Perkins 1103 User manual

REFERENCE ONLY
DPerkins®
Operation and Maintenance
Manual
1100A/BIC Series
Qty: 1
LIM of "'~a . ~r" ~ Eliot,
PIN SEBU7833-01
OPERATION & MA I NTENANCE ;
11 1 11 11 11 111 1111111 11111111 111 1 111111111111
Models DC, DO, OF , DG, OJ, OK,
RE, RG, RJ, RR and RS
SEBU 7833 - 01

REFERENCE ONLY
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to
the State
of California to cause cancer, birth defects, and other
reproductive harm.

REFERENCE ONLY
~Perkins o<
Operation and
Maintenance
Manual
1103 and 1104 Engines
DC (Engine)
DO (Engine)
OJ (Engine)
OK (Engine)
RE (Engine)
RG (Engine)
RJ (Engine)
RR (Engine)
RS (Engine)
OF (Engine)
OG (Engine)
SEBU7833-01
December 2004

REFERENCE ONLY
10 1658146
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety
ru les or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before
an accident occurs. A person must be ale rt to po tential hazards. This person should also
have the necessary training, ski
ll s and tools to perfo rm these functions properly.
Improper operation , lubrication , maintenance or repair of this product can be dangerous and
could result in injury or death.
Do
not operate or perform any lubrication, maintenance or repair on this product , until you have
read and
understood the operation , lubrication, maintenance and repair information .
Safety precautions and warnings are provided in this manual and on
th e product. If these hazard warnings
are not heeded, bodily injury or death cou
ld occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Wo
rd " such as
"DANGER", "WARN
IN G" or "CAUT ION ". The Safety Alert "WARNING" label is shown below.
A WARNING
The meaning of this safety alert sy mb ol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under
th e warning explains th e ha zard a nd ca n be either written or pictorially
presented.
Operations that may cause product damage are identified by "NOTICE" labels
on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard.
The
warnings in this publication and on the product are, therefore, not all i nclusive . If a tool ,
procedure , work method or operating technique that is not specifically recommended by Perkins
is used, you must sat i sfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation , lubrication, maintenance or
repair procedures that you choose .
The information, specifications, and illustrations
in this publication a re on th e basis of in formation that
was available at the
ti me that the publication was written. The specifications, torques, pressures,
measurements, adjustmen
ts , illustrations, and o th er items can change at any time. These changes can
affect the service that is given to the produ
ct. Obtain the complete an d most current informa ti on before you
sta
rt any job. Perkins dealers have the most cu rr en t information available.
A WARNING
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts or parts with equivalent
specifications including , but not limited to , phys-
ical dimensions , type, strength and material.
Failure
to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.

REFERENCE ONLY
SEBU7833-01
Table of Contents
Foreword ................................•............................... 4
Safety Section
Sa fety Messages ................................................... 5
General
Ha za rd Information . .. ............................... 5
Burn Prevention
.. .................................................... 7
Fire Preventi
on and Explosion Prevention .............. 7
Crushing Prevention and Cutting Pre
ve ntion .......... 9
Mounting and
Di smounti ng .................................... 9
Before Starting Engine .....
... ........... .. .................. 9
Engine Starting .................................................... 10
Engine Stopping ................
.. .. • ... ........................... 10
El ec tri ca l System .................. .. ..................... ... ...... 10
Product Information Section
Model Views .... ................ ... . .. .. .... ......... .. .... .. . ... . ... 12
Product Identificati on Information ........................ 18
Operation Section
Lifti ng and Storage ... . .... .................... .. .................. 21
Gauges and Indicators ....................••............•....... 24
Engine Starting ..................................................... 25
Engine Operation ..............................
... .......... .. ..... 28
Engine Stopping ................................................... 29
Cold Weather Operation ......................................
30
Maintenance Section
Refill Capacities ................................................... 34
Maintenan ce Interval Schedule ........................... 48
Warranty Section
Wa rr an ty In formation ................................ •.. ......... 76
Index Section
Index ............................... ... . .. ............................ 77
3
Table of Contents

