Двигатель перкинс 1104 руководство по ремонту

647016EN (16/06/2008)	ENGINE
	1104D EURO 3 — 80CV / 100CV
	Repair manual

MANITOU BF

B.P 249 — 44158 ANCENIS Cedex Tél. 33 (0) 2 40 09 10 11

Fax commercial France : 02 40 09 10 96 // Export : 33 2 40 09 10 97 www.manitou.com

647016EN	1st DATE OF ISSUE

	16 / 06 / 2008

ISSUE

16 / 06 / 2008	— 1st ISSUE
	Engine 1104D E3 — 80CV/ 100CV

THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE REPRODUCED EITHER TOTALLY OR PARTLY.

Speciﬁcations

1104D (Mech) Industrial Engine

NK (Engine)

NL (Engine)

NK (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 premature failures, product damage, personal injury or death.

KENR6245	3
	Table of Contents
Table of Contents
Speciﬁcations Section
Engine Design ……………………………………………..	4
Fuel Injection Lines ……………………………………….	4
Fuel Injection Pump ………………………………………	5
Fuel Injectors ……………………………………………….	6
Fuel Transfer Pump ………………………………………	6
Lifter Group …………………………………………………..	7
Rocker Shaft ………………………………………………..	7
Valve Mechanism Cover ………………………………..	8
Cylinder Head Valves …………………………………….	8
Cylinder Head ………………………………………………	10
Turbocharger ……………………………………………….	11
Exhaust Manifold ………………………………………….	12
Camshaft …………………………………………………….	12
Camshaft Bearings ……………………………………….	14
Engine Oil Filter ……………………………………………	14
Engine Oil Cooler ………………………………………….	15
Engine Oil Pump …………………………………………..	16
Engine Oil Pressure ………………………………………	18
Engine Oil Bypass Valve ………………………………..	18
Engine Oil Pan ……………………………………………..	19
Crankcase Breather ………………………………………	20
Water Temperature Regulator and Housing ………	22
Water Pump …………………………………………………	22
Cylinder Block ………………………………………………	22
Crankshaft …………………………………………………..	24
Crankshaft Seals ………………………………………….	26
Connecting Rod Bearing Journal …………………….	26
Main Bearing Journal ……………………………………..	27
Connecting Rod ……………………………………………	27
Piston and Rings …………………………………………..	29
Piston Cooling Jet ………………………………………….	30
Front Housing and Covers ……………………………..	31
Gear Group (Front) ………………………………………..	31
Flywheel ………………………………………………………	33
Flywheel Housing …………………………………………	34
Crankshaft Pulley ………………………………………….	34
Fan Drive …………………………………………………….	35
Engine Lifting Bracket …………………………………….	36
Alternator …………………………………………………….	36
Starter Motor ………………………………………………..	37
Glow Plugs …………………………………………………..	38
Index Section
Index ……………………………………………………………	40

4	KENR6245
Speciﬁcations Section

Speciﬁcations Section

When the camshaft is viewed from the front of the engine, the camshaft rotates in the following

direction: …………………………………………… Clockwise

Engine Design

i02655068

The front of the engine is opposite the ﬂywheel end. The left side and the right side of the engine are viewed from the ﬂywheel end. The No. 1 cylinder is the front cylinder.

i02656438

Fuel Injection Lines

Illustration 1	g01333480

Cylinder and valve location
(A) Inlet valve
(B) Exhaust valve
Bore …………………………………..	105 mm (4.133 inch)
Stroke ………………………………..	127 mm (5.000 inch)
Displacement ………………………………..	4.4 L (269 in3)
Cylinder arrangement ……………………………….	In-line
Type of combustion ……………………….	Direct injection
Compression ratio
Naturally aspirated engines	…………………. 19.3:1
Turbocharged engines …………………………	18.2:1
Number of cylinders …………………………………………	4
Valves per cylinder …………………………………………..	2
Valve lash
Inlet valve …………………….	0.20 mm (0.008 inch)
Exhaust valve ……………….	0.45 mm (0.018 inch)
Firing order ………………………………………….	1, 3, 4, 2

When the crankshaft is viewed from the front of the engine, the crankshaft rotates in the following

direction: …………………………………………… Clockwise

Illustration 2	g01334606

Typical example

(1) Tighten the union nuts for the fuel injector nozzles to the following torque. …………. 30 N·m (22 lb ft)

Tighten the union nuts for the fuel injection pump (not shown) to the following torque. ……. 30 N·m (22 lb ft)

KENR6245	5
	Speciﬁcations Section

i02663071

Fuel Injection Pump

Note: Before the fuel injection pump is removed from the engine the fuel injection pump shaft must be locked. Position the engine to TC compression stroke of number one cylinder before tightening the locking screw. The locking screw will prevent the shaft from rotating. If the fuel injection pump was removed prior to correctly timing the engine and locking the shaft, the fuel injection pump will need to be timed by trained personnel.

Illustration 3	g01352237

Typical example

Note: The solenoid on the fuel injection pump is a serviceable item. The fuel injection pump is a nonserviceable item.

(1)O-ring

(2)Locking screw

(3)Washer

Locking the shaft

Loosen locking screw (2) and move the washer

(3) to the locked position. Tighten the bolt to the following torque. …………………. 17 N·m (12 lb ft)

Unlocking the shaft

Loosen locking screw (2) and install the washer

(3) to the unlocked position. Tighten the bolt to the following torque. ………………. 12 N·m (9 lb ft)

Illustration 4	g01352239

Typical example of a support bracket
(4)	Tighten the mounting bolt to the following
	torque. ………………………………..	44 N·m (32 lb ft)
(5)	Tighten the mounting bolt and the nut to the
	following torque. …………………..	22 N·m (16 lb ft)

Note: The support bracket must be installed after the coolant pump is installed. In order to stop the distortion of the timing case, ﬁnger tighten the bolt

(4) and then tighten the nut and bolt (5). Tighten the bolt (4).

Tighten the bolts that hold the fuel pump to the front housing to the following torque. …… 25 N·m (18 lb ft)

6		KENR6245
Speciﬁcations Section
i02662510		i02661897
Fuel Injectors		Fuel Transfer Pump

Illustration 5	g00908211

Fuel injector clamp

(1) Tighten the bolt in the clamp for the fuel injector to the following torque. …………. 35 N·m (26 lb ft)

The fuel injector should be tested at the pressure in table 1.

Leakage in 10 seconds ……………………………

0 drops

Table 1

Service setting for the Fuel Injector

Injection Pressure

29.4 + 0.8 MPa (4264 + 116 psi)

(1)Retaining bolts

(2)Clip

(3)Spacer

(4)Fuel transfer pump

Type …………………….. 12 or 24 volt electric motor

(5)Fuel ﬁlter element

(6)O ring

(7)Fuel ﬁlter bowl

Note: Tighten the fuel ﬁlter bowl by hand. Rotate the bowl 1/8 of a turn more by hand.

KENR6245	7
	Speciﬁcations Section

i02677369

Lifter Group

(1) Diameter of the lifter body .. 18.987 to 19.012 mm (0.7475 to 0.7485 inch)

Clearance of the lifter in the cylinder block

bore ……. 0.038 to 0.095 mm (0.0015 to 0.0037 inch)

i02655105

Rocker Shaft

Table 2

Required Tools

	Part
Tool	Number	Part Description	Qty

A	27610227	Spacing Tool	4

Illustration 8	g01345401

The rocker shaft

Note: In order to install the rocker shaft assembly, Tooling (A) is required.

(1)Snap ring

(2)Washer

(3)Rocker arm

(4)Rocker arm bore

Diameter of the rocker arm

bore …………………………….	25.013 to 25.051 mm
	(0.9848 to 0.9863 inch)
Rocker arm

Clearance between the rocker arm and the rocker

shaft	……………………………….. 0.026 to 0.089 mm
	(0.0010 to 0.0035 inch)
Maximum permissible clearance between the
rocker arm and the rocker shaft	………… 0.17 mm
		(0.007 inch)

(5) Spring

Note: Install the longest screw at the front of the rocker shaft assembly.

(6)Tighten the screws evenly. Begin in the center and work toward the outside. Tighten the screws

to the following torque. ………….	35 N·m (26 lb ft)
(7) Rocker shaft
Diameter of the rocker
shaft …………………………….	24.962 to 24.987 mm
	(0.9828 to 0.9837 inch)

8	KENR6245
Speciﬁcations Section

(8)In order to install the rocker shaft assembly, ensure that the machined square is to the top of the rocker shaft.

(9)Locknut

Torque for the locknut …………… 27 N·m (20 lb ft)

i02551219

Valve Mechanism Cover

i02662486

Cylinder Head Valves

Tighten the bolts for the valve mechanism cover in the sequence that is shown to the following

torque. …………………………………………. 9 N·m (7 lb ft)

Illustration 10	g01345407

Cross section of cylinder head

(1)Valve spring

Naturally aspirated engines

The installed length of the valve
springs ……………………..	35.17 mm (1.3846 inch)
The load for the installed valve springs …..	335 N
		(75 lb)

Turbocharged engines

The installed length of the inlet valve springs

(high ratings) ……………..	35.17 mm (1.3846 inch)
The load for the installed inlet valve
springs …………………………………….	335 N (75 lb)

The installed length of the inlet valve springs (low

ratings) ……………………..	36.17 mm (1.4240 inch)
The load for the installed inlet valve
springs …………………………………….	312 N (70 lb)

The installed length of the exhaust valve springs

(all ratings) ………………..	36.17 mm (1.4240 inch)
The load for the installed exhaust valve
spring ………………………………………	312 N (70 lb)

KENR6245	9
	Speciﬁcations Section

Turbocharged aftercooled engines
The installed length of the valve
springs ……………………..	36.17 mm (1.4240 inch)
The load for the installed valve springs …..	312 N
		(70 lb)

(2)Valve spring recess

(3)The ﬁnished valve guides

Inside diameter of valve	9.000 to 9.022 mm
guide ……………………………….
	(0.3543 to 0.3552 inch)
Outside diameter of the valve
guide ……………………………	13.034 to 13.047 mm
	(0.5131 to 0.5137 inch)
Interference ﬁt of valve guide in cylinder
head ………………………………..	0.007 to 0.047 mm
	(0.0003 to 0.0019 inch)
Length of Valve guide ……….	51.00 to 51.50 mm
	(2.018 to 2.027 inch)
Projection of the valve guide above the valve
spring recess (2) ……………….	12.35 to 12.65 mm
	(0.486 to 0.498 inch)

Note: When new valve guides are installed, new valves and new valve seat inserts must be installed. The valve guides and the valve seat inserts are supplied as partially ﬁnished parts. The unﬁnished valve guides and unﬁnished valve seat inserts are installed in the cylinder head. The guides and inserts are then cut and reamed in one operation with special tooling. This procedure ensures the concentricity of the valve seat to the valve guide in order to create a seal that is tight. Refer to Disassembly and Assembly for removal and installation procedures.

(4) Exhaust valve

Diameter of the exhaust valve

stem	……………………………….. 8.938 to 8.960 mm
	(0.3519 to 0.3528 inch)
Clearance of valve in valve
guide …..	0.040 to 0.062 mm (0.0016 to 0.0024 inch)
Overall length of the exhaust
valve ……………………………..	128.184 to 128.634 mm
	(5.0466 to 5.0643 inch)

The face of the exhaust valve is recessed below the cylinder head by the following amount.

Naturally aspirated engines	………… 0.55 to 0.81 mm
	(0.0217 to 0.0319 inch)
Service limit ……………………….	1.06 mm (0.042 inch)
Turbocharged engines ………………..	1.55 to 1.81 mm
	(0.0610 to 0.0713 inch)

Service limit ………………………

2.06 mm (0.0811 inch)

Turbocharged aftercooled engines .. 1.55 to 1.81 mm (0.0610 to 0.0713 inch)

Service limit ……………………… 2.06 mm (0.0811 inch)

(5) Inlet valve

Diameter of the inlet valve

stem ………………………………..	8.953 to 8.975 mm
	(0.3525 to 0.3533 inch)
Clearance of valve in valve
guide ..	0.025 to 0.069 mm (0.001 to 0.0027 inch)
Overall length of the inlet
valve ……………………………..	128.838 to 129.288 mm
	(5.0724 to 5.0901 inch)

The face of the inlet valve is recessed below the cylinder head by the following amount.

