Perkins Engine 1104E Maintenance Manual
Operation and
Maintenance
Manual
SEBU8121
February 2005
1104E Engine
RF11-Up
RH11-Up (Machine)
RK11-Up (Machine)
(Machine)
i01658146
Important Safety Information
Most accidents t
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 necess
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate o
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
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 s hown below.
The meaning of this safety alert symbol is as follows:
Attention! Be
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations th
this publication.
hat involve product operation, maintenance and repair are caused by failure to observe
ary training, skills and tools to perform these functions properly.
r perform any lubrication, maintenance or repair on this product, until you have
, bodily injury or death could occur to you or to other persons.
come Alert! Your Safety is Involved.
at may cause product damage are identified by “NOTICE” labels on the product and in
Perkins cannot anticipa te e ver y p os sible c irc u mstance t hat m ight invol ve a pote n ti al hazard .
The warnings
proc edure, work me thod or ope rating technique tha t is not s pecific ally rec ommended by Perkins
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product w
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was availabl
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
s t ar t any jo
in this publication and on the product are, therefore, not all inclusive. If a tool,
ill not be damaged or be made unsafe by the operation, lubrication, maintenance or
e at the time that the publication was written. The specifications, torques, pressures,
b . Perkins dea le rs hav e t he m os t c ur r en t i nfo rm ati on a va il abl e.
When replacement parts are required for this
product Perkins re comme nds usi ng Perkins
e ment parts or parts w ith equiva lent
re pl ac
specifications including, but not limited to, physical dimensions, type , strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
SEBU8121 3
Table of Contents
Table of Contents
Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 5
General Hazard Information ................................... 5
Burn Prevention ...................................................... 7
Fire Prevention and Explosion Prevention .............. 7
Crushing Prevention and Cutting Prevention .......... 9
Before Starting Engine ............................................ 9
Engine Starting ....................................................... 9
Engine Stopping ................................................... 10
Electrical System .................................................. 10
Engine Electronics ................................................. 11
Warranty S ecti
Warranty Information ............................................ 81
on
Index Section
Index ..................................................................... 82
Product Information Section
General Information .............................................. 12
Model Views ......................................................... 13
Product Identification Information ........................ 17
Operation Section
Lifting and Storage ................................................ 19
Gauges and Indicators .......................................... 22
Features and Controls .......................................... 23
Engine Diagnostics ............................................... 27
Engine Starting ..................................................... 29
Engine Operation .................................................. 33
Engine Stopping ................................................... 34
Cold Weather Operation ....................................... 35
Maintenance Section
Refill Capacities .................................................... 39
Maintenance Interval Schedule ............................ 52
4 SEBU8121
Foreword
Foreword
Literature Information
This manual con
lubrication a nd 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.
arding your engine, or this manual, please
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
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.
n
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.
SEBU8121 5
Safety Section
Safety Messages
Safety Section
i02206606
Safety Me ssage s
There may be s
an engine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Ple
signs.
Ensure that a
the warning signs or replace the warning signs if
the words cannot be read or if the pictures are not
visible. Wh
cloth, water, and soap. Do not use solvent, gasoline,
or other harsh chemicals to clean the warning signs.
Solvents,
the adhesive that secures the warning signs. The
warning signs that are loosened could drop off of
the engine
Replace any damaged warning signs or missing
warning si
of the engine that is replaced, install a new warning
sign on the replacement part. Perkins dealers or
Perkins d
everal specific warning signs on
ase become familiar with all warning
ll of the warning signs are legible. Clean
en the warning signs are cleaned, use a
gasoline, or harsh chemicals could loosen
.
gns. If a warning sign is attached to a part
istributors can provide new warning signs.
Ether
The warning lab
front, the rear, or the side of the engine.
Never spray Ether starting aids into the air inl et.
el for ether is located on the top, the
g00640926
i02203039
General Hazard Information
Do not work on the engine and do not operate the
engine un
Operation and Maintenance Manual are understood.
