Perkins 1104E Systems Operation Testing And Adjusting
  1. Manuals
  2. Brands
  3. Perkins Manuals
  4. Engine
  5. 1104E Series
  6. Systems operation testing and adjusting
Perkins 1104E Systems Operation Testing And Adjusting

Perkins 1104E Systems Operation Testing And Adjusting

Hide thumbs Also See for 1104E:
Table of Contents

Advertisement

Quick Links

See also: Troubleshooting Manual
SENR9977
February 2005
Systems Operation
Testing and Adjusting
1104E Engine
RF11-Up (Machine)
RH11-Up (Machine)
RK11-Up (Machine)

Advertisement

Table of Contents
loading

Related Manuals for Perkins 1104E

Summary of Contents for Perkins 1104E

  • Page 1 SENR9977 February 2005 Systems Operation Testing and Adjusting 1104E Engine RF11-Up (Machine) RH11-Up (Machine) RK11-Up (Machine)
  • Page 2 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.

  • Page 3: Table Of Contents

    SENR9977 Table of Contents Table of Contents Flywheel Housing - Inspect ........54 Gear Group - Inspect ..........55 Electrical System Systems Operation Section Alternator - Test ............ 56 Battery - Test ............56 General Information V-Belt - Test ............57 Introduction ............

  • Page 4: Systems Operation Section General Information Introduction

    SENR9977 Systems Operation Section Systems Operation Section General Information i02245816 Introduction g01130896 Illustration 1 Left side view of a typical 1104C electronic engine...
  • Page 5 SENR9977 Systems Operation Section (1) Fuel lines (6) Electronic fuel injection pump (11) Alternator (2) Fuel Priming Pump (7) Engine oil pressure sensor (12) Engine coolant temperature sensor (3) Fuel Filter (8) Engine oil filter (13) Voltage Load Protection Module (4) Machine Interface Connector (MIC) (9) Water Pump (14) Electronic Control Module (ECM)

  • Page 6: Engine Operation

    SENR9977 Systems Operation Section Each cylinder has a piston cooling jet that is installed in the cylinder block. The piston cooling jet sprays engine oil onto the inner surface of the piston in order to cool the piston. The pistons have a Fastram combustion chamber in the top of the piston in order to provide an efficient mix of fuel and air.

  • Page 7: Air Inlet And Exhaust System

    SENR9977 Systems Operation Section • The engine has a cast iron cylinder head. The inlet Fuel injection pump manifold is integral within the cylinder head. An inlet • valve and an exhaust valve for each cylinder are Lower idler gear which turns the gear of the controlled by a pushrod valve system.
  • Page 8 SENR9977 Systems Operation Section Engines which are naturally aspirated pull outside air A turbocharger increases the temperature and the through an air cleaner directly into the inlet manifold density of the air that is sent to the engine cylinder. (6). The air flows from the intake manifold to the This condition causes a lower temperature of ignition engine cylinders (7).
  • Page 9 SENR9977 Systems Operation Section • The turbine wheel and the compressor wheel (3) are Rocker arms installed on the same shaft. Therefore, the turbine • wheel and the compressor wheel rotate at the same Valve springs rpm. The compressor wheel is enclosed by the compressor housing (2).

  • Page 10: Cooling System

    SENR9977 Systems Operation Section i02242619 Cooling System g00985481 Illustration 6 Flow diagram of the cooling system The coolant flows from the bottom of the radiator to The main flow of the coolant passes from the rear of the centrifugal water pump. The water pump assists the cylinder block into the rear of the cylinder head.

  • Page 11: Lubrication System

    SENR9977 Systems Operation Section i02242521 Lubrication System g01009682 Illustration 7 Flow diagram of the lubrication system Lubricating oil from the oil pan flows through a The lubricating oil flows from the outlet side of the oil strainer and a pipe (9) to the suction side of the pump (10) through a passage to the oil filter head engine oil pump (10).