Naturally aspirated engines	………… 0.60 to 0.85 mm
	(0.0236 to 0.0335 inch)

Turbocharged engines (high rating) .. 0.60 to 0.85 mm (0.0236 to 0.0335 inch)

Service limit ………………………. 1.09 mm (0.043 inch)

Turbocharged engines (low rating) .. 1.60 to 1.85 mm (0.0630 to 0.0728 inch)

Turbocharged aftercooled engines .. 1.60 to 1.85 mm (0.0630 to 0.0728 inch)

Service limit ……………………..	2.09 mm (0.0823 inch)
(6)	Exhaust valve face angle from the horizontal axis
	Valve face angle ………………………….	30 degrees
	Valve seat angle ………………………….	30 degrees
(7)	Diameter of the exhaust
	valve head ……………………….	41.51 to 41.75 mm
		(1.634 to 1.643 inch)
(8)	Diameter of the head of the inlet
	valve ……………………………….	46.28 to 46.53 mm
		(1.8220 to 1.8319 inch)
(9)	Angle of the inlet valve face from the vertical axis
	Valve face angle ………………………….	45 degrees
	Valve seat angle ………………………….	45 degrees

The valve lash is the following value when the engine is cold:

Inlet valves ……………………	0.20 mm (0.008 inch)
Exhaust valves ……………..	0.45 mm (0.018 inch)

10	KENR6245
Speciﬁcations Section

Illustration 11	g00809016

Recess for the valve seat insert

(10) Machine the recess in the head for valve seat inserts to the following dimensions.

Recess for Inlet Valve Seat for Naturally Aspirated Engines and high rated turbocharged engines

(A) …..	9.84 to 10.04 mm (0.3874 to 0.3953 inch)
(B) ……………………………….		47.820 to 47.845 mm
		(1.8827 to 1.8837 inch)
(C) Maximum radius	……… 0.38 mm (0.015 inch)

Recess for Exhaust Valve Seat for Naturally Aspirated Engines and high rated turbocharged engines

(A) …..	9.84 to 10.04 mm (0.3874 to 0.3953 inch)
(B) ……………………………….		42.420 to 42.445 mm
		(1.6701 to 1.6711 inch)
(C) Maximum radius	……… 0.38 mm (0.015 inch)

Recess for Inlet Valve Seat for low rated turbocharged engines and turbocharged aftercooled engines

(A) …. 10.84 to 11.04 mm (0.4268 to 0.4346 inch)

(B) ……………………………….	47.820 to 47.845 mm
	(1.8827 to 1.8837 inch)
(C) Maximum radius ………	0.38 mm (0.015 inch)

Recess for Exhaust Valve Seat for turbocharged engines and turbocharged aftercooled engines

(A) ….	10.84 to 11.04 mm (0.4268 to 0.4346 inch)
(B) ……………………………….		42.420 to 42.445 mm
		(1.6701 to 1.6711 inch)
(C) Maximum radius	……… 0.38 mm (0.015 inch)

i02662502

Cylinder Head

Table 3

Required Tools

	Part
Tool	Number	Part Description	Qty

A	21825607	Angle gauge	1

The maximum distortion of the cylinder head is given in table 4.

The cylinder head bolts are two different lengths. The following information provides the proper torque for the cylinder head bolts.

Illustration 12	g00987480

The tightening sequence

Lubricate the threads and the underside of the head bolts with clean engine oil.

Tighten the bolts in the sequence that is shown in


Illustrations to the following torque. ………	50 N·m
Tighten the bolts again to the following	(37 lb ft)

torque. ………………………………	100 N·m (74 lb ft)

KENR6245	11
	Speciﬁcations Section

Illustration 13	g00905621

The head bolts require an additional torque turn procedure. The numbers (1, 3, 4) are three long cylinder head bolts. All the other bolts are short bolts. The tightening sequence is shown in the Illustrations .

Place the angle gauge on the top of each bolt head. Tighten the short bolts to the additional amount. ……………………………………. 225 degrees Place the angle gauge on the top of each bolt head. Tighten the long bolts for the additional

amount. …………………………………….		270 degrees
Thickness of the cylinder head ..	117.95 to 118.05 mm
	(4.643 to 4.647 inch)
Minimum thickness of cylinder head	…….. 117.20 mm
		(4.614 inch)

Note: The maximum distortion of the cylinder head is given in table 4.

	Illustration 14	g01006568

	Table 4

	Dimension	Maximum Permissible
	Distortion

	Width (A)	0.03 mm (0.0012 inch)

	Length (B)	0.05 mm (0.0019 inch)

	Diagonal Line (C)	0.05 mm (0.0019 inch)

i02662519

Turbocharger

Illustration 15	g00991357

Typical turbocharger

(1)Actuator rod

(2)Actuator

(3)Turbocharger

(4)	Tighten the nuts to the following torque. .. 44 N·m
			(32 lb ft)
(5)	Tighten the bolt to the following torque.	….. 9 N·m
			(80 lb in)
(6)	Tighten the bolt to the following torque. …	22 N·m
			(16 lb ft)
The maximum test pressure for the
wastegate …………………………………	205 kPa (30 psi)
The movement for the rod actuator ……………..		1 mm
		(0.0394 inch)

12	KENR6245
Speciﬁcations Section

Table 5

The part number for	The pressure for the
the turbocharger		wastegate

2674A835	138	± 3 kPa
	(20.0155 ± 0.4351 psi)
2674A841	123	± 3 kPa
	(17.8399 ± 0.4351 psi)
2674A843	138	± 3 kPa
	(20.0155 ± 0.4351 psi)
2674A816	131	± 3 kPa
	(19.0002 ± 0.4351 psi)
2674A817	100	± 3 kPa
	(14.5040 ± 0.4351 psi)
2674A836	138	± 3 kPa
	(20.0155 ± 0.4351 psi)
2674A818	123	± 3 kPa
	(17.8399 ± 0.4351 psi)
2674A844	138	± 3 kPa
	(20.0155 ± 0.4351 psi)
2674A819	131	± 3 kPa
	(19.0002 ± 0.4351 psi)
2674A821	100	± 3 kPa
	(14.5040 ± 0.4351 psi)
2674A837	138	± 3 kPa
	(20.0155 ± 0.4351 psi)
2674A822	123	± 3 kPa
	(17.8399 ± 0.4351 psi)
2674A838	138	± 3 kPa
	(20.0155 ± 0.4351 psi)
2674A825	123	± 3 kPa
	(17.8399 ± 0.4351 psi)

2674A845	138	± 3 kPa
	(20.0155 ± 0.4351 psi)
2674A826	131	± 3 kPa
	(19.0002 ± 0.4351 psi)
2674A827	100	± 3 kPa
	(14.5040 ± 0.4351 psi)

2674A842	138	± 3 kPa
	(20.0155 ± 0.4351 psi)

i02662527

Exhaust Manifold

Illustration 16	g01337856

Typical example

Tighten the exhaust manifold bolts in the sequence that is shown in illustration 16 to the following

torque. ………………………………………	40 N·m (30 lb ft)
	i02662539

Camshaft

Illustration 17	g01277351

Checking the end play of the camshaft

KENR6245	13
	Speciﬁcations Section

(1) End play of a new camshaft	….. 0.10 to 0.55 mm
	(0.004 to 0.022 inch)
Maximum permissible end play of a worn
camshaft ……………………………	0.60 mm (0.023 inch)

Illustration 18	g01277354

Typical camshaft

(2) Bolt

Tighten the bolt to the following torque. … 95 N·m (70 lb ft)

(3) Camshaft thrust washer

Thickness of the thrust washer .. 5.49 to 5.54 mm (0.216 to 0.218 inch)

Depth of the recess in the cylinder block for the

thrust washer	………………………. 5.54 to 5.64 mm
	(0.218 to 0.222 inch)

Tolerance of the thrust washer in cylinder block

front face	……………………… −0.154 to −0.003 mm
	( − 0.0006 to −0.0001 inch)

(4)The diameters of the camshaft journals are given in the following table.

Table 6

Diameters of Camshaft Journals

	Camshaft Journals	Standard Diameter

	1	50.711 to 50.737 mm
	(1.9965 to 1.9975 inch)


	2	50.457 to 50.483 mm
	(1.9865 to 1.9875 inch)

	3	49.949 to 49.975 mm
	(1.9665 to 1.9675 inch)

Maximum wear on the camshaft journals … 0.05 mm (0.0021 inch)

Illustration 19	g01345411

Typical example
(5) Camshaft lobe lift
Naturally aspirated
Inlet lobe ………………………….	7.201 to 7.301 mm
	(0.2835 to 0.2874 inch)
Exhaust lobe …………………….	7.404 to 7.504 mm
	(0.2914 to 0.2954 inch)
Turbocharged
Inlet lobe ………………………….	7.527 to 7.627 mm
	(0.2963 to 0.3003 inch)
Exhaust lobe …………………….	7.363 to 7.463 mm
	(0.2899 to 0.2938 inch)
Turbocharged aftercooled
Inlet lobe ………………………….	7.031 to 7.131 mm
	(0.2768 to 0.2807 inch)
Exhaust lobe …………………….	7.363 to 7.463 mm
	(0.2899 to 0.2938 inch)

(6)Camshaft lobe height

(7)Base circle

To determine the lobe lift, use the procedure that follows:

1.Mount the camshaft between centers.

2.By using a dial indicator in contact with the surface of the lobe, rotate the camshaft and record the maximum and minimum lift.

14	KENR6245
Speciﬁcations Section

Note: There may be two lobes on the camshaft. Refer to illustration 19. The surface between the lobes may not return to the radius of the base circle. Using a micrometer to measure the diameter of the base circle may give a inaccurate result.

3.Subtract the smallest dimension from the largest dimension. The difference is the actual camshaft lobe lift.

Maximum permissible deviation between the actual lobe lift and the speciﬁed lobe lift of a new

camshaft ……………………………	0.05 mm (0.002 inch)
	i02656416

Camshaft Bearings

i02663064

Engine Oil Filter

Illustration 20 Typical example

Illustration 21	g01338237

Typical example
(1)	Setscrew
	Tighten the setscrews to the following
	torque. ………………………………..	22 N·m (16 lb ft)
(2)	Engine oil ﬁlter
	Tighten the engine oil ﬁlter to the following
	torque. ………………………………	12 N·m (106 lb in)

g01334592

(1) The diameter of the installed camshaft

bearing	………………………… 50.787 to 50.848 mm
	(1.9995 to 2.0019 inch)

KENR6245	15
	Speciﬁcations Section

Illustration 22	g01338238

Typical example
(3)	Setscrew
	Tighten the setscrews to the following
	torque. ………………………………..	22 N·m (16 lb ft)
(4)	Engine oil ﬁlter
	Tighten the engine oil ﬁlter to the following
	torque. ………………………………	12 N·m (106 lb in)
(5)	Plug
	Tighten the plug to the following torque. .. 12 N·m
		(106 lb in)

i02657143

Engine Oil Cooler

Illustration 23	g00952614

Typical example
(1)	Joint
(2)	Oil cooler
(3)	Housing
(4)	Setscrew
(5)	Seal
(6)	Setscrew
(7)	Setscrew

Illustration 24	g01334858

Setscrews

Tighten the setscrews (7) to the following torque. ……………………………….. 22 N·m (16 lb ft)

Setscrews

Tighten the setscrews (4) and (6) in the sequence that is in illustration 24 to the following torque. ……………………………….. 22 N·m (16 lb ft)

16	KENR6245
Speciﬁcations Section

i02656269

Engine Oil Pump

Engines with Balancer Group

Type ………………………..	Gear-driven differential rotor
Number of lobes
Inner rotor …………………………………………………	6
Outer rotor ………………………………………………..	7

Illustration 25	g01334408

The oil pump for the balancer

(1) Clearance of the outer rotor to the

body .. 0.130 to 0.24 mm (0.0050 to 0.0094 inch)

Illustration 26	g01334410

Inner rotor
(2) Clearance of inner rotor to outer
rotor ………………………………..	0.050 to 0.200 mm
	(0.0020 to 0.0079 inch)

Illustration 27	g01334412

The end play for the rotor
(3) End play of rotor assembly
Inner rotor …………………………….	0.04 to 0.11 mm
	(0.0016 to 0.0043 inch)
Outer rotor ……………………………	0.04 to 0.11 mm
	(0.0016 to 0.0043 inch)

KENR6245	17
	Speciﬁcations Section

Illustration 28	g01334415

The end cover

(4) Torque for cover bolts for oil pump ………. 26 N·m (19 lb ft)

Illustration 29	g01334416

Idler gear and pump gear

Note: Replace the idler gear bolt (5) and the nut for the oil pump gear (6).

(5) Tighten the idler gear bolt to the following torque. ……………………………….. 26 N·m (19 lb ft)

Note: Set the engine to the TC position. Refer to Systems Operation, Testing and Adjusting Manual, “Finding Top Center Position for No. 1 Piston”. Install the balancer. Refer to Disassembly and Assembly, “Balancer — Install”. Install the gear for the oil pump and tighten the nut (6).