Correct care is your responsibility. Failure to follow
the inst
result in injury or in death.
The warn
are illustrated and described.
less the instructions and warnings in the
ructions or failure to heed the warnings could
ing labels that may be found on the engine
Illustration 1
Attach a “
warning tag to the start switch or to the controls
before you service the equipment or before you
repair th
Do Not Operate” warning tag or a similar
eequipment.
g00104545
6 SEBU8121
Safety Section
General Hazard Information
Illustration 2
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
The maximum air
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi
Fluid Penetra
Pressure can be trapped in the hydraulic circuit long
after the eng
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly .
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur. Do
components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
informatio
relieve the hydraulic pressure.
n for any procedures that are required to
pressure for cleaning purposes
).
tion
ine has been stopped. The pressure can
not disassemble any hydraulic
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.
Note: Ensure that the power supply is disconnected
before you work on the bus bar or the glow plugs.
Unless you are instructed otherwise, 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.
When pressurized air and/or water is used for
cleaning, wear protective clothing, protective shoes,
and eye protection. Eye protection includes goggles
oraprotectivefaceshield.
Illustration 3
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.
Only use the tools that are suitable for containing
•
fluids and equipment that is suitable for containing
fluids.
SEBU8121 7
Safety Section
Burn Prevention
Obey all local r
egulations for the disposal of liquids.
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.
i02203164
Fire Prevention and Explosion
Prevention
on 4
Illustrati
All fuels, most lubricants, and some coolant mixtures
are flammab
Flammable fluids that are leaking or spilled onto hot
surfaces or
a fire. Fire may cause personal injury and property
damage.
le.
onto electrical components can cause
g00704000
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
withabarehand.Removethefillercapslowlyin
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.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after
an emergen
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.
cy shutdown.
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
Do not expose the engine to any flame.
8 SEBU8121
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 no
t 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
ame 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 6
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 5
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
SEBU8121 9
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.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Perkins dealer or your
Perkins dist
Check lines, tubes and hoses carefully. Do not use
your bare han
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions
are present:
End fittings are damaged or leaking.
•
Outer cover
•
Wires are exposed.
•
Outer coverings are ballooning.
•
Flexible pa
•
Outer covers have embedded armoring.
•
End fittings are displaced.
•
Make sure tha
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
parts, and e
pressure lines. Do not strike high
ributor for repair or for replacement parts.
dtocheckforleaks.Useaboardor
ings are chafed or cut.
rt of the hoses are kinked.
t all clamps, guards, and heat shields
xcessive heat.
i02143194
Chips or other d
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
ebris may fly off objects when objects
i02157341
Before Starting Engine
NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.
Overspeed shutdown should occur automatically.
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.
Crushing Prevention and
Cutting Pr
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. Le
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.
ave the guards in place until maintenance
evention
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.
See the Service Manual for repairs and for
adjustments.
i022072
Engine Starting
Do not use aerosol types of starting aids s uch as
ether. Such use could result in an explosion and
persona
linjury.
32
10 SEBU8121
Safety Section
Engine Stopping
If a warning tag
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning ta
All protective guards and all protective covers must
be installed
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the pa
Start the engine from the operator’s compartment or
from the engi
Always start the engine according to the procedure
that is descr
Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent maj
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
oil temperature gauge during the heater operation.
Engine exh
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If t
vent the engine exhaust to the outside.
Note: The
device for cold starting for normal conditions of
operation. If the engine will be operated in very cold
conditi
required. Normally, the engine will be equipped with
the correct type of starting aid for your region of
operati
The engines are equipped with a glow plug starting
aidinea
air in order to improve starting.
