Related Manuals for Perkins 1103D
Summary of Contents for Perkins 1103D
- Page 1 SEBU8352-02 (en-us) January 2021 Operation and Maintenance Manual 1103D Industrial Engine XK (Engine) XL (Engine) XM (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
SEBU8352-02 Table of Contents Table of Contents Maintenance Interval Schedule....... 46 Warranty Section Foreword ............4 Warranty Information........72 Safety Section Index Section Safety Messages..........6 Index..............73 General Hazard Information......7 Burn Prevention..........11 Fire Prevention and Explosion Prevention..11 Crushing Prevention and Cutting Prevention.. 13 Mounting and Dismounting ...... -
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 dealer or your distributor can provide new warning signs. (1) Universal Warning... -
Page 7: General Hazard Information
SEBU8352-02 Safety Section General Hazard Information Illustration 2 g01431463 (1) Ether Warning Label (2) Universal warning (2) Ether The ether warning label (1) is located on the front end of the inlet manifold cover. Refer to illustration 2 . i08312758 Do not use aerosol types of starting aids such as General Hazard Information ether. - Page 8 SEBU8352-02 Safety Section General Hazard Information Start the engine from the operators station (cab). Never short 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 combustion which may be harmful to your health.
- Page 9 SEBU8352-02 Safety Section General Hazard Information Obey all local regulations for the disposal of liquids. Static Electricity Hazard when Fueling with Ultra-low Sulfur Diesel Fuel The removal of sulfur and other compounds in ultra- low sulfur diesel fuel (ULSD fuel) decreases the conductivity of ULSD and increases the ability of ULSD to store static charge.
- Page 10 Inhaling this dust can be hazardous with applicable regulations and requirements where to your health. The components that may contain originally sold. Perkins recommends the use of only asbestos fibers are brake pads, brake bands, lining genuine Perkins replacement parts.
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Page 11: Burn Prevention
SEBU8352-02 Safety Section Burn Prevention Dispose of Waste Properly Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth. Oils Skin may be irritated following repeated or prolonged exposure to mineral and synthetic base oils. - 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 Inspect the steps, the handholds, and the work area can cause fires. Consult your Perkins dealer or your before mounting the engine. Keep these items clean Perkins distributor for repair or for replacement parts. -
Page 14: Before Starting Engine
SEBU8352-02 Safety Section Before Starting Engine If a warning tag is attached to the engine start switch i05874054 or to the controls, DO NOT start the engine or move Before Starting Engine the controls. Consult with the person that attached the warning tag before the engine is started. -
Page 15: Electrical System
SEBU8352-02 Safety Section Electrical System Use the Emergency Stop Button (if equipped) ONLY All grounds should be tight and free of corrosion. The in an emergency situation. Do not use the engine alternator must be grounded to the negative Emergency Stop Button for normal engine stopping. “-”... -
Page 16: Product Information Section
Product Information Section Model Views Product Information Section Model Views i02869409 Model View Illustrations 1103D Engine Model Views Illustration 12 g01439632 Typical example (1) Front lifting eye (4) Fuel filter (8) Oil filter (horizontal installation) (2) Water temperature regulator housing... - Page 17 The left and the right sides of the engine are determined from the flywheel end. The number 1 cylinder is the front cylinder. Perkins Engines are designed for the following applications: machine and industrial mobile equipment. The engines are available in the following types of aspiration: •...
- Page 18 Engine Service Life (B) Exhaust valves Engine efficiency and maximum utilization of engine Table 1 performance depend on the adherence to proper 1103D Industrial Engine Specifications operation and maintenance recommendations. In addition, use recommended fuels, coolants and Number of Cylinders 3 In-Line lubricants.
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Page 19: Product Identification Information
Information i02813999 Engine Identification Perkins engines are identified by a serial number. This number is shown on a serial number plate that is mounted on the left hand side of the engine block. An example of an engine number is XK12345U090001P. - Page 20 SEBU8352-02 Product Information Section Emissions Certification Film 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.
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Page 21: 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 22 SEBU8352-02 Operation Section Product Storage 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. Allow the coolant to drain. Install the drain plugs.
