Perkins Engine 1103D Service Manual

Operation and Maintenance Manual

SEBU8352

January 2008

1103D Industrial Engine

(Engine)

XK XL

(Engine)

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions 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.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

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 information, specifications, and illustrations in this publication are on the basis of information 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 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.

Failure to heed this warning can lead to premature failures, product damage, personal injury or

death.

SEBU8352 3

Table of Contents

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

Safety Section

Safety Messages .................................................... 5

General Hazard Information ................................... 6

Burn Prevention ...................................................... 8

Fire Prevention and Explosion Prevention .............. 8

Crushing Prevention and Cutting Prevention ........ 10

Mounting and Dismounting ................................... 10

Before Starting Engine .......................................... 10

Engine Starting ...................................................... 11

Engine Stopping .................................................... 11

Electrical System ................................................... 11

Index Section

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

Product Information Section

Model Views ......................................................... 13

Product Identiﬁcation Information ........................ 16

Operation Section

Lifting and Storage ................................................ 19

Gauges and Indicators .............................. ............ 22

Features and Controls .......................................... 23

Engine Starting ..................................................... 24

Engine Operation .................................................. 27

Engine Stopping ................................................... 28

Cold Weather Operation ....................................... 29

Maintenance Section

Reﬁll Capacities .................................................... 33

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

Warranty Section

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

4 SEBU8352 Foreword

Foreword

Literature Information

This manual con lubrication and maintenance information. This manual should be stored in or near the engine area in a literatur study and keep it with the literature and engine information.

English is the primary language for all Perkins publications. The English used facilitates translation and consiste

Some photographs or illustrations in this manual show details from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvemen may have caused changes to your engine which are not included in this manual. Whenever a question arises reg consult with your Perkins dealer or your Perkins distributor for the latest available information.

Safety

This safety section lists basic safety precautions. In addition, this section identiﬁes hazardous, warning si precautions listed in the safety section before operating or performing lubrication, maintenance and repair on

this product.

tains safety, operation instructions,

e holder or literature storage area. Read,

ncy.

or attachments that may be different

t and advancement of product design

arding your engine, or this manual, please

tuations. Read and understand the basic

Recommended se appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine a Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequen speciﬁed in the Maintenance Interval Schedule may be necessary.

The maintenance schedule items are organized for a preventive maintenance management program. If the prevent periodic tune-up is not required. The implementation of a preventive maintenance management program should mini avoidances resulting from reductions in unscheduled downtime and failures.

ive maintenance program is followed, a

mize operating costs through cost

rvice should be performed at the

lso governs the Maintenance Interval

t lubrication and maintenance than is

Maintenance Intervals

Perform maintenance on items at multiples of the original requirement. We recommend that the maintenan near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of

Your authorized Perkins dealer or your Perkins distribu maintenance schedule to meet the needs of your operating environment.

ce schedules be reproduced and displayed

the engine’s permanent record.

tor can assist you in adjusting your

Overhaul

Operatio

Operating techniques outlined in this manual are basic. Th techniques required to operate the engine more efﬁciently and economically. Skill and techniques develop engine and its capabilities.

The oper Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and sto discussion of electronic diagnostic information.

ey assist with developing the skills and

as the operator gains knowledge of the

ation section is a reference for operators.

pping the engine. This section also includes a

Maintenance

The mai The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance interv referenced to detailed instructions that follow.

ntenance section is a guide to engine care.

als. Items in the maintenance schedule are

Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the i interval. Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer or your P regarding overhaul programs. If you experience a major engine failure, there are also numerous after f your Perkins dealer or your Perkins distributor for information regarding these options.

nterval and the maintenance items in that

erkins distributor offers a variety of options

ailure overhaul options available. Consult with

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer,

defects, and other reproductive harm. Battery

birth posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

SEBU8352 5

Safety Section

Safety Messages

Safety Section

i02811420

Safety Messages

There may be s engine. The exact location and a description of the warning signs are reviewed in this section. Please become famil

Ensure that all of the warning signs are legible. Clean the warning s the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the warning other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the warning si could drop off of the engine.

