Perkins Engine 1104D Service Manual
Operation and
Maintenance
Manual
SEBU8172-02
July 20 12
1104D Industrial Engine
(Engine)
NH
NJ (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.
SEBU8172-02 3
Table of Contents
Table of Contents
Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 6
General Hazard Information ................................... 9
Burn Prevention .................................................... 10
Fire Prevention and Explosion Prevention ............. 11
Crushing Prevention and Cutting Prevention ........ 13
Mounting and Dismounting ................................... 13
High Pressure Fuel Lines ..................................... 13
Before Starting Engine .......................................... 15
Engine Starting ..................................................... 15
Engine Stopping ................................................... 16
Maintenance In
Warranty Sect
Warranty Information .......................................... 105
terval Schedule ............................ 69
ion
Index Section
Index ................................................................... 106
Electrical System .................................................. 16
Engine Electronics ................................................ 17
Product Information Section
Model Views ......................................................... 18
Product Identification Information ........................ 23
Operation Section
Lifting and Storage ................................................ 25
Gauges and Indicators .......................................... 27
Features and Controls .......................................... 29
Engine Diagnostics ............................................... 36
Engine Starting ..................................................... 40
Engine Operation .................................................. 43
Engine Stopping ................................................... 44
Cold Weather Operation ....................................... 46
Maintenance Section
Refill Capacities .................................................... 50
Maintenance Recommendations .......................... 67
4 SEBU8172-02
Foreword
Foreword
Literature Information
This manual co
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literatu
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 consist
Some photographs or illustrations in this manual
show detai
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improveme
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises re
consult with your Perkins dealer for the latest
available information.
ntains safety, operation instructions,
re holder or literature storage area. Read,
ency in electronic media delivery.
ls or attachments that may be different
nt and advancement of product design
garding your engine, or this manual, please
Use fuel consum
intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals
if they provid
approximate the indicated service meter reading.
Recommended
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engin
Schedule. Therefore, under extremely severe,
dusty, wet or freezing cold operating conditions,
more freque
specified in the Maintenance Interval Schedule may
be necessary.
The maintenance schedule items are organized for
a preventive maintenance management program. If
the preven
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should mi
avoidances resulting from reductions in unscheduled
downtime and failures.
nimize operating costs through cost
ption or service hours to determine
e more convenient schedules and
service should be performed at the
e also governs the Maintenance Interval
nt lubrication and maintenance than is
tive maintenance program is followed, a
Maintenance Intervals
Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
g situations. Read and understand the basic
warnin
precautions listed in the safety section before
operating or performing lubrication, maintenance and
on this product.
repair
Opera
Operating techniques outlined in this manual are
basic
techniques required to operate the engine more
efficiently and economically. Skill and techniques
deve
engine and its capabilities.
The o
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and
discussion of electronic diagnostic information.
tion
. They assist with developing the skills and
lop as the operator gains knowledge of the
peration section is a reference for operators.
stopping the engine. This section also includes a
Maintenance
e maintenance section is a guide to engine care.
Th
The illustrated, step-by-step instructions are grouped
by fuel consumption, service hours and/or calendar
me maintenance intervals. Items in the maintenance
ti
schedule are referenced to detailed instructions that
follow.
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in
depending upon your specific maintenance practices,
operation and application. We recommend that
the mai
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maint
See the section in the Operation and Maintenance
Manua
regarding documents that are generally accepted
as proof of maintenance or repair. Your authorized
Perkins dealer can assist you in adjusting your
maintena
operating environment.
each level should be shifted ahead or back
ntenance schedules be reproduced and
ained as part of the engine's permanent record.
l, “Maintenance Records” for information
chedule to meet the needs of your
nce s
Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
erval and the maintenance items in that interval.
int
Major repairs are best left to trained personnel or
an authorized Perkins dealer. Your Perkins
ler offers a variety of options regarding overhaul
dea
programs. If you experience a major engine failure,
there are also numerous after failure overhaul options
ailable from your Perkins de
av
dealer for information regarding these options.
your
aler. Consult with
SEBU8172-02 5
Foreword
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.
6 SEBU8172-02
Safety Section
Safety Messages
Safety Section
i02864025
Safety Me ssages
There may be
engine. The exact location and a description of the
warning signs are reviewed in this section. Please
become fam
Ensure that all of the warning signs are legible. Clean
the warnin
the words cannot be read or if the illustrations are
not visible. Use a cloth, water, and soap to clean
the warni
other harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
warning
could drop off of the engine.