  • Page 12: Electrical System

    SENR9977 Systems Operation Section Alternator Lubricating oil from the oil gallery flows through high pressure passages to the main bearings of the crankshaft (5). Then, the oil flows through the passages in the crankshaft to the connecting rod bearing journals (6). The pistons and the cylinder bores are lubricated by the splash of oil and the oil mist.
  • Page 13 SENR9977 Systems Operation Section The alternator is connected to the battery through the ignition switch. Therefore, alternator excitation occurs when the switch is in the ON position. Starting Motor g00956095 Illustration 9 24 Volt Starting Motor (1) Terminal for connection of the ignition (2) Terminal for connection of the battery switch cable...

  • Page 14: Fuel Injection

    SENR9977 Systems Operation Section i02247913 Fuel Injection g01131813 Illustration 11 Flow diagram of the fuel system (1) Fuel injectors (4) Fuel return lines (2) Fuel transfer pump and secondary fuel (5) Fuel lines filter (6) Fuel tank (3) Primary fuel filter and water separator (7) Fuel injection pump The 1104C electronic engine is equipped with a The axial piston distributor injection pump generates...
  • Page 15 SENR9977 Systems Operation Section When the engine is operated, the fuel is pulled from the fuel tank (6) through the primary fuel filter/water separator (3) by the fuel transfer pump (2). When the fuel passes through the water separator, any water in the fuel will go to the bottom of the bowl.
  • Page 16 SENR9977 Systems Operation Section Fuel Injection Pump g01132091 Illustration 12 Schematic of the Bosch VP30 fuel injection pump (1) Speed/timing sensor (8) Cam plate (2) Electronic control unit (ECU) for the fuel (9) Roller injection pump (10) Timing advance mechanism (3) Fuel transfer pump (11) Timing solenoid valve (4) Fuel solenoid valve...
  • Page 17 SENR9977 Systems Operation Section Delivery The eccentric position of the rotor is relative to the cam ring. A volume is created between the vanes, the rotor, and the cam ring. The fuel is transported by the eccentric position. The eccentric position is relative to the rotor and the outlet passage (19).
  • Page 18 SENR9977 Systems Operation Section The cam plate moves the distributor plunger toward the head of the distributor (26). The high pressure is created by a decrease in the volume between the distributor plunger and the head of the distributor. The cam plate is pressed to the ring by two springs (28).
  • Page 19 SENR9977 Systems Operation Section 1. The ECU sends a signal to the timing solenoid valve. 2. The timing mechanism is triggered by the timing solenoid valve. 3. The timing solenoid valve changes the pressure in the timing mechanism. 4. The timing mechanism changes the position of the cam ring.
  • Page 20 SENR9977 Systems Operation Section g01133212 Illustration 22 The timing wheel and the secondary speed/timing sensor (32) Secondary speed/timing sensor (33) Timing wheel The ECU for the fuel injection pump is mounted on the top of the pump. The ECU has a connection g01133213 Illustration 23 to the engine ECM and a connection to the...
  • Page 21 SENR9977 Systems Operation Section Fuel Injectors g01142467 Illustration 24 Each fuel injector is held into the cylinder head by a clamp around the fuel injector. The fuel injectors are not serviceable but the nozzles can be removed in order to clean the orifice. The fuel injection pump forces the fuel to flow under high pressure to the hole in the fuel inlet.

  • Page 22: Electronic Control System

    SENR9977 Systems Operation Section i02251280 Electronic Control System g01133227 Illustration 25 Schematic of the electronic control system (1) Voltage load-dump protection module (4) ECM (8) Intake manifold pressure sensor (VLPM) (5) Coolant temperature sensor (9) Primary speed/timing sensor (2) Service tool connector (6) Intake manifold temperature sensor (10) Timing wheel (3) Machine interface connector...
  • Page 23 SENR9977 Systems Operation Section Electronic Control Module (ECM) Flash programming is the method of programming or updating the personality module. Refer to Troubleshooting, RENR2696, “Flash Programming ” for the instructions on the flash programming of the personality module. The ECM is sealed and the ECM needs no routine adjustment or maintenance.
  • Page 24 SENR9977 Systems Operation Section Primary Speed/Timing Sensor The engine oil pressure sensor is also an active sensor with three wires and a power supply. The sensor provides the ECM with a measurement of engine oil pressure. The ECM can warn the operator of possible conditions that can damage the engine.

