Perkins 1103 And 1104 Industrial Engines Operation And Maintenance Manual

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Operationand Maintenance Manual

1103and1104IndustrialEngines

DC(Engine)

DD(Engine)

DJ (Engine)

DK (Engine)

RE (Engine)

RG (Engine)

RJ(Engine) RR(Engine) RS(Engine) RT(Engine) DF(Engine) DG (Engine)

ImportantSafetyInformation

Mostaccidentsthatinvolveproductoperation,maintenanceandrepairarecausedbyfailureto observebasicsafetyrulesorprecautions.Anaccidentcanoftenbeavoidedbyrecognizingpotentially hazardoussituationsbeforeanaccidentoccurs.Apersonmustbealerttopotentialhazards.This personshouldalsohavethenecessarytraining,skillsandtoolstoperformthesefunctionsproperly. Improperoperation,lubrication,maintenanceorrepairofthisproductcanbedangerousand couldresultininjuryordeath.

Donotoperateorperformanylubrication,maintenanceorrepaironthisproduct,untilyouhave readandunderstoodtheoperation,lubrication,maintenanceandrepairinformation.

Safetyprecautionsandwarningsareprovidedinthismanualandontheproduct.Ifthesehazard warningsarenotheeded,bodilyinjuryordeathcouldoccurtoyouortootherpersons.

Thehazardsareidentifiedbythe“SafetyAlertSymbol”andfollowedbya“SignalWord”suchas “DANGER”,“WARNING”or“CAUTION”.TheSafetyAlert“WARNING”labelisshownbelow.

Themeaningofthissafetyalertsymbolisasfollows:

Attention!BecomeAlert!YourSafetyisInvolved.

Themessagethatappearsunderthewarningexplainsthehazardandcanbeeitherwrittenor pictoriallypresented.

Operationsthatmaycauseproductdamageareidentifiedby“NOTICE”labelsontheproductandin thispublication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warningsinthispublicationandontheproductare,therefore,notallinclusive.Ifatool,procedure, work method or operating technique that is not specifically recommended by Perkins is used, youmustsatisfyyourselfthatitissafeforyouandforothers.Youshouldalsoensurethatthe productwillnotbedamagedorbemadeunsafebytheoperation,lubrication,maintenanceor repairproceduresthatyouchoose.

Theinformation,specifications,andillustrationsinthispublicationareonthebasisofinformationthat wasavailableatthetimethatthepublicationwaswritten.Thespecifications,torques,pressures, measurements,adjustments,illustrations,andotheritemscanchangeatanytime.Thesechangescan affecttheservicethatisgiventotheproduct.Obtainthecompleteandmostcurrentinformationbefore you start any job. Perkins dealers or Perkins distributors have the most current information available.

LiteratureInformation

Thismanualcontainssafety,operationinstructions, lubricationandmaintenanceinformation.Thismanual shouldbestoredinorneartheengineareaina literatureholderorliteraturestoragearea.Read, studyandkeepitwiththeliteratureandengine information.

EnglishistheprimarylanguageforallPerkins publications.TheEnglishusedfacilitatestranslation andconsistency.

Somephotographsorillustrationsinthismanual showdetailsorattachmentsthatmaybedifferent fromyourengine.Guardsandcoversmayhavebeen removedforillustrativepurposes.Continuing improvementandadvancementofproductdesign mayhavecausedchangestoyourenginewhichare notincludedinthismanual.Wheneveraquestion arisesregardingyourengine,orthismanual,please consultwithyourPerkinsdealeroryourPerkins distributorforthelatestavailableinformation.

Safety

Thissafetysectionlistsbasicsafetyprecautions.In addition,thissectionidentifieshazardous,warning situations.Readandunderstandthebasic precautionslistedinthesafetysectionbefore operatingorperforminglubrication,maintenanceand repaironthisproduct.

Operation

Operatingtechniquesoutlinedinthismanualare basic.Theyassistwithdevelopingtheskillsand techniquesrequiredtooperatetheenginemore efficientlyandeconomically.Skillandtechniques developastheoperatorgainsknowledgeofthe engineanditscapabilities.

Theoperationsectionisareferenceforoperators. Photographsandillustrationsguidetheoperator throughproceduresofinspecting,starting,operating andstoppingtheengine.Thissectionalsoincludesa discussionofelectronicdiagnosticinformation.

Maintenance

Themaintenancesectionisaguidetoenginecare. Theillustrated,step-by-stepinstructionsaregrouped byservicehoursand/orcalendartimemaintenance intervals.Itemsinthemaintenancescheduleare referencedtodetailedinstructionsthatfollow.