Replace
missing.Ifawarningsignisattachedtoapartofthe
engine that is replaced, install a new warning sign on
the rep
distributor can provide new warning signs.
lacement part. Your Perkins dealer or your
several specific warning signs on your
iliar with all warning signs.
g signs or replace the warning signs if
ng signs. Do not use solvents, gasoline, or
signs. The warning signs that are loosened
any warning sign that is damaged or
The Universal W
sides of the valve mechanism cover base. Refer to
illustration 1.
arning label (1) is located on both
(1) Universal Warning
Do not operate or work on this equipment unless
ave read and understand the instructions
you h
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
the warnings could result in serious injury
heed
or death.
Illustration 1
ypical example
T
g01154807
SEBU8172-02 7
Safety Section
Safety Messages
Illustration 2
ersal warning
(1) Univ
(2) Han
d (High Pressure)
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu-
ay may cause a fire hazard. Failure to fol-
el spr
low these inspection, maintenance and service instructions may cause personal injury or death.
g01268960
8 SEBU8172-02
Safety Section
Safety Messages
Illustration 3
(2) Hand
Illustration 4
Typical example
(High Pressure)
(3) Ethe
r
g01154858
The warning label for the Hand (High Pressure) (2)
is located on the top of the fuel manifold. Refer to
illustration 4.
(3) Ether
g01426636
Illustration 5
Typical example
g01154809
The ether warning label (3) is located on the cover of
the inlet manifold. Refer to illustration 4.
Note: The location of this label will depend on the
application of the engine.
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
SEBU8172-02 9
Safety Section
General Hazard Information
i02328435
General Hazard Information
Illustration 6
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before y
ou service the equipment or before you
repair the equipment.
g0010454
Report all nece
ssary repairs.
Do not allow unauthorized personnel on the
equipment.
Ensure that the power supply is disconnected before
youworkonth
e bus bar or the glow plugs.
Perform maintenance on the engine with the
equipment i
ntheservicingposition.Refertothe
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 i
5
The direct application of pressurized air or
pressuri
injury.
When pres
cleaning, wear protective clothing, protective shoes,
and eye protection. Eye protection includes goggles
or a prot
njury.
zed water to the body could result in personal
surized air and/or water is used for
ective face shield.
02020
Illustration 7
g007
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
lkways, and from steps.
wa
The maximum air pressure for cleaning purposes
must be b
elow 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
hydraulic fluid or items such as pipe plugs to
cause
escape rapidly if the pressure is not relieved correctly.
Do not
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
comp
or personal injury may occur. Refer to the OEM
information for any procedures that are required to
reli
remove any hydraulic components or parts
onents or parts until pressure has been relieved
eve the hydraulic pressure.
Never put maintenance fluids into glass containers.
rain all liquids into a suitable container.
D
Obey all local regulations for the disposal of liquids.
Use all cleaning solutions with care.
10 SEBU8172-02
Safety Section
Burn Prevention
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
After the engine has stopped, you must wait for 60
seconds in order to allow the fuel pressure to be
purged from the high pressure fuel lines before any
service or repair is performed on the engine fuel lines.
Illustration 8
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 fluidwitha
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.
Only use the tools that are suitable for containing
•
fluids and equipment that is suitable for containing
fluids.
Allow the pressure to be purged in the air system, in
the hydraulic system, in the lubrication 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.
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 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.
Obey all local regulations for the disposal of liquids.
i02334785
n P revention
Bur
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance is
rformed on the engine.
pe
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.
SEBU8172-02 11
Safety Section
Fire Prevention and Explosion Prevention
i04823662
Fire Prevention and Explosio n
Prevention
tion 9
Illustra
All fuels, most lubricants, and some coolant mixtures
are flamm
Flammable fluids that are leaking or spilled onto hot
surface
a fire. Fire may cause personal injury and property
damage.
After the emergency stop button is operated, ensure
that you allow 15 minutes, before the engine covers
are rem
Determine whether the engine will be operated in an
envir
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
prop
If the application involves the presence of combustible
gase
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
materials or conductive materials to accumulate on
the engine.
able.
s or onto electrical components can cause
oved.
onment that allows combustible gases to be
erty damage, or engine damage could result.
s, consult your Perkins dealer and/or your
engine. Do not allow any flammable combustible
g00704000
Exhaust shield
components from oil or fuel spray in a line, a tube,
or a seal failure. Exhaust shields must be installed
correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or fl
Wiring must be kept in good condition. Ensure that
all electri
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate the
engine. Cl
all electrical connections.
Eliminate
Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or ci
Arcing or sparking could cause a fire. Secure
connecti
maintained battery cables will help to prevent arcing
or sparking.
Contac
penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow the
structions may cause personal injury or death.