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Page 23: 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 24: Features And Controls
SEBU8352-02 Operation Section Features and Controls Features and Controls i02690464 Fuel Shutoff The fuel shutoff solenoid 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 “Closed”... -
Page 25: Engine Starting
SEBU8352-02 Operation Section Engine Starting Engine Starting • 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 start switch or i02675151 to the controls. Before Starting Engine •... - Page 26 SEBU8352-02 Operation Section Cold Weather Starting 1. If equipped, move the throttle lever to the full NOTICE throttle position before you start the engine. Do not crank the engine for more than 30 seconds. Allow the electric starting motor to cool for two mi- NOTICE nutes before cranking the engine again.
- Page 27 SEBU8352-02 Operation Section After Starting Engine Note: If it is possible, first diagnose the reason for the i06791278 starting failure. Make any necessary repairs. If the After Starting Engine engine will not start only due to the condition of the battery, either charge the battery, or start the engine with jump start cables.
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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
SEBU8352-02 Operation Section Engine Stopping Engine Stopping i02818879 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
Cold Weather Operation • Install the correct specification of engine lubricant before the beginning of cold weather. Perkins Diesel Engines can operate effectively in • Check all rubber parts (hoses, fan drive belts.) cold weather. During cold weather, the starting and weekly. - Page 31 An electric block heater can be activated once the • Pushrods may become bent. engine is stopped. An effective block heater is typically a 1250/1500 W unit. Consult your Perkins • Other damage to valve train components can dealer or your Perkins distributor for more result.
- Page 32 Pour point is the last temperature before the fuel flow dissipation. stops and waxing of the fuel will start. Note: Perkins discourages the use of all air flow Be aware of these properties when diesel fuel is restriction devices such as radiator shutters.
- Page 33 SEBU8352-02 Operation Section Fuel Related Components in Cold Weather i01903588 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.
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Page 34: Maintenance Section
SEBU8352-02 Maintenance Section Refill Capacities Maintenance Section 1103D Engine Table 3 Refill Capacities 1103D Naturally Aspirated Engine without an oil cooler Compartment or System Quarts Liters i02814021 Engine Only 4.21 Refill Capacities External cooling system capacity (OEM recommendation) Total Cooling System... - Page 35 1 oils. This feature reduces the variation in CD-2 performance that can occur when base stocks are The oil CD-2 is for a two-cycle diesel engine. Perkins does not changed in commercial oil formulations. sell engines that utilize CD-2 oil.
- Page 36 1.5 percent: intervals. API CH-4 oils are recommended for conditions that demand a premium oil. Your Perkins • Choose an oil with the highest TBN that meets dealer or your Perkins distributor has specific one of these classifications: EMA DHD-1 and API guidelines for optimizing oil change intervals.
- Page 37 Aftermarket Oil Additives Perkins does not recommend the automatic extending of the oil change intervals for any type of Perkins does not recommend the use of aftermarket oil. additives in oil. It is not necessary to use aftermarket additives in order to achieve the engine's maximum Re-refined Base Stock Oils service life or rated performance.
- Page 38 To achieve the best performance from a Perkins engine, conform to the following guidelines: i02883936 • Select the correct oil, or a commercial oil that Fluid Recommendations meets the “EMA Recommended Guideline on...
- Page 39 SEBU8352-02 Maintenance Section Fluid Recommendations This is an indication of the mixture of different These fuels need additives to achieve lubricity of 650 hydrocarbons in the fuel. A high ratio of light weight micrometers wear scar and the reliability of the fuel hydrocarbons can affect the characteristics of pump and fuel injectors will be reduced.
- Page 40 10% at 282 °C (540 °F) maximum NOTICE Distillation “D86” Operating with fuels that do not meet the Perkins rec- 90% at 360 °C ommendations can cause the following effects: Start- (680 °F) ing difficulty, poor combustion, deposits in the fuel maximum...
- Page 41 SEBU8352-02 Maintenance Section Fluid Recommendations These fuels are lighter than the No. 2 grades of fuel. Many engine failures are related to the cooling The cetane number of the fuels in Table 9 must be at system. The following problems are related to cooling least 40.
