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SEBU8121 February 2005 Operation and Maintenance Manual 1104E Engine RF11-Up (Machine) RH11-Up (Machine) RK11-Up (Machine)
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Obtain the complete and most current information before you s t ar t any jo 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.
SEBU8121 Table of Contents Table of Contents Warranty Section Warranty Information ..........81 Foreword ..............4 Index Section Safety Section Index ..............82 Safety Messages ............ 5 General Hazard Information ........5 Burn Prevention ............7 Fire Prevention and Explosion Prevention ....7 Crushing Prevention and Cutting Prevention ..
They assist with developing the skills and Perkins authorized personnel. Your Perkins dealer techniques required to operate the engine more or your Perkins distributor offers a variety of options efficiently and economically. Skill and techniques regarding overhaul programs. If you experience...
If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Perkins dealers or Perkins distributors can provide new warning signs. Do not work on the engine and do not operate the engine unless the instructions and warnings in the Operation and Maintenance Manual are understood.
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SEBU8121 Safety Section General Hazard Information The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi). Fluid Penetration Pressure can be trapped in the hydraulic circuit long after the engine has been stopped.
Oils If the application involves the presence of combustible gases, consult your Perkins dealer and/or your Hot oil and hot lubricating components can cause Perkins distributor for additional information about personal injury. Do not allow hot oil to contact the suitable protection devices.
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SEBU8121 Safety Section Fire Prevention and Explosion Prevention Exhaust shields (if equipped) protect hot exhaust Use caution when you are refueling an engine. Do components from oil or fuel spray in case of a line, not smoke while you are refueling an engine. Do not a tube, or a seal failure.
Before Starting Engine Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for repair or for replacement parts. Check lines, tubes and hoses carefully. Do not use NOTICE your bare hand to check for leaks.
SEBU8121 Safety Section Engine Stopping If a warning tag is attached to the engine start switch Use the Emergency Stop Button (if equipped) ONLY or to the controls, DO NOT start the engine or move in an emergency situation. Do not use the Emergency the controls.
Note: Many of the engine control systems and display modules that are available for Perkins Engines will work in unison with the Engine Monitoring System. Together, the two controls will provide the engine monitoring function for the specific engine application.
SEBU8121 Product Information Section General Information Product Information Section General Information i01889424 Welding on Engines with 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 compo- nent.
SEBU8121 Product Information Section Model Views Model Views i02247468 Model View Illustrations 1104 Engine Views g01131700 Illustration 8 Left side view of the 1104 engine Typical example of the 1104 engine...
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The number 1 cylinder is the front cylinder. Electronic Engine Features The Perkins 1104 Electronic Engine is designed with electronic controls. The integral on board computer controls the operation of the engine. Current operating conditions are monitored.
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Product Information Section Model Views Engine Diagnostics Engine Service Life The Perkins 1104 engine has built-in diagnostics Engine efficiency and maximum utilization of engine in order to ensure that all of the components are performance depend on the adherence to proper functioning properly.
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.
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SEBU8121 Product Information Section Product Identification Information Engine Full Load rpm _________ ____________________________ Primary Fuel Filter _________ ________________________________ Water Separator Element _________ _______________________ Secondary Fuel Filter Element _________ _________________ Lubrication Oil Filter Element _________ __________________ Auxiliary Oil Filter Element _________ ______________________ Total Lubrication System Capacity _________ ____________ Total Cooling System Capacity...
Engine Lifting fixtures obsolete. If alterations are made, ensure that correct lifting devices are provided. Consult your Perkins dealer or your Perkins distributor for information regarding fixtures for correct engine lifting. i02248407...
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Note: Certain corrosion inhibitors could cause following guidelines: damage to some engine components. Contact the Service Department of Perkins for advice. NOTICE Do not drain the coolant while the engine is still hot and 8. Operate the engine for a short period in order to...
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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.
Determine and correct the cause of any significant change in the readings. Consult your Perkins dealer or your Perkins distributor for assistance. Ammeter – This gauge indicates the amount of charge or discharge in the battery charging circuit.
Indicator Lamps. For more information or assistance for repairs, consult If the Warning/Derate/Shutdown mode has been your Perkins dealer or your Perkins distributor. selected and the warning indicator activates, bring the engine to a stop whenever possible. De- pending on the application, special precautions should be taken to avoid personal injury.
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SEBU8121 Operation Section Features and Controls i02259829 Sensors and Electrical Components Sensor Locations for the 1104 Engine g00894185 Illustration 15 Left side view of the 1104 engine Typical example of a 1104 engine (1) Electronic control module (ECM) (3) Intake manifold pressure sensor (5) Engine oil pressure sensor (2) Intake manifold temperature sensor (4) Speed/timing sensor...
