PDF Operating and Maintenance Manual Perkins 1103 and 1104 Industrial Engines - 716 KB
Keep your Perkins 1103 and 1104 series industrial engines running reliably with this official operating and maintenance manual.
It details the correct operating procedures, fluid specifications, and service intervals.
This guide is essential for preventing premature wear and ensuring your engine delivers the power and longevity it was designed for.
Proper care starts with having the right information.
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SEBU7833-03
September 2008
Operation and
Maintenance
Manual
1103 and 1104 Industrial Engines
DC (Engine)
DD (Engine)
DJ (Engine)
DK (Engine)
RE (Engine)
RG (Engine)
RJ (Engine)
RR (Engine)
RS (Engine)
RT (Engine)
DF (Engine)
DG (Engine)
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SEBU7833-03 11
Safety Section
Engine Starting
Do not bypass the automatic shutoff circuits. Do not Note: The engine is equipped with an automatic
disable the automatic shutoff circuits. The circuits are device for cold starting for normal conditions of
provided in order to help prevent personal injury. The operation. If the engine will be operated in very cold
circuits are also provided in order to help prevent conditions, then an extra cold starting aid may be
engine damage. required. Normally, the engine will be equipped with
the correct type of starting aid for your region of
See the Service Manual for repairs and for operation.
adjustments.
The engines are equipped with a glow plug starting
aid in each individual cylinder that heats the intake
i02207232
air in order to improve starting.
Engine Starting
i01928905
Engine Stopping
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and Stop the engine according to the procedure in
personal injury. the Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
If a warning tag is attached to the engine start switch the engine components.
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached Use the Emergency Stop Button (if equipped) ONLY
the warning tag before the engine is started. in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
All protective guards and all protective covers must emergency stop, DO NOT start the engine until the
be installed if the engine must be started in order problem that caused the emergency stop has been
to perform service procedures. To help prevent an corrected.
accident that is caused by parts in rotation, work
around the parts carefully. Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an engine
Start the engine from the operator’s compartment or that has been overhauled. This may be accomplished
from the engine start switch. by shutting off the fuel supply to the engine and/or
shutting off the air supply to the engine.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
i02176668
Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Electrical System
Knowing the procedure will also help to prevent
personal injury.
Never disconnect any charging unit circuit or battery
To ensure that the jacket water heater (if equipped) circuit cable from the battery when the charging unit
and/or the lube oil heater (if equipped) is working is operating. A spark can cause the combustible
correctly, check the water temperature gauge and the gases that are produced by some batteries to ignite.
oil temperature gauge during the heater operation.
To help prevent sparks from igniting combustible
Engine exhaust contains products of combustion gases that are produced by some batteries, the
which can be harmful to your health. Always start the negative “−” jump start cable should be connected
engine and operate the engine in a well ventilated last from the external power source to the negative
area. If the engine is started in an enclosed area, “−” terminal of the starting motor. If the starting motor
vent the engine exhaust to the outside. is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.
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SEBU7833-03 21
Product Information Section
Product Identification Information
g01173630
Illustration 17
This typical example of a label is installed on engines that have electronic fuel injection systems and installed on engines that have electronic
fuel injection pumps.
g01156733
Illustration 18
This typical example of a label is installed on engines that have mechanical fuel injection pumps.
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SEBU7833-03 31
Operation Section
Engine Operation
Engine Operation i02330149
Fuel Conservation Practices
i02176671
Engine Operation
The efficiency of the engine can affect the fuel
economy. Perkins design and technology in
manufacturing provides maximum fuel efficiency in
Correct operation and maintenance are key factors all applications. Follow the recommended procedures
in obtaining the maximum life and economy of in order to attain optimum performance for the life
the engine. If the directions in the Operation and of the engine.
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized. • Avoid spilling fuel.
