is found on the top of the filler cap. Engine Oil Cooler - Inspect 6. If the filler cap is damaged, replace the filler cap. Testing The Radiator And Cooling System For Leaks Hot oil and hot components can cause personal... -
Page 36: Water Temperature Regulator - Test
KENR6912 Testing and Adjusting Section 4. Inspect the oil cooler body (2) for cracks and 5. After ten minutes, remove the water temperature dents. Replace the oil cooler body if cracks or regulator housing. Immediately measure the dents exist. opening of the water temperature regulator. Refer to Specifications, “Water Temperature 5. -
Page 37: Basic Engine
KENR6912 Testing and Adjusting Section Basic Engine 2. Fit new piston rings (2) in the piston grooves (1). Refer to Disassembly and Assembly, “Pistons and Connecting Rods - Assemble” for the correct procedure. i02875271 Piston Ring Groove - Inspect 3. Check the clearance for the piston ring by placing Tooling (A) between piston groove (1) and the top of piston ring (2). -
Page 38: Connecting Rod - Inspect
KENR6912 Testing and Adjusting Section If the piston pin bearing is not removed, the limits i02801084 are reduced to ± 0.06 mm (± 0.0025 inch). Connecting Rod - Inspect 3. Inspect the piston pin bearing and the piston pin for wear and other damage. This procedure determines the following 4. -
Page 39: Cylinder Head - Inspect
KENR6912 Testing and Adjusting Section 4. Check the camshaft bearing for wear. If a new bearing is needed, use a suitable adapter to press the bearing out of the bore. Ensure that the oil hole in the new bearing faces the front of the block. The oil hole in the bearing must be aligned with the oil hole in the cylinder block. -
Page 40: Piston Height - Inspect
KENR6912 Testing and Adjusting Section i02406197 Piston Height - Inspect Table 11 Required Tools Part Tool Number Part Description 21825617 Dial Gauge 21825496 Dial gauge holder If the height of the piston above the cylinder block is not within the tolerance that is given in the Specifications Module, “Piston and Rings”, the bearing for the piston pin must be checked. -
Page 41: Flywheel Housing - Inspect
KENR6912 Testing and Adjusting Section Alignment of the Flywheel Face Flywheel Runout g01240628 g01240629 Illustration 31 Illustration 32 Typical example Typical example 1. Install Tooling (A). Refer to Illustration 31. 1. Install Tooling (A). Refer to Illustration 32. 2. Set the pointer of the dial on Tooling (A) to 0 mm 2. - Page 42 KENR6912 Testing and Adjusting Section g01226662 g01226662 Illustration 33 Illustration 34 Typical example Typical example 1. Install Tooling (A). Tooling (A) is shown in 1. Install Tooling (A). Tooling (A) is shown in Illustration 33. Illustration 34. 2. Set the pointer of Tooling (A) to 0 mm (0 inch). 2.
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Page 43: Gear Group - Inspect
KENR6912 Testing and Adjusting Section 4. Measure the backlash between the fuel injection i02484861 pump gear (3) and the idler gear (2). Refer to Gear Group - Inspect Specifications, “Gear Group (Front)” for the backlash measurement. 5. Measure the end play on idler gear (2). Refer to Disassembly and Assembly, “Idler Gear - Install”... -
Page 44: Electrical System
KENR6912 Testing and Adjusting Section Electrical System 4. Turn the ignition switch to the ON position. Check the voltage between terminal (B) and ground. If the voltage is more than 2 Volts the alternator needs to be replaced. i02875331 Alternator - Test Warning Light is On When the Engine is Running 1. -
Page 45: Electric Starting System - Test
KENR6912 Testing and Adjusting Section When the magnetic force increases in both coils, the pinion gear moves toward the ring gear of the flywheel. Then, the solenoid contacts close in order Never disconnect any charging unit circuit or bat- to provide power to the starting motor. When the tery circuit cable from the battery when the charg- solenoid contacts close, the ground is temporarily ing unit is operated. - Page 46 KENR6912 Testing and Adjusting Section Diagnosis Procedure • The voltage at the battery post is within 2 volts of the lowest value in the applicable temperature The procedures for diagnosing the starting motor range of Table 15. are intended to help the technician determine if a •...
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Page 47: Glow Plugs - Test
KENR6912 Testing and Adjusting Section a. If the crankshaft is stuck or difficult to turn, Table 17 repair the engine. 12 Volt System b. If the engine is not difficult to turn, go to Step 6. Time (sec) Initial 6. Attempt to crank the starting motor. a. - Page 48 KENR6912 Testing and Adjusting Section Table 19 Belt Tension Chart Gauge Reading Size of Belt Width of Belt Initial Belt Tension Used Belt Tension 13.89 mm (0.547 Inch) 535 N (120 lb) 355 N (80 lb) Measure the tension of the belt that is farthest from the engine. Initial Belt Tension refers to a new belt.
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Page 49: Index
KENR6912 Index Section Index Engine Valve Lash - Inspect/Adjust ....... 25 Valve Lash Adjustment ........26 Air in Fuel - Test............. 18 Valve Lash Setting ..........25 Air Inlet and Exhaust System ......9, 23 Excessive Bearing Wear - Inspect......30 Cylinder Head And Valves ......... - Page 50 KENR6912 Index Section Main Bearings - Inspect......... 38 Piston Height - Inspect .......... 40 Piston Ring Groove - Inspect......... 37 Inspect the Clearance of the Piston Ring... 37 Inspect the Piston and the Piston Rings .... 37 Inspect the Piston Ring End Gap....... 37 Systems Operation Section ........
- Page 51 KENR6912 Index Section This document has been printed from SPI². Not for Resale...
- Page 52 ©2008 Perkins Engines Company Limited Printed in U. K. All Rights Reserved This document has been printed from SPI². Not for Resale...
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