(6) Tighten the nut to the following torque. …. 95 N·m
		(70 lb ft)
Tighten the bolts that hold the balancer to the cylinder
block to the following torque. ……….	54 N·m (40 lb ft)
Engines without Balancer Group
Type ………………………..	Gear-driven differential rotor
Number of lobes
Inner rotor …………………………………………………		5
Outer rotor ………………………………………………..		6

Illustration 30	g00938064

The oil pump
(1) Clearance of the outer rotor to the
body ………………………………..	0.152 to 0.330 mm
	(0.0059 to 0.0129 inch)

Illustration 31	g00938061

Checking the clearance
(2) Clearance of inner rotor to outer
rotor ………………………………..	0.040 to 0.127 mm
	(0.0015 to 0.0050 inch)

18	KENR6245
Speciﬁcations Section

Illustration 32	g00938799

Checking the end play
(3) End play of rotor assembly
Inner rotor ………………………..	0.038 to 0.089 mm
	(0.0014 to 0.0035 inch)
Outer rotor ……………………….	0.025 to 0.076 mm
	(0.0010 to 0.0029 inch)

Tighten the bolts that hold the front cover of the oil

pump assembly to the following torque.	…….. 10 N·m
	(89 lb in)
	i02731019

Engine Oil Pressure

The minimum oil pressure at the maximum engine speed and at normal operating temperature is the following value. …………………………. 280 kPa (41 psi)

i02505676

Engine Oil Bypass Valve

Installed in the Oil Pump

Illustration 33	g00919893

Typical engine oil pump

Illustration 34	g00921377

Relief valve and spring

(1)Tighten the plug for the relief valve to the following torque. ………………….. 35 N·m (26 lb ft)

(2)Plunger

Diameter of the plunger ….. 19.186 to 19.211 mm

(0.7554 to 0.7563 inch)

Clearance of plunger in bore .. 0.039 to 0.114 mm (0.0015 to 0.0045 inch)

(3)Spring

Length of the spring …… 80.94 mm (3.1866 inch)

KENR6245	19
	Speciﬁcations Section

Installed in the Balancer

Illustration 35	g00919890

Plug

Illustration 36		g00921379

The relief valve for the balancer
(1)	Tighten the plug for the relief valve to the
	following torque. …………………..	35 N·m (26 lb ft)
(2)	Plunger
	Diameter of the plunger ……..	14.46 to 14.48 mm
			(0.5692 to 0.5700 inch)
	Clearance of the plunger in the
	bore ….	0.04 to 0.08 mm (0.0015 to 0.0031 inch)
(3)	Spring
	Length of the spring ………..	67 mm (2.6378 inch)

i02662550

Engine Oil Pan

Table 7

Required Tools

Tool	Part Number	Part Description	Qty

A	21826038	POWERPART	1
Retainer

Front sealant

Illustration 37	g01254690

Applying sealant

If the gasket that is between the front housing and the cylinder block is not renewed, apply Tooling (A) to the cylinder block and to the front housing. If a new gasket is installed, Tooling (A) is not required.

Note: Apply a sealant bead of 3.5 mm (0.1378 inch) that is shown in illustration 37.

Rear sealant

Note: Install the rear oil seal before sealant is applied to the bridge.

20		KENR6245
Speciﬁcations Section
	Tighten the remaining bolts to the following
	. ………………………………………torque	22 N·m (16 lb ft)
	(2) Drain plug
	Tighten the drain plug for the engine oil pan to
	the following torque. ……………..	34 N·m (25 lb ft)
		i02662638

Crankcase Breather

		Table 8
				Required Tools

			Part
		Tool	Number		Part Description	Qty
					POWERPART red rubber
Illustration 38	g01254887	A	21820221		1
		grease
Applying sealant

Apply Tooling (A) to the bridge. The sealant must not protrude more than 5 mm (0.1969 inch) above the bridge.

Illustration 39	g01255016

Typical example

(1) Tighten the four front bolts in position (X) to the following torque. ………………….. 22 N·m (16 lb ft)

Illustration 40	g00926199

Breather valve

(1)Cover

(2)Cover plate

(3)Screws

Tighten the screws for the cover plate with a composite valve mechanism cover to the

following torque. ………………. 1.3 N·m (11.5 lb in)

(4)Diaphragm

(5)Cap

KENR6245	21
		Speciﬁcations Section
(6) Spring		Breather Canister

Illustration 41	g00926200

Typical example

(7) O-ring

Note: Apply Tooling (A) to the O-ring before installing the breather pipe in the valve mechanism cover.

(8)Tighten the bolts that secure the breather pipe to the cylinder head to the following torque. .. 9 N·m

(80 lb in)

Illustration 42	g01277902

Typical example
(1)	Connection
(2)	Clamp
(3)	Hose
(4)	Filter base
(5)	Bolts
(6)	Clamp
(7)	Hose
(8)	Canister

(2) Tighten the clamps to the following

torque. …………………………………. 3 N·m (26 lb in)

(5) Tighten the bolts to the following torque. .. 22 N·m (16 lb ft)

(6) Tighten the clamp to the following torque. .. 3 N·m (26 lb in)

(8) Tighten the canister to the following

torque. ……………………………… 12 N·m (106 lb in)

22	KENR6245
Speciﬁcations Section

i02504533

Water Temperature Regulator and Housing

Table 9

Required Tools

Tool	Part Number	Part Description	Qty

A	21820221	POWERPART Red	1
Rubber Grease

Illustration 43	g01253716

Typical example

Note: Apply Tooling (A) to the O-ring (4) in order to install the water temperature regulator housing (2).

(1) Tighten the bolts that fasten the housing to the following torque. ………………….. 44 N·m (32 lb ft)

(2)Water temperature regulator housing

(3)Water temperature regulator

Opening temperature ……………………		82° to 87°C
(179.6000° to 156.6000°F)
Full opening temperature ….	95 °C (203.0000 °F)
Minimum stroke at full temperature	……….. 9 mm
		(0.3543 inch)

i02363605

Water Pump

Illustration 44	g01183807

Tightening sequence

Tighten the setscrews in the numerical sequence that is shown in illustration 44 to the following

torque. ………………………………………	22 N·m (16 lb ft)
	i02663067

Cylinder Block

Table 10

Required Tools

Tool	Part Number	Part Description	Qty

A	21826038	POWERPART	1
Retainer

KENR6245	23
	Speciﬁcations Section

Illustration 45	g00924764

Typical example
(1) Cylinder block
(2) Cylinder bore …………….	105.000 to 105.025 mm
	(4.1338 to 4.1348 inch)
The ﬁrst oversize bore
diameter …………………………….	105.5 to 105.525 mm
	(4.1535 to 4.1545 inch)
The second oversize bore
diameter …………………………	106.000 to 106.025 mm
	(4.1732 to 4.1742 inch)

The maximum permissible wear for the cylinder bore

…………………………… 0 to 0.15 mm (0 to 0.0059 inch)

(3)Camshaft bearings

Diameter of the bore in the cylinder

block for the number 1 camshaft

bearing	………………………… 55.563 to 55.593 mm
	(2.1875 to 2.1887 inch)

Diameter of the bore in the cylinder block for the number 2 camshaft

journal	…………………………. 50.546 to 50.597 mm
	(1.9900 to 1.9920 inch)

	Diameter of the bore in the cylinder
	block for the number 3 camshaft
	journal ………………………….	50.038 to 50.089 mm
		(1.9700 to 1.9720 inch)
(4)	Main bearings
	Bore in the cylinder block for the main
	bearings ……………………….	80.416 to 80.442 mm
		(3.1660 to 3.1670 inch)
(5)	Main bearing cap bolts

Use the following procedure in order to install the main bearing cap bolts:

1.Apply clean engine oil to the threads of the main bearing cap bolts.

2.Put the main bearing caps in the correct position that is indicated by a number on the top of the main bearing cap. Install the main bearing caps with the locating tabs in correct alignment with the recess in the cylinder block.

3.Evenly tighten the main bearing cap bolts. Torque for the main bearing cap bolts. …. 245 N·m

(180 lb ft)

Illustration 46	g00938203

Use the following procedure in order to install the allen head bolts for the bridge.

Note: Install the rear seal before sealant is applied.

1.Use a straight edge in order to ensure that the bridge is aligned with the rear face of the cylinder block.

2.Tighten the allen head bolts (6) for the bridge. Torque for the allen head bolts … 16 N·m (12 lb ft)

3.When the bridge is installed on the cylinder block, apply Tooling (A) into groove (7) at each end of the bridge. Apply the sealant into the groove until the sealant is forced through the bottom end of the groove in the bridge.

Note: The oil pan must be installed within 10 minutes of applying the sealant.

Total height of the cylinder block between the top and

the bottom faces.	……………. 441.173 to 441.274 mm
	(17.3689 to 17.3729 inch)

24	KENR6245
Speciﬁcations Section

Crankshaft

i02663072 Note: All new turbocharged engines and turbocharged aftercooled engines have crankshafts that are nitrocarburised. The crankshaft can also be nitrided for 20 hours, if the nitrocarburised process is not available. After a crankshaft has been machined, the crankshaft must be rehardened. Inspect the crankshaft for cracks before machining and after machining. Naturally aspirated engines have induction hardened crankshafts.

Illustration 47	g01338264

Typical example

(1) Crankshaft

The maximum end play of the crankshaft … 0.51 mm (0.0201 inch)

(2)	Thrust washers
	Standard thickness ……………….	2.26 to 2.31 mm
		(0.089 to 0.091 inch)
	Oversize thickness ……………….	2.45 to 2.50 mm
		(0.097 to 0.098 inch)
(3)	The crankshaft gear
Maximum permissible temperature of the gear for
installation on the crankshaft ………..	180 °C (356 °F)

Note: The timing mark is toward the outside of the crankshaft when the gear is installed on the crankshaft.

KENR6245	25
	Speciﬁcations Section

Illustration 48	g01338265

Note: Refer to illustration 48 in order to use table 11.

Table 11

The undersize diameter of the Crankshaft Journals

NUMBER	0.25 mm (0.010 inch)	0.51 mm (0.020 inch)	0.76 mm (0.030 inch)

1	75.905 to 75.926 mm	75.651 to 75.672 mm	75.397 to 75.418 mm
(2.9884 to 2.9892 inch)	(2.9784 to 2.9792 inch)	(2.9684 to 2.9692 inch)


2	63.216 to 63.236 mm	62.962 to 62.982 mm	62.708 to 62.728 mm
(2.4888 to 2.4896 inch)	(2.4788 to 2.4796 inch)	(2.4688 to 2.4696 inch)

3	39.47 mm (1.5539 inch)	N/A	N/A
maximum

4	37.44 mm (1.4740 inch)	N/A	N/A
maximum

5	44.68 mm (1.7591 inch)	N/A	N/A
maximum

6	40.55 mm (1.5965 inch)	N/A	N/A
maximum


7	Do not machine this diameter.	N/A	N/A

8	3.68 mm (0.1449 inch) to	N/A	N/A
3.96 mm (0.1559 inch)

9	4.36 to 4.60 mm	N/A	N/A
(0.1717 to 0.1811 inch)

Refer to table 12 for the maximum run out of the crankshaft journals.

26	KENR6245
Speciﬁcations Section

Table 12

Journal	Excessive run out

(1)	Mounting

(2)	0.08 mm (0.0031 inch)

(3)	0.15 mm (0.0059 inch)

(4)	0.08 mm (0.0031 inch)

(5)	Mounting

Refer to Speciﬁcations, “Connecting Rod Bearing Journal” for more information on the connecting rod bearing journals and connecting rod bearings.

Refer to Speciﬁcations, “Main Bearing Journal” for information on the main bearing journals and for information on the main bearings.

i02658811

Crankshaft Seals

Illustration 49	g01335894

Typical example

(1)Crankshaft

(2)Crankshaft seal

(3)Plastic sleeve

(4)Alignment tool

Illustration 50	g00915076

(5)Tighten bolts 1, 2, 3, 4, 5, 6, 7, and 10 in the sequence that is shown in Illustration 50 to the

following torque. …………………..	22 N·m (16 lb ft)
Remove the alignment tool.

Tighten bolts 8 and 9 in the sequence that is shown

in Illustration 50 to the following torque.	…….. 22 N·m
	(16 lb ft)
	i02504771

Connecting Rod Bearing

Journal

Refer to Speciﬁcations, “Crankshaft” for information on the undersize crankshaft journals.

The original size of the connecting rod bearing journal … 63.47 to 63.49 mm (2.4988 to 2.4996 inch)

Maximum permissible wear of a bearing journal on a

new connecting rod …………..	0.04 mm (0.0016 inch)
Width of the connecting rod bearing
journals	……………………………..	40.348 to 40.424 mm
		(1.5885 to 1.5915 inch)
Radius of the ﬁllet of the connecting rod bearing
journals ………	3.68 to 3.96 mm (0.145 to 0.156 inch)
Surface ﬁnish of connecting rod bearing
journals ………………………………………		Ra 0.4 microns

KENR6245	27
	Speciﬁcations Section

Surface ﬁnish of radii ……………………

Ra 1.3 microns

i02656267

Main Bearing Journal

Refer to Speciﬁcations, “Crankshaft” for information on the undersize main bearing journals, and information on the width of main bearing journals.

