Perkins 1104d Industrial Engines Operation And Maintenance Manual

SEBU8172-02
Full download: http://manualplace.com/download/perkins-1104d-industrial-engines-operation-and-maintenance-manual/
July 2012

Operation and
Maintenance
Manual
1104D Industrial Engine
NH (Engine)
NJ (Engine)

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 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.
SEBU8172-02 3
Table of Contents

Table of Contents Maintenance Interval Schedule ............................ 69

Warranty Section
Foreword ................................................................. 4
Warranty Information .......................................... 105
Safety Section
Index Section
Safety Messages .................................................... 6
Index ................................................................... 106
General Hazard Information ................................... 9

Burn Prevention .................................................... 10

Fire Prevention and Explosion Prevention ............. 11

Crushing Prevention and Cutting Prevention ........ 13

Mounting and Dismounting ................................... 13

High Pressure Fuel Lines ..................................... 13

Before Starting Engine .......................................... 15

Engine Starting ..................................................... 15

Engine Stopping ................................................... 16

Electrical System .................................................. 16

Engine Electronics ................................................ 17

Product Information Section

Model Views ......................................................... 18

Product Identification Information ........................ 23

Operation Section
Lifting and Storage ................................................ 25

Gauges and Indicators .......................................... 27

Features and Controls .......................................... 29

Engine Diagnostics ............................................... 36

Engine Starting ..................................................... 40

Engine Operation .................................................. 43

Engine Stopping ................................................... 44

Cold Weather Operation ....................................... 46

Maintenance Section
Refill Capacities .................................................... 50

Maintenance Recommendations .......................... 67

4 SEBU8172-02
Foreword

Foreword Use fuel consumption or service hours to determine

intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals
Literature Information if they provide more convenient schedules and
approximate the indicated service meter reading.
This manual contains safety, operation instructions,
lubrication and maintenance information. This Recommended service should be performed at the
manual should be stored in or near the engine area appropriate intervals as indicated in the Maintenance
in a literature holder or literature storage area. Read, Interval Schedule. The actual operating environment
study and keep it with the literature and engine of the engine also governs the Maintenance Interval
information. Schedule. Therefore, under extremely severe,
dusty, wet or freezing cold operating conditions,
English is the primary language for all Perkins more frequent lubrication and maintenance than is
publications. The English used facilitates translation specified in the Maintenance Interval Schedule may
and consistency in electronic media delivery. be necessary.
Some photographs or illustrations in this manual The maintenance schedule items are organized for
show details or attachments that may be different a preventive maintenance management program. If
from your engine. Guards and covers may have the preventive maintenance program is followed, a
been removed for illustrative purposes. Continuing periodic tune-up is not required. The implementation
improvement and advancement of product design of a preventive maintenance management program
may have caused changes to your engine which are should minimize operating costs through cost
not included in this manual. Whenever a question avoidances resulting from reductions in unscheduled
arises regarding your engine, or this manual, please downtime and failures.
consult with your Perkins dealer for the latest
available information.
Maintenance Intervals
Safety Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
This safety section lists basic safety precautions. items in each level should be shifted ahead or back
In addition, this section identifies hazardous, depending upon your specific maintenance practices,
warning situations. Read and understand the basic operation and application. We recommend that
precautions listed in the safety section before the maintenance schedules be reproduced and
operating or performing lubrication, maintenance and displayed near the engine as a convenient reminder.
repair on this product. We also recommend that a maintenance record be
maintained as part of the engine's permanent record.
Operation
See the section in the Operation and Maintenance
Operating techniques outlined in this manual are Manual, “Maintenance Records” for information
basic. They assist with developing the skills and regarding documents that are generally accepted
techniques required to operate the engine more as proof of maintenance or repair. Your authorized
efficiently and economically. Skill and techniques Perkins dealer can assist you in adjusting your
develop as the operator gains knowledge of the maintenance schedule to meet the needs of your
engine and its capabilities. operating environment.

The operation section is a reference for operators. Overhaul

Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating Major engine overhaul details are not covered in the
and stopping the engine. This section also includes a Operation and Maintenance Manual except for the
discussion of electronic diagnostic information. interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
Maintenance an authorized Perkins dealer. Your Perkins
dealer offers a variety of options regarding overhaul
The maintenance section is a guide to engine care. programs. If you experience a major engine failure,
The illustrated, step-by-step instructions are grouped there are also numerous after failure overhaul options
by fuel consumption, service hours and/or calendar available from your Perkins dealer. Consult with
time maintenance intervals. Items in the maintenance your dealer for information regarding these options.
schedule are referenced to detailed instructions that
follow.
SEBU8172-02 5
Foreword

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.
6 SEBU8172-02
Safety Section
Safety Messages

Safety Section The Universal Warning label (1) is located on both

sides of the valve mechanism cover base. Refer to
illustration 1.
i02864025

Safety Messages

There may be several specific warning signs on your

engine. The exact location and a description of the
warning signs are reviewed in this section. Please
become familiar with all warning signs.

