Perkins 1104D NH1 User manual

RENR7967
September 2006
Systems Operation
Testing and Adjusting
1104D Industrial Engine
NH (Engine)
NJ (Engine)

Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform 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 the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can 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 inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy 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 are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.

RENR7967 3
Table of Contents
Table of Contents
Systems Operation Section
General Information
Introduction ............................................................ 4
Engine Operation
Basic Engine ........................................................... 6
Air Inlet and Exhaust System ................................ 11
Cooling System .................................................... 14
Lubrication System .............................................. 16
Electrical System ................................................. 17
Cleanliness of Fuel System Components ............. 18
Fuel Injection ....................................................... 20
Electronic Control System ................................... 27
Power Sources ..................................................... 36
Glossary of Electronic Control Terms ................... 39
Testing and Adjusting Section
Fuel System
Fuel System - Inspect ........................................... 45
Air in Fuel - Test .................................................... 45
Finding Top Center Position for No. 1 Piston ........ 46
Fuel Injection Timing - Check ............................... 47
Fuel Quality - Test ................................................. 48
Fuel System - Prime ............................................. 49
Gear Group (Front) - Time .................................... 50
Air Inlet and Exhaust System
Air Inlet and Exhaust System - Inspect ................. 51
Turbocharger - Inspect .......................................... 52
Compression - Test ............................................... 55
Engine Valve Lash - Inspect/Adjust ...................... 56
Valve Depth - Inspect ............................................ 58
Valve Guide - Inspect ............................................ 59
Lubrication System
Engine Oil Pressure - Test .................................... 61
Engine Oil Pump - Inspect .................................... 61
Excessive Bearing Wear - Inspect ........................ 62
Excessive Engine Oil Consumption - Inspect ....... 62
Increased Engine Oil Temperature - Inspect ........ 63
Cooling System
Cooling System - Check ....................................... 64
Cooling System - Inspect ...................................... 64
Cooling System - Test ........................................... 65
Engine Oil Cooler - Inspect ................................... 66
Water Temperature Regulator - Test ..................... 67
Water Pump - Inspect ........................................... 68
Basic Engine
Piston Ring Groove - Inspect ................................ 69
Connecting Rod - Inspect ..................................... 69
Cylinder Block - Inspect ........................................ 72
Cylinder Head - Inspect ........................................ 72
Piston Height - Inspect .......................................... 72
Flywheel - Inspect ................................................. 73
Flywheel Housing - Inspect ................................... 74
Gear Group - Inspect ............................................ 75
Crankshaft Pulley - Check .................................... 76
Electrical System
Alternator-Te
st .................................................... 78
Battery - Test ......................................................... 79
V-Belt - Test .......................................................... 79
Charging System - Test ........................................ 80
Electric Starting System - Test .............................. 81
Glow Plugs - Test .................................................. 83
Index Section
Index ..................................................................... 84

4RENR7967
Systems Operation Section
Systems Operation Section
General Information
i02517251
Introduction
The following model views show a typical 1104D
engine. Due to individual applications, your engine
may appear different from the illustrations.
g01245941
Illustration 1
Front left engine view
(1) Front lifting eye
(2) Water outlet
(3) Rear lifting eye
(4) Fuel manifold (rail)
(5) Electronic control module
(6) Oil gauge
(7) Secondary fuel filter
(8) Oil filler
(9) Oil sampling valve
(10) Oil filter
(11) Crankshaft pulley
(12) Water pump
(13) Belt tensioner

RENR7967 5
Systems Operation Section
g01245940
Illustration 2
Rear right engine view
(14) Turbocharger
(15) Alternator
(16) Exhaust manifold
(17) Wastegate solenoid
(18) Starting motor
(19) Oil pan
(20) Drain plug
(21) Primary fuel filter
(22) Hand fuel priming pump
(23) Flywheel housing
(24) Heat shield
Note: The primary fuel filter is mounted off the
engine.
The 1104D models NH1 and NJ1 diesel engines are
electronically controlled. The 1104D engine uses
an Electronic Control Module (ECM) that receives
signals from the fuel injection pump and other
sensors in order to control the fuel injectors. The
pump supplies fuel to the fuel injectors.
The four cylinders are arranged in-line. The cylinder
head assembly has two inlet valves and two exhaust
valves for each cylinder. The ports for the exhaust
valves are on the right side of the cylinder head. The
ports for the inlet valves are on the left side of the
cylinder head. Each cylinder valve has a single valve
spring.
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 Quiescent
combustion chamber in the top of the piston in order
to achieve clean exhaust emissions. The piston pin is
off-center in order to reduce the noise level.
The pistons have two compression rings and an oil
control ring. The groove for the top ring has a hard
metal insert in order to reduce wear of the groove.
Theskirthasacoatingofgraphiteinordertoreduce
wear when the engine is new. The correct piston
height is important in order to ensure that the piston
does not contact the cylinder head. The correct
piston height also ensures the efficient combustion
of fuel which is necessary in order to conform to
requirements for emissions.