  • Page 25: Power Sources

    SENR9977 Systems Operation Section Voltage Load-dump Protection Module (VLPM) g01133354 Illustration 31 (1) VLPM The VLPM monitors the voltage of the system and the VLPM will protect the ECU on the fuel injection pump against voltage spikes and reverse polarity. The fuel injection pump will be shutdown if there is high voltage on the system.
  • Page 26 SENR9977 Systems Operation Section ECM Power Supply g01141374 Illustration 32 Power Supply for the ECM The power supply to the ECM and the system The display screen on the electronic service tool can is drawn from the 24 volt or the 12 volt battery. be used in order to check the voltage supply.
  • Page 27 SENR9977 Systems Operation Section Power Supply for the Fuel Injection Pump g01141661 Illustration 33 Power supply for the fuel injection pump g00931447 g01143327 Illustration 34 Illustration 35 Connection for the fuel injection pump (J40/P40) Connector for the fuel injection pump (J40) (1) Can - (2) Can + (3) Unused...
  • Page 28 SENR9977 Systems Operation Section Power Supply for the Pressure Sensors g01143335 Illustration 36 Schematic for pressure sensors The ECM supplies 5.0 ± 0.2 DC volts through the ECM connector to each sensor. The power supply is protected against short circuits. A short in a sensor or a wiring harness will not cause damage to the ECM.

  • Page 29: Glossary Of Electronic Control Terms

    SENR9977 Systems Operation Section Diagnostic Lamp – A diagnostic lamp is sometimes i02285310 called the check engine light. The diagnostic lamp Glossary of Electronic Control is used to warn the operator of the presence of an Terms active diagnostic code. Direct Current (DC) –...
  • Page 30 Original Equipment Manufacturer (OEM) – An OEM is the manufacturer of a vehicle that utilizes a Perkins engine. Parameter – A parameter is a programmable value which affects the characteristics or the behavior of the engine and/or vehicle.
  • Page 31 SENR9977 Systems Operation Section Supply Voltage – Supply voltage is a constant voltage that is supplied to a component in order to provide electrical power for operation. Supply voltage may be generated by the ECM. Supply voltage may also be the battery voltage of the vehicle that is supplied by the vehicle wiring.

  • Page 32: Testing And Adjusting Section

    SENR9977 Testing and Adjusting Section Testing and Adjusting 2. Install a suitable fuel flow tube with a visual sight gauge in the fuel return line. When possible, install Section the sight gauge in a straight section of the fuel line that is at least 304.8 mm (12 inches) long.

  • Page 33: Finding Top Center Position For No. 1 Piston

    SENR9977 Testing and Adjusting Section If excessive air is not seen at the inlet to the fuel transfer pump, the air is entering the system after the fuel transfer pump. Refer to the Testing and Adjusting, “Fuel System - Prime”. If excessive air is seen at the inlet to the fuel transfer pump, air is entering through the suction side of the fuel system.

  • Page 34: Fuel Injection Timing - Adjust

    SENR9977 Testing and Adjusting Section 6. Insert the 27610032 Timing Pin through the hole i02285307 in the fuel pump gear and through the slot in the Fuel Injection Timing - Adjust hub. Push the timing pin fully into the hole in the body of the fuel injection pump.

  • Page 35: Fuel Injection Timing - Check

    SENR9977 Testing and Adjusting Section 4. Remove all three timing pins and install the i02253244 removed components. Fuel Injection Timing - Check i02243111 Fuel Quality - Test Table 3 Required Tools Part Part Description Use the following procedure to test for problems Number regarding fuel quality: 27610032...

  • Page 36: Fuel System - Prime

    SENR9977 Testing and Adjusting Section i02253606 i02253617 Fuel System - Prime Fuel System Pressure - Test If air enters the fuel system, the air must be purged before the engine can be started. Air can enter the fuel system when the following events occur: •...
  • Page 37 SENR9977 Testing and Adjusting Section 7. Start the engine and check for any leakage of fuel or air from the fuel lines. Check the Function of the Pressure Regulator 1. Remove the fuel line from the outlet for the supply for the fuel injection pump (3).