, check the water temperature gauge and the
he engine is started in an enclosed area,
ons, then an extra cold starting aid may be
on.
ch individual cylinder that heats the intake
is attached to the engine start switch
g before the engine is started.
if the engine must be started in order
rts carefully.
ne start switch.
ibed in the Operation and Maintenance
or damage to the engine components.
aust contains products of combustion
engine is equipped with an automatic
i01928905
Engine Stopping
Use the Emergen
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency sto
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 been
by shutting off the fuel supply to the engine and/or
shutting off the air supply to the engine.
cy Stop Button (if equipped) ONLY
p, DO NOT start the engine until the
overhauled. This may be accomplished
i02176668
Electrical S ys tem
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 “−” jump start 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 jump start cable to the engine block.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. See
the Operation and Maintenance Manual for specific
starting instructions.
Grounding Practices
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.
Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.
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.
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 function correctly, an engine-to-frame
ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct
engine ground to the frame.
SEBU8121 11
Safety Section
Engine Electronics
All grounds sho
engine alternator must be grounded to the negative
“-” battery terminal with a wire that is adequate to
handle the ful
uldbetightandfreeofcorrosion.The
l charging current of the alternator.
i01885770
Engine Electron ics
Tampering with the electronic system installation
or the OEM wir
and could result in personal injury or death and/or
engine damage.
This engine has a comprehensive, programmable
Engine Monitoring System. The Electronic Control
Module (ECM
operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
initiate a
n immediate action.
ing installation can be dangerous
) has the ability to monitor the engine
The following actions are available for engine
monitorin
SHUTDOWN. These engine monitoring modes have
the ability to limit engine speed and/or the engine
power.
Engine Coolant Temperature
•
Engine Oil Pressure
•
Engine Spe
•
Fuel Temperature
•
Intake Manifold Air Temperature
•
System Vol
•
The Engine Monitoring package can vary for different
engine mo
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Note: Many of the engine control systems and display
modules that are available for Perkins Engines will
work in un
Together, the two controls will provide the engine
monitoring function for the specific engine application.
Refer to
more information on the Engine Monitoring System.
g control: WARNING, DERATE, and
ed
tage
dels and different engine applications.
ison with the Engine Monitoring System.
the Electronic Troubleshooting Manual for
12 SEBU8121
Product Information Section
General Information
Product Information
Section
General Information
i01889424
Welding on Engines w it h
Electronic Controls
NOTICE
Proper welding procedures are necessary in order
to avoid damage to the engine’s ECM, sensors, and
associated components. When possible, remove the
component from the unit and then weld the component. If removal of the component is not possible,
the following procedure must be followed when you
weld with a unit that is equipped with an Electronic
Engine. The following procedure is considered to be
the safest procedure to weld a component. This procedure should provide a minimum risk of damage to
electronic components.
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
components, electrical components, and other components.
Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the possibility of damage.
1. Stop the engine. Turn the switched power to the
OFF position.
2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided,
open the switch.
Illustration 7
Use the example above. The current flow from the w elder to
the ground clamp of the welder will not cause damage to any
associated components.
(1) Engine
(2) Welding rod
(3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Maximum distance between the component that is being
welded and any electrical/electronic component
(9) The com ponent that is being welded
(10) Current path of the welder
(11) Ground clamp for the welder
4. Connect the welding ground cable directly to the
part that will be welded. Place the ground cable as
close as possible to the weld in order to reduce the
possibility of welding current damage to bearings,
hydraulic components, electrical components, and
ground straps.
Note: If electrical/electronic components are used
as a ground for the welder, or electrical/electronic
components are located between the welder ground
and the weld, current flow from the welder could
severely damage the component.
g00765012
3. Disconnect the J1/P1 connectors from the ECM.
Move the harness to a position that will not allow
the harness to accidentally move back and make
contact with any of the ECM pins.
5. Protect the wiring harness from welding debris
and spatter.
6. Use standard welding practices to weld the
materials.