Replace an missing.Ifawarningsignisattachedtoapartofthe engine that is replaced, install a new warning sign on the replac distributor can provide new warning signs.

everal speciﬁc warning signs on your

iar with all warning signs.

igns or replace the warning signs if

signs. Do not use solvents, gasoline, or

gns. The warning signs that are loosened

y warning sign that is damaged or

ement part. Your Perkins dealer or your

(1) Un iversal Warning

Do not operate or work on this equipment unless you have r and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the or death.

ead and understand the instructions

warnings could result in serious injury

Illustration 1

lexample

Typica

The Universal Warning label (2) is located on the rear end of t

he inlet manifold cover. Refer to illustration 2.

g01154807

6 SEBU8352 Safety Section General Hazard Information

Illustration 2

(1) Ether

Warning Label

(2) Unive

rsal warning

(2) Ether

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and

ration 3

l injury.

g01154809

persona

Illust

Typical example

g01431463

i0232843

General Hazard Information

Illustration 4

Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before

you service the equipment or before you

repair the equipment.

g00104

545

The ether warning label (1) is located on the front end of the inlet manifold cover. Refer to illustration 2.

SEBU8352 7

Safety Section

General Hazard Information

Illustration 5

Wear a hard hat, protective glasses, and other protective equipment, as required.

Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine.

Make sure that all protective guards and all covers are secured in place on the engine.

Keep the engine free from foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, and from steps.

g00702020

When pressuriz cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protectiv

The maximum air pressure for cleaning purposes must be below water pressure for cleaning purposes must be below 275 kPa (40 psi).

ed air and/or water is used for

efaceshield.

205 kPa (30 psi). The maximum

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydrau escape rapidly if the pressure is not relieved correctly.

Do not remove until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve th

lic ﬂuid or items such as pipe plugs to

any hydraulic components or parts

or parts until pressure has been relieved

e hydraulic pressure.

Never put maintenance ﬂuids into glass containers. Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care.

Report all necessary repairs.

Do not allow unauthorized personnel on the equipment.

Ensure that the power supply is disconnected before you work on the bus bar or the glow plugs.

Perform maintenance on the engine with the equipment in the servicing position. Refer to the OEM information for the procedure for placing the equipment in the servicing position.

Pressure Air and Water

Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury.

The direct application of pressurized air or pressurized water to the body could result in personal injury.

Illustration 6

Always use a board or cardboard when you check for a leak. Leaking ﬂuid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If ﬂuid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

g00687600

Containing Fluid Spillage

Care must be taken in order to ensure that ﬂuids are contained during performance of inspection, maintenance, testing, adjusting and repair of the engine. Make provision to collect the ﬂuid with a suitable container before any compartment is opened or before any component is disassembled.

Only use the tools that are suitable for collecting

•

ﬂuids and equipment that is suitable for collecting ﬂuids.

8 SEBU8352 Safety Section Burn Prevention

Only use the too

•

ﬂuids and equipment that is suitable for containing ﬂuids.

Obey all local regulations for the disposal of liquids.

ls that are suitable for containing

i02143195

Burn Prevention

Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine. Relieve all pressure in the air system, in the hydraulic system, in the lubrication system, in the fuel system, or in the cooling system before any lines, ﬁttings or related items are disconnected.

Coolant

When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant.

Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained.

Check the coolant level after the engine has stopped and the engine has been allowed to cool.

i02813488

Fire Prevention and Explosion Prevention

on 7

Illustrati

All fuels, most lubricants, and some coolant mixtures are ﬂammabl

Flammable ﬂuids that are leaking or spilled onto hot surfaces or a ﬁre. Fire may cause personal injury and property damage.

A ﬂash ﬁre may result if the covers for the engine crankcase are removed within ﬁfteen minutes after an emergen

onto electrical components can cause

cy shutdown.

g00704000

Ensure that the ﬁller cap is cool before removing the ﬁller cap. The ﬁller cap must be cool enough to touch withabarehand.Removetheﬁller cap slowly in order to relieve pressure.

Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.

Oils

Hot oil and hot lubricating components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not allow hot components to contact the skin.

Batteries

Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended.

