PDF Disassembly & Assembly Manual Perkins 1103 & 1104 Industrial Engines - 1 MB
For technicians performing major overhauls, this disassembly and assembly manual for Perkins 1103 and 1104 industrial engines is indispensable.
The guide provides meticulous, step-by-step instructions for taking the engine apart and putting it back together according to factory specifications.
Detailed diagrams and torque values are included to ensure every repair is done correctly.
This manual is the key to a successful engine rebuild.
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SENR9779-03
January 2007
Disassembly and
Assembly
1103 and 1104 Industrial Engines
DC (Engine)
DD (Engine)
DJ (Engine)
DK (Engine)
RE (Engine)
RG (Engine)
RJ (Engine)
RR (Engine)
RS (Engine)
DF (Engine)
DG (Engine)
This document has been printed from SPI². Not for Resale
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SENR9779-03 11
Disassembly and Assembly Section
Installation Procedure i02216956
NOTICE
Fuel Injection Pump - Remove
Keep all parts clean from contaminants. (Delphi DP210)
Contaminants may cause rapid wear and shortened
component life.
Note: The installation procedure is identical for the
four cylinder and the three cylinder engines. The
illustration shows the four cylinder engine.
Removal Procedure
Start By:
a. Remove the fuel injection lines. Refer to this
Disassembly and Assembly Manual, “Fuel
Injection Lines - Remove”.
g01011111
Illustration 15
Typical example b. Remove the crankshaft pulley. Refer to this
Disassembly and Assembly Manual, “Crankshaft
1. Thoroughly clean all of the inner surfaces of the Pulley - Remove and Install”.
cover (1) for the fuel injectors.
c. Remove the front cover. Refer to this Disassembly
2. Install the cover (1). and Assembly Manual, “Front Cover - Remove
and Install”.
3. Install the setscrews (2) for the cover (1). Tighten
the setscrews (2) to a torque of 9 N·m (7 lb ft). Note: The removal procedure is identical for the
four cylinder and the three cylinder engines. The
illustrations show the four cylinder engine.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
1. Ensure that the No. 1 cylinder is at top dead
center on the compression stroke. Refer to the
Testing and Adjusting Manual, “Finding Top Center
Position for No. 1 Piston”.
This document has been printed from SPI². Not for Resale
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SENR9779-03 21
Disassembly and Assembly Section
1. Ensure that the No. 1 cylinder is at top dead center Note: Ensure that the mating surfaces of the fuel
on the compression stroke. Refer to the Testing injection pump gear and the shaft of the fuel injection
and Adjusting Manual, “Fuel Injection Timing - pump are clean. Lubricate the threads of the shaft for
Check”. the fuel injection pump. The nut (7) must turn freely
until contact is made with the fuel injection pump
gear.
5. Position the fuel injection pump gear (8) onto the
shaft of the fuel injection pump. Install the washer
and the nut (7). Rotate the fuel injection pump
gear (8) in a counterclockwise direction in order
to remove the backlash. Tighten the nut (7) to a
torque of 24 N·m (17 lb ft).
g01062396
Illustration 37
Note: Do not lubricate the new O-ring (9). The O-ring
should be installed dry.
2. Install the new O-ring (9) onto the fuel injection
pump. Position the fuel injection pump onto the
front housing. Install the setscrews (14). Tighten
the setscrews (14) to a torque of 25 N·m (18 lb ft).
g01062395
Illustration 39
3. Install the setscrew (12) and the bracket (11) onto
the cylinder block if the bracket was previously 6. Connect the harness assembly to the timing
removed. Ensure that the bracket (11) supports advance solenoid (6).
the fuel injection pump without applying any other
external force on the fuel injection pump. Tighten 7. Connect the harness assembly (4).
the setscrew (12) to a torque of 44 N·m (32 lb ft).
8. Remove all of the dust caps from the connectors
4. Install the bolt (13) and the nut (10). on the fuel injection pump. Remove all of the plugs
from the fuel hose assemblies and from the tube
assemblies.
9. Connect the fuel line (5) to the fuel injection pump.
Connect the fuel return line (3) to the fuel injection
pump.
g01062397
Illustration 38
Typical example
This document has been printed from SPI². Not for Resale
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SENR9779-03 31
Disassembly and Assembly Section
Note: The top flange of the oil drain tube assembly
(9) is secured to the turbocharger (1) with 6 mm
setscrews (8). The bottom flange of the oil drain tube
assembly (9) is secured to the cylinder block with 8
mm setscrews (11).
8. Position a new joint (10) and the oil drain tube
assembly (9) onto the bottom of the turbocharger
(1). Install the 6 mm setscrews (8). Tighten the 6
mm setscrews (8) to a torque of 9 N·m (80 lb in).