  • Page 38: Air Inlet And Exhaust System

    SENR9977 Testing and Adjusting Section Air Inlet and Exhaust i02254115 Wastegate - Test System i02253770 Air Inlet and Exhaust System - Inspect Hot engine components can cause injury from A general visual inspection should be made to the air burns. Before performing maintenance on the inlet and exhaust system.

  • Page 39: Compression - Test

    Repeat the test several times. This will ensure that an accurate reading is obtained. 4. For more information on installing a new turbocharger, contact your Perkins dealer or your To prevent possible injury, do not use the starter Perkins distributor.
  • Page 40 SENR9977 Testing and Adjusting Section • Broken socket on the upper end of a pushrod b. Place the appropriate feeler gauge (2) between the rocker arm and the valve. Turn adjustment • Loose adjustment screw for the valve lash screw (1) while the valve adjustment screw locknut is being held from turning.

  • Page 41: Valve Depth - Inspect

    SENR9977 Testing and Adjusting Section 3. Inspect the valves for cracks and other damage. i01889422 Check the valve stems for wear. Check that the Valve Depth - Inspect valve springs are the correct length under the test force. Refer to Specifications, “Cylinder Head Valves”...
  • Page 42 SENR9977 Testing and Adjusting Section 5. Move the valve in a radial direction toward the dial indicator as far as possible. Note the distance of movement which is indicated on the dial indicator. If the distance is greater than the maximum clearance of the valve in the valve guide, replace the valve guide.

  • Page 43: Lubrication System

    SENR9977 Testing and Adjusting Section Lubrication System Perform the following procedures in order to inspect the oil pump for clearances and torques. Refer to the Specifications Module, “Engine Oil i01854908 Pump”. Engine Oil Pressure - Test 1. Remove the oil pump from the engine. Refer to the Disassembly and Assembly, “Engine Oil Pump - Remove”.

  • Page 44: Excessive Bearing Wear - Inspect

    SENR9977 Testing and Adjusting Section i01126690 Excessive Bearing Wear - Inspect When some components of the engine show bearing wear in a short time, the cause can be a restriction in an oil passage. An engine oil pressure indicator may show that there is enough oil pressure, but a component is worn due to a lack of lubrication.

  • Page 45: Increased Engine Oil Temperature - Inspect

    SENR9977 Testing and Adjusting Section • Overfilling of the crankcase • Wrong dipstick or guide tube • Sustained operation at light loads Excessive consumption of engine oil can also result if engine oil with the wrong viscosity is used. Engine oil with a thin viscosity can be caused by fuel leakage into the crankcase or by increased engine temperature.

  • Page 46: Cooling System

    SENR9977 Testing and Adjusting Section Cooling System 8. Check the filler cap. A pressure drop in the cooling system can cause the boiling point to be lower. This can cause the cooling system to boil. Refer to Testing and Adjusting, “Cooling System - Test”. i02274237 Cooling System - Check 9.

  • Page 47: Cooling System - Inspect

    SENR9977 Testing and Adjusting Section i01889427 i01964006 Cooling System - Inspect Cooling System - Test This engine has a pressure type cooling system. A Remember that temperature and pressure work pressure type cooling system gives two advantages: together. When a diagnosis is made of a cooling system problem, temperature and pressure must •...
  • Page 48 SENR9977 Testing and Adjusting Section Checking the Filler Cap Remove any deposits that are found on these items, and remove any material that is found on One cause for a pressure loss in the cooling system these items. can be a faulty seal on the radiator pressure cap. 3.

  • Page 49: Engine Oil Cooler - Inspect

    SENR9977 Testing and Adjusting Section • The dial indicator remains constant beyond five 5. Refer to Disassembly and Assembly, “Engine Oil minutes. Cooler - Install” for installation of the engine oil cooler. The inside of the cooling system has leakage only if the following conditions exist: 6.

  • Page 50: Basic Engine

    SENR9977 Testing and Adjusting Section Basic Engine Note: Some pistons have a tapered top groove and the piston ring is wedged. The clearance for the top piston ring cannot be checked by the above method when this occurs. i01889476 Piston Ring Groove - Inspect Inspect the Piston Ring End Gap Inspect the Piston and the Piston Rings...