SEBU8121 13
Product Information Section
Model Views
Model Views
i02247468
Model View Illustrations
1104 Engine Vi
ews
Illustration 8
Left side view of the 1104 engine
Typical example of the 1104 engine
g01131700
14 SEBU8121
Product Information Section
Model Views
(1) Fuel lines
(2) Fuel primin
(3) Fuel filter
(4) Machine int
(5) Speed/timin
(6) Electronic f
(7) Engine oil pr
g pump
erface connector (MIC)
gsensor
uel injection pump
essure sensor
(8) Engine oil f
(9) Water pump
(10) Crankshaf
(11) Alternato
(12) Engine cool
(13) Voltage loa
(14) Electronic
r
ilter
t pulley
ant temperature sensor
d protection module
control module (ECM)
Illustration 9
Right side view of the 1104 engine
Typical example of the 1104 engine
(1) Exhaust elbow
(2) Turbocharger
(3) Wastegate actuator
(4) Starter motor
g01131701
(5) Flywheel housing
SEBU8121 15
Product Information Section
Model Views
i02247483
Engine Description
The Perkins110
the following applications: machine and industrial
mobile equipment. The engines are available in the
following typ
Turbocharged aftercooled
•
Turbocharged
•
Naturally asp
•
Engine Specif
Note: The front end of the engine is opposite the
flywheel end
sides of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder.
4 Electronic Engine is designed for
es of aspiration:
irated
ications
of the engine. The left and the right
Table 1
1104 Electronic Engine Specifications
Number of Cylinders 4 In-Line
Bore
Stroke 127 mm (5.0 inch)
Aspiration
Compression
Displacement
Firing Order 1-3-4-2
Rotation (flywheel end) Counterclockwise
Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)
Valve Lash Setting
(Exhaust)
lectronic Engine Featur es
E
The Perkins 1104 Electronic Engine is designed with
lectronic controls. The integral on board computer
e
controls the operation of the engine. Current
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:
Ratio
105 mm (4.134 inch)
Turbocharged, aftercooled
Turbocharged
Naturally aspirated
NA 19.25:1 NA
T 18.23:1 T, TA
4.4L(268in3)
0.45 mm (0.018 inch)
Illustration 10
Typical example
1104 Electronic engine
(A) Inlet valves
(B) Exhaust valves
g00984281
Engine monitoring
•
Engine speed governing
•
Cold start strategy
•
Automatic air/fuel ratio control
•
Torque rise shaping
•
Automatic altitude compensation
•
Fuel temperature compensation
•
Injection timing control
•
System diagnostics
•
For more information on electronic engine features,
refer to the Operation and Maintenance Manual,
“Features and Controls” topic (Operation Section).
16 SEBU8121
Product Information Section
Model Views
Engine Diagnostics
The Perkins 110
in order to ensure that all of the components are
functioning properly. The operator will be informed of
anychangetoa
be alerted to the condition by a “Stop or Warning”
lamp that may be mounted on the dashboard or
on the contro
engine horsepower and the vehicle speed may be
limited. The electronic service tool may be used to
display the d
There are three types of diagnostic codes: active,
logged, and
Most of the diagnostic codes are logged and stored
in the ECM. F
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
desired en
Engine Coo
4 engine has built-in diagnostics
programmed limit. The operator will
l panel. Under certain conditions, the
iagnostic codes.
event.
or additional information, refer to
gine rpm.
ling and Lubrication
Engine Service Life
Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operation and maintenance recommendations. In
addition, use recommended fuels, coolants and
lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.
Expected engine life is generally predicted by the
average power that is demanded. The average power
that is demanded is based on fuel consumption of
the engine over a period of time. Reduced hours of
operation at full throttle and/or operating at reduced
throttle settings result in a lower average power
demand. Reduced hours of operation will increase
the length of operating time before an engine
overhaul is required.