REFERENCE ONLY
4
Foreword
Foreword
Literature Information
Th is manual contains safety, operation instructions,
lubrication and maintenance information.
Th is
manual should be stored in or near the engine area
in a literature holder or literature storage area. Read,
study and keep
it with the literature and engine
information.
English is the primary language for all Perkins
publications. The Engl
is h used facilitates translation
and consistency.
Some photographs or illustrations
in this manual
show details or attachments that may
be different
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvement and advancement of product design
may
ha ve caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Perkins dealer or your Perkins
distributor for the latest available information.
Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
warning situations. Read and understand the basic
precautions listed
in the safety section before
operating or performing lubrication, maintenance and
repair
on this product.
Operation
Operating techniques outlined in this manual are
basic. They assist with developing
th e skills and
techniques required
to operate the engine more
efficiently and economically. Skill and techniques
develop
as the operator gains knowledge of the
engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures
of inspecting, starting, operating
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by service hours andlor calendar time maintenance
intervals. Items
in the maintenance schedule are
referenced to detailed instructions that follow.
SEBU7833-01
Recommended service should
be performed at the
appropriate intervals as indicated
in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely seve
re ,
dusty, wet or freezing cold operating conditions,
more frequent lubrication and maintenance than
is
specified in the Maintenance Interval Schedule may
be necessary.
The maintenance schedule items are organized for
a preventive maintenance management program. If
the preventive
ma intenance program is followed, a
periodic tune-up
is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions
in unscheduled
downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of
the original requirement.
We recommend that the
maintenance schedules
be reproduced and displayed
near the engine as a convenient reminder. We also
recommend that a maintenance record
be maintained
as part of the engine's permanent record.
Your authorized Perkins dealer or your Perkins
distributor
can assist yo u in adjusting your
maintenance schedule
to meet the needs of your
operating environment.
Overhaul
Major engine overhaul details are not covered in
the Operation and Maintenance Manual except
for the interval and the maintenance items
in that
interval. Major repairs should only
be carried out by
Perkins authorized personnel. Your Perkins dealer
or your Perkins distributor offers a variety of options
regarding overhaul programs. If
you experience
a major engine failure, there are also numerous
after failure overhaul options available. Consult with
your Perkins dealer or your Perkins distributor for
information regarding these options.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known
to the State of California to cause cancer,
birth defects, and other reproductive harm. Battery
posts, terminals and related accessories contain lead
and lead compounds. Wash
hands after handling .

REFERENCE ONLY
SEBU7833-01
Safety Section
i02206606
Safety Messages
There may be several specific warning signs on
an engine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiar with all warning
signs.
Ensure that all ofthe warning signs are legible. Clean
the warning signs or replace the warning signs if
the words cannot
be read or if the pictures are not
visible. When the warning signs are cleaned, use a
cloth, water, and soap. Do not use solvent, gasoline,
or other harsh chemicals to clean the warning signs.
Solvents, gasoline, or harsh chemicals could loosen
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 signs. 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.
Correct care is your responsibility. Failure
to follow
the instructions or failure
to heed the warnings could
result
in injury or in death.
The warning labels that may
be found on the engine
are illustrated and described.
Ether
5
Safety Section
Safety Messages
The warning label for ether is located
on the top, the
front, the rear, or the side of the engine.
A. WARNING
g00640926
Never spray Ether starting aids into the air intet.
i02203039
General Hazard Information
Illustration 1 g00104545
Attach a "Do Not Operate" warning tag or a similar
warning tag to
the start switch or to the controls
before you service the equipment or before you
repair the equipment.

REFERENCE ONLY
6
Safety Section
General Hazard Information
, .
a
~
(i) 'd
~
~
ee>
~
Ill us t ration 2 900702020
Wear a hard hat, protective glasses, and other
protective equipment, as required.
Do not wear loose clothing orjewelry 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.
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.
Un less you are instructed otherwise, perform
maintenance
on the engine with the equipment in
the servicing position. Refer
to the OEM informati on
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
or a protective face shield.
SEBU7833-
01
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. The pressure can
cause hydraulic fiuid or items such as pipe plugs
to
escape rapidly ifthe pressure is not relieved correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur.
Do not disassemble any hydraulic
components or parts until pressure has been relieved
or personal injury may occur. Refer
to the OEM
information for any procedures that are required
to
relieve the hydraulic pressure.
Illus tr at io n 3 g00687600
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. Iffiuid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that
is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken in order to ensure that fluids
are contained
du ring performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Make provision
to collect the fiuid 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
su itable for containing
fluids and equipment that
is suitable for containing
fluids.