The original size of the main bearing

journal ……………………………….	76.159 to 76.180 mm
	(2.9984 to 2.9992 inch)
Maximum permissible wear of the main bearing
journals ………………………….	0.040 mm (0.0016 inch)
Radius of the ﬁllet of the main bearing
journals …..	3.68 to 3.69 mm (0.1448 to 0.1452 inch)
Surface ﬁnish of bearing journals, crank pins and
radii ……………………………..	0.4 microns (16 µ inches)

The shell for the main bearings

The shells for the main bearings are available for remachined journals which have the following undersize dimensions.

Undersize bearing shell ….	0.25 mm (0.010 inch)
Undersize bearing shell ….	0.51 mm (0.020 inch)
Undersize bearing shell ….	0.75 mm (0.030 inch)

Thickness at center of the shells	.. 2.083 to 2.089 mm
(0.0820 to 0.0823 inch)
Width of the main bearing shells	.. 31.62 to 31.88 mm
	(1.244 to 1.255 inch)

Clearance between the bearing shell and the main

bearing journals	……………………… 0.057 to 0.117 mm
	(0.0022 to 0.0046 inch)

i02662161

Connecting Rod

Illustration 51	g00907738

The mating surfaces of the connecting rod are produced by hydraulically fracturing the forged connecting rod.

(1)Tighten the torx screws for the connecting rod to the following torque. …………….. 18 N·m (13 lb ft)

Tighten the torx screws for the connecting rod again to the following torque. ……………….. 70 N·m (52 lb ft)

Tighten the torx screws for the connecting rod for an additional 120 degrees. The torx screws for the connecting rod (1) must be replaced after this procedure.

Note: Always tighten the connecting rod cap to the connecting rod, when the assembly is out of the engine. Tighten the assembly to the following torque 20 N·m (14 lb ft).

(2) The bearing shell for the connecting rod

28		KENR6245
Speciﬁcations Section

Illustration 52	g00995584

Alignment of the bearing shell

Note: The bearing shell for the connecting rod must be aligned equally from both ends of the connecting rod. Refer to (A) in ﬁgure 52. Refer to Disassembly and Assembly for information on the alignment tool.

Table 13

Bearing Width for the	31.62	to 31.88 mm
Connecting Rod	(1.245 to 1.255 inch)

Bearing Width for the	31.62	to 31.88 mm
Connecting Rod Cap	(1.2449 to 1.2551 inch)
Thickness of Connecting	1.835	to 1.842 mm
Rod Bearing at the
(0.0723 to 0.0725 inch)
Center


Thickness of Connecting	1.835	to 1.842 mm
Rod Bearing for the Cap
(0.0722 to 0.0725 inch)
at the Center


Bearing Clearance	0.034	to 0.081 mm
(0.0013 to 0.0032 inch)

Table 14

Undersized Connecting Rod Bearing

0.25 mm (0.010 inch)

0.51 mm (0.020 inch)

0.76 mm (0.030 inch)

Illustration 53	g00907744

(3)	Inside diameter of the small
	bush …………………………….	39.723 to 39.738 mm
		(1.5639 to 1.5645 inch)
(4)	Distance between the parent
	bores ……………………………	219.05 to 219.10 mm
		(8.624 to 8.626 inch)
(5)	Diameter for the parent bore for the connecting
	rod bearing ………………………	67.21 to 67.22 mm
		(2.6460 to 2.6465 inch)

Illustration 54	g00915056

KENR6245	29
	Speciﬁcations Section

Connecting rods are color coded. The color code is a reference for the length (Y) of the connecting rod. Refer to table 15 for the different lengths of connecting rods.

Table 15

Length Grades for Connecting Rods

Grade Letter	Color Code	Length (Y)

F	Red	165.728 to 165.761 mm
(6.5247 to 6.5260 inch)

G	Orange	165.682 to 165.715 mm
(6.5229 to 6.5242 inch)

H	White	165.637 to 165.670 mm
(6.5211 to 6.5224 inch)

J	Green	165.591 to 165.624 mm
(6.5193 to 6.5206 inch)

K	Purple	165.545 to 165.578 mm
(6.5175 to 6.5188 inch)

L	Blue	165.499 to 165.532 mm
(6.5157 to 6.4961 inch)


		i02662142

Piston and Rings

Illustration 55	g01363510

Typical example

(1)Top compression ring

Naturally Aspirated

The shape of the top compression

ring …………………. Rectangular with a barrel face

Width of the top compression

ring …… 2.47 to 2.49 mm (0.0972 to 0.0980 inch)

Clearance between the top compression ring and the piston groove …………………. 0.09 to 0.13 mm

(0.0035 to 0.0051 inch)

Ring gap ……………………………..	0.30 to 0.55 mm
	(0.0118 to 0.0217 inch)
Turbocharged
The shape of the top compression
ring ………………………	Keystone with a barrel face
Width of the top compression ring ……….	tapered
Ring gap ……………………………..	0.30 to 0.45 mm
	(0.0118 to 0.0177 inch)

Note: When you install a new top compression ring, make sure that the word “TOP” is facing the top of the piston. New top piston rings for naturally aspirated engines have a red identiﬁcation mark which must be on the left of the ring end gap when the top piston ring is installed on an upright piston. New top piston rings for turbocharged engines have a yellow identiﬁcation mark which must be on the left of the ring end gap when the top piston ring is installed on an upright piston.

(2) Intermediate compression ring

The shape of the intermediate compression

ring …………………………….	Internal chamfer in the
bottom edge with a tapered face
Width of intermediate compression ring for
naturally aspirated engines	……. 2.47 to 2.49 mm
		(0.097 to 0.098 inch)
Width of intermediate compression ring for
turbocharged engines ………..		2.470 to 2.495 mm
	(0.0972 to 0.0982 inch)

Clearance between the intermediate compression ring and the piston groove for naturally aspirated engines … 0.05 to 0.09 mm (0.002 to 0.003 inch)

Clearance between the intermediate compression ring and the piston groove for turbocharged

engines	……………………………. 0.065 to 0.110 mm
	(0.0026 to 0.0043 inch)
Ring gap for naturally aspirated
engines	………………………………. 0.70 to 0.95 mm
	(0.0275 to 0.0374 inch)
Ring gap for turbocharged
engines ……………………………….	0.65 to 0.85 mm
	(0.0256 to 0.0335 inch)

Note: When you install a new intermediate compression ring, make sure that the word “TOP” is facing the top of the piston. New intermediate rings for naturally aspirated engines have a green identiﬁcation mark which must be on the left of the ring end gap when the top piston ring is installed on an upright piston. New intermediate rings for

turbocharged engines have a blue identiﬁcation mark which must be on the left of the ring end gap when the top piston ring is installed on an upright piston.

30			KENR6245
Speciﬁcations Section
(3) Oil control ring	Piston pin
Shape of	oil control	Diameter of a new piston
ring …………	a two-piece coil that is spring loaded	pin ……………………………….	39.694 to 39.700 mm
Width of oil control ring for naturally aspirated		(1.5628 to 1.5630 inch)
Diameter of the bore for the piston
engines ……………………………….	3.47 to 3.49 mm
	(0.1366 to 0.1374 inch)	pin ……………………………….	39.703 to 39.709 mm
Width of oil control ring for turbocharged		(1.5631 to 1.5633 inch)
engines ……………………………….	2.97 to 2.99 mm
	(0.1169 to 0.1177 inch)		i02665602

Clearance between the oil control ring and the groove in the piston for naturally aspirated

engines ……………………………….	0.03 to 0.07 mm
	(0.0011 to 0.0027 inch)
Ring gap ……………………………..	0.30 to 0.55 mm
	(0.0118 to 0.0216 inch)

Note: A pin is used in order to hold both ends of the spring of the oil control ring in position. The ends of the spring of the oil control ring must be installed opposite the end gap of the oil control ring.

Note: Ensure that the ring end gaps of the piston rings are spaced 120 degrees from each other.

Piston

Note: An arrow which is marked on the piston crown must be toward the front of the engine.

The combustion bowl re-entrant angle for the

turbocharged engine ………………………….	72 degrees
The combustion bowl re-entrant angle for the
naturally aspirated engine …………………..	70 degrees
Piston height above cylinder block ..	0.21 to 0.35 mm
	(0.008 to 0.014 inch)
Width of top groove in piston for the naturally
aspirated engine ………………………..	2.58 to 2.60 mm
	(0.1016 to 0.1024 inch)
Width of top groove in piston for the turbocharged
engine ………………………………………………….		Tapered
Width of second groove in piston for naturally
aspirated engines ………………………	2.54 to 2.56 mm
	(0.1000 to 0.1008 inch)
Width of second groove in piston for turbocharged
engines …..	2.56 to 2.58 mm (0.1008 to 0.1016 inch)

Width of third groove in piston for naturally aspirated engines ….. 3.52 to 3.54 mm (0.1386 to 0.1394 inch)

Piston Cooling Jet

Illustration 56	g00942652

(1) Installed piston cooling jets

The valve must move freely. Tighten the bolt to the following torque. ……………………………. 9 N·m (7 lb ft)

Piston Cooling Jet Alignment

Illustration 57	g01006929

(2)Piston cooling jet

(3)Rod

(4)Cylinder block

Width of third groove in piston for turbocharged engines …… 3.02 to 3.04 mm (0.1189 to 0.1197 inch)

Use the following procedure in order to check the alignment of the piston cooling jet.

KENR6245	31
	Speciﬁcations Section

1.Insert rod (3) into the end of the piston cooling jet (2). Rod (3) has a diameter of 1.70 mm (0.067 inch). Rod (3) must protrude out of the top of the cylinder block.

2.Dimension (A) is 50.75 mm (1.9980 inch) and dimension (B) is 9.35 mm (0.3681 inch).

Dimension (A) and dimension (B) are tangential to the cylinder bore (4).

3.The position of the rod (3) must be within dimension (C). Dimension (C) is 10 mm (0.3937 inch).

Note: Ensure that the rod (3) can not damage the piston cooling jet when the alignment is checked. The piston cooling jets can not be adjusted. If a piston cooling jet is not in alignment the piston cooling jet must be replaced.

i02662168

Front Housing and Covers

The front housing must be aligned to the cylinder

block face.	…………………….. + 0.05 to minus 0.05 mm
	(+ 0.0020 to minus 0.0020 inch)

Illustration 59	g00918672

Front cover

(2)Tighten the bolts that fasten the water pump to the front housing to the following torque. ……. 22 N·m

(16 lb ft)

Note: Refer to Speciﬁcations, “Water Pump” for the correct bolt tightening sequence for the water pump.

i02662183

Gear Group (Front)

Illustration 58	g01337594

Alignment

(1)Tighten the bolts that fasten the front cover to the front housing to the following torque. ……. 22 N·m

(16 lb ft)

Illustration 60	g00995886

Gear train

32	KENR6245
Speciﬁcations Section

(1) Fuel injection pump drive gear
Tighten the nut to the following torque.	… 24 N·m
	(18 lb ft)
Release the lock on the fuel injection pump shaft.
Torque the nut to the following torque. ….	90 N·m
	(66 lb ft)
Number of teeth ……………………………………….	68

Note: Refer to Speciﬁcations, “Fuel Injection Pump” for the locking torque for the fuel injection pump shaft.