Determinewhethertheenginewillbeoperatedinan environme drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, property

If the application involves the presence of combustible gases, co 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 engi materials or conductive materials to accumulate on the engine.

Store fuels and lubricants in correctly marked containers away from unauthorized persons. Store oily rag containers. Do not smoke in areas that are used for storing ﬂammable materials.

Do not expose the engine to any ﬂame.

nt that allows combustible gases to be

damage, or engine damage could result.

nsult your Perkins dealer and/or your

ne. Do not allow any ﬂammable combustible

s and any ﬂammable materials in protective

SEBU8352 9

Safety Section

Fire Prevention and Explosion Prevention

Exhaust shield

s (if equipped) protect hot exhaust components from oil or fuel spray in case of a line, a tube, or a seal failure. Exhaust shields must be installed cor

rectly.

Do not weld on lines or tanks that contain ﬂammable

ﬂuids. Do not

ﬂame cut lines or tanks that contain

ﬂammable ﬂuid. Clean any such lines or tanks

thoroughly with a nonﬂammable solvent prior to welding or ﬂ a

me cutting.

Wiring must be kept in good condition. All electrical wires must be

correctly routed and securely attached. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Cle

an all electrical connections and tighten

all electrical connections.

Eliminate a

ll wiring that is unattached or unnecessary. Do not use any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or cir

cuit breakers.

Arcing or sparking could cause a ﬁre. Secure connectio

ns, recommended wiring, and correctly maintained battery cables will help to prevent arcing or sparking.

Inspect all lines and hoses for wear or for deterioration. The hoses must be correctly routed. The lines

and hoses must have adequate support and secure clamps. Tighten all connections to the recommended torque. Leaks can cause ﬁres.

Oil ﬁlters and fuel ﬁlters must be correctly installed. The ﬁlter housings must be tightened to the correct torque.

Use caution whe

n you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open ﬂames or sparks. Always stop the engin

Illustration 9

e before refueling.

g00704135

Gases from a battery can explode. Keep any open ﬂames or sparks away from the top of a battery. Do not smoke in battery charging areas.

Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or ahydrometer.

Incorrect jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for speciﬁc instructions.

Illustration 8

Do not charge a frozen battery. This may cause an explosion.

The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the recommended cables, connections, and battery box covers when the engine is operated.

Fire Extinguisher

Make sure that a ﬁre extinguisher is available. Be familiar with the operation of the ﬁre extinguisher. Inspect the ﬁre extinguisher and service the ﬁre extinguisher regularly. Obey the recommendations on the instruction plate.

g00704059

10 SEBU8352 Safety Section Crushing Prevention and Cutting Prevention

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not install any lines that are bent or damaged. Do not clip any other items to the high pressure line

Repair any lines that are loose or damaged. Leaks can cause ﬁre Perkins distributor for repair or for replacement parts.

Check lines, your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recomm

Replace the parts if any of the following conditions are present:

End ﬁttings are damaged or leaking.

•

Outer coverings are chafed or cut.

•

Wires are ex

•

Outer coverings are ballooning.

•

pressure lines. Do not strike high

s. Consult your Perkins dealer or your

tubes and hoses carefully. Do not use

ended torque.

posed.

When objects ar order to avoid injury to the eyes.

Chips or other are struck. Before objects are struck, ensure that no one will be injured by ﬂying debris.

e struck, wear protective glasses in

debris may ﬂy off objects when objects

i01372247

Mounting and Dismounting

Inspect the steps, the handholds, and the work area before mounting the engine. Keep these items clean and keep these items in good repair.

Mount the engine and dismount the engine only at locations that have steps and/or handholds. Do not climb on the engine, and do not jump off the engine.

Face the engine in order to mount the engine or dismount the engine. Maintain a three-point contact with the steps and handholds. Use two feet and one hand or use one foot and two hands. Do not use any controls as handholds.

Flexible part of the hoses are kinked.

•

Outer cover

•

End ﬁttings are displaced.

•

Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, this will help to parts, and excessive heat.

Crushing P

s have embedded armoring.

prevent vibration, rubbing against other

i02143194

revention and

Cutting Prevention

Support the component correctly when work beneath the compon

Unless other maintenance instructions are provided, never att running.