The engine can be operated at the rated rpm after the Fuel expands when the fuel is warmed up. The fuel
engine reaches operating temperature. The engine may overflow from the fuel tank. Inspect fuel lines for
will reach normal operating temperature sooner leaks. Repair the fuel lines, as needed.
during a low engine speed (rpm) and during a low
power demand. This procedure is more effective than • Be aware of the properties of the different fuels.
idling the engine at no load. The engine should reach Use only the recommended fuels.
operating temperature in a few minutes.
• Avoid unnecessary idling.
Gauge readings should be observed and the data
should be recorded frequently while the engine Shut off the engine rather than idle for long periods of
is operating. Comparing the data over time will time.
help to determine normal readings for each gauge.
Comparing data over time will also help detect • Observe the air cleaner service indicator frequently.
abnormal operating developments. Significant Keep the air cleaner elements clean.
changes in the readings should be investigated.
• Maintain the electrical systems.
i01929404 One damaged battery cell will overwork the alternator.
Engine Warm-up This will consume excess power and excess fuel.
• Ensure that the drive belts are correctly adjusted.
The drive belts should be in good condition.
1. Run the engine at low idle for three to five minutes,
or run the engine at low idle until the jacket water • Ensure that all of the connections of the hoses are
tight. The connections should not leak.
temperature starts to rise.
More time may be necessary when the • Ensure that the driven equipment is in good
working order.
temperature is below −18°C (0°F).
2. Check all of the gauges during the warm-up • Cold engines consume excess fuel. Utilize heat
from the jacket water system and the exhaust
period.
system, when possible. Keep cooling system
components clean and keep cooling system
3. Perform a walk-around inspection. Check the
components in good repair. Never operate the
engine for fluid leaks and air leaks.
engine without water temperature regulators.
All of these items will help maintain operating
4. Increase the rpm to the rated rpm. Check for
temperatures.
fluid leaks and air leaks. The engine may be
operated at full rated rpm and at full load when
the temperature of the water jacket reaches 60°C
(140°F).
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SEBU7833-03 41
Maintenance Section
Refill Capacities
Some synthetic base oils have performance
characteristics that enhance the service life of the NOTICE
oil. Perkins does not recommend the automatic Shortened engine service life could result if second
extending of the oil change intervals for any type of choice oils are used.
oil.
Re-refined base stock oil Aftermarket Oil Additives
Re-refined base stock oil are acceptable for use in Perkins does not recommend the use of aftermarket
Perkins engines if these oils meet the performance additives in oil. It is not necessary to use aftermarket
requirements that are specified by Perkins.Re-refined additives in order to achieve the engine’s maximum
base stock oil can be used exclusively in finished oil service life or rated performance. Fully formulated,
or in a combination with new base stock oil . The US finished oils consist of base oils and of commercial
military specifications and the specifications of other additive packages. These additive packages are
heavy equipment manufacturers also allow the use of blended into the base oils at precise percentages in
re-refined base stock oil that meet the same criteria. order to help provide finished oils with performance
characteristics that meet industry standards.
The process that is used to make re-refined base
stock oil should adequately remove all wear metals There are no industry standard tests that evaluate
that are in the used oil and all the additives that the performance or the compatibility of aftermarket
are in the used oil. The process that is used to additives in finished oil. Aftermarket additives may
make re-refined base stock oil generally involves the not be compatible with the finished oil’s additive
process of vacuum distillation and hydrotreating the package, which could lower the performance of the
used oil. Filtering is adequate for the production of finished oil. The aftermarket additive could fail to
high quality, re-refined base stock oil. mix with the finished oil. This could produce sludge
in the crankcase. Perkins discourages the use of
aftermarket additives in finished oils.
Lubricants for Cold Weather
To achieve the best performance from a Perkins
When an engine is started and an engine is operated engine, conform to the following guidelines:
in ambient temperatures below −20 °C (−4 °F), use
multigrade oils that are capable of flowing in low • Select the correct oil, or a commercial oil that meets
temperatures. the “EMA Recommended Guideline on Diesel
Engine Oil” or the recommended API classification.