9. Position a new joint and the oil drain tube
assembly (9) onto the cylinder block. Tighten the 8
mm setscrews (11) to a torque of 22 N·m (16 lb ft).
g01038456
10. Position the new washers (7) and the oil supply Illustration 61
tube assembly (6) onto the turbocharger (1).
Install the banjo bolt (5). Tighten the banjo bolt (5) 15. Tighten the three nuts finger tight in the sequence
to a torque of 22 N·m (16 lb ft). (17), (18), and (19). Tighten the nuts (17), (18),
and (19) in the same sequence to a torque of
Note: Ensure that the oil supply tube assembly (6) 25 N·m (18 lb ft).
does not come into contact with any other component
when the assembly is installed onto the engine. 16. Ensure that there is no restriction in the inlet hose.
Position the air inlet hose on the turbocharger
11. Install the new washers and the oil supply tube compressor housing. Install the hose clamps.
assembly (6) to the cylinder block. Tighten the Tighten the hose clamps to a torque of 5 N·m
banjo bolt to a torque of 22 N·m (16 lb ft). (44 lb in).
12. If the studs (12) were previously removed, install Note: The air inlet hose has a reflective heat shield
the studs into the turbocharger housing. that partially covers the hose. The reflective heat
shield must be installed toward the engine. The
reflective heat shield must be kept clean and free
from dust, oil or paint.
Note: Apply a solution of water and 5% soap to the
inlet of the turbocharger in order to install a new air
inlet hose. Do not use oil or grease in order to install
the air inlet hose.
17. Position the exhaust pipe onto the exhaust elbow
or onto the turbocharger outlet (3). Refer to the
OEM information for the correct procedure in
order to install the exhaust pipe.
g01038406 i01946913
Illustration 60
Typical example Exhaust Manifold - Remove
13. Position the exhaust adapter (3) onto the studs
and Install
(12). Install the nuts (2). Do not tighten the nuts
(2) at this time.
Note: Exhaust elbows are only an option for the four Removal Procedure for the Three
cylinder engines. Cylinder Engine
14. If equipped, install the exhaust elbow onto the Start By:
exhaust adapter (3). Refer to this Disassembly
and Assembly Manual, “Exhaust Elbow - Remove a. Remove the turbocharger, if equipped. Refer
and Install”. to this Disassembly and Assembly Manual,
“Turbocharger - Remove”.
This document has been printed from SPI². Not for Resale
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SENR9779-03 41
Disassembly and Assembly Section
i01947654 Note: If the cylinder head has been previously
ground then the bottom face of valve seat must be
Inlet and Exhaust Valve Seat ground in order to ensure that the valve seat will be
Inserts - Remove and Install installed correctly into the cylinder head. A 30 degree
chamfer must be machined to the outer edge of the
valve seat after the back face of the valve insert
has been ground to the correct dimensions. The
30 degree chamfer must be within the tolerance of
Removal Procedure 0.91 mm (0.036 inch) to 1.3 mm (0.051 inch). Also,
the chamfer must be inclined to the vertical face of
Start By: the valve insert.
a. Remove the inlet valves and the exhaust valves. Note: Do not use a hammer in order to install the
Refer to this Disassembly and Assembly Manual, valve insert into the machined recess in the cylinder
“Inlet and Exhaust Valves - Remove and Install”. head.
NOTICE Note: Do not apply any lubricant before the new
Keep all parts clean from contaminants. valve seat insert is installed into the cylinder head.
Contaminants may cause rapid wear and shortened 1. Use a suitable tool to install the valve seat insert
component life. into the machined recess in the cylinder head.
Note: When new valve seat inserts are installed, new
valves and new valve guides must be installed.
1. Remove the appropriate valve guides. Install
partially finished valve guides. Refer to this
Disassembly and Assembly Manual, “Inlet and
Exhaust Valve Guides - Remove and Install”.
Note: The inserts for the inlet valves are a larger
diameter than the exhaust valve inserts.
2. Use the partially finished bore of the valve guide
as a pilot bore in order to remove the valve insert
by machining. Also use the partially finished bore
of the valve guide as a pilot bore in order to
machine a recess for a new valve seat. Refer to
the Specifications Manual, “Cylinder Head Valves”
for the required dimensions of the recess for the
valve seat. Remove all debris from the cylinder
head ports and passages.
g01016768
Illustration 77
3. Repeat the Step 2 for all of the appropriate valve
seats. 2. If necessary, a suitable tool can be manufactured.
Refer to the illustration 77. Also refer to the table 8
and refer to the table 9 for suitable dimensions.