Stay clea parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, reinstal

Keep objects away from moving fan blades. The fan blades w

ent is performed.

empt adjustments while the engine is

r of all rotating parts and of all moving

l the guards.

ill throw objects or cut objects.

Do not stand on components which cannot support your weight. Use an adequate ladder or use a work platform. Secure the climbing equipment so that the equipment will not move.

Do not carry tools or supplies when you mount the engine or when you dismount the engine. Use a hand line to raise and lower tools or supplies.

i02813489

Before Starting Engine

Before the initial start-up of an engine that is new, serviced or repaired, make provision to shut the engine off, in order to stop an overspeed. This may be accomplished by shutting off the air and/or fuel supply to the engine.

Overspeed shutdown should occur automatically for engines that are controlled electronically. If automatic shutdown does not occur, press the emergency stop button in order to cut the fuel and/or air to the engine.

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel.

SEBU8352 11

Safety Section

Engine Starting

If equipped, en engine is suitable for the conditions. Ensure that all lights work correctly, if equipped.

All protective guards and all protective covers must be installed if the engine must be started in order to perform se accident that is caused by parts in rotation, work around the parts carefully.

Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are provided in o circuits are also provided in order to help prevent engine damage.

See the Service Manual for repairs and for adjustments.

sure that the lighting system for the

rvice procedures. To help prevent an

rder to help prevent personal injury. The

i02207232

Engine Starting

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.

If a warning tag is attached to the engine start switch or to the controls, DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.

Engine exhaust which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the en vent the engine exhaust to the outside.

Note: The eng device for cold starting for normal conditions of operation. If the engine will be operated in very cold conditions, required. Normally, the engine will be equipped with the correct type of starting aid for your region of operation.

The engines are equipped with a glow plug starting aidineachi air in order to improve starting.

contains products of combustion

gine is started in an enclosed area,

ine is equipped with an automatic

then an extra cold starting aid may be

ndividual cylinder that heats the intake

i01928905

Engine Stopping

Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine components.

Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected.

All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.

Start the engine from the operator’s compartment or from the engine start switch.

Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Knowing the correct procedure will help to prevent major damage to the engine components. Knowing the procedure will also help to prevent personal injury.

To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is working correctly, check the water temperature gauge and the oil temperature gauge during the heater operation.

Stop the engine if an overspeed condition occurs during the initial start-up of a new engine or an engine that has been overhauled. This may be accomplished by shutting off the fuel supply to the engine and/or shutting off the air supply to the engine.

i02176668

Electr

Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is oper gases that are produced by some batteries to ignite.

To help gases that are produced by some batteries, the negative “−” jump start cable should be connected last f “−” terminal of the starting motor. If the starting motor is not equipped with a negative “−” terminal, connect the ju

ical System

ating. A spark can cause the combustible

prevent sparks from igniting combustible

rom the external power source to the negative

mp start cable to the engine block.

12 SEBU8352 Safety Section Electrical System

Check the elect loose or frayed. Tighten all loose electrical wires before the engine is started. Repair all frayed electrical wi the Operation and Maintenance Manual for speciﬁc starting instructions.

rical wires daily for wires that are

res before the engine is started. See

Grounding Practices

Correct grounding for the engine electrical system is necessary for optimum engine performance and reliabil uncontrolled electrical circuit paths and in unreliable electrical circuit paths.

Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft bearing journal sur

Engines that are installed without engine-to-frame ground stra discharge.

To e ns u re t systems function correctly, an engine-to-frame ground strap with a direct path to the battery must be used. This engine ground to the frame.

ity. Incorrect grounding will result in

faces, and to aluminum components.

ps can be damaged by electrical

hat the engine and the engine electrical

path may be provided by way of a direct

All ground engine alternator must be grounded to the negative “-” battery terminal with a wire that is adequate to handle th

s should be tight and free of corrosion. The

e full charging current of the alternator.