The cooling system consists of the following
component
Gear-driven centrifugal water pump
•
Water temperature regulators which regulate the
•
engine coolant temperature
Gear-driven oil pump (gear type)
•
Oil cooler
•
The engine lubricating oil is supplied by a gear
type pump
the engine lubricating oil is filtered. Bypass valves
provide unrestricted flow of lubrication oil to the
engine pa
can also provide unrestricted flow of lubrication oil
to the engine parts if the oil cooler should become
plugged
plugged.
Engine e
engine performance depend on adherence to proper
operation and maintenance recommendations.
Engine p
the use of recommended fuels, lubrication oils, and
coolants. Refer to the Operation and Maintenance
Manual
information on maintenance items.
s:
. The engine lubricating oil is cooled and
rts when oil viscosity is high. Bypass valves
or if the oil filter element should become
fficiency, efficiency of emission controls, and
erformance and efficiency also depend on
, “Maintenance Interval Schedule” for more
SEBU8121 17
Product Information Section
Product Identification Information
Product Identification
Information
i02280116
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
RE12345U090001H.
_______________________________________ ___ Type of engine
RE
RE12345
U
____________________________Built in the United Kingdom
090001
H
________________________________ _____ Year of Manufacture
Perkins dealers need these numbers in order to
determine the components that were included with
the engine. This permits accurate identification of
replacement part numbers.
____________________________ Engine List Number
___________________________Engine Serial Number
Serial Number Plate
Illustration 11
Typical serial number plate
(1) Temporary Parts List number
(2) Type
(3) Serial number
(4) List number
i01940474
g00994966
The Serial Number Plate is located on the left side of
the cylinder block behind the high pressure pipes of
the Fuel injection pump.
The following information is stamped on the Serial
Number Plate: Engine serial number, Model, and
Arrangement number.
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 ______________________________________
18 SEBU8121
Product Information Section
Product Identification Information
drpm
Engine Full Loa
_____________________________________
Primary Fuel Filter _________________________________________
Water Separator Element ________________________________
Secondary Fue
l Filter Element
__________________________
Lubrication Oil Filter Element ___________________________
Auxiliary Oil Filter Element _______________________________
Total Lubrica
tion System Capacity
_____________________
Total Cooling System Capacity _________________________
Air Cleaner Element ______ _________________________________
Fan Drive Belt
______________________________________________
Alternator Belt ______________________________________________
i02272778
Emissions Certification Film
Label for compliant engines
Illustration 12
Typical example
This label is installed on engines that com ply with em issions.
g01127835
SEBU8121 19
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage
Engine Lifting
i02164186
Some removals r
obtain correct balance and safety.
To r e mov e th e e
are on the engine.
Lifting eyes a
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
information
lifting.
equire lifting the fixtures in order to
ngine ONLY, use the lifting eyes that
re designed and installed for specific
olete. If alterations are made, ensure
regarding fixtures for correct engine
i02248407
Engine Storage
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.
Illustration 13
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyeb
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object becomes le
When it is necessary to remove a component at an
angle, o
the weight.
Use a ho
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parall
be perpendicular to the top of the object that is being
lifted.
olts and the brackets under tension. Remem-
ss than 90 degrees.
nly use a link bracket that is properly rated for
ist to remove heavy components. Use
el to each other. The chains and cables should
g01097527
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 :
Completely clean the outside of the engine.
•
Drain the fuel system completely and refill
•
the system with preservative fuel.1772204
POWERPARTLay-Up1canbemixedwith
the normal fuel in order to change the fuel into
preservative fuel.
If preservative fuel is not available, the fuel system
•
canbefilledwithnormalfuel.Thisfuelmustbe
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.
20 SEBU8121
Operation Section
Lifting and Storage
Renew the canis
•
Fill the oil pan to the Full Mark on the dipstick
•
with new, clea
POWERPARTLay-Up2totheoilinorderto
protect the engine against corrosion. If 1762811
POWERPART La
preservative of the correct specification instead
of the lubricating oil. If a preservative is used,
this must be d
storage period and the oil pan must be refilled to
the correct level with normal lubricating oil.
ter(s) of the lubricating oil filter.
n lubricating oil. Add 1762811
y-Up 2 is not available, use a
rained completely at the end of the
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 fr
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
om the engine. This is important if the sys-
has been used.