REFERENCE ONLY
SEBU7833-01
Obey all local regulations 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. Relie ve 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.
Ensure that the filler cap
is cool before removing the
filler cap. The filler cap must
be cool enough to touch
with a bare hand. Remove the filler cap slowly in
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.
7
Safety Section
Burn Pre
ve ntion
i02203164
Fire Prevention and Explosion
Prevention
Ill ustration 4
900704000
All fuels, most lubricants, and some coolant mixtures
are flammable.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.
A flash fire may result if the covers for
the engine
crankcase are removed within fifteen minutes after
an emergency shutdown.
Determine whether the engine will
be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
Ifthe application involves the presence ofcombustible
gases, consult your Perkins dealer andlor your
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 engine.
Do not allow any flammable combustible
materials or conductive materials to accumulate
on
the engine.
Store fuels and lubricants in correctly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials
in protective
containers. Do not smoke
in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.

REFERENCE ONLY
8
Safety Section
Fire Prevention and Explosion Prevention
Exhaust shields (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 correctly.
Do not weld on lines or tanks that contain flammable
fluids.
Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior
to
welding or flame cutting.
Wiring must be kept in good condition. All electrical
wires must
be correctly routed and securely attacheo.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.
Eliminate all 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 circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, 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.
•
Illu s tration 5 g00704059
SEBU7833-01
Use caution when 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 engine before refueling.
Ill ustration 6
g0 0704135
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
a hydrometer.
Incorrect jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
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.

REFERENCE ONLY
SEBU7833-01
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike 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 distributor for repair or for replacement parts.
Check lines, tubes and hoses carefully.
Do not use
your bare hand
to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace
th e parts if any of the following conditions
are present:
• End fittings are damaged or leaking.
Outer coverings are chafed or
cut.
Wires are exposed.
• Outer coverings are ballooning.
• Flexible part of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
will help
to prevent vibration, rubbing against other
parts, and excessive heat.
Crushing Prevention and
Cutting Prevention
i0 21 431 94
Support the component correctly when work beneath
the component
is performed.
Un less other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Leave the guards
in place until maintenance
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.
9
Safety Section
Crushing Prevention and Cutting Prevention
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that
no
one will be injured by flying debris.
i01372247
Mounting and Dismounting
Inspect the step s, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these items
in good repair.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds.
Do not
climb
on the engine, and do not jump off the engin e.
Face the engine in order to mount th e engine or
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use one foot and two hands.
Do not use any
controls as handholds.
Do not stand
on components which cannot support
your weight. Use
an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
i021 57341
Before Starting Engine
NOTICE
For initial start-up of a new or rebuilt engi
ne , 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.

REFERENCE ONLY
I' 10
Safety Section
Engine Starting
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.
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.
Engine Starting
A WARNING
1 022 0 7232
Do not use aerosol types of starting aids such as
ether.
Such use could result in an explosion and
personal injury.
If a warning tag is attached to the engine start switch
or to the controls,
DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine rnust 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.
Start the engine from the operator's compartment or
from the engine start switch.
Always start the engine according to the procedure
that
is described in the Operation and Maintenance
Manual, "Engine Starting" topic
in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
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, check the water temperature gauge and the
oil temperature gauge during the heater operation.
Engine exhaust contains products
of combustion
which can
be harmful to your health. Always start the
engine and operate the engine
in a well ventilated
area. If the engine is started
in an enclosed area,
vent the engine exhaust
to the outside.
SEBU7833-01
Note: The engine
is equipped with an automatic
de vice for cold starting for normal conditions of
operation. If the engine will
be operated in very cold
conditions, then
an extra cold starting aid may be
required. Normally, the engine will be equipped with
the correct type of starting
aid for your region of
operation.
The engines are equipped with a glow plug starting
aid
in each individual cylinder that heats the intake
air
in order to improve starting.
i01928905
Engine Stopping
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.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After
an
emergency stop, DO NOT start the engi ne until the
problem that caused the emergency stop has been
corrected.
Stop the engine if
an overspeed condition occurs
during the initial start-up ofa new engine or
an engine
that has been overhauled. This may
be accomplished
by shutting off the fuel supply
to the engine and/or
shutting off the air supply
to the engine.
i0 2176668
Electrical System
Ne ver 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.