After
order to allow the fuel pressure to be purged from the
high-pressure fuel lines before any service or repair
is pe
Ensure that the engine is stopped. Inspect all lines
and h
route all hoses. The lines and hoses must have
adequate support and secure clamps.
Properly install oil filters and fuel filters. The filter
housings must be tightened to the correct torque.
Ref
more information.
t with high pressure fuel may cause fluid
se inspection, maintenance and service in-
the engine has stopped, wait for 60 seconds in
rformed on the engine fuel lines.
oses for wear or for deterioration. Properly
er to the Disassembly and Assembly manual for
s (if equipped) protect hot exhaust
flame cut lines or tanks that contain
ame cutting.
cal wires are correctly routed and securely
ean all electrical connections and tighten
all wiring that is unattached or unnecessary.
rcuit breakers.
ons, recommended wiring, and correctly
Store fuels and lubricants in correctly marked
containers away from unauthorized persons. Store
ly rags and any flammable materials in protective
oi
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.
12 SEBU8172-02
Safety Section
Fire Prevention and Explosion Prevention
Illustration 10
Use caution when 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 engine before refueling.
g00704059
Incorrect jump
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions
Do not charge a frozen battery.Charging a frozen
battery may c
The batteries must be kept clean. The covers
(if equippe
recommended cables, connections, and battery box
covers when the engine is operated.
er cable connections can cause
.
ause an explosion.
d) must be kept on the cells. Use the
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect th
extinguisher regularly. Obey the recommendations
on the instruction plate.
e fire extinguisher and service the fire
Lines, Tubes, and Hoses
Do not bend high-pressure lines. Do not strike
high-pressure lines. Do not install any lines that are
damaged
.
Illustration 11
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.
g02298225
Leaks can cause fires. Consult your Perkins dealer
or your P
Replace the parts if any of the following conditions
are pre
High-pressure fuel line or lines are removed.
•
End fittings are damaged or leaking.
•
Outer
•
Wires are exposed.
•
Outer coverings are ballooning.
•
Flex
•
Outer covers have embedded armoring.
•
End fittings are displaced.
•
Mak
are installed correctly in order to prevent vibration,
rubbing against other parts, and excessive heat.
erkins distributor for replacement parts.
sent:
coverings are chafed or cut.
ible parts of the hoses are kinked.
e sure that all clamps, guards, and heat shields
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
ahydrometer.
SEBU8172-02 13
Safety Section
Crushing Prevention and Cutting Prevention
i02143194
Crushing Prevention and
Cutting Preve
Support the component correctly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Lea
is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will
ve the guards in place until maintenance
be injured by flying debris.
ntion
i02861106
High Pressure Fuel Lines
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel spray may
low these inspection, maintenance and service instructions may cause personal injury or death.
cause a fire hazard. Failure to fol-
i02235492
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.
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.
14 SEBU8172-02
Safety Section
High Pressure Fuel Lines
Illustration 12
(1)Highpressureline
(2)Highpressureline
(3) High pre ssure line
(4) High pre ssure line
The high pressure fuel lines are the fuel lines that
are between the high pressure fuel pump and the
high pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel
systems.
This is because of the following differences:
The high pressure fuel lines are constantly charged
•
with high pressure.
The internal pressures of the high pressure fuel
•
lines are higher than other types of fuel system.
The high pressure fuel lines are formed to shape
•
and then strengthened by a special process.
Do not step on the high pressure fuel lines. Do not
deflect the high pressure fuel lines. Do not bend or
strike the high pressure fuel lines. Deformation or
damage of the high pressure fuel lines may cause a
point of weakness and potential failure.
g01425090
(5) High pressure fuel manifold (rail)
(6) High pressure line
Do not check the high pressure fuel lines with the
engine or the starting motor in operation. After the
engine has stopped allow 60 seconds to pass in order
to allow the pressure to be purged before any service
or repair is performed on the engine fuel lines.
Do not loosen the high pressure fuel lines in order
to remove air from the fuel system. This procedure
is not required.
Visually inspect the high pressure fuel lines before
the engine is started. This inspection should be each
day.
If you inspect the engine in operation, always use
the proper inspection procedure in order to avoid
a fluid penetration hazard. Refer to Operation and
Maintenance Manual, “General Hazard Information”.
Inspect the high pressure for the following:
•
damage, deformation, a nick, a cut, a crease, or
adent
SEBU8172-02 15
Safety Section
Before Starting Engine
Do not operate t
•
isaleakdonottightentheconnectioninorder
to stop the leak. The connection must only be
tightened to t
Disassembly and Assembly Manual, “Fuel Injection
Lines - Remove and Fuel Injection Lines - Install”.