4. Open the tap or r
bottom of the radiator in order to drain the radiator.
If the radiator does not have a tap or a drain plug,
disconnect th
5. Flush the cooling system with clean water.
6. Fit the drain plugs and the filler cap. Close the tap
or connect the radiator hose.
7. Fill the cooling system with an approved
antifreeze mixture because this gives protection
against corr
(0.2200 Imp gal) per minute in order to fill the
system.
Note: Certain corrosion inhibitors could cause
damage to some engine components. Contact the
Service Dep
8. Operate the engine for a short period in order to
circulate t
engine.
9. Disconnect
storage in a fully charged condition. Before the
battery is put into storage, protect the terminals
against co
3 can be used on the terminals.
10. Clean the c
Seal the end of the pipe.
11. Remove the
1762811 POWERPART Lay-Up 2 for one or two
seconds into each cylinder bore with the piston
at BDC.
artment of Perkins for advice.
he lubricating oil and the coolant in the
rrosion.1734115 POWERPART Lay-Up
emove the drain plug at the
e hose at the bottom of the radiator.
osion. The maximum flow rate is 1 L
the battery. Put the battery into safe
rankcase breather if one is installed.
fuel injector nozzles and spray
Illustration 14
1. Ensure that the engine is on level ground.
2. Remove t
3. Remove the drain plug (1) from the side of the
cylinde
that the drain hole is not restricted.
he filler cap of the cooling system.
r block in order to drain the engine. Ensure
g010039
12. Slowly rotate the crankshaft for one complete
revoluti
nozzles.
on and then replace the fuel injector
Induction System
Remove th
•
remove the pipes that are installed between
the air filter assembly and the turbocharger.
Spray 17
turbocharger. The duration of the spray is printed
on the container. Seal the turbocharger with
waterpr
28
Exhaust
Remove the exhaust pipe. Spray 1762811
•
POWERP
duration of the spray is printed on the container.
Seal the turbocharger with waterproof tape.
e air filter assembly. If necessary,
62811 POWERPARTLay-Up2intothe
oof tape.
System
ART Lay-Up 2 into the turbocharger. The
SEBU8121 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 1762811 POWERPART
Lay-Up 2 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
•
1734115 POWERPART Lay-Up 3. 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 SEBU8121
Operation Section
Gauges and Indicators
Gauges an d Indicators
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 w ith the pressurized cooling system at
ture reading may vary according to load. The
gine is operating above the normal range
ter Coolant Temperature –
SEBU8121 23
Operation Section
Features and Controls
Features and Controls
i02259828
Monitoring System
If the Shutdown mode has been selec ted and the
warning indi
take as little as 20 seconds from the time the warning indicator is activated. Depending on the application, s
avoid personal injury. The engine can be restarted
following shutdown for emergency maneuvers, if
necessary.
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 manifold air temperature
•
Intake manifold air pressure
•
Oil pressure
•
Fuel temperature
•
cator activates, engine shutdown may
pecial precautions should be taken to
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 power
begin to flash when the derating occurs.
Theenginewi
preset operational limits. The engine derate is
achieved by restricting the amount of fuel that is
available f
reduction of fuel is dependent on the severity of the
fault that has caused the engine derate, typically up
to a limit o
predetermined reduction in engine power.
“Warning/
The “Diagnostic” lamp turns “ON” and the warning
signal (re
the engine power will be derated. The engine will
continue at the rpm of the set derate until a shutdown
of the engi
after a shutdown for use in an emergency.