REFERENCE ONLY
SEBU7833-01
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.
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.
All grounds should
be tight and free of corrosion. The
engine alternator must
be grounded to the negative
"- " battery terminal with a wire that is adequate to
handle the full charging current of the alternator.
11
Safety Section
Electrical System

REFERENCE ONLY
12
Product Information Section
Model Views
Product Information
Section
Model Views
i01928892
Model View Illustrations
1104 Engine Model Views
9
Illust ra tion 7
(1) Valve mechanism cover
(2) Crankcase breather
(3) Fuel
fi lter
(4) Fu
el injection pump
(5) En
gi ne oil filter
(6) Crankshaft pulley
(7)
Wa ter pump
(8) F
an pulley
SEBU7833-
---.!!J-i---
2
3
901012
(9) Water temperature regulator housing

REFERENCE ONLY
SEBU7833-01
8
7
I llustration 8
(1) Oil filler cap
(2) Exhaust manifold
(3) Alternator
(4) Tu rbo charger
(5) Starter motor
(6) Flywheel housing
(7) Flywheel
(8) Air intake
13
Product Information Section
Model Views
2
3
g01012281

REFERENCE ONLY
•
I I
14
Product Information Section
Model Views
1103 Engine Model Views
Illustration 9
(1 ) Alternator
(2) Fan pulley
6
5
4 (
3
, (
1~1
J
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1 0,<01
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V
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,~ I J:
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[d
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B e ]
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;-- gj ,.t:i]d
f-
=
0- ~
f-
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WI
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11
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(3) Turbocharger oil supply
(4) Turboc harger oil drain
,--
~
1
1 /1 11
(5) Tu r boc harger
(6) exhaust
man i fold
SEBU7833-01
2
g 01 011348

REFERENCE ONLY
SEBU7833-01
10
[
8
7
Illu s tr at i on 10
(1) Fuel tr ansfer pump
(2) Oi l filler cap
(3) Fuel filter
If _
8
-L
p'
k
L~'\ Il
(6) Oil filter
(7) Oil pan
~ I=; Id
01 1
lca)
(8) C ra n ks haft pulley
(9) Water pump
(Irl
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11
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r-
~6
15
Product tnformation Section
Model Views
h
'=
r
-
-
g01011349
(4) Starter motor
(5) Dipstick (10) Water temperat ure regu la tor housing
i0 2196981
Engine Description
Perkins Engines are designed for the following
applications: machine, genset, and industrial mobile
equipment. The engines are available
in the following
types of aspiration:
• Turbocharged aftercooled
• Turbocharged
• Naturally aspirated
Engine Specifications
Note: The front end of the engine is opposite the
flywheel end
of the engine. The left and the right
sides of the engine are determined from the flywheel
end. The number 1 cylinder
is the front cylinder.