SEBU8352 13

Product Information Section

Model Views

Product Information Section

Model Views

i02869409

Model View Illustrations

1103D Engine Model Views

Illustration 10

Typical example

(1) Front lifting eye (2) Water temperature regulator housing

(horizontal outlet)

(3) Fuel priming pump

(4) Fuel ﬁlter (5) B reather tube (6) Water pump (7) S tarting motor

g01439632

(8) Oil ﬁlter (horizontal installation) (9) Cran kshaft pulley (10) Oil pan

14 SEBU8352 Product Information Section Model Views

Illustration 11

Typical example

(11) Inlet manifold adapter (12) Top cover (13) Exhaust manifold

(14) Turbocharger (if equipped) (15) Turbocharger oil supply (if equipped) (16) Turbocharger oil return (if equipped)

i02813494

Engine Description

Perkins 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

•

Naturally aspirated

•

g01434352

(17) Rear lifting eye (18) F lywheel housing (19) Flywheel

Engine Speciﬁcations

Note: The front end of the engine is opposite the

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.

SEBU8352 15

Product Information Section

Model Views

Illustration 12

A typical example of the layout of the valves

(A) Inlet valv es (B) Exhaust v alves

Table 1

1103D Industrial Engine Speciﬁcations

Number of Cylinders

Bore

Stroke 127 mm (5.0 inch)

Aspiration Turbocharged

Compression Ratio

Displacement 3.3 L (201 in3)

Firing Order

Rotation (ﬂywheel end) Counterclockwise

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

3 In-Line

105 mm (4.134 inch)

Naturally aspirated

NA 19.25:1

T 18.25:1

123

0.45 mm (0.018 inch)

g01222531

The engine lubr

icating oil is supplied to the engine by a gear-driven pump. The engine lubricating oil is cooled and the engine lubricating oil is ﬁltered. Bypass valves

provide unrestricted ﬂow of lubrication oil to the engine parts when oil viscosity is high. Bypass valves can also provide unrestricted ﬂow of lubricati

on oil to the 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 proper operation a

nd maintenance recommendations. Engine performance and efﬁciency also depend on the use of recommended fuels, lubrication oils, and coolants. R

efer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information on maintenance items.

Engine Service Life

Engine efﬁciency and maximum utilization of engine performance depend on the adherence to proper operation addition, use recommended fuels, coolants and lubricants. Use the Operation and Maintenance Manual as

Expected engine life is generally predicted by the average p that is demanded is based on fuel consumption of the engine over a period of time. Reduced hours of operatio throttle settings result in a lower average power demand. Reduced hours of operation will increase the leng overhaul is required.

and maintenance recommendations. In

a guide for required engine maintenance.

ower that is demanded. The average power

n at full throttle and/or operating at reduced

th of operating time before an engine

Engine Cooling and Lubrication

The cooling system consists of the following components:

Gear-driven centrifugal water pump

•

Water temperature regulator which regulates the

•

engine coolant temperature

Gear-driven oil pump (gear type)

•

Oil cooler

•

16 SEBU8352 Product Information Section Product Identiﬁcation Information

Product Identiﬁcation 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.

__________________________________________ Type of engine

XK12345

____________________________ Built in the United Kingdom

090001

_____________________________________ Year of Manufacture

____________________________ Engine List Number

___________________________ Engine Serial Number

Perkins distributors need these numbers in order to determine the components 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 engine block above the fuel injection pump.

Illustration 13

Location of serial number plate

Illustration 14

Typical serial number plate

(1) Temporary Parts List number (2) List numb er (3) Serial number (4) Type

g01431025

g01431032

The following information is stamped on the Serial Number Plate: Engine serial number, Model, and Arrangement number.

SEBU8352 17

Product Information Section

Product Identiﬁcation Information

i02164876

Reference Numbers

S/N: XK11-Up

S/N: XL11-Up

Information for the following items may be needed to order parts. Locate the information for your engine. Record the inf Make a copy of this list for a record. Keep the information for future reference.

Record for Reference

Engine Model _______________________________________________

ormation in the appropriate space.

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 _______________________________

Total Lubrication System Capacity _____________________

Total Coolin

g System Capacity

_________________________

Air Cleaner Element _______________________________________

Fan Drive Belt _ _____________________________________________

______________________________________________

Alternator B

elt

18 SEBU8352 Product Information Section Product Identiﬁcation Information

i02869408

Emissions Certiﬁcation Film

Illustration 15

Typical example

g01350379

SEBU8352 19

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

i02677363

Product Lifting

Illustration 16

NOTICE Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees.