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SEBU8121 Operation Section Features and Controls g00915291 Illustration 17 Right side view of the 1104 engine Typical example of a 1104 engine (8) Engine coolant temperature sensor Failure of Sensors Engine Oil Pressure Sensor The engine oil pressure sensor is an absolute All Sensors pressure sensor that measures the engine oil pressure in the main oil gallery.
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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.
ECM. The codes Perkins Electronic Engines have the capability to that have been logged by the ECM can be identified perform a self-diagnostics test. When the system by the electronic service tool.
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SEBU8121 Operation Section Engine Diagnostics i01902995 Engine Operation with Intermittent Diagnostic Codes If a diagnostic lamp illuminates during normal engine operation and the diagnostic lamp shuts off, an intermittent fault may have occurred. If a fault has occurred, the fault will be logged into the memory of the Electronic Control Module (ECM).
SEBU8121 Operation Section Engine Starting Engine Starting • Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls. i02194223 Before Starting Engine •...
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SEBU8121 Operation Section Engine Starting 2. Turn the keyswitch to the RUN position. Leave the i01903593 keyswitch in the RUN position for 20 seconds. Starting with Jump Start Cables 3. Turn the keyswitch to the START position in order to engage the electric starting motor and crank the engine.
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SEBU8121 Operation Section Engine Starting 3. Connect one negative end of the jump start cable to the negative cable terminal of the electrical NOTICE source. Connect the other negative end of the Do not crank the engine for more than 30 seconds. jump start cable to the engine block or to the Allow the electric starting motor to cool for two minutes chassis ground.
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SEBU8121 Operation Section Engine Starting i01903609 After Starting Engine Note: In temperatures from 0 to 60°C (32 to 140°F), the warm-up time is approximately three minutes. In temperatures below 0°C (32°F), additional warm-up time may be required. When the engine idles during warm-up, observe the following conditions: •...
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 all applications. Follow the recommended procedures Correct operation and maintenance are key factors...
SEBU8121 Operation Section Engine Stopping Engine Stopping i01903608 After Stopping Engine i01929389 Stopping the Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan. NOTICE •...
These Viscosity of the Engine Lubrication factors and recommendations from your Perkins dealer or your Perkins distributor are based on past proven practices. The information that is contained in this section should be combined in order to provide Correct engine oil viscosity is essential.
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An effective block heater components will be maintained. is typically a 1250/1500 W unit. Consult your Perkins dealer or your Perkins distributor for more In addition, the engine must be thoroughly warmed in information. order to keep other engine parts in better condition and the service life of the engine will be generally extended.
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Problems can result due to changes in temperature. Perkins prefer only Group 1 and Group 2 fuels for use in this series of engines. Group 3 fuels include Low Before troubleshooting for low power or for poor Temperature Fuels and Aviation Kerosene Fuels.
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SEBU8121 Operation Section Cold Weather Operation i01903588 Fuel Related Components in Cold Weather Fuel Tanks Condensation can form in partially filled fuel tanks. Top off the fuel tanks after you operate the engine. Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks.
Total Engine Manufacturers Association (EMA) Cooling System. Oils The “Engine Manufacturers Association Recommended Guideline on Diesel Engine Oil” is recognized by Perkins. For detailed information about this guideline, see the latest edition of EMA publication, “EMA DHD -1”.
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The classifications CD-2 and American Petroleum Institute CH-4 classification. Therefore, these oils will also CF-2 are for two-cycle diesel engines. Perkins does not sell meet the requirements for diesel engines that require engines that utilize CD-2 and API CF-2 oils.
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API CH-4 oils may be must be 10 times the fuel sulfur level. The TBN is used in Perkins engines that use API CG-4 and API defined by “ASTM D2896”. The minimum TBN of the CF-4 oils.
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Re-refined base stock oil Greater than 1.0 0.50 of normal Re-refined base stock oil are acceptable for use in Perkins engines if these oils meet the performance Lubricant Viscosity Recommendations requirements that are specified by Perkins.Re-refined for Direct Injection (DI) Diesel Engines base stock oil can be used exclusively in finished oil or in a combination with new base stock oil .
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Aftermarket Oil Additives • Tests are conducted in order to detect Perkins does not recommend the use of aftermarket contamination of the oil by water, glycol or fuel. additives in oil. It is not necessary to use aftermarket additives in order to achieve the engine’s maximum •...
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SEBU8121 Maintenance Section Refill Capacities High sulfur content of the fuel is not normally found “ASTM D975 - 91 Class 1D” in Europe, North America or Australasia. This can cause engine wear. When only high sulfur fuels “JP7, Mil T38219” are available, it will be necessary that high alkaline lubricating oil is used in the engine or that the “NATO F63”...