REFERENCE ONLY
I I
I
16
Product Information Section
Model Views
,----
f 1 2 3 4
~~~~
Illustration 11
o
A •
B
-
g00984281
A typical example of the layout of the valves
(A) Inlet valves
(8) Exhaust valves
Table 1
1104 Industrial Engine Specifications
Number of Cylinders 4 In-Line
Bore 105
mm (4 .134 inch)
Stroke 127
mm (5.0 inch)
Aspiration Turbocharged aftercooled
Turbocharged
Naturally aspirated
Compression Ratio
NA 19.25:1 NA
T 18.23:1
T, TA
Displacement 4.4 L (268 in ')
Firing Order 1 3 4 2
Rotation (flywheel end) Counterclockwise
Valve Lash Setting (Inlet) 0.20
mm (0.008 inch)
Valve Lash Setting 0.45
mm (0.018 inch)
(Exhaust)
SEBU7833-01
Table 2
1103 Industrial Engine Specificalions
Number of Cylinders 3 In-Line
Bore 105
mm (4.134 inch)
Stroke 127
mm (5.0 inch)
Aspiration Turbocharged
Naturally aspirated
Compression Ratio NA 19.25:1
T 18.25:1
Displacement 3.3 L
(201 in')
Fi
ring Order 123
Rotation (flywheel end) Counterclockwise
Valve Lash Setting (Inlet) 0.20 mm (0.008 inc h)
Valve Lash Setting 0.45 mm (0.018 inch)
(Exhaust)
Table 3
1104 Genset Specifications
Number of Cylinders 4 In-Line
Bore 105 mm (4 .134 inch)
Stroke
127 mm (5.0 inch)
Aspiration Turbocharged aftercooled
Turbocharged
Naturally aspirated
Compression Ratios NA 19 . 25 :1
T 17.25:1, T 18.23:1,
TA 18 .23:1
Displacement 4.4 L (268
in ')
Firing Order 1 3 4 2
Rotation (flywheel end) Counterclockwise
Valve Lash Setting (Inlet) 0.20
mm (0.008 inch)
Valve Lash Setting 0.45
mm (0 .018 inch)
(Exhaust)

REFERENCE ONLY
SEBU7833-01
Table 4
1103 Genset Specifications
Number of Cylinders 3 In-Line
Bore
105 mm (4 .134 inch)
Stroke 127
mm (5 .0 inch)
Aspiration Turbocharged
Naturally aspirated
Compressi on Ratio
NA 19 .25:1
T 17.25:1
Displacement 3.3 L
(201 in ')
Firing Order
123
Rotation (flywheel end)
Counterclockwise
Valve Lash Setting (Inlet) 0.20
mm (0 .008 inch)
Valve Lash Setting 0.45
mm (0 ,018 inch)
(Exhaust)
Engine Cooling and Lubrication
The cooling system consists of the following
components:
• Gear-driven centrifugal water pump
• Water temperature regulator which regulates 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 cooled and
the engine lubricating
oil is filtered. Bypass valves
provide unrestricted flow
of lubrication oil to the
engine parts when oil viscosity
is high, Bypass valves
can also provide unrestricted flow of lubrication oil
to the engine parts
if the oil cooler should become
plugged or if the oil filter element should become
plugged.
Engine efficiency, efficiency of emission controls, and
engine performance depend
on adherence to proper
operation and maintenance recommendations,
Engine performance and efficiency also depend
on
the use of recommended fuels, lubrication oils, and
coolants, Refer to the Operation
and Maintenance
Manual, "Maintenance Interval Schedule" for more
information
on maintenance items.
17
Product Information Section
Model Views
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 powerthat
is demanded, The average power
that
is demanded is based on fuel consumption of
the engine over a period oftime, Reduced hours of
operation at full throttle and/or operating at reduced
throttle settings result
in a lower average power
demand, Reduced hours of operati
on will increase
the length of operating time before
an engine
overhaul
is required.

REFERENCE ONLY
I
"
18
Product Information Section
Product Identification Information
Product Identification
Information
Engine Identification i0
19 40475
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 REU090001H.
RE
______ _ _____ Type of engine
U
_________ Built in the United Kingdom
0900001
________ Engine Serial Number
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.
Serial Number Plate
i!8perklnsl ]EJIIGIAI'm ~ j- 1
o 0
l ~ g l ~ r: t
4 3 2
Illustrat i on 12
Ty pical serial number plate
(1 ) Temporary Pa rts Li st number
(2) Type
(3) Ser ia l number
(4) list number
i0 19 40474
900994966
SEBU7833-01
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 Numbers
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
___________ _
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
_______ _
Air Cleaner Element ___________ _
Fan Drive Belt
_____________ _
Alternator Belt
_____________ _
i02197956
Emissions Certification Film
Label for compliant engines
Examples of emissions labels