- Page 42 • Formation of gel compounds Coolant Recommendations • Reduction of heat transfer The following two coolants are used in Perkins diesel engines: • Leakage of the water pump seal Preferred – Perkins Extended Life Coolant (ELC) •...
- Page 43 SEBU8352-02 Maintenance Section Fluid Recommendations Table 13 Coolant Service Life Containers of several sizes are available. Consult your Perkins dealer or your Perkins distributor for the Coolant Type Service Life part numbers. 6,000 Service Hours or Three Perkins ELC ELC Cooling System Maintenance...
- Page 44 Then, fill the cooling system with premixed ELC. 4. Use Perkins cleaner to clean the system. Follow This should lower the contamination to less than the instruction on the label. 10 percent.
- Page 45 15 L (4 US gal) × 0.014 0.2 L (7 oz) Use the equation that is in Table 15 to determine the amount of Perkins SCA that is required when the cooling system is initially filled. Cleaning the System of Heavy-Duty Table 15...
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Page 46: Maintenance Interval Schedule
SEBU8352-02 Maintenance Section Maintenance Interval Schedule “ Radiator - Clean” ......67 i02818827 Maintenance Interval Schedule Every 1000 Service Hours “... - Page 47 SEBU8352-02 Maintenance Section Aftercooler Core - Clean/Test i02690449 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 48 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 21 g01003936 alternator. Inspect the alternator for loose Typical example connections and correct battery charging.
- Page 49 SEBU8352-02 Maintenance Section Battery - Replace 2. Move the alternator in order to increase or 6. Install the new battery. decrease the belt tension. Tighten the alternator Note: Before the cables are connected, ensure that pivot bolt and the link bolt to 22 N·m (16 lb ft).(1). the engine start switch is OFF.
- Page 50 SEBU8352-02 Maintenance Section Battery or Battery Cable - Disconnect i07819485 i05901701 Battery or Battery Cable - Cooling System Coolant Disconnect (Commercial Heavy-Duty - Change NOTICE The battery cables or the batteries should not be Care must be taken to ensure that fluids are con- removed with the battery cover in place.
- Page 51 Operation and Maintenance Manual, “Fluid Recommendations” topic (Maintenance Section) For information regarding the disposal and the for more information on cooling system recycling of used coolant, consult your Perkins dealer specifications. Do not install the cooling system or your Perkins distributor. filler cap.
- Page 52 ELC is drained and ant for reuse in engine cooling systems. The full distil- replaced. lation procedure is the only method acceptable by Perkins to reclaim the coolant.
- Page 53 Remove the cooling system filler cap. Open the drain cock or remove In order for Perkins ELC to achieve 12000 hours an the drain plug on the engine. Open the drain cock extender must be added at 6000 hours. For a or remove the drain plug on the radiator.
- Page 54 SEBU8352-02 Maintenance Section Cooling System Coolant Level - Check 1. Observe the coolant level in the coolant recovery Note: The coolant will expand as the coolant heats up during normal engine operation. The additional tank. Maintain the coolant level to “COLD FULL” volume will be forced into the coolant recovery tank mark on the coolant recovery tank.
- Page 55 Note: The air filter system may not have been provided by Perkins. The procedure that follows is for Make sure that the electrical system is OFF. Lock a typical air filter system. Refer to the OEM out the starting controls and tag the controls “ “ DO information for the correct procedure.
- Page 56 SEBU8352-02 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace Replace the dirty air cleaner elements with clean air 5. Remove the tape for the air inlet. Install the cleaner elements. Before installation, the air cleaner secondary air cleaner element. Install a primary air elements should be thoroughly checked for tears cleaner element that is new or cleaned.
- Page 57 SEBU8352-02 Maintenance Section Engine Air Cleaner Element (Single Element) - Inspect/Replace Pressurized Air Inspecting the Primary Air Cleaner Elements Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times. Pressurized air will not remove deposits of carbon and oil.
- Page 58 Any engine mount that shows deterioration should be replaced. Refer to the OEM information for the recommended torques. When the engine mounts are supplied by Perkins the maintenance procedure will be supplied in the Disassembly and Assembly manual for your engine.
- Page 59 SEBU8352-02 Maintenance Section Engine Oil Sample - Obtain 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 used. The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation.