If the high pressure fuel lines are torqued correctly
•
and the high pressure fuel lines are leaking the
high pressu
Ensure that all clips on the high pressure fuel lines
•
areinplace
that are damaged, missing or clips that are loose.
Do not atta
•
fuel lines.
Loosened h
•
replaced. Also removed high pressure fuel lines
must be replaced. Refer to Disassembly and
Assembly
he engine with a fuel leak. If there
he recommended torque. Refer to
re fuel lines must be replaced.
. Do not operate the engine with clips
ch any other item to the high pressure
igh pressure fuel lines must be
Manual, “ Fuel Injection Lines - Install”.
i02813489
Before Starting Engine
See the Service
adjustments.
Manual for repairs and for
i02251260
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.
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.
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.
If equipped, ensure that the lighting system for the
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 service procedures. To help prevent an
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 order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.
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/or the oil temperature gauge during the heater
operation.
Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
Note: The engine is equipped with a device for cold
starting. If the engine will be operated in very cold
conditions, then an extra cold starting aid may be
required. Normally, the engine will be equipped with
the correct type of starting aid for your region of
operation.
These engines are equipped with a glow plug starting
aid in each individual cylinder that heats the intake
air in order to improve starting.
16 SEBU8172-02
Safety Section
Engine Stopping
i02234873
Engine Stopping
Stop the engin
the Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating
the engine components.
Use the Emer
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency
problem that caused the emergency stop has been
corrected.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an engine
that has b
To stop an electronically controlled engine, cut the
power to t
to the engine.
e according to the procedure in
of the engine and accelerated wear of
gency Stop Button (if equipped) ONLY
stop, DO NOT start the engine until the
een overhauled.
he engine and/or shutting off the air supply
i02234878
Grounding Practices
Illustration 13
Typical example
(1) Starting motor to engine block
(2) Ground to starting m otor
(3) Ground to battery
g01162916
Electrical System
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” cable should be connected last from the
external power source to the negative “−” terminal
of the starting motor. If the starting motor is not
equipped with a negative “−” terminal, connect the
cable to the engine block.
Check the electrical wires daily for wires that
are loose or frayed. Tighten all loose electrical
connections before the engine is started. Repair all
frayed electrical wires before the engine is started.
See the Operation and Maintenance Manual for
specific starting instructions.
Illustration 14
Typical example
(4) Ground to engine
(5) Ground to battery
g01162918
Correct grounding for the engine electrical system
is necessary for optimum engine performance
and reliability. Incorrect grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
SEBU8172-02 17
Safety Section
Engine Electronics
Uncontrolled e
damage to the crankshaft bearing journal surfaces
and to aluminum components.
Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
discharge.
To ensure that the engine and the engine electrical
systems fun
ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct
engine grou
The connections for the grounds should be tight and
free of cor
grounded to the negative “-” battery terminal with
a wire that is adequate to handle the full charging
current of
The power supply connections and the ground
connecti
be from the isolator to the battery.
lectrical circuit paths can result in
ction correctly, an engine-to-frame
nd to the frame.
rosion. The engine alternator must be
the alternator.
ons for the engine electronics should always
i02650954
Engine Electronics
Derate
•
Shutdown
•
The following monitored engine operating conditions
have the ability to limit engine speed and/or the
engine power
Engine Coolant Temperature
•
Engine Oil Pressure
•
Engine Spee
•
Intake Manifold Air Temperature
•
The Engine Monitoring package can vary for different
engine models and different engine applications.
However, t
monitoring control will be similar for all engines.
Note: Man
modules that are available for Perkins Engines will
work in unison with the Engine Monitoring System.
Together
monitoring function for the specific engine application.
Refer to Troubleshooting for more information on the
Engine M
:
d/Timing
he monitoring system and the engine
y of the engine control systems and display
, the two controls will provide the engine
onitoring System.
Tampe
or the OEM wiring installation can be dangerous
and could result in personal injury or death and/or
engin
Electrical Shock Hazard. The electronic unit injectors use DC voltage. The ECM sends this voltage
to the electronic unit injectors. Do not come in
contact with the harness connector for the electronic unit injectors while the engine is operating.
Failure to follow this instruction could result in
personal injury or death.
This engine has a comprehensive, programmable
Engine Monitoring System. The Electronic Control
Module (ECM) has the ability to monitor the engine
operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
initiate an immediate action.
The following actions are available for engine
monitoring control:
ring with the electronic system installation
e damage.