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(continued) maximum at 25 °C (77 °F) Perkins fuel systems and engine components can operate on high sulfur fuels. Fuel sulfur levels affect exhaust emissions. High sulfur fuels also increase the potential for corrosion of internal components. Fuel sulfur levels above 0.5 percent may significantly shorten the oil change...
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SEBU8121 Maintenance Section Refill Capacities Cooling System Specifications NOTICE Operating with fuels that do not meet the Perkins rec- General Coolant Information ommendations can cause the following effects: Start- ing difficulty, poor combustion, deposits in the fuel in- NOTICE jectors, reduced service life of the fuel system, de- Never add coolant to an overheated engine.
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Property Maximum Limit • Cavitation of the water pump Chloride (Cl) 40 mg/L For optimum performance, Perkins recommends a Sulfate (SO 100 mg/L 1:1 mixture of a water/glycol solution. Total Hardness 170 mg/L Note: Use a mixture that will provide protection...
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Perkins POWERPART 3000 Service Hours or Coolant Recommendations Two Years Commercial SCA and 3000 Service Hours or The following two coolants are used in Perkins diesel Water Two Years engines: Preferred – Perkins Extended Life Coolant (ELC) Extended Life Coolant (ELC) Acceptable –...
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Mixing Extended Life Coolant with other products re- duces the Extended Life Coolant service life. Failure to NOTICE follow the recommendations can reduce cooling sys- When using Perkins ELC, do not use standard SCA’s tem components life unless appropriate corrective ac- or SCA filters. tion is performed.
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Then, fill the cooling system with premixed ELC. This should 4. Use Perkins cleaner to clean the system. Follow lower the contamination to less than 10 percent. the instruction on the label.
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Refill Capacities Use the equation that is in Table 17 to determine the Table 20 amount of Perkins SCA that is required when the Example Of The Equation For Adding The SCA To cooling system is initially filled. The Heavy-Duty Coolant For Maintenance...
SEBU8121 Maintenance Section Aftercooler Core - Clean/Test Inspect the aftercooler for these items: damaged fins, i01853891 corrosion, dirt, grease, insects, leaves, oil, and other Aftercooler Core - Clean/Test debris. Clean the aftercooler, if necessary. For air-to-air aftercoolers, use the same methods that are used for cleaning radiators.
Maintenance Section Alternator - Inspect i02176674 Alternator - Inspect Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and correct battery charging. Inspect the ammeter (if equipped) during engine operation in order to ensure correct battery performance and/or correct performance of the electrical system.
SEBU8121 Maintenance Section Battery - Replace 8. Connect the cable from the NEGATIVE “-” terminal i02150857 on the starting motor to the NEGATIVE “-” battery Battery - Replace terminal. i02177936 Battery Electrolyte Level - Check Batteries give off combustible gases which can explode.
SEBU8121 Maintenance Section Battery or Battery Cable - Disconnect i02150865 NOTICE Battery or Battery Cable - Keep all parts clean from contaminants. Disconnect Contaminants may cause rapid wear and shortened component life. Clean the cooling system and flush the cooling system before the recommended maintenance The battery cables or the batteries should not be interval if the following conditions exist:...
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Operation and Maintenance Manual, for reuse in engine cooling systems. The full distillation “Fluid Recommendations” topic (Maintenance procedure is the only method acceptable by Perkins to Section) for more information on cooling system reclaim the coolant. specifications. Do not install the cooling system filler cap.
The full distillation • Foaming is observed. procedure is the only method acceptable by Perkins to reclaim the coolant. • The oil has entered the cooling system and the coolant is contaminated.
Allow the water to drain. Flush the cooling system with clean water. The Perkins Extended Life Coolant (ELC) does not need the frequent addition of Supplemental Coolant Fill Additives (SCA) that are associated with conventional coolants.
SEBU8121 Maintenance Section Cooling System Supplemental Coolant Additive (SCA) - Test/Add Pressurized System: Hot coolant can cause seri- ous burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pres- sure.
SEBU8121 Maintenance Section Crankcase Breather (Canister) - Replace Test for SCA Concentration 4. Clean the cooling system filler cap. Inspect the gaskets of the cooling system filler cap. If the gaskets are damaged, replace the old cooling Heavy-Duty Coolant/Antifreeze and SCA system filler cap with a new cooling system filler cap.
SEBU8121 Maintenance Section Driven Equipment - Check i01909392 Engine - Clean Personal injury or death can result from high volt- age. Moisture can create paths of electrical conductiv- ity. Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls “DO NOT OPERATE”.
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.
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SEBU8121 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace Cleaning the Primary Air Cleaner Elements NOTICE Observe the following guidelines if you attempt to clean the filter element: Do not tap or strike the filter element in order to re- move dust.