- Page 60 Use of an oil filter that is not recommended by Perkins could result in severe damage to the en- Failure to follow this recommended procedure will gine bearings, crankshaft, etc., as a result of the larg-...
- Page 61 SEBU8352-02 Maintenance Section Engine Oil and Filter - Change Illustration 34 g02659217 Illustration 33 g01356034 Typical example (2) Filter head (3) O ring seal Fill the Engine Crankcase 3. Clean the sealing surface of the oil filter head (2). Ensure that the union (4) in the oil filter head is 1.
- Page 62 NOTICE Only qualified service personel should perform this maintenance. Refer to the Service Manual or your au- thorized Perkins dealer or your Perkins distributor for the complete valve lash adjustment procedure. Operation of Perkins engines with incorrect valve lash can reduce engine efficiency, and also reduce engine component life.
- Page 63 Disassembly and Assembly Manual for more below: information. Consult your authorized Perkins dealer or your Perkins distributor for assistance. • The engine will not start or the engine is difficult to start.
- Page 64 Note: In order to purge air from the fuel injection pump on Perkins engines with a fixed throttle, the engine should be run at full load for thirty seconds. This should be repeated three times. This will assist in removing trapped air from the fuel injection pump.
- Page 65 SEBU8352-02 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 1. Turn the fuel supply valve (if equipped) to the OFF i02875191 position. Fuel System Primary Filter 2. Place a suitable container under the water (Water Separator Element - separator.
- Page 66 SEBU8352-02 Maintenance Section Hoses and Clamps - Inspect/Replace Spin-on filter Turn the valves for the fuel lines (if equipped) to the OFF position before performing this maintenance. Place a tray under the fuel filter in order to catch any fuel that might spill. Clean up any spilled fuel immediately.
- Page 67 Refer to the OEM information for further information on removing and replacing fuel hoses (if equipped). The radiator is not usually supplied by Perkins. The The coolant system and the hoses for the coolant following text describes a typical cleaning procedure system are not usually supplied by Perkins.
- Page 68 Refer to the standards for the engine or consult your the fan's air flow. Hold the nozzle approximately Perkins dealer or your Perkins distributor in order to 6 mm (0.25 inch) away from the radiator fins. Slowly determine if the engine is operating within the defined move the air nozzle in a direction that is parallel with parameters.
- Page 69 Perkins dealer or your Test” for more information on the checking procedure Perkins distributor. Refer to the Disassembly and and for specifications consult your Perkins dealer or Assembly Manual, “Turbocharger - Remove and your Perkins distributor for assistance.
- Page 70 Disassembly and Assembly Manual, “Water Pump - Remove and Install” for more pipe to the turbocharger housing. information or consult your Perkins dealer or your Perkins distributor. i02177973 • Inspect the lubrication system for leaks at the front...
- Page 71 SEBU8352-02 Maintenance Section Water Pump - Inspect Note: The water pump seal is lubricated by the coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and parts contract. Visually inspect the water pump for leaks.
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Page 72: 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 73: Index
SEBU8352-02 Index Section Index After Starting Engine ........27 Driven Equipment - Check ......55 After Stopping Engine ........29 Aftercooler Core - Clean/Test......47 Aftercooler Core - Inspect ....... 47 Electrical System..........15 Alternator - Inspect .......... 48 Grounding Practices ........15 Alternator and Fan Belts - Inspect/Adjust/ Emergency Stopping........ - Page 74 Maintenance Section........34 Removal and Installation of the Fuel Model View Illustrations ........16 Injectors ............. 63 1103D Engine Model Views......16 Fuel Related Components in Cold Weather ... 33 Model Views ............ 16 Fuel Filters ........... 33 Mounting and Dismounting ......13 Fuel Heaters ..........
- Page 75 SEBU8352-02 Index Section Incorrect Operating Procedures ....68 Starting Motor - Inspect ........69 Starting the Engine.......... 25 Starting with Jump Start Cables...... 26 Stopping the Engine ........29 Table of Contents ..........3 Turbocharger - Inspect (If Equipped) ....69 Inspecting ............
- Page 77 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 78 SEBU8352 ©2021 Perkins Engines Company Limited All Rights Reserved January 2021...