Recommendedserviceshouldbeperformedatthe appropriateintervalsasindicatedintheMaintenance IntervalSchedule.Theactualoperatingenvironment oftheenginealsogovernstheMaintenanceInterval Schedule.Therefore,underextremelysevere,dusty, wetorfreezingcoldoperatingconditions,more frequentlubricationandmaintenancethanis specifiedintheMaintenanceIntervalSchedulemay benecessary.

Themaintenancescheduleitemsareorganizedfora preventivemaintenancemanagementprogram.Ifthe preventivemaintenanceprogramisfollowed,a periodictune-upisnotrequired.Theimplementation ofapreventivemaintenancemanagementprogram shouldminimizeoperatingcoststhroughcost avoidancesresultingfromreductionsinunscheduled downtimeandfailures.

MaintenanceIntervals

Performmaintenanceonitemsatmultiplesofthe originalrequirement.Werecommendthatthe maintenanceschedulesbereproducedanddisplayed neartheengineasaconvenientreminder.Wealso recommendthatamaintenancerecordbemaintained aspartoftheengine'spermanentrecord.

YourauthorizedPerkinsdealeroryourPerkins distributorcanassistyouinadjustingyour maintenancescheduletomeettheneedsofyour operatingenvironment.

Overhaul

Majorengineoverhauldetailsarenotcoveredinthe OperationandMaintenanceManualexceptforthe intervalandthemaintenanceitemsinthatinterval. MajorrepairsshouldonlybecarriedoutbyPerkins authorizedpersonnel.YourPerkinsdealeroryour Perkinsdistributoroffersavarietyofoptions regardingoverhaulprograms.Ifyouexperiencea majorenginefailure,therearealsonumerousafter failureoverhauloptionsavailable.Consultwithyour PerkinsdealeroryourPerkinsdistributorfor informationregardingtheseoptions.

CaliforniaProposition65Warning

Dieselengineexhaustandsomeofitsconstituents areknowntotheStateofCaliforniatocausecancer, birthdefects,andotherreproductiveharm.Battery posts,terminalsandrelatedaccessoriescontainlead andleadcompounds. Washhandsafterhandling.

SafetySection

SafetyMessages

i05898546

Theremaybeseveralspecificwarningsignsonan engine.Theexactlocationofthehazardsandthe descriptionofthehazardsarereviewedinthis section.Becomefamiliarwithallwarningsigns.

Ensurethatallofthewarningsignsarelegible.Clean thewarningsignsorreplacethewarningsignsifthe wordscannotbereadorifthepicturesarenotvisible. Whenthewarningsignsarecleaned,useacloth, water,andsoap.Donotusesolvent,gasoline,or otherharshchemicalstocleanthewarningsigns. Solvents,gasoline,orharshchemicalscouldloosen theadhesivethatsecuresthewarningsigns.The warningsignsthatareloosenedcoulddropoffthe engine.

Replaceanydamagedwarningsignsormissing warningsigns.Ifawarningsignisattachedtoapart oftheenginethatisreplaced,installanewwarning signonthereplacementpart.Perkinsdealersor Perkinsdistributorscanprovidenewwarningsigns.

Donotworkontheengineanddonotoperatethe engineunlesstheinstructionsandwarningsinthe OperationandMaintenanceManualareunderstood. Correctcareisyourresponsibility.Failuretofollow theinstructionsorfailuretoheedthewarningscould resultininjuryorindeath.

Illustration1 g01154807 Typicalexample

TheUniversalWarninglabel (1) willbelocatedonthe valvemechanismcover.Refertoillustration 2

Note: Thelocationofthislabelwilldependonthe applicationoftheengine.

Donotoperateorworkonthisequipmentunless

Illustration3 g01682820

Theetherwarninglabel (2) islocatedonthecoverof theinletmanifold.Refertoillustration 2

Illustration5 g03715821 3CylinderEngine. (1) UniversalWarningLabel (2) EtherWarningLabel

Theuniversalwarninglabel (1) islocatedattherear ofthevalvemechanismcoveronthethreecylinder engine.Theetherwarninglabel (2) islocatedatthe frontofthevalvemechanismcoveronthethree cylinderengine. i05875556

General Hazard Information

Illustration4 g03715988 Typicalexampleofafourcylinderengine

Illustration6 g00104545

Attacha “DoNotOperate” warningtagorasimilar warningtagtothestartswitchortothecontrols beforeyouservicetheequipmentorbeforeyourepair theequipment.

Wearahardhat,protectiveglasses,andother protectiveequipment,asrequired.

Donotwearlooseclothingorjewelrythatcansnag oncontrolsoronotherpartsoftheengine.

Makesurethatallprotectiveguardsandallcovers aresecuredinplaceontheengine.

Keeptheenginefreefromforeignmaterial.Remove debris,oil,tools,andotheritemsfromthedeck,from walkways,andfromsteps.