A shutdow
as 20 seconds. The engine can be restarted after
a shutdown for use in an emergency. However,
the cause
Theenginemayshutdownagaininaslittleas20
seconds.
will be derated. The warning lamp will
ll be derated if the engine exceeds
or each injection. The amount of this
f 50%. This reduction in fuel results in a
Derate/Shutdown”
d lamp) is activated. After the warning,
ne occurs. The engine can be restarted
n of the engine may occur in as little
of the initial shutdown may still exist.
Engine speed/timing
•
Programmable Options 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 a pplication, 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
order to
For each of the programmed modes, refer to
Trouble
information on Indicator Lamps.
For more
your Perkins dealer or your Perkins distributor.
verify the condition.
shooting Guide, “Indicator Lamps” for more
information or assistance for repairs, consult
24 SEBU8121
Operation Section
Features and Controls
i02259829
Sensors and Electrical
Components
Sensor Locations for the 1104
Engine
Illustration 15
Left side view of the 1104 engine
Typical example of a 1104 engine
(1) Electronic control module (ECM)
(2) Intake manifold temperature sensor
Illustration 16
(7) Typical location of the voltage load protection module by the
ECM
(3) Intake manifold pressure sensor
(4) Speed/timing sensor
g00915
g00894185
(5) Engine oil pre ssure sensor
(6) Machine interface connector
275
SEBU8121 25
Operation Section
Features and Controls
Illustration 17
Right side
Typical example of a 1104 engine
(8) Engine coolant temperature sensor
view of the 1104 engine
Failure of Sensors
All Senso
A failure of any of the sensors may be caused by one
of the fol
Sensor output is open.
•
Sensor output is shorted to “- battery” or “+ battery”.
•
Measured
•
specification.
rs
lowing malfunctions:
reading of the sensor is out of the
Intake Manifold Pressure Sensor
The inta
signal which corresponds to the intake manifold
pressure to the ECM. The ECM can control injection
timing a
When the throttle is increased and when the engine
demands more fuel, the fuel limit is controlled in order
to redu
ke manifold pressure sensor provides a
nd the amount of fuel that is injected.
ce overall smoke levels of the engine exhaust.
g00915291
Engine Oil Pressure Sensor
The engin
pressure sensor that measures the engine oil
pressure in the main oil gallery. The engine oil
pressur
diagnostic purposes. The engine oil pressure sensor
sendsasignaltotheECM.
e oil pressure sensor is an absolute
e sensor detects engine oil pressure for
Intake Manifold Temperature
Sensor
The inta
the inlet air temperature. A signal is sent to the
Electronic Control Module (ECM). The intake
manifo
ECM to determine initiation of the Cold Start Strategy
and control for appropriate start of injection timing
while t
ke manifold temperature sensor measures
ld temperature sensor is also used by the
he engine is warming up.
26 SEBU8121
Operation Section
Features and Controls
Coolant Temperature Sensor
The coolant temperature sensor monitors the engine
coolant temperature. The output of the ECM can
indicate a high coolant temperature through a relay
or a lamp. The coolant temperature sensor is used
by the ECM to determine initiation of the Cold Start
Condition and control for appropriate start of injection
timing while the engine is warming up.
Speed/Timing Sensor
If the ECM does not receive a signal from the primary
speed/timing sensor the “DIAGNOSTIC” lamp will
indicate a diagnostic fault code which will be logged
in the ECM memory.
If the ECM does not receive a signal from the primary
speed/timing sensor, the ECM will read the signal
from the secondary speed/timing sensor. The ECM
continually checks in order to determine if there is a
signal from both sensors. If either sensor fails, the
faulty sensor should be replaced.
Intermittent failure of the sensors will cause erratic
engine control.
Throttle Position Sensor
The throttle position sensor (TPS) eliminates the
mechanical throttle and governor linkages. The TPS
interprets the position of the throttle lever into an
electrical signal that is sent to the ECM. The throttle
position signal and the engine speed/timing signal
are processed by the ECM in order to precisely
control engine speed.
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