Warning
•
18 SEBU8172-02
Product Information Section
Model Views
Product Information
Section
Model Views
i02861104
Model View Illustrations
The following model views show typical features
of the engine. Due to individual applications, your
engine may appear different from the illustrations.
Illustration 15
The 1104D NJ engine is turbocharged and aftercooled.
g01425089
SEBU8172-02 19
Product Information Section
Model Views
Illustration 16
The 1104D NH engine is turbocharged.
Front left engine view
(1) Front lifting eye
(2) Water outlet
(3) Rear lifting eye
(4) Fuel manifold (rail)
(5) Electronic control module
(6) Secondary fuel filter
(7) Water pump
(8) Oil Filler
(9) Oil gauge
(10) Oil sampling valve
g01428165
(11) Oil filter
(12) Crankshaft pulley
(13) Drive Belt
(14) Belt tensioner
20 SEBU8172-02
Product Information Section
Model Views
Illustration 17
Rear right engine view
(15) Alternator
(16) Exhaust manifold
(17) Turbocharger
(18) Wastegate solenoid
(19) Drain plug or coolant sampling valve
(20) Starting Motor
(21) Oil drain plug
(22) Primary fuel filter
Note: The primary fuel filter may be mounted off the
engine.
i04925801
Engine Description
The 1104 Electronic Engine models NH and NJ are
designed for the following applications: machine and
industrial mobile equipment. The engine is available
in the following type of aspiration:
Turbocharged
•
Turbocharged aftercooled
•
In-line 4 cylinder
•
g01428176
(23) Hand fuel priming pump
(24) Flywheel
(25) Flywheel housing
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.
Emissions Control Systems
NH - Direct Diesel Injection, Turbocharger, and
Engine Control Module
NJ - Direct Diesel Injection, Turbocharger with Air to
Air Charge Cooler and Engine Control Module
SEBU8172-02 21
Product Information Section
Model Views
Illustration 18
(A) Exhaust valves
(B) Inlet valves
Table 1
1104 Electronic Engine Specifications
Operating Range (rpm)
Number of Cylinders
Bore
Stroke 127 mm (5.0 inch)
Aspiration NH Turbocharged engine
Compression Ratio 16.2:1
Displacement
Firing Order 1,3,4,2
Rotation (flywheel end) Counterclockwise
Valve Lash Setting (Inlet) 0.35 mm (0.013 inch)
lve Lash Setting
Va
(Exhaust)
(1)
The operating rpm is dependent on the engine rating, the
application, and the configuration of the throttle.
750 to 2640
4 In-Line
105 mm (4.13 inch)
NJ Turbocharged engine
that is aftercooled
4.4 L (269 in
0.35 mm (0.013 inch)
g01187485
(1)
3
)
Electronic Engine Features
The engine operating conditions are monitored.
The Electronic Control Module (ECM) controls the
response of the engine to these conditions and to
the demands of the operator. These conditions and
operator demands determine the precise control of
fuel injection by the ECM. The electronic engine
control system provides the following features:
Engine monitoring
•
Engine speed go
•
Control of the injection pressure
•
Cold start strategy
•
Automatic ai
•
Torque rise shaping
•
Injection timing control
•
System diag
•
verning
r/fuel ratio co ntrol
nostics
For more information on electronic engine features,
refer to th
e Operation and Maintenance Manual,
“Features and Controls” topic (Operation Section).
Engine Diagnostics
The engin
that the engine systems are functioning correctly. The
operator will be alerted to the condition by a “Stop or
Warning”
horsepower and the vehicle speed may be limited.
Theelectronicservicetoolmaybeusedtodisplay
the diag
There are three types of diagnostic codes: active,
logged,
Most of the diagnostic codes are logged and stored
in the E
the Operation and Maintenance Manual, “Engine
Diagnostics” topic (Operation Section).
The ECM provides an electronic governor that
controls the injector output in order to maintain the
desir
Engin
The cooling system consists of the following
comp
Gear-driven centrifugal water pump
•
Water temperature regulator which regulates the
•
engine coolant temperature
Gear-driven rotor type oil pump
•
Oil
•
The engine lubricating oil is supplied by a rotor type
l pump. The engine lubricating oil is cooled and the
oi
engine lubricating oil is filtered. The bypass valves
can provide unrestricted flow of lubrication oil to
e engine if the oil filter element should become
th
plugged.
e has built-in diagnostics in order to ensure
lamp. Under certain conditions, the engine
nostic codes.
and event.
CM. For additional information, refer to
ed engine rpm.
e Cooling and Lubrication
onents:
cooler
22 SEBU8172-02
Product Information Section
Model Views
Engine efficien
engine performance depend on adherence to proper
operation and maintenance recommendations.