When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight.

g00103219

i02677364

Product Storage

Table 2

Required Tools

Part

Tool

If the engine will not be started for several weeks, the lubricating oil will drain from the cylinder walls and from the piston rings. Rust can form on the cylinder walls. Rust on the cylinder walls will cause increased engine wear and a reduction in engine service life.

Number Part Descript

1772204

1762811

1734115

POWERPART Lay-Up 1

POWERPART Lay-Up 2

POWERPART Lay-Up 3

Lubrication System

To help prevent excessive engine wear, use the following guidelines:

Complete all of the lubrication recommendations that are listed in this Operation and Maintenance Manual, “Maintenance Interval Schedule” (Maintenance Section).

If an engine is out of operation and if use of the engine is not planned, special precautions should be made. If the engine will be stored for more than one month, a complete protection procedure is recommended.

Use the following guidelines :

ion

Qty

Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted.

Some removals require lifting the ﬁxtures in order to obtain proper balance and safety.

ToremovetheengineONLY,usetheliftingeyesthat are on the engine.

Lifting eyes are designed and installed for speciﬁc engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting ﬁxtures obsolete. If alterations are made, ensure that proper lifting devices are provided. Consult your Perkins dealer for information regarding ﬁxtures for proper engine lifting.

Completely clean the outside of the engine.

•

Drain the fuel system completely and reﬁll the

•

system with preservative fuel. Tooling (A) can be mixed with the normal fuel in order to change the fuel into preservative fuel.

If preservative fuel is not available, the fuel system

•

can be ﬁlled with normal fuel. This fuel must be discarded at the end of the storage period together with the fuel ﬁlter elements.

Operate the engine until the engine reaches normal

•

operating temperature. Stop any leaks from fuel, lubricating oil or air systems. Stop the engine and drain the lubricating oil from the oil pan.

Renew the canister(s) of the lubricating oil ﬁlter.

•

20 SEBU8352 Operation Section Lifting and Storage

Fill the oil pan

•

new, clean lubricating oil. Add Tooling (B) to the oil in order to protect the engine against corrosion. If Tooling (B) is the correct speciﬁcation instead of the lubricating oil. If a preservative is used, this must be drained completely a theoilpanmustbereﬁlled to the correct level with normal lubricating oil.

to the Full Mark on the dipstick with

not available, use a preservative of

t the end of the storage period and

Cooling System

To help prevent excessive engine wear, use the following guidelines:

NOTICE Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can

If freezing temperatures are expected, check the cooling sys freezing. See this Operation and Maintenance Manual, “General Coolant Information” (Maintenance Section).

To prevent frost damage, ensure that all the coolant is removed fro tem is drained after it has been ﬂushed with water, or if an antifreeze solution too weak to protect the system from frost

be discharged.

tem for adequate protection against

NOTICE

m the engine. This is important if the sys-

has been used.

3. Remove the drai cylinder block in order to drain the engine. Ensure that the drain hole is not restricted.

4. Open the tap or remove the drain plug at the bottom of the radiator in order to drain the radiator. If the radiat disconnect the hose at the bottom of the radiator.

5. Flush the coo

6. Fit the drain plugs and the ﬁller cap. Close the tap

or connect th

7. Fill the cooling system with an approved antifreeze mixture beca corrosion.

Note: Certai damage to some engine components. Contact the Service Department of Perkins for advice.

8. Operate the engine for a short period in order to circulate the lubricating oil and the coolant in the engine.

9. Disconnect the battery. Put the battery into safe storage in a battery is put into storage, protect the terminals against corrosion. Tooling (C) can be used on the terminals

10. Clean the crankcase breather if one is installed. Seal the en

n corrosion inhibitors could cause

nplug(1)fromthesideofthe

or does not have a tap or a drain plug,

ling system with clean water.

e radiator hose.

use this gives protection against

fully charged condition. Before the

d of the pipe.