6RENR7967
Systems Operation Section
A piston and a connecting rod are matched to
each cylinder. The piston height is controlled by the
distance between the center of the big end bearing
and the center of the small end bearing of the
connecting rod. Three different lengths of connecting
rods are available in order to attain the correct piston
height. The three different lengths of connecting rods
are made by machining the blank small end bearing
of each rod at three fixed distances vertically above
the centerline of the big end bearing. .
The crankshaft has five main bearing journals. End
play is controlled by thrust washers which are located
on both sides of the number three main bearing.
The timing case is made of aluminum. The timing
gears are stamped with timing marks in order to
ensure the correct assembly of the gears. When the
number 1 piston is at the top center position on the
compression stroke, the marked teeth on the idler
gear will match with the marks that are on the fuel
injection pump, the camshaft, and the gear on the
crankshaft.Thereisnotimingmarkontherearface
of the timing case.
The crankshaft gear turns the idler gear which then
turns the following gears:
•the camshaft gear
•the fuel injection pump
The camshaft and the fuel injection pump run at half
the rpm of the crankshaft. The cylinder bores are
machined into the cylinder block.
g01259333
Illustration 3
The fuel injection pump (1) that is installed on the
left side of the engine is gear-driven from the timing
case. The fuel transfer pump (25) is attached to the
fuel injection pump (1). The fuel transfer pump draws
low pressure fuel from the primary fuel filter. The
fuel transfer pump delivers the fuel to the secondary
filter at a pressure of 400 kPa (58 psi) to 500 kPa
(72.5200 psi). The fuel injection pump draws fuel
from the secondary filter. The fuel injection pump
increases the fuel to a maximum pressure of 130 MPa
(18855 psi). The fuel injection pump delivers the fuel
to the fuel manifold. The fuel injection pump is not
serviceable. Adjustments to the pump timing should
only be made by personnel that have had the correct
training. The fuel injection pump uses the engine
ECM to control the engine RPM.
The specifications for the 1104D refer to the
Specifications, “Engine Design”.
Engine Operation
i02525716
Basic Engine
Introduction (Basic Engine)
The eight major mechanical components of the basic
engine are the following parts:
•Cylinder block
•Cylinder head
•Pistons
•Connecting rods
•Crankshaft
•Timing gear case and gears
•Camshaft
•Rocker shaft assembly

RENR7967 7
Systems Operation Section
Cylinder Block and Cylinder Head
g01263698
Illustration 4
Typical Cylinder Block
The cast iron cylinder block for the 1104D engine
has four cylinders which are arranged in-line. The
cylinder block is made of cast iron in order to provide
support for the full length of the cylinder bores. Worn
cylinders may be rebored in order to accommodate
oversize pistons and rings.
The cylinder block has five main bearings which
support the crankshaft. Thrust washers are installed
on both sides of number three main bearing in order
to control the end play of the crankshaft.
Passages supply the lubrication for the crankshaft
bearings. These passages are cast into the cylinder
block.
The cylinders are honed to a specially controlled
finish in order to ensure long life and low oil
consumption.
The cylinder block has a bush that is installed for the
front camshaft journal. The other camshaft journals
run directly in the cylinder block.
The engine has a cooling jet that is installed in the
cylinder block for each cylinder. The piston cooling
jet sprays lubricating oil onto the inner surface of the
piston in order to cool the piston.
A multi-layered steel (MLS) cylinder head gasket is
used between the engine block and the cylinder head
in order to seal combustion gases, water, and oil.
Cylinder head
g01263700
Illustration 5
Typical cylinder head
The engine has a cast iron cylinder head. The inlet
manifold is integral within the cylinder head. There
are two inlet valves and two exhaust valve for each
cylinder. Each pair of valves are connected by a valve
bridge that is controlled by a pushrod valve system.
The ports for the inlet valves are on the left side of
the cylinder head. The ports for the exhaust valves
are on the right side of the cylinder head. The valve
stems move in valve guides that are machined into
the cylinder head. There is a renewable valve stem
seal that fits over the top of the valve guide.