(2) Camshaft gear

Tighten the bolt for the camshaft gear to the

following torque.	………………….. 95 N·m (70 lb ft)
Bore diameter of the camshaft
gear ………………………………..	34.93 to 34.95 mm
	(1.3750 to 1.3760 inch)

Outside diameter of the camshaft

hub .. 34.90 to 34.92 mm (1.3741 to 1.3747 inch)

Clearance between the camshaft gear and the

camshaft hub ……………………	0.003 to 0.048 mm
	(0.0001 to 0.0019 inch)
Number of teeth ……………………………………….	68
(3) Idler gear and hub

Tighten the bolts for the idler gear to the following

torque.	………………………………..	44 N·m (33 lb ft)
Bore diameter of the idler gear
……..	57.14 to 57.18 mm (2.2495 to 2.2512 inch)
Bore diameter of the idler gear with roller
bearings …………………………..	72.35 to 72.36 mm
		(2.8484 to 2.8488 inch)
Width of idler gear and split bearing
assembly …………………………	30.14 to 30.16 mm
		(1.186 to 1.187 inch)
Inside diameter of idler gear bearings with
ﬂanges …………………………….	50.78 to 50.80 mm
		(1.999 to 2.000 inch)
Outside diameter of idler gear
hub ..	50.70 to 50.74 mm (1.9961 to 1.9976 inch)
Outside diameter of idler gear hub with roller
bearings ……………………….	49.975 to 49.988 mm
		(1.9675 to 1.9680 inch)
Clearance of idler gear bearing on
hub ……	0.04 to 0.10 mm (0.0016 to 0.0039 inch)
Idler gear end play ………………..	0.10 to 0.20 mm
		(0.004 to 0.008 inch)
Idler gear end play with roller
bearings ………………………………	0.10 to 0.75 mm
		(0.0039 to 0.0295 inch)

Maximum permissible end play	………… 0.38 mm
	(0.015 inch)
Number of teeth ……………………………………….	73

Illustration 61	g00996214

The gear train for the oil pump

(4)Crankshaft gear

Bore diameter of crankshaft gear

…. 47.625 to 47.650 mm (1.8750 to 1.8760 inch)

Outside diameter of crankshaft
hub ………………………………	47.625 to 47.645 mm
	(1.8750 to 1.8758 inch)
Clearance of gear	on
crankshaft …………………….	−0.020 to +0.020 mm
	(−0.0008 to +0.0008 inch)
Number of teeth ……………………………………….		34
(5) Oil pump idler gear
Inside diameter of oil pump idler gear
bearing …………………………	16.012 to 16.038 mm
	(0.6304 to 0.6314 inch)
Outside diameter of oil pump idler gear
shaft …………………………….	15.966 to 15.984 mm
	(0.6286 to 0.6293 inch)
Clearance of oil pump idler gear bearing on
shaft ………………………………..	0.028 to 0.072 mm
	(0.0011 to 0.0028 inch)
End play of the oil pump idler
gear ………………………………..	0.050 to 0.275 mm
	(0.0019 to 0.0108 inch)
(6) Oil pump gear
The number of teeth on the oil pump gear …..	17
Backlash values
Backlash between the idler gear (5) and the oil
pump drive gear (6)	………….. 0.046 to 0.106 mm
	(0.0018 to 0.0041 inch)

KENR6245	33
	Speciﬁcations Section

Backlash between the oil pump idler gear (5) and

the crankshaft gear (4)	……… 0.095 to 0.160 mm
	(0.0037 to 0.0063 inch)
Backlash between the idler gear (3) and the
crankshaft gear (4) ……………	0.064 to 0.124 mm
	(0.0025 to 0.0049 inch)

Backlash between the camshaft gear (2) and the

idler gear (3)	……………………. 0.052 to 0.107 mm
	(0.0020 to 0.0042 inch)

Backlash between the fuel injection pump gear

(1) and the idler gear (3)	……. 0.054 to 0.109 mm
	(0.0021 to 0.0043 inch)

Backlash between the water pump gear (not shown) and the fuel injection pump gear

(1) … 0.073 to 0.133 mm (0.0028 to 0.0052 inch) Backlash between the power take-off

drive (if equipped) and the idler gear

(3) …. 0.112 to 0.172 mm (0.0044 to 0.0068 inch)

Engines that have a Balancer

		g00996003
Illustration 62
Balancer gears
(7) Idler gear for the oil pump that has a balancer
The number of teeth on the gear	……………….. 44
The bore diameter of the idler
gear …………………………….	37.197 to 37.212 mm
	(1.4644 to 1.4650 inch)
The hub diameter for the idler
gear …………………………….	37.152 to 37.162 mm
	(1.4627 to 1.4631 inch)
The end play for the idler gear ..	0.12 to 0.27 mm
	(0.0047 to 0.0106 inch)
(8) Gear for the oil pump that has a balancer
The number of teeth on the gear	……………….. 17

Backlash between the oil pump gear (8) and the idler gear (7) … 0.097 to 0.17 mm (0.0038 to 0.0067 inch)

i02503254

Flywheel

Illustration 63	g00584712

Typical example

(1) Flywheel ring gear

Heat the ﬂywheel ring gear to the following temperature. ………………………… 250 °C (480 °F)

Note: Do not use an oxyacetylene torch to heat the ﬂywheel ring gear.

(2)Flywheel

(3)Bolt

Tighten the ﬂywheel bolts to the following torque. ………………………………. 115 N·m (85 lb ft)

34		KENR6245
Speciﬁcations Section
i02663068		i02662798
Flywheel Housing		Crankshaft Pulley

Illustration 64	g01338247

Typical example

(1)Bolt

Tighten the bolts for the cast iron ﬂywheel housing to the following torque:

M10	“8.8” …………………………….	44	N·m (33 lb ft)
M10	“10.9” …………………………..	63	N·m (47 lb ft)
M12	“8.8” …………………………….	75	N·m (55 lb ft)
M12	“10.9” ………………………….	115	N·m (85 lb ft)

Illustration 65	g00915497

A standard pulley

(1)Tighten the three bolts for the crankshaft pulley to the following torque. ………… 115 N·m (85 lb ft)

Note: Recheck the torque of the bolts (1) once.

(2) Thrust block

Note: The chamfers on the bolt holes must face toward the front of the engine.

(3) Crankshaft pulley

KENR6245	35
	Speciﬁcations Section

Crankshaft Pulley for the Poly V-Belt

Illustration 66	g01337951

Typical example

(1)Bolt

(2)Thrust block

(3)Crankshaft adapter

(4)Crankshaft pulley

(5)Bolt

(1)Tighten the three bolts for the thrust block to the following torque. …………………. 115 N·m (85 lb ft)

Note: Recheck the torque of the bolts (1) once.

Note: The chamfers on the bolt holes must face toward the front of the engine.

(5)Tighten the three bolts for the crankshaft pulley to the following torque. …………. 78 N·m (58 lb ft)

Non — Standard Pulley

Illustration 67	g01337945

(1)T Mark

(2)Alignment mark

Note: The marks (1 and 2) on the pulley must be vertical when the pulley is installed on the engine. Number one piston of the engine must be at top dead center.

i02663070

Fan Drive

Illustration 68	g01338248

Typical example

(1) Tighten the bolts to the following torque. .. 22 N·m (16 lb ft)

Fan drive housing

Tighten the bolts (2) that secure the fan drive housing (3) to the cylinder head to the following torque. ……………………………………… 44 N·m (32 lb ft)

Maximum permissible end play of the shaft .. 0.20 mm (0.0079 inch)

36				KENR6245
Speciﬁcations Section
i01721280	(2)	Terminal “D+”
Engine Lifting Bracket		Tighten the terminal nut to the following
		torque. ……………………………….	3.7	N·m (33 lb in)
	(3)	Terminal “B+”
		Tighten the terminal nut to the following
All engines are equipped with two engine lifting		torque. ………………………………….	7	N·m (62 lb in)
brackets.

Tighten the two bolts on each engine lifting bracket to the following torque. .. 44 N·m (32 lb ft)

i02656398

Alternator

The 12 Volt and 24 Volt Denso

Alternators

Three types of alternator are available.

Output
Two 12 volt alternators are
available. …………………..	100 Amp and 120	Amp
One 24 volt alternator ………………………..	80	Amp

Illustration 69	g01332517

Typical example

(1) Terminal “W”

Tighten the terminal nut to the following

torque. ………………………………. 3.7 N·m (33 lb in)

The 12 Volt and 24 Volt Iskra

Alternator

12 volt output
Two alternators are
available. …………………..	150 Amp and 175	Amp
24 volt output
The 24 volt alternator ……………………….	100	Amp

Illustration 70	g01332519

Typical example
(1)	Terminal “B+”
	Tighten the terminal nut to the following
	torque. ………………………………..	11 N·m (97 lb in)
(2)	Terminal “D+”
	Tighten the terminal nut to the following
	torque. ………………………………….	3 N·m (26 lb in)
(3)	The terminal “W” is spade-type.

KENR6245	37
	Speciﬁcations Section

i02656404

Starter Motor

24 Volt Starting Motor

Illustration 71	g00974968

The 24 volt starting motor which shows the electrical connections
(1)	Tighten the negative terminal nut to the following
	torque. ………………………………..	16 N·m (12 lb ft)
(2)	Tighten the positive terminal nut to the following
	torque. ………………………………..	21 N·m (15 lb ft)
(3)	Tighten the solenoid terminal to the following
	torque. ……………………………….	3.6 N·m (32 lb in)
Rated voltage …………………………………………	24 volts

38	KENR6245
Speciﬁcations Section

12 Volt Starting Motor

Illustration 72

The 12 volt starting motor which shows the electrical connections

(1)	Tighten the solenoid terminal to the following
	torque. …………………………………	8 N·m ( 70 lb in)
(2)	Tighten the positive terminal nut to the following
	torque. …………………………………	6 N·m ( 53 lb in)

(3)Tighten the negative terminal nut to the following torque. ………………………………… 8 N·m (70 lb in)

Rated voltage …………………………………………

12 volts

Glow Plugs

Illustration 73	g01334536

Typical example

(1) Tighten the glow plugs (3) in the cylinder head to the following torque. ……………… 15 N·m (11 lb ft)

KENR6245	39
	Speciﬁcations Section
Tighten the nuts (2) for the bus bar (1) that is
installed on top of the glow plugs to the following
torque. ………………………………………..	2 N·m (18 lb in)
Voltage ………………………………………….	12 or 24 volts

Note: Glow plugs are not installed on all engines. Engines that do not have glow plugs are installed with threaded plugs.

40	KENR6245
Index Section

Index
A
Alternator………………………………………………………	36
The 12 Volt and 24 Volt Denso Alternators……..	36
The 12 Volt and 24 Volt Iskra Alternator …………	36
C
Camshaft ………………………………………………………	12
Camshaft Bearings …………………………………………	14
Connecting Rod……………………………………………..	27
Connecting Rod Bearing Journal………………………	26
Crankcase Breather………………………………………..	20
Breather Canister………………………………………..	21
Crankshaft ……………………………………………………	24
Crankshaft Pulley …………………………………………..	34
Crankshaft Pulley for the Poly V-Belt……………..	35
Non — Standard Pulley………………………………….	35
Crankshaft Seals ……………………………………………	26
Cylinder Block………………………………………………..	22
Cylinder Head………………………………………………..	10
Cylinder Head Valves ……………………………………..	8
E
Engine Design ……………………………………………….	4
Engine Lifting Bracket……………………………………..	36
Engine Oil Bypass Valve …………………………………	18
Installed in the Balancer……………………………….	19
Installed in the Oil Pump ………………………………	18
Engine Oil Cooler …………………………………………..	15
Engine Oil Filter ……………………………………………..	14
Engine Oil Pan……………………………………………….	19
Front sealant ………………………………………………	19
Rear sealant……………………………………………….	19
Engine Oil Pressure………………………………………..	18
Engine Oil Pump…………………………………………….	16
Engines with Balancer Group ……………………….	16
Engines without Balancer Group …………………..	17
Exhaust Manifold……………………………………………	12
F
Fan Drive………………………………………………………	35
Fan drive housing ……………………………………….	35
Flywheel ……………………………………………………….	33
Flywheel Housing …………………………………………..	34
Front Housing and Covers……………………………….	31
Fuel Injection Lines…………………………………………	4
Fuel Injection Pump………………………………………..	5
Fuel Injectors…………………………………………………	6
Fuel Transfer Pump………………………………………..	6

G
Gear Group (Front)…………………………………………	31
Engines that have a Balancer……………………….	33
Glow Plugs ……………………………………………………	38
I
Important Safety Information ……………………………	2
L
Lifter Group……………………………………………………	7
M
Main Bearing Journal………………………………………	27
The shell for the main bearings……………………..	27
P
Piston and Rings ……………………………………………	29
Piston………………………………………………………..	30
Piston Cooling Jet…………………………………………..	30
Piston Cooling Jet Alignment ………………………..	30
R
Rocker Shaft………………………………………………….	7
S
Speciﬁcations Section …………………………………….	4
Starter Motor………………………………………………….	37
12 Volt Starting Motor ………………………………….	38
24 Volt Starting Motor ………………………………….	37
T
Table of Contents……………………………………………	3
Turbocharger …………………………………………………	11
V
Valve Mechanism Cover………………………………….	8
W
Water Pump…………………………………………………..	22

KENR6245	41
	Index Section
Water Temperature Regulator and Housing ……….	22

42	KENR6245
Index Section

KENR6245	43
	Index Section

Copyright © 2007 Perkins Engine Company Limited	Printed in U. K.
All Rights Reserved

Systems Operation

Testing and Adjusting

1104D (Mech) Industrial Engine

NK (Engine)

NL (Engine)

NM (Engine)

Important Safety Information

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 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.