Ensure that all of the warning signs are legible. Clean

the warning signs or replace the warning signs if
the words cannot be read or if the illustrations are
not visible. Use a cloth, water, and soap to clean
the warning signs. Do not use solvents, gasoline, or
other harsh chemicals. 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 warning sign that is damaged or

missing. If a warning sign is attached to a part of the
engine that is replaced, install a new warning sign on
the replacement part. Your Perkins dealer or your
distributor can provide new warning signs.

(1) Universal Warning

Do not operate or work on this equipment unless

you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
heed the warnings could result in serious injury
or death.

g01154807
Illustration 1
Typical example
SEBU8172-02 7
Safety Section
Safety Messages

g01268960
Illustration 2
(1) Universal warning

(2) Hand (High Pressure)

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.
8 SEBU8172-02
Safety Section
Safety Messages

g01426636
Illustration 3
(2) Hand (High Pressure) (3) Ether

g01154858 g01154809
Illustration 4 Illustration 5
Typical example Typical example

The warning label for the Hand (High Pressure) (2) The ether warning label (3) is located on the cover of
is located on the top of the fuel manifold. Refer to the inlet manifold. Refer to illustration 4.
illustration 4.
Note: The location of this label will depend on the
application of the engine.
(3) Ether

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
personal injury.
SEBU8172-02 9
Safety Section
General Hazard Information

i02328435 Report all necessary repairs.

General Hazard Information Do not allow unauthorized personnel on the
equipment.

Ensure that the power supply is disconnected before

you work on the bus bar or the glow plugs.

Perform maintenance on the engine with the

equipment in the servicing position. Refer to the
OEM information 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.

Illustration 6
g00104545 The direct application of pressurized air or
pressurized water to the body could result in personal
Attach a “Do Not Operate” warning tag or a similar injury.
warning tag to the start switch or to the controls
before you service the equipment or before you When pressurized air and/or water is used for
repair the equipment. cleaning, wear protective clothing, protective shoes,
and eye protection. Eye protection includes goggles
or a protective face shield.

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 fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
g00702020
Illustration 7
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
Wear a hard hat, protective glasses, and other may occur. Do not disassemble any hydraulic
protective equipment, as required. components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
Do not wear loose clothing or jewelry that can snag information for any procedures that are required to
on controls or on other parts of the engine. relieve the hydraulic pressure.
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.

Perkins 1104d Industrial Engines Operation And Maintenance Manual
10
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Safety Section
Burn Prevention

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.

After the engine has stopped, you must wait for 60

seconds in order to allow the fuel pressure to be
purged from the high pressure fuel lines before any
service or repair is performed on the engine fuel lines.

g00687600 Allow the pressure to be purged in the air system, in

Illustration 8
the hydraulic system, in the lubrication system, or in
the cooling system before any lines, fittings or related
Always use a board or cardboard when you check items are disconnected.
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 Coolant
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment When the engine is at operating temperature, the
from a doctor that is familiar with this type of injury. 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.
Containing Fluid Spillage
Any contact with hot coolant or with steam can cause
Care must be taken in order to ensure that fluids severe burns. Allow cooling system components to
are contained during performance of inspection, cool before the cooling system is drained.
maintenance, testing, adjusting and repair of the
engine. Make provision to collect the fluid with a Check the coolant level after the engine has stopped
suitable container before any compartment is opened and the engine has been allowed to cool.
or before any component is disassembled.
Ensure that the filler cap is cool before removing the
• Only use the tools that are suitable for collecting filler cap. The filler cap must be cool enough to touch
fluids and equipment that is suitable for collecting with a bare hand. Remove the filler cap slowly in
fluids. order to relieve pressure.
• Only use the tools that are suitable for containing Cooling system conditioner contains alkali. Alkali can
fluids and equipment that is suitable for containing cause personal injury. Do not allow alkali to contact
fluids. the skin, the eyes, or the mouth.
Obey all local regulations for the disposal of liquids.
Oils
i02334785 Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
Burn Prevention skin. Also, do not allow hot components to contact
the skin.

Do not touch any part of an operating engine. Batteries

Allow the engine to cool before any maintenance is
performed on the engine. 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.

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