8RENR7967
Systems Operation Section
Pistons, Rings and Connecting
Rods
g01263701
Illustration 6
Typical example
The pistons have a Quiescent combustion chamber
inthetopofthepistoninordertoprovideanefficient
mix of fuel and air. The piston pin is off-center in
order to reduce the noise level.
The pistons have two compression rings and an oil
control ring. The groove for the top ring has a hard
metal insert in order to reduce wear of the groove.
The piston skirt has a coating of graphite in order to
reduce the risk of seizure when the engine is new.
The correct piston height is important in order to
ensure that the piston does not contact the cylinder
head. The correct piston height also ensures the
efficient combustion of fuel which is necessary in
order to conform to requirements for emissions.
The connecting rods are machined from forged
molybdenum steel. The connecting rods have
bearing caps that are fracture split. The bearing caps
on fracture split connecting rods are retained with
Torx screws. Connecting rods with bearing caps that
are fracture split have the following characteristics:
•The splitting produces an accurately matched
surfaceoneachsideofthefractureforimproved
strength.
Crankshaft
g01263702
Illustration 7
The crankshaft is a chromium molybdenum forging.
The crankshaft has five main journals. Thrust
washers are installed on both sides of number three
main bearing in order to control the end play of the
crankshaft.
The crankshaft changes the linear energy of the
pistons and connecting rods into rotary torque in
order to power external equipment.
Ageara
t the front of the crankshaft drives the timing
gears. The crankshaft gear turns the idler gear which
then turns the following gears:
•Camshaft gear
•Fuel injection pump and fuel transfer pump

RENR7967 9
Systems Operation Section
•Lower idler gear which turns the gear of the
lubricating oilpump.
Lip type seals are used on both the front of the
crankshaft and the rear of the crankshaft.
A timing ring is installed to the crankshaft. The timing
ring is used by the ECM in order to measure the
engine speed and the engine position.
g01263703
Illustration 8
Gears and Timing Gear Case
g01263705
Illustration 9
The crankshaft oil seal is mounted in the aluminum
timing case. The timing case cover is made from
pressed steel.
Thetiminggearsaremadeofsteel.
The crankshaft gear drives an upper idler gear and
a lower idler gear. The upper idler gear drives the
camshaft and the fuel injection pump. The lower idler
gear drives the oil pump. The water pump drive gear
is driven by the fuel injection pump gear.
The camshaft and the fuel injection pump rotate at
half the engine speed.
Camshaft
g01263706
Illustration 10
The engine has a single camshaft. The camshaft
is made of cast iron. The camshaft lobes are chill
hardened.
The camshaft is driven at the front end. As the
camshaft turns, the camshaft lobes move the valve
system components. The valve system components
move the cylinder valves.
The camshaft gear must be timed to the crankshaft
gear. The relationship between the lobes and the
camshaft gear causes the valves in each cylinder to
open at the correct time. The relationship between
the lobes and the camshaft gear also causes the
valves in each cylinder to close at the correct time.

10 RENR7967
Systems Operation Section
Rocker Shaft Assembly
g01263708
Illustration 11
The camshaft has two camshaft lobes for each
cylinder. The lobes operate either a pair of inlet
valves or a pair of exhaust valves. As the camshaft
turns, lobes on the camshaft cause the lifter to move
the pushrod up and down. Upward movement of the
pushrod against rocker arm results in a downward
movement that acts on the valve bridge. This action
opens a pair of valves which compresses the valve
springs. When the camshaft has rotated to the
peak of the lobe, the valves are fully open. When
the camshaft rotates further, the two valve springs
under compression start to expand. The valve stems
are under tension of the springs. The stems are
pushed upward in order to maintain contact with the
valve bridge. The continued rotation of the camshaft
causes the rocker arm, the pushrods and the lifters
to move downward until the lifter reaches the bottom
of the lobe. The valves are now closed. The cycle is
repeated for all the valves on each cylinder.