Engine perfor
the use of recommended fuels, lubrication oils, and
coolants. Refer to this Operation and Maintenance
Manual, “Mai
information on maintenance items.
cy, efficiency of emission controls, and
mance and efficiency also depend on
ntenance Interval Schedule” for more
SEBU8172-02 23
Product Information Section
Product Identification Information
Product Identification
Information
Plate Locations and Film
Locations
i02378644
Perkins dealer
these numbers in order to determine the components
that were included with the engine. This permits
accurate iden
The numbers for fuel setting information for electronic
engines are s
These numbers can be read by using the Electronic
Service Tool.
s or Perkins distributors need all of
tification of replacement part numbers.
tored within the personality module.
Serial Number Plate (1)
The engine serial number plate is located on the left
side of the cylinder block to the rear of the engine.
Illustration 19
Location of the serial number plate
Perkins engines are identified by an engine serial
number.
An example of an engine number is
NH*****U000001J.
*****
____________________The list number for the engine
_____________________ _____________ _______Type of engine
NH
____________________________Built in the United Kingdom
U
000001
J
___________________________Engine Serial Number
_____________________________________ Year of Manufacture
g01248563
Illustration 20
Serial number plate
g01094203
i02164876
Reference N umbers
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.
Record for Reference
Engine Model _ ______________________________________________
Engine Serial number _____________________________________
Engine Low Idle rpm ______________________________________
Engine Full Load rpm _____________________________________
Primary Fuel Filter _________________________________________
Water Separator Element ________________________________
Secondary Fuel Filter Element __________________________
24 SEBU8172-02
Product Information Section
Product Identification Information
Lubrication Oi
l Filter Element
___________________________
Auxiliary Oil Filter Element _______________________________
Total Lubrication System Capacity _____________________
Total Coolin
g System Capacity
_________________________
Air Cleaner Element _______________________________________
Fan Drive Belt ______________________________________________
______________________________________________
Alternator
Emissions
Belt
i02861254
Certification Film
Illustration 21
Typical e xample
g01440937
SEBU8172-02 25
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage
Engine Lifting
i02164186
Some removals r
obtain correct balance and safety.
To re m o ve th e e
are on the engine.
Lifting eyes
engine arrangements. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obs
that correct lifting devices are provided. Consult
your Perkins dealer or your Perkins distributor for
informatio
lifting.
n regarding fixtures for correct engine
equire lifting the fixtures in order to
ngine ONLY, use the lifting eyes that
are designed and installed for specific
olete. If alterations are made, ensure
i02308881
Engine Storage
If the engine is not started for a month or longer 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.
Illustration 22
NOTICE
Never bend the eyebolts and the brackets. Only load
eyebolts and the brackets under tension. Remem-
the
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
es less than 90 degrees.
com
When it is necessary to remove a component at an
gle, only use a link bracket that is properly rated for
an
the weight.
se a hoist to remove heavy components. Use
U
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
arallel to each other. The chains and cables should
p
be perpendicular to the top of the object that is being
lifted.
g01097527
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.
If an engine is out of operation and if use of the
engine is not planned for more than one month, a
complete protection procedure is recommended.
To help prevent excessive engine wear and corrosion
to the engine, use the following guidelines:
1. Completely clean the outside of the engine.
2. Ensure that the vehicle is on level ground.
3. Drain the fuel system completely and refill
thesystemwithpreservativefuel.1772204
POWERPARTLay-Up1canbemixedwith
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.
26 SEBU8172-02
Operation Section
Lifting and Storage
Personal injury can result from hot coolant. Any
contact with hot coolant or with steam c an cause
severe burns. Allow cooling system components
to cool before the cooling system is drained.
4. Drain and refill the cooling system. Refer to this
Operation and Maintenance Manual, “Cooling
System coolant (Commercial Heavy Duty Change or Cooling System coolant (ELC) Change” for information on draining, flushing and
refilling the cooling system.
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
5. Operate the engine until the engine reaches
normal operating temperature. Stop the engine.
After the engine has stopped, you must wait for 60
seconds in order to allow the fuel pressure to be
purged from the high pressure fuel lines before any
service or repair is performed on the engine fuel
lines. If necessary, perform minor adjustments.
Repair any leaks from the low pressure fuel
system and from the cooling, lubrication or air
systems. Replace any high pressure fuel line that
has leaked. Refer to Disassembly and assembly
Manual, “Fuel Injection Lines - Install”.
6. Drain the lubricating oil from the oil pan.
Renew the canister(s) of the lubricating oil filter.
9. If equipped, re
element. Seal the end of the breather pipe.