Installation Procedure
Table 7
Required Tools
Part Number Part Description Qty
Valve Guide/Valve Seat
27610030 1
Reamer/Cutter
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
This document has been printed from SPI². Not for Resale
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SENR9779-03 51
Disassembly and Assembly Section
Installation Procedure i01958108
NOTICE
Engine Oil Relief Valve -
Keep all parts clean from contaminants. Remove and Install
Contaminants may cause rapid wear and shortened (Balancer Unit for the 1104
component life. engines only)
1. Clean the spring (3) and the plunger (4) of the
engine oil relief valve. Check the spring (3) and
the plunger (4) for wear or for other damage. The
plunger (4) must slide easily within the bore of
the oil relief valve within the engine oil pump (1).
Lubricate the spring (3) and the plunger (4) with
clean engine oil.
Removal Procedure
Start By:
a. Remove the engine oil pan. Refer to this
Disassembly and Assembly Manual, “Engine Oil
Pan - Remove and Install”.
NOTICE
Keep all parts clean from contaminants.
g00959674 Contaminants may cause rapid wear and shortened
Illustration 96
component life.
Improper assembly of parts that are spring loaded
can cause bodily injury.
To prevent possible injury, follow the established
assembly procedure and wear protective equip-
ment.
2. Install the plunger (4) and the spring (3) in the
engine oil pump (1).
3. Install the plug (2). Tighten the plug (2) to a torque
of 22 N·m (16 lb ft).
g00979780
Illustration 97
End By:
a. Install the engine oil pan. Refer to this Disassembly
and Assembly Manual, “Engine Oil Pan - Remove
and Install”. Personal injury can result from being struck by
parts propelled by a released spring force.
Make sure to wear all necessary protective equip-
ment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
This document has been printed from SPI². Not for Resale
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SENR9779-03 61
Disassembly and Assembly Section
i02259836 3. Remove the remaining setscrews (1) that secure
flywheel (3) to the crankshaft and then remove
Flywheel - Remove the flywheel.
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
g01020099
Illustration 122
4. Check the condition of the ring gear (4). Remove
the ring gear (4) if the ring gear is worn or
damaged.
Note: Identify the orientation of the ring gear on the
flywheel and the position of the chamfer on the teeth
for the correct positioning when the new ring gear
is installed.
5. Place the flywheel (3) and the ring gear (4) on a
suitable support. Use a hammer and a chisel in
order to remove the ring gear (4) from the flywheel
(3).
i02231069
g00905926
Illustration 120
Flywheel - Install
1. Remove the two setscrews (1).
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Always wear protective gloves when handling
Illustration 121
g01020091 parts that have been heated.
Typical example
1. Thoroughly clean the flywheel housing. Inspect
2. Install two suitable studs (2) as guides. the crankshaft rear seal for leaks. If there are any
oil leaks refer to this Disassembly and Assembly
Note: The flywheel (3) is heavy. Use suitable lifting Manual, “Crankshaft Rear Seal - Remove”.
equipment to support the flywheel (3) before the
remainder of the setscrews (1) are removed.
This document has been printed from SPI². Not for Resale
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SENR9779-03 71
Disassembly and Assembly Section
4. Align the pulley with the “T” mark (8) at the top and
in line with the center line of the engine and then NOTICE
install the pulley on the crankshaft. Use a suitable Care must be taken to ensure that fluids are contained
straight edge (7) against the guide pins (9) to aid during performance of inspection, maintenance, test-
alignment of the pulley. ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
Note: The pulley can be rotated by a maximum of 4 ing any compartment or disassembling any compo-
degrees in a clockwise direction or a counterclockwise nent containing fluids.
direction in order to align the splines in the pulley
with the splines on the crankshaft. This is within Dispose of all fluids according to local regulations and
acceptable limits. mandates.
5. Remove the straight edge (7) and the two guide
pins (9). Note: Do not remove the crankshaft front seal at this
time if the housing (front) will also be removed. It is
6. Lubricate the threads and the shoulder of the easier to remove the crankshaft front seal when the
setscrews (1) with clean engine oil. Position the housing (front) has been removed from the engine.
thrust block (2) and install the setscrews (1). Refer to this Disassembly and Assembly Manual,
Tighten the setscrews evenly to a final torque of “Housing (Front) - Remove”.
115 N·m (85 lb ft).
7. Tighten each of the setscrews (1) again to the
same torque in order to ensure that the setscrews
are still at the required torque.
End By:
a. Install the V-Belts. Refer to this Disassembly and
Assembly, “V-Belts - Remove and Install”.
i01964539
Crankshaft Front Seal -
g01020672
Remove Illustration 148
1. Install the legs of the puller (1) under the
crankshaft front seal (2) and lock the legs into
position.