Illustration 17

1. Ensure that the vehicle is on level ground.

2. Remove the ﬁller cap of the cooling system.

g01356026

11. Remove the fuel injector nozzles and spray To o li ng ( cylinder bore with the piston at BDC.

12. Slowly ro revolution and then replace the fuel injector nozzles.

B) for one or two seconds into each

tate the crankshaft for one complete

Induction System

Remove the air ﬁlter assembly. If necessary,

•

remove the pipes that are installed between the air ﬁlter ass (B) into the turbocharger. The duration of the spray is printed on the container. Seal the turbocharger with wat

Exhaust

Remove the exhaust pipe. Spray Tooling (B) into

•

the turb printed on the container. Seal the turbocharger with waterproof tape.

embly and the turbocharger. Spray Tooling

erproof tape.

System

ocharger. The duration of the spray is

SEBU8352 21

Operation Section

Lifting and Storage

General Items

If the lubricating oil ﬁller is installed on the rocker

•

cover, remove the ﬁller cap. If the lubricating oil ﬁller cap is not installed on the rocker cover, remove the rocker cover. Spray Tooling (B) around the rocker shaft assembly. Replace the ﬁller cap or the rocker cover.

Seal the vent of the fuel tank or the fuel ﬁller cap

•

with waterproof tape.

Remove the alternator drive belts and put the drive

•

belts into storage.

In order to prevent corrosion, spray the engine

•

with Tooling (C). Do not spray the area inside the alternator.

When the engine protection has been completed in accordance with these instructions, this ensures that no corrosion will occur. Perkins are not responsible for damage which may occur when 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.

22 SEBU8352 Operation Section Gauges and Indicators

Gauges and Ind icators

i02164190

Gauges and Indicators

Your engine m the gauges that are described. For more information about the gauge package, see the OEM information.

Gauges provide indications of engine performance. Ensure that the gauges are in good working order. Determine th the gauges over a period of time.

Noticeable c potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the r Determine and correct the cause of any signiﬁcant change in the readings. Consult your Perkins dealer or your Per

If no oil pressure is indicated, STOP the engine. If maximum co the engine. Engine damage can result.

SAE10W30 rpm.

ay not have the same gauges or all of

e normal operating range by observing

hanges in gauge readings indicate

eadings are within speciﬁcations.

kins distributor for assistance.

NOTICE

olant temperature is exceeded, STOP

Engine Oil

should be greatest after a cold engine is started. The typical engine oil pressure with

is 207 to 413 kPa (30 to 60 psi) at rated

Pressure – The oil pressure

1. Reduce the load

2. Inspect the cooling system for leaks.

3. Determine if the engine must be shut down

immediately or if the engine can be cooled by reducing the l

Tachometer – This gauge indicates engine speed (rpm). W

ismovedtothefullthrottlepositionwithout load, the engine is running at high idle. The engine is running at th lever is at the full throttle position with maximum rated load.

To help prevent engine damage, never exceed the high idle rpm. Overspeeding can result in serious damage to the engine. The engine can be operated at high idle without damage, but should never be allowedtoexceedhighidlerpm.

indicator should be to the right side of “0” (zero).

is in the “ON” position.

efullloadrpmwhenthethrottlecontrol

Ammeter – This gauge indicates the

amount of charge or discharge in the

battery charging circuit. Operation of the

Fuel Level – This gauge indicates the fuel

level in the fuel tank. The fuel level gauge

operates when the “START/STOP” switch

Service Hour Meter – The gauge indicates

operating time of the engine.

and the engine rpm.

oad.

hen the throttle control lever

NOTICE

A lower oil pressure is normal at low idle. If the load is stable the following procedure:

1. Remove th

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

tempera 48 kPa (7 psi) is 110°C (230°F). Higher temperatures may occur under certain conditions. The water tempera reading should never exceed the boiling point for the pressurized system that is being used.

If the en and steam becomes apparent, perform the following procedure:

and the gauge reading changes, perform

e load.

Jacket Wa

Typical temperature range is 71 to 96°C (160 to 205°F). The maximum allowable

ture with the pressurized cooling system at

ture reading may vary according to load. The

gine is operating above the normal range

ter Coolant Temperature –

SEBU8352 23

Operation Section

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” position.

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