10. Remove the val
1762811 POWERPART Lay-Up 2 around the
rocker shaft assembly.
11. Remove the glow plugs. Slowly rotate the
crankshaft. By checking the valves, position the
piston at BD
Lay-Up 2 for two seconds into the cylinder bore.
This procedure must be carried out on each
cylinder.
12. Install the glow plugs. Install the valve mechanism
cover.
13. Remove the pipes that are installed between
the air filt
Spray 1762811 POWERPART Lay-Up 2 into
the turbocharger. The duration of the spray is
printed o
with waterproof tape.
14. Remove th
the turbocharger. Spray 1762811 POWERPART
Lay-Up 2 into the turbocharger. The duration of
the spra
turbocharger with waterproof tape.
15. Seal the
with waterproof tape.
16. Remove
belt into storage.
17. In o rd
of the engine, spray the engine with 1734115
POWERPART Lay-Up 3. Do not spray the area
insid
y is printed on the container. Seal the
er to prevent corrosion to the outside
e the alternator.
place the crankcase breather
ve mechanism cover. Spray
C. Spray 1762811 POWERPART
er assembly and the turbocharger.
n the container. Seal the turbocharger
e exhaust pipe from the output side of
vent of the fuel tank or the fuel filler cap
the alternator drive belt and put the drive
Fill the oil pan to the Full Mark on the engine oil
level gauge with new, clean lubricating oil. Add
1762811 POWERPARTLay-Up2totheoilin
order to protect the engine against corrosion. If
1762811 POWERPART Lay-Up 2 is not available,
use a preservative of the correct specification
instead of the lubricating oil. If a preservative is
used, this must be drained completely at the end
of the storage period and the oil pan must be
refilled to the correct level with normal lubricating
oil.
7. Operate the engine in order to circulate engine oil.
8. Disconnect the battery. Ensure that the battery is
in a fully charged condition. Protect the terminals
against corrosion. 1734115 POWERPART
Lay-Up 3 can be used on the terminals. Put the
battery into safe storage.
SEBU8172-02 27
Operation Section
Gauges and Indicators
Gauges and Ind icators
i02861754
Gauges and Indicators
Your engine
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
the gauges over a period of time.
Noticeab
potential gauge or engine problems. Problems may
also be indicated by gauge readings that change
even if t
Determine and correct the cause of any significant
change in the readings. Consult your Perkins dealer
or your P
Some engine applications are equipped with Indicator
Lamps.
aid. There are two lamps. One lamp has an orange
lens and the other lamp has a red lens.
These indicator lamps can be used in two ways:
The in
•
current operational status of the engine. The
indicator lamps can also indicate that the engine
has a f
via the ignition switch.
The i
•
diagnostic codes. This system is activated by
pressing the Flash Code button.
Refer to the Troubleshooting Guide, “Indicator
Lamps” for further information.
If no oil pressure is indicated, STOP the engine. If
maximum coolant temperature is exceeded, STOP
the engine. Engine damage can result.
SAE10W40is350to450kPa(50to65psi)atrated
rpm.
A lower oil pressure is normal at low idle. If the load
is stable and the gauge reading changes, perform
the following procedure:
may not have the same gauges or all of
the normal operating range by observing
le changes in gauge readings indicate
he readings are within specifications.
erkins distributor for assistance.
Indicator lamps can be used as a diagnostic
dicatorlampscanbeusedtoidentifythe
ault. This system is automatically operated
ndicator lamps can be used to identify active
NOTICE
Engine Oil Pressure – Th e oil pressure
should be greatest after a cold engine is
started. The typical engine oil pressure with
1. Remove the load
2. Stop the engine.
3. Check and maintain the oil level.
Jacket Water
Typical temperature range is 83° to 95°C
(181.4° to 171°F). The maximum allowable
temperatur
system at 48 kPa (7 psi) is 103 °C (217.4 °F). Higher
temperatures may occur under certain conditions.
The water te
to load. The temperature reading should never
exceed 7 °C (44.6 °F) below the boiling point for the
pressuriz
A 100 kPa (14.5 psi) radiator cap may be installed on
the cooling system. The temperature of this cooling
system mus
If the engine is operating above the normal range
and steam
procedure:
1. Reduce t
2. Determine if the engine must be shut down
immedia
reducing the load.
3. Inspec
load, the engine is running at high idle. The engine is
runni
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. Operation at speeds exceeding high idle rpm should be kept to a minimum.
indicator should be to the “+” side of “0” (zero).
is in the “on” position.
e at sea level with the pressurized cooling
mperature reading may vary according
ed system that is being used.
t not exceed 112 °C (233.6 °F).
becomes apparent, perform the following
he load and the engine rpm.
tely or if the engine can be cooled by
t the cooling system for leaks.