  • Page 51: Connecting Rod Bearings - Inspect

    SENR9977 Testing and Adjusting Section i01748770 Connecting Rod Bearings - Inspect Check the connecting rod bearings and the connecting rod bearing journal for wear or other damage. Connecting rod bearings are available with a smaller inside diameter than the original size bearings. These bearings are for crankshafts that have been ground.

  • Page 52: Cylinder Head - Inspect

    SENR9977 Testing and Adjusting Section Refer to Specifications, “Cylinder Head” for the i01905914 requirements of flatness. Cylinder Head - Inspect Remachining the Cylinder Head The bottom face of cylinder head can be resurfaced if 1. Remove the cylinder head from the engine. any of the following conditions exist: 2.

  • Page 53: Flywheel - Inspect

    SENR9977 Testing and Adjusting Section The correct piston height must be maintained in order i01897548 to ensure that the engine conforms to the standards Flywheel - Inspect for emissions. Note: The top of the piston should not be machined. If the original piston is installed, be sure that the Alignment of the Flywheel Face original piston is assembled to the correct connecting rod and installed in the original cylinder.

  • Page 54: Flywheel Housing - Inspect

    SENR9977 Testing and Adjusting Section Flywheel Runout g00913387 Illustration 62 g00987752 Illustration 61 1. Install the 21825617 dial gauge. See Illustration 1. Install the dial indicator. Refer to Illustration 61. 2. Set the pointer of the 21825617 dial gauge to 2.

  • Page 55: Gear Group - Inspect

    SENR9977 Testing and Adjusting Section i02270822 Gear Group - Inspect g01137592 Illustration 64 (1) Fuel pump drive gear g00913389 Illustration 63 (2) Idler gear (3) Camshaft drive gear 1. Install the 21825617 dial gauge. See Illustration Remove the front timing cover and inspect the gears. The timing marks on the gears indicate the front side 2.

  • Page 56: Electrical System

    SENR9977 Testing and Adjusting Section Electrical System 4. Turn the ignition switch to the ON position. Check the voltage between terminal (B) and ground. If the voltage is more than 2 Volts the alternator needs to be replaced. i01899123 Alternator - Test Warning Light is On When the Engine is Running 1.

  • Page 57: V-Belt - Test

    SENR9977 Testing and Adjusting Section Never disconnect any charging unit circuit or bat- tery circuit cable from the battery when the charg- ing unit is operated. A spark can cause an explo- sion from the flammable vapor mixture of hydro- gen and oxygen that is released from the elec- trolyte through the battery outlets.

  • Page 58: Electric Starting System - Test

    SENR9977 Testing and Adjusting Section When it is possible, make a test of the charging When the magnetic force increases in both coils, unit and voltage regulator on the engine, and use the pinion gear moves toward the ring gear of the wiring and components that are a permanent part of flywheel.
  • Page 59 SENR9977 Testing and Adjusting Section • Voltage drops that are greater than the amounts The voltage at the battery post is within 2 volts in Table 10 are caused most often by the following of the lowest value in the applicable temperature conditions: range of Table 9.

  • Page 60: Glow Plugs - Test

    SENR9977 Testing and Adjusting Section 5. Rotate the crankshaft by hand in order to ensure 3. Place a suitable ammeter on the power supply that the crankshaft is not stuck. Check the oil wire. viscosity and any external loads that could affect the engine rotation.

  • Page 61: Index

    SENR9977 Index Section Index Engine Oil Pressure - Test........43 High Oil Pressure..........43 Air in Fuel - Test............. 32 Low Oil Pressure..........43 Air Inlet and Exhaust System ......7, 38 Engine Oil Pump - Inspect........43 Cylinder Head And Valves ........9 Engine Operation.............
  • Page 62 SENR9977 Index Section Main Bearings - Inspect......... 51 Piston Height - Inspect .......... 52 Piston Ring Groove - Inspect......... 50 Inspect the Clearance of the Piston Ring... 50 Inspect the Piston and the Piston Rings .... 50 Inspect the Piston Ring End Gap....... 50 Power Sources ............
  • Page 63 SENR9977 Index Section...
  • Page 64 ©2005 Perkins Engines Company Limited A ll R i ght s R es er ve d Printed in U.K.

Table of Contents