Neverputmaintenancefluidsintoglasscontainers. Drainallliquidsintoasuitablecontainer.

Obeyalllocalregulationsforthedisposalofliquids.

Useallcleaningsolutionswithcare.

Reportallnecessaryrepairs.

Donotallowunauthorizedpersonnelonthe equipment.

Disconnectthebatterieswhenmaintenanceis performedorwhentheelectricalsystemisserviced. Disconnectthebatterygroundleads.Tapetheleads inordertohelppreventsparks.Ifequipped,allowthe dieselexhaustfluidtobepurgedbefore disconnectingthebattery.

Performmaintenanceontheenginewiththe equipmentintheservicingposition.RefertotheOEM informationfortheprocedureforplacingthe equipmentintheservicingposition.

Donotattemptanyrepairsthatarenotunderstood. Usethepropertools.Replaceanyequipmentthatis damagedorrepairtheequipment.

Forinitialstart-upofanewengineorforstartingan enginethathasbeenserviced,makeprovisionsto stoptheengineifanoverspeedoccurs.Thestopping oftheenginemaybeaccomplishedbyshuttingoff thefuelsupplyand/ortheairsupplytotheengine. Ensurethatonlythefuelsupplylineisshutoff. Ensurethatthefuelreturnlineisopen.

Starttheenginefromtheoperatorsstation(cab). Nevershortacrossthestartingmotorterminalsorthe batteries.Thisactioncouldbypasstheengineneutral startsystemand/ortheelectricalsystemcouldbe damaged.

Engineexhaustcontainsproductsofcombustion whichmaybeharmfultoyourhealth.Alwaysstartthe engineandoperatetheengineinaventilatedarea.If theengineisinanenclosedarea,venttheengine exhausttotheoutside.

Usecautionwhencoverplatesareremoved. Graduallyloosen,butdonotremovethelasttwobolts ornutsthatarelocatedatoppositeendsofthecover plateorthedevice.Beforeremovingthelasttwobolts ornuts,prythecoverlooseinordertorelieveany springpressureorotherpressure.

PressureAirandWater

Pressurizedairand/orwatercancausedebrisand/or hotwatertobeblownout.Thisactioncouldresultin personalinjury.

Thedirectapplicationofpressurizedairor pressurizedwatertothebodycouldresultinpersonal injury.

Whenpressurizedairand/orwaterisusedfor cleaning,wearprotectiveclothing,protectiveshoes, andeyeprotection.Eyeprotectionincludesgoggles oraprotectivefaceshield.

Themaximumairpressureforcleaningpurposes mustbebelow205kPa (30psi).Themaximumwater pressureforcleaningpurposesmustbebelow 275kPa (40psi)

FluidPenetration

Pressurecanbetrappedinthehydrauliccircuitlong aftertheenginehasbeenstopped.Thepressurecan causehydraulicfluidoritemssuchaspipeplugsto escaperapidlyifthepressureisnotrelievedcorrectly.

Donotremoveanyhydrauliccomponentsorparts untilpressurehasbeenrelievedorpersonalinjury mayoccur.Donotdisassembleanyhydraulic componentsorpartsuntilpressurehasbeenrelieved orpersonalinjurymayoccur.RefertotheOEM informationforanyproceduresthatarerequiredto relievethehydraulicpressure.

SafetySection BurnPrevention

Anycontactwithhotcoolantorwithsteamcancause severeburns.Allowcoolingsystemcomponentsto coolbeforethecoolingsystemisdrained.

Checkthatthecoolantlevelaftertheenginehas stoppedandtheenginehasbeenallowedtocool.

Ensurethatthefillercapiscoolbeforeremovingthe fillercap.Thefillercapmustbecoolenoughtotouch withabarehand.Removethefillercapslowlyin ordertorelievepressure.

Coolingsystemconditionercontainsalkali.Alkalican causepersonalinjury.Donotallowalkalitocontact theskin,theeyes,orthemouth.

Oils

Alwaysuseaboardorcardboardwhenyoucheckfor aleak.Leakingfluidthatisunderpressurecan penetratebodytissue.Fluidpenetrationcancause seriousinjuryandpossibledeath.Apinholeleakcan causesevereinjury.Iffluidisinjectedintoyourskin, youmustgettreatmentimmediately.Seektreatment fromadoctorthatisfamiliarwiththistypeofinjury.

ContainingFluidSpillage

Caremustbetakeninordertoensurethatfluidsare containedduringperformanceofinspection, maintenance,testing,adjusting,andrepairofthe engine.Makeprovisiontocollectthefluidwitha suitablecontainerbeforeanycompartmentisopened orbeforeanycomponentisdisassembled.

• Onlyusethetoolsthataresuitableforcollecting fluidsandequipmentthatissuitableforcollecting fluids.