Tachometer – This gauge indicates engine
speed (
ismovedtothefullthrottlepositionwithout
ng at the full load rpm when the throttle control
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
.
Coolant Temperature –
rpm). When the throttle control lever
NOTICE
28 SEBU8172-02
Operation Section
Gauges and Indicators
Service Hour Meter – The gauge indicates
total operating hours of the engine.
SEBU8172-02 29
Operation Section
Features and Controls
Features and Controls
i02651062
Monitoring System
If the Shutdown mode has been selected and the
warning in
take as little as 20 seconds from the time the warning indicator is activated. Depending on the application
avoid personal injury. The engine can be restarted
following shutdown for emergency maneuvers, if
necessar
The Engine Monitoring System is not a guarantee
against catastrophic failures. Programmed delays
and derate schedules are designed to minimize false
alarms and provide time for the operator to stop the
engine.
The following parameters are monitored:
Coolant temperature
•
Intake air temperature
•
Engine intake manifold pressure
•
Engine Oil pressure
•
Pressure in the fuel rail
•
dicator activates, engine shutdown may
, special precautions should be taken to
y.
NOTICE
“Warning”
The “Warning” lamp and the warning signal (orange
lamp) turn “ON
continuously in order to alert the operator that one or
more of the engine parameters is not within normal
operating ra
” and the warning signal is activated
nge.
“Warning/Derate”
The “Diagnostic” lamp turns “ON” and the warning
signal (red lamp) is activated. After the warning, the
engine powe
begin to flash when the derating occurs.
The engine
preset operational limits. The engine derate is
achieved by restricting the amount of fuel that is
available
reduction of fuel is dependent on the severity of the
fault that has caused the engine derate, typically up
to a limit
predetermined reduction in engine power.
“Warnin
The “Diagnostic” lamp turns “ON” and the warning
signal (
the engine power will be derated. The engine will
continue at the rpm of the set derate until a shutdown
of the e
after a shutdown for use in an emergency.
Ashutd
as 20 seconds. The engine can be restarted after
a shutdown for use in an emergency. However,
the ca
Theenginemayshutdownagaininaslittleas20
seconds.
r will be derated. The warning lamp will
will be derated if the engine exceeds
for each injection. The amount of this
of 50%. This reduction in fuel results in a
g/Derate/Shutdown”
red lamp) is activated. After the warning,
ngine occurs. The engine can be restarted
own of the engine may occur in as little
use of the initial shutdown may still exist.
Engine speed/timing
•
Programmable O ptions and
Systems Operation
If the Warning/Derate/Shutdown mode has been
selected and the warning indicator activates,
bring the engine to a stop whenever possible. Depending on the application, special precautions
should be taken to avoid personal injury.
The engine can be programmed to the following
modes:
If there is a signal for low oil pressure or for coolant
temperature, there will be a two second delay in
r to verify the condition.
orde
For each of the programmed modes, refer to
bleshooting , “Indicator Lamps” for more
Trou
information on Indicator Lamps.
more information or assistance for repairs, consult
For
your Perkins dealer or your Perkins distributor.
30 SEBU8172-02
Operation Section
Features and Controls
i02296746
Monitoring System
Table 2
Warning
Lamp
ON ON
OFF OFF
ON OFF
ON FLASHING
FLASHING OFF
FLASHING FLASHING
ON ON
Shutdown
Lamp
Lamp Status Description of lamp status Engine Status
Lamp check When the engine start switch is turned to the
“ON” position both lamps will illuminate for 2
seconds only.
No faults There are no active diagnostic faults.
Active
diagnostic
fault
Active
diagnostic
fault
Warning One or more of the engine protection values
Derate and
warning
Engine
shutdown
An active diagnostic fault has been detected.
A serious active diagnostic fault has been
detected and an engine derate has been
invoked.
has been exceeded.
One or more of the engine protection values
has been exceeded.
One or more of the engine protection values has
been exceeded or a serious active diagnostic
as been detected.
fault h
The engine has not been
started.
Theengineisrunning
normally.
Theengineisrunning
normally.
Theengineisrunning
but the engine has been
derated.
Theengineisrunning
normally.
Theengineisrunning
but the engine has been
derated.
The engine is shutdown or
shutdown is imminent.
i02861773
Sensors and Electrical
Components
Sensor Locations
ustration 23 shows the typical locations of the
Ill
sensors and the ECM on the engine. Specificengines
may appear different from the illustration due to
ferences in applications.
dif
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