When replacement parts are required for this product Perkins recommends using Perkins replacement parts.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

KENR6246	3
	Table of Contents

Table of Contents
Systems Operation Section
Engine Design ……………………………………………….	4
General Information …………………………………………	4
Fuel System …………………………………………………..	7
Air Inlet and Exhaust System ……………………………	9
Lubrication System ……………………………………….	12
Cooling System …………………………………………….	14
Basic Engine …………………………………………………	15
Electrical System ………………………………………….	15
Testing and Adjusting Section
Fuel System
Fuel System — Inspect …………………………………….	18
Air in Fuel — Test …………………………………………….	18
Finding Top Center Position for No. 1 Piston ……..	19
Fuel Injection Pump Timing — Check …………………	20
Fuel Injection Pump Timing — Adjust …………………	20
Fuel Quality — Test ………………………………………….	20
Fuel System — Prime ………………………………………	20
Fuel System Pressure — Test ……………………………	21
Air Inlet and Exhaust System
Air Inlet and Exhaust System — Inspect ……………..	22
Turbocharger — Inspect ……………………………………	22
Compression — Test ………………………………………..	25
Engine Valve Lash — Inspect/Adjust ………………….	25
Valve Depth — Inspect ……………………………………..	26
Valve Guide — Inspect ……………………………………..	27
Lubrication System
Engine Oil Pressure — Test ………………………………	28
Engine Oil Pump — Inspect ………………………………	28
Excessive Bearing Wear — Inspect ……………………	29
Excessive Engine Oil Consumption — Inspect …….	29
Increased Engine Oil Temperature — Inspect ……..	30
Cooling System
Cooling System — Check (Overheating) …………….	31
Cooling System — Inspect ………………………………..	32
Cooling System — Test …………………………………….	32
Engine Oil Cooler — Inspect ……………………………..	34
Water Temperature Regulator — Test …………………	34
Basic Engine
Piston Ring Groove — Inspect …………………………..	36
Connecting Rod — Inspect ……………………………….	36
Connecting Rod Bearings — Inspect ………………….	37
Main Bearings — Inspect ………………………………….	37
Cylinder Block — Inspect ………………………………….	37
Cylinder Head — Inspect ………………………………….	38
Piston Height — Inspect ……………………………………	38
Flywheel — Inspect ………………………………………….	39
Flywheel Housing — Inspect ……………………………..	40
Gear Group — Inspect ……………………………………..	41
Electrical System
Alternator — Test …………………………………………….	42

Battery — Test …………………………………………………	43
Electric Starting System — Test …………………………	43
Glow Plugs — Test …………………………………………..	45
V-Belt — Test ………………………………………………….	46
Index Section
Index ……………………………………………………………	48

4	KENR6246
Systems Operation Section

Systems Operation Section

i02680003

Engine Design

Illustration 1	g01346235

Typical example of the layout of the valves
(A) Inlet valve
(B) Exhaust valve

1104D Engine Speciﬁcation

Industrial
Type ……………………….	Four cylinder and four stroke
Type of combustion ……………………….		Direct injection
Bore …………………………………..		105 mm (4.134 inch)
Stroke ………………………………….		127 mm (5.00 inch)
Displacement ………………………………..		4.4 L (268 in3)
Compression ratio
Naturally aspirated ……………………………………		19.3:1
Turbocharged …………………………………………..		18.2:1
Turbocharged, aftercooled	………………………… 18.2:1
Number of cylinders …………………………………………		4
Cylinder arrangement ……………………………….		In-line
Firing order ………………………………………….		1, 3, 4, 2

The front of the engine is opposite the ﬂywheel end of the engine. The left side of the engine and the right side of the engine are determined from the ﬂywheel end. Number 1 cylinder is the front cylinder of the engine.

i02680006

General Information

Engine Description

Note: When you are ordering new parts, refer to the engine identiﬁcation number in order to receive the correct parts. Refer to the Operation and Maintenance Manual, “Product Identiﬁcation

Information” for the correct numbers for your engine.

The engine cylinders are arranged in-line. The engines are controlled by a mechanically governed fuel injection pump.

The cylinder head assembly has one inlet valve and one exhaust valve for each cylinder. Each valve has one valve spring. The pistons have two compression rings and an oil control ring.

It is important to ensure the correct piston height so that the piston does not contact the cylinder head. The correct piston height also ensures the efﬁcient combustion of fuel.

The 1104D engine crankshaft has ﬁve main journals. End play is controlled by thrust washers that are located on both sides of the center main bearing.

The timing case has a hole that corresponds with a hole in the crankshaft. Use an alignment pin to ﬁnd TC. The camshaft gear has a timing hole that corresponds with a timing hole in the timing case. The timing holes ensure that the camshaft and the crankshaft are in time with each other.

The crankshaft gear rotates the idler gear. The idler gear rotates the camshaft gear and the fuel injection pump gear. The idler gear for the engine oil pump is rotated by the crankshaft gear. This idler rotates the engine oil pump.

The fuel injection pump is a gear-driven pump that is mounted to the back of the front housing. The fuel transfer pump is electrically operated. The fuel transfer pump has an integral fuel ﬁlter. The fuel transfer pump is usually located on the left hand side of the cylinder block. Some applications may have the fuel transfer pump and the water separator (if equipped) relocated off the engine.

The oil pump is driven by an idler gear. The engine oil pump sends lubricating oil to the main oil gallery. The oil relief valve is internal to the oil pump.

Coolant from the bottom of the radiator passes through the water pump. The water pump is driven by the idler gear.

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Источник

Perkins Service and Parts Information System содержит каталоги запасных частей, руководства по диагностике, обслуживанию и ремонту двигателей Perkins общего и промышленного назначения, а так же двигателей для дизельных электростанций.

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Руководство на английском языке по техническому обслуживанию и ремонту автомобильных двигателей Perkins Phaser и промышленных двигателей Perkins 1000-й серии.

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Издательство: Perkins Engines Ltd.
Год издания: 2002
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Руководство на английском языке по техническому обслуживанию и ремонту автомобильных дизельных двигателей Perkins моделей 4.99/4.107/4.108.

Автор: —
Издательство: Perkins Engines Ltd.
Год издания: 1983
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Размер: 5,3 Mb

Справочник на английском языке с техническими данными двигателей Perkins объемом до 8,85 л.

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Руководство на английском языке по техническому обслуживанию и ремонту автомобильных дизельных двигателей Perkins моделей 4.99M/4.107M/4.108M.

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Издательство: Perkins Engines Ltd.
Год издания: 1978
Страниц: 134
Формат: PDF
Размер: 9,2 Mb

Руководство по техническому обслуживанию и ремонту двигателя Perkins модели 1104D-E44TA.

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Издательство: Терция
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Источник

Manuals
Brands
Perkins Manuals
Engine
1104

Manuals and User Guides for Perkins 1104. We have 5 Perkins 1104 manuals available for free PDF download: Disassembly And Assembly, Operation And Maintenance Manual, Workshop Manual

SEBU9066

March 2014

Operation and

Maintenance

Manual

1104D-E44T and 1104D-E44TA Industrial Engines

NP (Engine)

NR (Engine)

Important Safety Information

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 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.

When replacement parts are required for this product Perkins recommends using Perkins replacement parts.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

Table of Contents
Foreword………………………… ………………………..	4
Safety Section
Safety Messages………………….. …………………..	5
General Hazard Information…………… …………..	7
Burn Prevention…………………… ……………………	8
Fire Prevention and Explosion Prevention …. …	9
Crushing Prevention and Cutting Prevention . .	11
Mounting and Dismounting…………… ……………	11
High Pressure Fuel Lines ……………. …………….	11
Before Starting Engine …………….. ………………	13
Engine Starting…………………… …………………..	13
Engine Stopping ………………….. ………………….	14
Electrical System…………………. ………………….	14
Engine Electronics………………… …………………	15
Product Information Section
General Information……………….. ………………..	16
Product Identification Information………. ………	22
Operation Section
Lifting and Storage………………… …………………	24
Features and Controls……………… ………………	26
Engine Diagnostics………………… ………………..	37
Engine Starting…………………… …………………..	44
Engine Operation…………………. ………………….	47
Cold Weather Operation…………….. …………….	48
Engine Stopping ………………….. ………………….	52

Maintenance Section
Refill Capacities………………….. …………………..	54
Maintenance Recommendations………. ……….	67
Maintenance Interval Schedule……….. ………..	69
Warranty Section
Warranty Information……………… ………………	100
Reference Information Section
Reference Materials ……………… ……………….	101
Index Section
Index…………………………. …………………………	102

Foreword

Literature Information

This manual contains safety, operation instructions,

lubrication and maintenance information. This 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 English 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 have 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 the 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 and/or calendar time maintenance

intervals. Items in the maintenance schedule are referenced to detailed instructions that follow.

SEBU9066

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 severe, 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 maintenance 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 you 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.

SEBU9066

Safety Section

i05461290

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. 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.

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 Perkins 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.

Typical example

The Universal Warning label (1) is located on both sides of the valve mechanism cover base.

Safety Section

Safety Messages

Safety Section

Safety Messages

2 Hand (High Pressure)

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

	The warning label for the Hand (High Pressure) (2) is
	a wrap around label that is located on the rear injector
Illustration 3	line.
g01154858
Typical example	Ether

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.

Safety Section

General Hazard Information

Typical example

The ether warning label is supplied loose for the original equipment manufacture to install the label.

i05737934

General Hazard Information

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.

Wear a hard hat, protective glasses, and other protective equipment, as required.

Do not wear loose clothing or jewelry 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.

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 action could result in personal injury.

The direct application of pressurized air or pressurized water to the body 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.

Safety Section

Burn Prevention

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.

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.

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. If fluid 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 during performance of inspection,

maintenance, testing, adjusting, and repair of the engine. Make provision to collect the fluid 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 suitable for containing fluids and equipment that is suitable for containing fluids.

Obey all local regulations for the disposal of liquids.

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Static Electricity Hazard when Fueling with Ultra-low Sulfur Diesel Fuel

The removal of sulfur and other compounds in ultralow sulfur diesel fuel (ULSD fuel) decreases the conductivity of ULSD and increases the ability of ULSD to store static charge. Refineries may have treated the fuel with a static dissipating additive. Many factors can reduce the effectiveness of the additive over time. Static charges can build up in ULSD fuel while the fuel is flowing through fuel delivery systems. Static electricity discharge when combustible vapors are present could result in a fire or explosion. Ensure that the entire system used to refuel your machine (fuel supply tank, transfer pump, transfer hose, nozzle, and others) is properly grounded and bonded. Consult with your fuel or fuel system supplier to ensure that the delivery system complies with fueling standards for proper grounding and bonding.

Avoid static electricity risk when fueling. Ultra-low sulfur diesel fuel (ULSD fuel) poses a greater static ignition hazard than earlier diesel formulations with a higher sulfur contents. Avoid death or serious injury from fire or explosion. Consult with your fuel or fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

i05302522

Burn Prevention

Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine.

NOTICE

The low-pressure fuel system can be pressurized for a time period after the engine has stopped operating. The operating pressure of the low-pressure fuel system can be 500 kPa (73 psi). The secondary fuel filters should be drained before any maintenance of the low-pressure fuel system is carried out.

SEBU9066

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.

Allow the pressure to be purged in the air system, in the hydraulic system, in the lubrication 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 that 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.

Safety Section

Fire Prevention and Explosion Prevention

i04823662

Fire Prevention and Explosion

Prevention

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.

After the emergency stop button is operated, ensure that you allow 15 minutes, before the engine covers are removed.

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.

If the application involves the presence of combustible gases, consult your Perkins dealer and/ or 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.

Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in a line, a tube, or

a seal failure. Exhaust shields must be installed correctly.

Safety Section

Fire Prevention and Explosion Prevention

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. Ensure that all electrical wires are correctly routed and securely attached. 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.

After the engine has stopped, 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.

Ensure that the engine is stopped. Inspect all lines and hoses for wear or for deterioration. Properly route all hoses. The lines and hoses must have adequate support and secure clamps.

Properly install oil filters and fuel filters. The filter housings must be tightened to the correct torque. Refer to the Disassembly and Assembly manual for more information.

Illustration 10

g00704059

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.

Illustration 11

g02298225

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.

Safety Section

Crushing Prevention and Cutting Prevention

Do not charge a frozen battery.Charging a frozen battery 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.

Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike highpressure lines. Do not install any lines that are damaged.

Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for replacement parts.

Replace the parts if any of the following conditions are present:

•High-pressure fuel line or lines are removed.

•End fittings are damaged or leaking.

•Outer coverings are chafed or cut.

•Wires are exposed.

•Outer coverings are ballooning.

•Flexible parts 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 in order to prevent vibration, rubbing against other parts, and excessive heat.

i02143194

Crushing Prevention and

Cutting Prevention

Support the component correctly when work beneath the component is performed.

Unless 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.

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.

i05463929

Mounting and Dismounting

Do not climb on the engine. The engine has not been designed with mounting or dismounting locations.

Refer to the Original Equipment Manufacture (OEM) for the location of foot and hand holds for your specific application.

i05463931

High Pressure Fuel Lines

Safety Section

High Pressure Fuel Lines

Illustration 12		g03452057
(1) High-pressure line	(4) High-pressure line	(7) High-pressure supply line
(2) High-pressure line	(5) High-pressure fuel manifold (rail)
(3) High-pressure line	(6) High-pressure supply line

The high-pressure fuel lines are the fuel lines that are between the high-pressure fuel pump and the highpressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head. These

fuel lines are different from fuel lines on other fuel systems.

This difference is because of the following items:

•The high-pressure fuel lines are constantly charged with high pressure.

•The internal pressures of the high-pressure fuel lines are higher than other types of fuel system.

•The high-pressure fuel lines are formed to shape and then strengthened by a special process.

Do not step on the high-pressure fuel lines. Do not deflect the high-pressure fuel lines. Do not bend or strike the high-pressure fuel lines. Deformation or damage of the high-pressure fuel lines may cause a point of weakness and potential failure.