Removal Procedure
2. Install a suitable adapter (3) between the
Table 13 crankshaft (4) and the puller (1).
Required Tools
Part Number Part Description Qty NOTICE
Ensure that the main lip is used in order to remove the
27610230 Three legged puller 1 crankshaft front seal. Do not damage the edge of the
housing for the crankshaft front seal.
Start By:
3. Use the puller (1) in order to remove the crankshaft
a. Remove the crankshaft pulley. Refer to this
front seal (2). Discard the crankshaft front seal (2).
Disassembly and Assembly Manual, “Crankshaft
Pulley - Remove and Install”.
b. Thoroughly clean the area around the housing for
the crankshaft front seal.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
This document has been printed from SPI². Not for Resale
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SENR9779-03 81
Disassembly and Assembly Section
4. In order to assemble the heavy-duty idler gear,
install the circlip (17) into the back face of the idler
gear (8). Place the back face of the idler gear
(8) onto a clean, flat surface. Insert the thrust
washer (18) through the idler gear (8) and onto
the circlip (17). Ensure that the flange face of the
bearing assembly (16) is toward the bottom and
that the protective sleeve is still in place. Insert
the new bearing assembly (16) into the idler gear
(8). Push the new bearing assembly (16) into the
idler gear (8) until the bearing assembly comes
into contact with the thrust washer (18). As the
bearing assembly (16) is pushed into the idler
gear (8) the protective sleeve will remain on the
g01024432
top face of the idler gear. Discard the protective
Illustration 172 sleeve. Install the thrust washer (15) and install
Standard idler gear assembly the circlip (14). Lightly lubricate the hub (12) with
clean engine lubricating oil. Press the hub (12)
3. Assemble the assembly (9) of the idler gear into the idler gear (8).
and the hub. In order to assemble the standard
assembly, press new bushes (13) into the idler
gear (8) if the bushes were previously removed.
Lubricate the hub (12 ) with clean engine
lubricating oil. Slide the hub (12) into the idler gear
(8). Ensure that the oil hole (20) is to the top of the
hub (12) and ensure that the marks (19) are to the
front of the idler gear (8).
g01023843
Illustration 174
g01023942
Illustration 173
Heavy-duty idler gear assembly
Note: The new bearing assembly (16) is supplied with
a protective sleeve. Do not remove this protective
sleeve. The protective sleeve prevents the rollers
from falling out of the roller bearings.
g01038902
Illustration 175
This document has been printed from SPI². Not for Resale
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SENR9779-03 91
Disassembly and Assembly Section
2. If the valve mechanism cover (1) is equipped 6. If you are working on a four cylinder engine,
with an oil filler cap, check the condition of the tighten the fasteners for the valve mechanism
O-ring for the oil filler cap. If necessary, replace cover in the sequence that is shown in Illustration
the O-ring. 200. Tighten the fasteners to a torque of 9 N·m
(80 lb in).
3. Install a new joint to the valve mechanism cover
(1) and install the valve mechanism cover onto 7. Connect the breather tube (3) to the valve
the cylinder head. mechanism cover (1). Refer to this Disassembly
and Assembly Manual, “Crankcase Breather -
4. Check the condition of the fasteners (2). Replace Remove and Install”.
the fasteners (2), if necessary. Install the fasteners
(2). End By:
a. Install the cover for the fuel injectors. Refer to this
Disassembly and Assembly Manual, “Fuel Injector
Cover - Remove and Install”.
b. If equipped, ensure that the heat shields are clean
and free from dust, oil, and paint. Install the heat
shields.
i01947657
Rocker Shaft and Pushrod -
Remove
Removal Procedure
Table 20
Required Tools
g01018519
Illustration 199
Part
Sequence for tightening the fasteners for the three cylinder engine Part Description Qty
Number
5. If you are working on a four cylinder engine, 27610227 Rocker Assembly Tool 4
go to Step 6. If you are working on a three
cylinder engine, tighten the fasteners for the valve Start By:
mechanism cover in the sequence that is shown in
Illustration 199. Tighten the fasteners to a torque a. Remove the valve mechanism cover. Refer to
of 9 N·m (80 lb in). Go to Step 7 this Disassembly and Assembly Manual, “Valve
Mechanism Cover - Remove and Install”.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Note: The removal procedure is identical for the
three cylinder and the four cylinder engines. The
illustrations show the four cylinder engine.
g00908011
Illustration 200
Sequence for tightening the fasteners for the four cylinder engine
This document has been printed from SPI². Not for Resale
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SENR9779-03 101
Disassembly and Assembly Section
i01977579
Camshaft - Remove and Install