• Onlyusethetoolsthataresuitableforcontaining fluidsandequipmentthatissuitableforcontaining fluids.

Obeyalllocalregulationsforthedisposalofliquids. i05875580

BurnPrevention

Donottouchanypartofanoperatingengine.Allow theenginetocoolbeforeanymaintenanceis performedontheengine.Relieveallpressureinthe airsystem,inthehydraulicsystem,inthelubrication system,inthefuelsystem,orinthecoolingsystem beforeanylines,fittings,orrelateditemsare disconnected.

Coolant

Whentheengineisatoperatingtemperature,the enginecoolantishot.Thecoolantisalsounder pressure.Theradiatorandalllinestotheheatersor totheenginecontainhotcoolant.

Skinmaybeirritatedfollowingrepeatedorprolonged exposuretomineralandsyntheticbaseoils.Referto yoursuppliersMaterialSafetyDataSheetsfor detailedinformation.Hotoilandlubricating componentscancausepersonalinjury.Donotallow hotoiltocontacttheskin.Appropriatepersonal protectiveequipmentshouldbeused.

DieselFuel

Dieselmaybeirritatingtotheeyes,respiratory system,andskin.Prolongedexposuretodieselmay causevariousskinconditions.Appropriatepersonal protectiveequipmentshouldbeused.Referto supplierMaterialsafetyDatasheetsfordetailed information.

Batteries

Electrolyteisanacid.Electrolytecancausepersonal injury.Donotallowelectrolytetocontacttheskinor theeyes.Alwayswearprotectiveglassesfor servicingbatteries.Washhandsaftertouchingthe batteriesandconnectors.Useofglovesis recommended.

Fire Preventionand Explosion Prevention

Donotweldonlinesortanksthatcontainflammable fluids.Donotflamecutlinesortanksthatcontain flammablefluid.Cleananysuchlinesortanks thoroughlywithanonflammablesolventpriorto weldingorflamecutting.

Wiringmustbekeptingoodcondition.Ensurethatall electricalwiresarecorrectlyinstalledandsecurely attached.Checkallelectricalwiresdaily.Repairany wiresthatarelooseorfrayedbeforeyouoperatethe engine.Cleanallelectricalconnectionsandtightenall electricalconnections.

Eliminateallwiringthatisunattachedorunnecessary. Donotuseanywiresorcablesthataresmallerthan therecommendedgauge.Donotbypassanyfuses and/orcircuitbreakers.

Arcingorsparkingcouldcauseafire.Secure connections,recommendedwiring,andcorrectly maintainedbatterycableswillhelptopreventarcing orsparking.

Illustration9 g00704000

Allfuels,mostlubricants,andsomecoolantmixtures areflammable.

Flammablefluidsthatareleakingorspilledontohot surfacesorontoelectricalcomponentscancausea fire.Firemaycausepersonalinjuryandproperty damage.

Aflashfiremayresultifthecoversfortheengine crankcaseareremovedwithin15minutesafteran emergencyshutdown.

Determinewhethertheenginewillbeoperatedinan environmentthatallowscombustiblegasestobe drawnintotheairinletsystem.Thesegasescould causetheenginetooverspeed.Personalinjury, propertydamage,orenginedamagecouldresult.

Iftheapplicationinvolvesthepresenceof combustiblegases,consultyourPerkinsdealerand/ oryourPerkinsdistributorforadditionalinformation aboutsuitableprotectiondevices.

Removeallflammablecombustiblematerialsor conductivematerialssuchasfuel,oil,anddebrisfrom theengine.Donotallowanyflammablecombustible materialsorconductivematerialstoaccumulateon theengine.

Storefuelsandlubricantsincorrectlymarked containersawayfromunauthorizedpersons.Store oilyragsandanyflammablematerialsinprotective containers.Donotsmokeinareasthatareusedfor storingflammablematerials.

Donotexposetheenginetoanyflame.

Exhaustshields(ifequipped)protecthotexhaust componentsfromoilorfuelsprayincaseofaline,a tube,orasealfailure.Exhaustshieldsmustbe installedcorrectly.

Inspectalllinesandhosesforwearorfor deterioration.Thehosesmustbecorrectlyrouted. Thelinesandhosesmusthaveadequatesupport andsecureclamps.Tightenallconnectionstothe recommendedtorque.Leakscancausefires.

Oilfiltersandfuelfiltersmustbecorrectlyinstalled. Thefilterhousingsmustbetightenedtothecorrect torque.

Illustration10 g00704059

Usecautionwhenyouarerefuelinganengine.Donot smokewhileyouarerefuelinganengine.Donot refuelanenginenearopenflamesorsparks.Always stoptheenginebeforerefueling.