Do not check the high-pressure fuel lines with the engine or the starting motor in operation. After the engine has stopped, allow 90 seconds to pass in order to allow the pressure to be purged before any service or repair is performed on the engine fuel lines.

Do not loosen the high-pressure fuel lines in order to remove air from the fuel system. This procedure is not required.

Visually inspect the high-pressure fuel lines before the engine is started. This inspection should be each day.

If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”.

Safety Section

Before Starting Engine

•Inspect the high-pressure fuel lines for damage, deformation, a nick, a cut, a crease, or a dent.

•Do not operate the engine with a fuel leak. If there is a leak, do not tighten the connection in order to stop the leak. The connection must only be tightened to the recommended torque. Refer to Disassembly and Assembly, “Fuel injection lines — Remove and Fuel injection lines — Install”.

•If the high-pressure fuel lines are torqued correctly and the high-pressure fuel lines are leaking, the high-pressure fuel lines must be replaced.

•Ensure that all clips on the high-pressure fuel lines are in place. Do not operate the engine with clips that are damaged, missing, or loose.

•Do not attach any other item to the high-pressure fuel lines.

•Loosened high-pressure fuel lines must be replaced. Also removed high-pressure fuel lines must be replaced. Refer to Disassembly and assembly manual, “Fuel Injection Lines — Install”.

NOTICE

i02813489

Before Starting Engine

Before the initial start-up of an engine that is new, serviced or repaired, make provision to shut the engine off, in order to stop an overspeed. This may be accomplished by shutting off the air and/or fuel supply to the engine.

Overspeed shutdown should occur automatically for engines that are controlled electronically. 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.

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.

i02251260

Engine Starting

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 NOTstart the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.

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/or 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.

Safety Section

Engine Stopping

Note: The engine is equipped with a device for cold starting. 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.

These engines are equipped with a glow plug starting aid in each individual cylinder that heats the intake air in order to improve starting.

i02234873

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 NOTstart the engine until the problem that caused the emergency stop has been corrected.

Stop the engine if an overspeed condition occurs during the initial start-up of a new engine or an engine that has been overhauled.

To stop an electronically controlled engine, cut the power to the engine and/or shutting off the air supply to the engine.

i05464430

Electrical System

Never 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 “−” cable should be connected last from the external power source to the primary position for grounding.

Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical connections 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.

SEBU9066

Grounding Practices

Illustration 13

g03452577

(1)Ground to battery

(2)Ground to starting motor

(3)Starting motor to engine block

Illustration 14

g03452579

(4)Battery to ground

(5)Ground to engine block

(6)Primary position for grounding

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.

SEBU9066

Uncontrolled electrical circuit paths can result in damage to the 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.

The connections for the grounds should be tight and free of corrosion. The engine alternator must be grounded to the negative “-” battery terminal. The wire used must be adequate to handle the full charging current of the alternator.

The power supply connections and the ground connections for the engine electronics should always be from the isolator to the battery.

i05272352

Engine Electronics

Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/or engine damage.

Electrical Shock Hazard. The electronic unit injectors use DC voltage. The ECM sends this voltage to the electronic unit injectors. Do not come in contact with the harness connector for the electronic unit injectors while the engine is operating. Failure to follow this instruction could result in personal injury or death.

This engine has a comprehensive, programmable Engine Monitoring System . The Electronic Control Module (ECM) monitors the engine operating conditions. If any of the engine parameters extend outside an allowable range, the ECM will initiate an immediate action.

The following actions are available for engine monitoring control:

•Warning

•Derate

•Shutdown

Safety Section

Engine Electronics

The following monitored engine operating conditions have the ability to limit engine speed and/or the engine power:

•Engine Coolant Temperature

•Engine Oil Pressure

•Engine Speed

•Intake Manifold Air Temperature

•Intake Manifold Air pressure

The Engine Monitoring package can vary for different engine models and different engine applications. However, the monitoring system and the engine monitoring control will be similar for all engines.

Note: Many of the engine control systems and display modules that are available for Perkins Engines will work in unison with the Engine Monitoring System. Together, the two controls will provide the engine monitoring function for the specific engine application. Refer to the Troubleshooting for more information on the Engine Monitoring System.

Product Information Section

Model View Illustrations

Product Information

Section

General Information

i05536748

Model View Illustrations

The following model views show typical features of the engine Due to individual applications, your engine may appear different from the illustrations.

Turbocharged Aftercooled Engine

Illustration 15

g03453518

Typical example

(1) Open Breather System	(4) Oil Level Gauge (Dipstick)	(7) Oil Filler
(2) Air Intake	(5) Location for Oil Sample Valve	(8) Secondary Fuel Filters
(3) Electronic Control Module	(6) Oil Filter

General Information

Model View Illustrations

Illustration 16		g03453526
Typical example
(9) Front Lifting Eye	(11) Coolant Intake	(13) Belt
(10) Water Pump	(12) Tensioner	(14) Coolant Outlet

General Information

Model View Illustrations

Illustration 17		g03453529
Typical example
(15) Rear Lifting Eye	(18) Starter Solenoid	(21) Flywheel
(16) Alternator	(19) Starting Motor	(22) Flywheel Housing
(17) Turbocharger	(20) Oil Drain Plug	(23) Coolant Drain Plug

General Information

Model View Illustrations

Turbocharge Engine View

Illustration 18

g03506649

Typical example

General Information

Product Description

Off Engine Parts and Options

Illustration 19		g03467856
Typical examples
(24) Electric Priming Pump	(26) Mechanical Priming Pump	(28) Spin on Crankcase Breather
(25) Primary Fuel Filter	(27) Primary Fuel Filter

Note: Item (28) is part of the filtered breather system.

i05536753

Product Description

There are two different variants of this Perkins engine. Engines with prefix NR are turbocharged

aftercooled engines 1104D-E44TA. Engines with prefix NP are turbocharged engines 1104D-E44T.

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.

Illustration 20

g01187485

Cylinder and valve location

(A)Exhaust valves

(B)Inlet valves

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Table 1

Engine Specifications

	Operating Range (rpm)	900 to 2800(1)
	Number of Cylinders	4 In-Line
	Bore	105 mm (4.13 inch)
	Stroke	127 mm (5 inch)
	Aspiration	Turbocharged or
		Turbocharged Aftercooled
	Compression Ratio	16.2:1
	Displacement	4.4 L (268.5 cubic inch)
	Firing Order	1-3-4-2
	Rotation (flywheel end)	Counterclockwise
	Number of valves for each	4
	cylinder

	Valve Lash Setting (Inlet)	0.35 mm (0.013 inch)
	Valve Lash Setting (Exhaust)	0.35 mm (0.013 inch)

(1)The operating rpm is dependent on the engine rating, the application, and the configuration of the throttle.

Electronic Engine Features

The engine operating conditions are monitored. The Electronic Control Module (ECM) controls the response of the engine to these conditions and to the demands of the operator. These conditions and operator demands determine the precise control of fuel injection by the ECM. The electronic engine control system provides the following features:

•Engine monitoring

•Engine speed governing

•Control of the injection pressure

•Cold start strategy

•Automatic air/fuel ratio control

•Torque rise shaping

•Injection timing control

•System diagnostics

For more information on electronic engine features, refer to the Operation and Maintenance Manual, “Features and Controls” topic (Operation Section).

General Information

Product Description

Engine Diagnostics

The engine has built-in diagnostics in order to ensure that the engine systems are functioning correctly. The operator will be alerted to the condition by a “Stop or Warning” lamp. Under certain conditions, the engine power and the engine speed may be limited. The electronic service tool may be used to display the diagnostic codes.

There are two types of diagnostic codes: active and logged.

Most of the diagnostic codes are logged and stored in

the ECM. For additional information, refer to the Operation and Maintenance Manual, “Engine

Diagnostics” topic (Operation Section).

The ECM provides an electronic governor that controls the injector output in order to maintain the desired engine rpm.

For more information refer to Troubleshooting manual.

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 rotor type oil pump

•Oil cooler

The engine lubricating oil is supplied by a rotor type oil pump. The engine lubricating oil is cooled and the engine lubricating oil is filtered. The bypass valve can provide unrestricted flow of lubrication oil to the engine 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 this Operation and Maintenance

Manual, “Maintenance Interval Schedule” for more information on maintenance items.

Option Section

There are two different types of fuel priming pump available, hand primer or an electrically operated primer. There are two different types of crankcase breather, open breather or filtered open breather.

Product Identification Information

Plate Locations and Film Locations

Product Identification

Information

i05536932

Plate Locations and Film

Locations

Illustration 22

g02433756

Typical example

Illustration 21

g03453612

Perkins engines are identified by an engine serial number.

An example of an engine number is N-

*****R000001X.

*****	The list number for the engine
N-	Type of engine
R	Built-in China
000001	Engine Serial Number
X	Year of Manufacture

Perkins dealers or Perkins distributors need all of these numbers in order to determine the components

that were included with the engine. This information permits accurate identification of replacement part numbers.

Serial Number Plate (1)

The engine serial number plate is located on the left side of the cylinder block to the rear of the front engine mounting.

Product Identification Information

Emissions Certification Film

i05536952

Emissions Certification Film

Illustration 23	g03506769
Typical example
i05465764	(If equipped) Filtered Breather

Reference Information

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

Secondary Fuel Filter Element

Lubrication Oil Filter

Total Lubrication System Capacity

Total Cooling System Capacity

Air Cleaner Element

Drive Belt

Operation Section

Product Lifting

Operation Section

Lifting and Storage

i02677363

Product Lifting

Illustration 24

g00103219

NOTICE

Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees.

When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight.

Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted.

Some removals require lifting the fixtures in order to obtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes that are on the engine.

Lifting eyes are designed and installed for specific engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting

fixtures obsolete. If alterations are made, ensure that proper lifting devices are provided. Consult your

Perkins dealer for information regarding fixtures for proper engine lifting.

SEBU9066

i04151489

Product Storage

Perkins are not responsible for damage which may occur when an engine is in storage after a period in service.

Your Perkins dealer or your Perkins distributor can assist in preparing the engine for extended storage periods.

Condition for Storage

The engine must be stored in a water proof building. The building must be kept at a constant temperature. Engines that are filled with Perkins ELC will have coolant protection to an ambient temperature of −36° C (−32.8° F). The engine must not be subjected to extreme variations in temperature and humidity.

Storage Period

An engine can be stored for up to 6 months provided all the recommendation are adhered to.

Storage Procedure

Keep a record of the procedure that has been completed on the engine.

Note: Do not store an engine that has biodiesel in the fuel system.

1.Ensure that the engine is clean and dry.

a.If the engine has been operated using biodiesel, the system must be drained and new filters installed. The fuel tank will require flushing.

b.Fill the fuel system with an acceptable fuel. For more information on acceptable fuels refer to this Operation and Maintenance Manual, “Fluid recommendations”. Operate the engine for 15 minutes in order to remove all biodiesel from the system.

2.Drain any water from the primary filter water separator. Ensure that the fuel tank is full.

3.The engine oil will not need to be drained in order to store the engine. Provided the correct specification of engine oil is used the engine can be stored for up to 6 months. For the correct specification of engine oil refer to this Operation and Maintenance Manual, “Fluid recommendations”.

4.Remove the drive belt from the engine.

SEBU9066

Sealed Coolant System

Ensure that the cooling system is filled with Perkins

ELC, or an antifreeze that meets “ASTM D6210” specification.

Open Cooling System

Ensure that all cooling drain plugs have been opened. Allow the coolant to drain. Install the drain plugs. Place a vapor phase inhibitor into the system. The coolant system must be sealed once the vapor phase inhibitor has been introduced. The effect of the vapor phase inhibitor will be lost if the cooling system is open to the atmosphere.

For maintenance procedures refer to this Operation and Maintenance Manual.

Monthly Checks

The crankshaft must be rotated in order to change the spring loading on the valve train. Rotate the crankshaft more than 180 degrees. Visibly check for damage or corrosion to the engine.

Ensure that the engine is covered completely before storage. Log the procedure in the record for the engine.

Lifting and Storage

Product Storage

Features and Controls

Alarms and Shutoffs

Features and Controls

i05251301

Alarms and Shutoffs

Shutoffs

The shutoffs are electrically operated or mechanically operated. The electrically operated shutoffs are controlled by the ECM.

Shutoffs are set at critical levels for the following items:

•Operating temperature

•Operating pressure

•Operating level

•Operating rpm

The particular shutoff may need to be reset before the engine will start.

NOTICE

Always determine the cause of the engine shutdown. Make necessary repairs before attempting to restart the engine.

Be familiar with the following items:

•Types and locations of shutoff

•Conditions which cause each shutoff to function

•The resetting procedure that is required to restart the engine

Alarms

The alarms are electrically operated. The operation of the alarms is controlled by the ECM.

The alarm is operated by a sensor or by a switch. When the sensor or the switch is activated, a signal is sent to the ECM. An event code is created by the ECM. The ECM will send a signal in order to illuminate the lamp.