SEBU8121 Maintenance Section Engine Air Cleaner Element (Single Element) - Inspect/Replace Inspect the clean, dry primary air cleaner element. Some engines are equipped with a differential gauge Use a 60 watt blue light in a dark room or in a similar for inlet air pressure.
Note: The engine mounts may not have been Operating your engine when the oil level is above the supplied for this installation by Perkins. Refer to the “FULL” mark could cause your crankshaft to dip into OEM information for further information on the engine the oil.
Use of an oil filter that is not recommended the engine lubrication system with the new oil. by Perkins could result in severe damage to the en- gine bearings, crankshaft, etc., as a result of the larger waste particles from unfiltered oil entering the engine lubricating system.
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SEBU8121 Maintenance Section Engine Oil and Filter - Change Replace the Element for the Oil 2. Cut the oil filter open with a suitable tool. Break apart the pleats and inspect the oil filter for metal Filter debris. An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure.
To prevent damage to the engine, your authorized oil and that the oil filters are filled. Inspect the oil Perkins dealer or your Perkins distributor should filter for oil leaks. perform the tests.
NOTICE Only qualified service personel should perform this maintenance. Refer to the Service Manual or your au- thorized Perkins dealer or your Perkins distributor for the complete valve lash adjustment procedure. Operation of Perkins engines with incorrect valve lash can reduce engine efficiency, and also reduce engine component life.
Refer to the Disassembly and Assembly Manual for more information. Consult your authorized Perkins dealer or your Perkins distributor NOTICE for assistance. Do not crank the engine continuously for more than 30 seconds.
SEBU8121 Maintenance Section Fuel System Primary Filter/Water Separator - Drain i02211066 Fuel System Primary Filter/Water Separator - Drain 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.
SEBU8121 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 2. Place a suitable container under the water i02206563 separator. Clean the outside of the water Fuel System Primary Filter separator. (Water Separator) Element - 3. Open the drain (5). Allow the fluid to drain into the Replace container.
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SEBU8121 Maintenance Section Fuel System Secondary Filter - Replace 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.
SEBU8121 Maintenance Section Fuel Tank Water and Sediment - Drain g01121723 Illustration 45 4. Lubricate the sealing ring (4) with clean fuel oil. 5. Install the spin-on filter (2) into the top of the filter head (1). g01121396 Illustration 44 6.
SEBU8121 Maintenance Section Hoses and Clamps - Inspect/Replace Fuel Tank If a bulk storage tank has been refilled or moved recently, allow adequate time for the sediment to Fuel quality is critical to the performance and to the settle before filling the engine fuel tank. Internal service life of the engine.
Radiator - Clean fittings Replace the Hoses and the Clamps The radiator is not usually supplied by Perkins. The Refer to the OEM information for further information following text describes a typical cleaning procedure on removing and replacing fuel hoses (if equipped).
Installation • Operating outside the intended application Refer to the standards for the engine or consult your Perkins dealer or your Perkins distributor in order to Incorrect Maintenance Procedures determine if the engine is operating within the defined parameters. •...
Adjusting Manual, “Electric Starting System - Assembly Manual, “Turbocharger - Remove and Test” for more information on the checking procedure Turbocharger - Install” for further information. and for specifications or consult your Perkins dealer or your Perkins distributor for assistance. Inspecting i02184788...
Cracks in the cylinder head and/or seal, refer to the Disassembly and Assembly Manual, “Water Pump - Remove and Install” for more • A piston seizure information or consult your Perkins dealer or your Perkins distributor. • Other potential damage to the engine •...
Emissions Warranty. Consult your authorized Perkins dealer or your authorized Perkins distributor in order to determine if your engine is emissions certified and if your engine is subject to an Emissions Warranty.
SEBU8121 Index Section Index After Starting Engine ..........32 Diagnostic Lamp............ 27 After Stopping Engine..........34 Driven Equipment - Check........62 Aftercooler Core - Clean/Test ........ 53 Aftercooler Core - Inspect........53 Alternator - Inspect ..........54 Alternator and Fan Belts - Inspect/Adjust/ Replace..............
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SEBU8121 Index Section Fault Logging............27 Important Safety Information ........2 Features and Controls ........... 23 Fire Prevention and Explosion Prevention ....7 Fire Extinguisher ..........8 Lines, Tubes and Hoses ........9 Fluid Recommendations........39 Lifting and Storage ..........19 Cooling System Specifications......
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SEBU8121 Index Section Severe Service Application - Check ...... 78 Environmental Factors ........78 Incorrect Maintenance Procedures ....78 Incorrect Operating Procedures......78 Starting Motor - Inspect ......... 78 Starting the Engine ..........29 Starting a Cold Engine ........29 Starting a Warm Engine........
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Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number:...