These oils have lubricant viscosity grades of SAE
0W or SAE 5W. • See the appropriate “Lubricant Viscosities” table in
order to find the correct oil viscosity grade for your
When an engine is started and operated in ambient engine.
temperatures below −30 °C (−22 °F), use a synthetic
base stock multigrade oil with an 0W viscosity grade • At the specified interval, service the engine. Use
or with a 5W viscosity grade. Use an oil with a pour new oil and install a new oil filter.
point that is lower than −50 °C (−58 °F).
• Perform maintenance at the intervals that are
The number of acceptable lubricants is limited in specified in the Operation and Maintenance
cold weather conditions. Perkins recommends the Manual, “Maintenance Interval Schedule”.
following lubricants for use in cold weather conditions:
First Choice – Use oil with an EMA DHD-1 S·O·S Oil analysis
Recommended Guideline. Use a CH-4 oil that has
an API license. The oil should be either SAE 0W20, Some engines may be equipped with an oil sampling
SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40 valve. If S·O·S oil analysis is required the oil sampling
lubricant viscosity grade. valve is used to obtain samples of the engine oil. The
S·O·S oil analysis will complement the preventive
Second Choice – Use an oil that has a CH-4 maintenance program.
additive package. Although the oil has not been
tested for the requirements of the API license, the oil The S·O·S oil analysis is a diagnostic tool that is used
must be either SAE 0W20, SAE 0W30, SAE 0W40, to determine oil performance and component wear
SAE 5W30, or SAE 5W40. rates. Contamination can be identified and measured
through the use of the S·O·S oil analysis. The S·O·S
oil analysis includes the following tests:
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SEBU7833-03 51
Maintenance Section
Maintenance Interval Schedule
i03302982 Every 2 Years
Maintenance Interval Schedule Cooling System Coolant - Change ....................... 58
Every 3000 Service Hours
When Required Fuel Injector - Test/Change ................................... 68
Battery - Replace .................................................. 54 Every 3000 Service Hours or 2 Years
Battery or Battery Cable - Disconnect .................. 55
Engine - Clean ...................................................... 60 Cooling System Coolant (Commercial Heavy-Duty) -
Engine Air Cleaner Element (Dual Element) - Change ............................................................... 55
Clean/Replace .................................................... 61
Engine Air Cleaner Element (Single Element) - Every 4000 Service Hours
Inspect/Replace .................................................. 63
Engine Oil Sample - Obtain .................................. 64 Aftercooler Core - Clean/Test ............................... 52
Fuel Injector - Test/Change ................................... 68
Fuel System - Prime ............................................. 69 Every 6000 Service Hours or 3 Years
Severe Service Application - Check ..................... 75
Cooling System Coolant Extender (ELC) - Add .... 59
Daily Every 12 000 Service Hours or 6 Years
Alternator and Fan Belts - Inspect/Adjust/
Cooling System Coolant (ELC) - Change ............. 57
Replace ............................................................... 53
Cooling System Coolant Level - Check ................ 59
Driven Equipment - Check .................................... 60
Engine Air Cleaner Service Indicator - Inspect ..... 63
Engine Oil Level - Check ...................................... 64
Fuel System Primary Filter/Water Separator -
Drain ................................................................... 70
Walk-Around Inspection ........................................ 77
Every 50 Service Hours or Weekly
Fuel Tank Water and Sediment - Drain ................. 73
Every 500 Service Hours or 1 Year
Battery Electrolyte Level - Check .......................... 54
Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................... 61
Engine Air Cleaner Element (Single Element) -
Inspect/Replace .................................................. 63
Engine Ground - Inspect/Clean ............................ 64
Engine Oil and Filter - Change ............................. 65
Fuel System Primary Filter (Water Separator)
Element - Replace .............................................. 70
Fuel System Secondary Filter - Replace .............. 71
Hoses and Clamps - Inspect/Replace .................. 74
Radiator - Clean .................................................... 75
Every 1000 Service Hours
Engine Valve Lash - Inspect/Adjust ...................... 67
Every 2000 Service Hours
Aftercooler Core - Inspect ..................................... 52
Alternator - Inspect ............................................... 53
Engine Mounts - Inspect ....................................... 64
Starting Motor - Inspect ........................................ 76
Turbocharger - Inspect .......................................... 76
Water Pump - Inspect ........................................... 78
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SEBU7833-03 61
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace
i01915869 Dual Element Air Cleaners
Engine Air Cleaner Element The dual element air cleaner contains a primary air
(Dual Element) - Clean/Replace cleaner element and a secondary air cleaner element.