Your engine may be equipped with the following sensors or switches:

Coolant level – The low coolant level switch indicates when the coolant level is low.

Coolant temperature – The coolant temperature sensor indicates high jacket water coolant temperature.

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Intake manifold air temperature – The intake manifold air temperature sensor indicates high intake air temperature.

Intake manifold pressure – The intake manifold pressure sensor checks the rated pressure in the

engine manifold.

Fuel rail pressure – The fuel rail pressure sensor checks for high pressure or low pressure in the fuel rail.

Engine oil pressure – The engine oil pressure sensor indicates when oil pressure drops below rated system pressure, at a set engine speed.

Engine overspeed – The primary speed/timing sensor checks the engine speed. The alarm is activated at 3000 RPM.

Air filter restriction – The switch checks the air filter when the engine is operating.

User-defined switch – This switch can shut down the engine remotely.

Water in fuel switch – This switch checks for water in the primary fuel filter when the engine is operating.

Note: The sensing element of the coolant temperature switch must be submerged in coolant in order to operate.

Engines may be equipped with alarms in order to alert the operator when undesirable operating conditions occur.

NOTICE

When an alarm is activated, corrective measures must be taken before the situation becomes an emergency in order to avoid possible engine damage.

If corrective measures are not taken within a reasonable time, engine damage could result. The

alarm will continue until the condition is corrected. The alarm may need to be reset.

Testing

Turning the keyswitch to the ON position will check the indicator lights on the control panel. All the indicator lights will be illuminated for 2 seconds after the keyswitch is operated. Replace suspect bulbs immediately.

Refer to Troubleshooting for more information.

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Gauges and Indicators

Your engine may not have the same gauges or all of the gauges that are described. For more information about the gauge package, see the OEM information.

Gauges provide indications of engine performance. Ensure that the gauges are in good working order. Determine the normal operating range by observing the gauges over a period.

Noticeable changes in gauge readings indicate potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the readings are within specifications. Determine and correct the cause of any significant change in the readings. Consult your Perkins dealer or your distributor Perkins for assistance.

Some engine applications are equipped with Indicator Lamps. Indicator lamps can be used as a diagnostic aid. There are two lamps. One lamp has an orange lens and the other lamp has a red lens.

These indicator lamps can be used in two ways:

•The indicator lamps can be used to identify the current operational status of the engine. The indicator lamps can also indicate that the engine has a fault. This system is automatically operated via the ignition switch.

•The indicator lamps can be used to identify active diagnostic codes.

Refer to the Troubleshooting Guide, “Indicator Lamps” for further information.

NOTICE

If no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded, STOP the engine. Engine damage can result.

Engine Oil Pressure – The oil pressure should be greatest after a cold engine is started. The typical engine oil pressure with SAE10W40 is 350 to 450 kPa ( 50 to 65 psi) at

rated rpm.

A lower oil pressure is normal at low idle. If the load is stable and the gauge reading changes, perform the following procedure:

1.Remove the load.

2.Stop the engine.

3.Check and maintain the oil level.

Features and Controls

Gauges and Indicators

Jacket Water Coolant Temperature – Typical temperature range is 83° to 95°C (181.4° to 171°F). The maximum

allowable temperature at sea level with the pressurized cooling system at 48 kPa (7 psi) is 103 °C (217.4 °F). Higher temperatures may occur under certain conditions. The water temperature reading may vary according to load. The temperature reading should never exceed 7 °C (44.6 °F) below the boiling point for the pressurized system that is being used.

A 100 kPa (14.5 psi) radiator cap may be installed on the cooling system. The temperature of this cooling system must not exceed 112 °C (233.6 °F).

If the engine is operating above the normal range and steam becomes apparent, perform the following procedure:

1.Reduce the load and the engine rpm.

2.Determine if the engine must be shut down immediately or if the engine can be cooled by reducing the load.

3.Inspect the cooling system for leaks.

Tachometer – This gauge indicates engine speed (rpm). When the throttle control lever is moved to the full throttle

position without load, the engine is running at high idle. The engine is running at the full load rpm when the throttle control lever is at the full throttle position with maximum rated load.

NOTICE

To help prevent engine damage, never exceed the high idle rpm. Overspeeding can result in serious damage to the engine. Operation at speeds exceeding high idle rpm should be kept to a minimum.

Ammeter – This gauge indicates the amount of charge or discharge in the battery charging circuit. Operation of the

indicator should be to the ““+”” side of ““0”” (zero).

Fuel Level – This gauge indicates the fuel level in the fuel tank. The fuel level gauge operates when the ““START/

STOP”” switch is in the ““on”” position.

Service Hour Meter – The gauge indicates total operating hours of the engine.

Indicator Lamps

There are four main indicator lamps that are available.

Features and Controls

Gauges and Indicators

•Shutdown Lamp

•Warning Lamp

•Wait to Start Lamp

•Low Oil Pressure Lamp

For information, refer to this manual, “Monitoring System (Table for the Indicator Lamps)” for the sequence of operation of the shutdown lamp and the warning lamp.

The function of the wait to start lamp is automatically controlled at engine start-up.

The function of the low oil pressure lamp is controlled by the engine ECM. If low oil pressure is detected, the lamp will be illuminated. The reason for the illumination of the low-pressure lamp should be investigated immediately.

All lamps will illuminate for 2 seconds in order to check that the lamps are functioning when the keyswitch is turned to the ON position. If any of the lamps stay illuminated, the reason for illumination should be investigated immediately.

The glow plug warning lamp will flash in order to show that the engine is been held at low speed. This function will be performed at engine starting and the duration will depend on ambient temperature and engine temperature.

Instrument panels and Displays

In order to monitor the engine a wide verity of instrument panels are available. These instrument panels can contain the indicator lamps and the gauges for the application.

Also available are mini power displays and performance monitors. These displays and monitors can show the operator the following engine information.

•The system configuration parameters

•The customer specified parameters

•Diagnostic codes

•Event codes

•Coolant temperature

•Oil temperature

•Oil pressure

•Intake temperature

•Intake pressure

•Fuel temperature

Features and Controls

Monitoring System

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Monitoring System

Table 2

Warning Lamp

Shutdown

Lamp

ON ON

OFF OFF

ON OFF

ON FLASHING

FLASHING OFF

FLASHING FLASHING

ON ON

Lamp Status	Description of lamp status	Engine Status
Lamp check	When the engine start switch is turned to the “ON” po-	The engine has not been
	sition both lamps will illuminate for 2 seconds only.	started.
No faults	There are no active diagnostic faults.	The engine is running normally.
Active diagnostic	An active diagnostic fault has been detected.	The engine is running normally.
fault
Active diagnostic	A serious active diagnostic fault has been detected and	The engine is running but the
fault	an engine derate has been invoked.	engine has been derated.
Warning	One or more of the engine protection values has been	The engine is running normally.
	exceeded.
Derate and	One or more of the engine protection values has been	The engine is running but the
warning	exceeded.	engine has been derated.
Engine shutdown	One or more of the engine protection values has been	The engine is shutdown or shut-
	exceeded or a serious active diagnostic fault has been	down is imminent.
	detected.

i05546770

Monitoring System

If the Shutdown mode has been selected and the warning indicator activates, engine shutdown may take as little as 20 seconds from the time the warning indicator is activated. Depending on the application, special precautions should be taken to avoid personal injury. The engine can be restarted following shutdown for emergency maneuvers, if necessary.

NOTICE

The Engine Monitoring System is not a guarantee against catastrophic failures. Programmed delays and derate schedules are designed to minimize false alarms and provide time for the operator to stop the engine.

The following parameters are monitored:

•Coolant temperature

•Intake manifold air temperature

•Intake manifold air pressure

•Oil pressure

•Pressure in the fuel rail

•Engine speed/timing

Programmable Options and

Systems Operation

If the Warning/Derate/Shutdown mode has been selected and the warning indicator activates, bring the engine to a stop whenever possible. Depending on the application, special precautions should be taken to avoid personal injury.

The engine can be programmed to the following modes:

Features and Controls

Overspeed

““Warning””

The “Warning” lamp and the warning signal (orange lamp) turn “ON” and the warning signal is activated continuously in order to alert the operator that one or more of the engine parameters is not within normal operating range.

““Warning/Derate”

The “Diagnostic” lamp turns “ON” and the warning signal (red lamp) is activated. After the warning, the engine power will be derated. The warning lamp will begin to flash when the derating occurs.

The engine will be derated if the engine exceeds preset operational limits. The engine derate is achieved by restricting the amount of fuel that is available for each injection. The amount of this reduction of fuel is dependent on the severity of the fault that has caused the engine derate, typically up

to a limit of 50%. This reduction in fuel results in a predetermined reduction in engine power.

““Warning/Derate/Shutdown”

The “Diagnostic” lamp turns “ON” and the warning signal (red lamp) is activated. After the warning, the engine power will be derated. The engine will continue at the rpm of the set derate until a shutdown of the engine occurs. The engine can be restarted after a shutdown for use in an emergency.

A shutdown of the engine may occur in as little as 20 seconds. The engine can be restarted after a shutdown for use in an emergency. However, the cause of the initial shutdown may still exist. The engine may shut down again in as little as 20 seconds.

If there is a signal for low oil pressure or for coolant temperature, there will be a two second delay in order to verify the condition.

For each of the programmed modes, refer to Troubleshooting Guide, “Indicator Lamps” for more information on Indicator Lamps.

For more information or assistance for repairs, consult your Perkins dealer or your Perkins distributor.

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Overspeed

An overspeed condition is detected by the Electronic Control Module (ECM). The event code E190 will be logged if the engine speed exceeds 3300 rpm. The “DIAGNOSTIC” lamp will indicate a diagnostic fault code. The diagnostic fault code will remain active until the engine speed drops to 2800 rpm.

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Sensors and Electrical

Components

The illustrations within the following sections are typical location of the sensors or electrical components for an industrial engine. Specific engines may appear different due to differences in applications.

Features and Controls

Sensors and Electrical Components

Illustration 25		g03470316
Typical example
(1) Coolant Temperature Sensor	(4) Connector for Injectors 1 and Injector 2	(7) Fuel Rail Pressure Sensor
(2) Inlet Manifold Pressure Sensor	(5) Connector for Injectors 3 and Injector 4	(8) Diagnostic Connector
(3) Bus Bar for Glow Plugs	(6) Inlet Manifold Temperature Sensor

Features and Controls

Sensors and Electrical Components

Illustration 26		g03470317
Typical example
(9) Electronic Control Module	(11) Oil Pressure Sensor	(13) Solenoid for the high-pressure fuel
(10) Primary Speed/Timing sensor	(12) Secondary Speed/Timing sensor	pump

Loading…

SEBU9066

March 2014

Operation and

Maintenance

Manual

1104D-E44T and 1104D-E44TA Industrial Engines

NP (Engine)

NR (Engine)

Important Safety Information

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 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.

When replacement parts are required for this product Perkins recommends using Perkins replacement parts.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

Table of Contents
Foreword………………………… ………………………..	4
Safety Section
Safety Messages………………….. …………………..	5
General Hazard Information…………… …………..	7
Burn Prevention…………………… ……………………	8
Fire Prevention and Explosion Prevention …. …	9
Crushing Prevention and Cutting Prevention . .	11
Mounting and Dismounting…………… ……………	11
High Pressure Fuel Lines ……………. …………….	11
Before Starting Engine …………….. ………………	13
Engine Starting…………………… …………………..	13
Engine Stopping ………………….. ………………….	14
Electrical System…………………. ………………….	14
Engine Electronics………………… …………………	15
Product Information Section
General Information……………….. ………………..	16
Product Identification Information………. ………	22
Operation Section
Lifting and Storage………………… …………………	24
Features and Controls……………… ………………	26
Engine Diagnostics………………… ………………..	37
Engine Starting…………………… …………………..	44
Engine Operation…………………. ………………….	47
Cold Weather Operation…………….. …………….	48
Engine Stopping ………………….. ………………….	52

Maintenance Section
Refill Capacities………………….. …………………..	54
Maintenance Recommendations………. ……….	67
Maintenance Interval Schedule……….. ………..	69
Warranty Section
Warranty Information……………… ………………	100
Reference Information Section
Reference Materials ……………… ……………….	101
Index Section
Index…………………………. …………………………	102

Foreword

Literature Information

This manual contains safety, operation instructions,

lubrication and maintenance information. This 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 English used facilitates translation and consistency.

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

Maintenance

The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance

intervals. Items in the maintenance schedule are referenced to detailed instructions that follow.

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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 you 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

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.

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Safety Section

i05461290

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. 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.

(1) Universal Warning

Typical example

The Universal Warning label (1) is located on both sides of the valve mechanism cover base.

Safety Section

Safety Messages

Safety Section

Safety Messages

2 Hand (High Pressure)

	The warning label for the Hand (High Pressure) (2) is
	a wrap around label that is located on the rear injector
Illustration 3	line.
g01154858
Typical example	Ether