The primary air cleaner element can be used up
to six times if the element is properly cleaned and
properly inspected. The primary air cleaner element
should be replaced at least one time per year. This
NOTICE replacement should be performed regardless of the
Never run the engine without an air cleaner element number of cleanings.
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with The secondary air cleaner element is not serviceable
damaged pleats, gaskets or seals. Dirt entering the or washable. Refer to the OEM information for
engine causes premature wear and damage to engine instructions in order to replace the secondary air
components. Air cleaner elements help to prevent air- cleaner element. When the engine is operating in
borne debris from entering the air inlet. environments that are dusty or dirty, air cleaner
elements may require more frequent replacement.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Servicing the Air Cleaner Elements
Note: The air filter system may not have been
provided by Perkins. The procedure that follows
is for a typical air filter system. Refer to the OEM
information for the correct procedure.
If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal Illustration 33
g00736431
engine wear. Refer to the OEM information for the
(1) Cover
correct air cleaner elements for your application. (2) Primary air cleaner element
(3) Secondary air cleaner element
• Check the precleaner (if equipped) and the dust (4) Air inlet
bowl daily for accumulation of dirt and debris.
Remove any dirt and debris, as needed. 1. Remove the cover. Remove the primary air
cleaner element.
• Operating conditions (dust, dirt and debris) may
require more frequent service of the air cleaner 2. The secondary air cleaner element should be
element. removed and discarded for every three cleanings
of the primary air cleaner element.
• The air cleaner element should be replaced at least
one time per year. This replacement should be Note: Refer to “Cleaning the Primary Air Cleaner
performed regardless of the number of cleanings. Elements”.
Replace the dirty air cleaner elements with clean air 3. Cover the air inlet with tape in order to keep dirt
cleaner elements. Before installation, the air cleaner out.
elements should be thoroughly checked for tears
and/or holes in the filter material. Inspect the gasket 4. Clean the inside of the air cleaner cover and body
or the seal of the air cleaner element for damage. with a clean, dry cloth.
Maintain a supply of suitable air cleaner elements
for replacement purposes. 5. Remove the tape for the air inlet. Install the
secondary air cleaner element. Install a primary
air cleaner element that is new or cleaned.
6. Install the air cleaner cover.
7. Reset the air cleaner service indicator.
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SEBU7833-03 71
Maintenance Section
Fuel System Secondary Filter - Replace
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Element filter
Turn the valves for the fuel lines (if equipped) to the
OFF position before performing this maintenance.
Place a tray under the fuel filter in order to catch
any fuel that might spill. Clean up any spilled fuel
immediately.
g01118416
Illustration 46
(1) Screw
(2) Element
(3) Glass bowl
(4) Sensor connection
(5) Drain
(6) Bottom cover
1. Place a suitable container below the water
separator. g01010637
Illustration 47
2. Open the drain (5). Allow the fluid to drain into (1) Drain
(2) Filter bowl
the container.
3. When clean fuel drains from the water separator 1. Close the valves for the fuel lines (if equipped).
close the drain (5). Tighten the drain by hand
pressure only. Dispose of the drained fluid 2. Clean the outside of the fuel filter assembly. Open
correctly. the fuel drain (1) and drain the fuel into a suitable
container.
i02469473
Fuel System Secondary Filter -
Replace
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.