Perkins 1100 Series

Models RE,RF,RG,RH,RJ,RK

USERS HANDBOOK
4 cylinder diesel engines for industrial, agricultural and construction applications

Publication TPD1477, issue 2. Proprietary information of Perkins Engines Company Limited, all rights reserved. The information is correct at the time of print. Published in Dec 2002 by Technical Publications. Perkins Engines Company Limited, Peterborough PE1 5NA England. i

This publication is w ritten in Perkins A pproved Clear English

This publication is divided into six chapters: 1 2 3 4 5 6 General information Engine views Operation instructions Preventive maintenance Engine fluids Fault diagnosis

The following pages contain a detailed table of contents

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Contents
1 General information
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 General safety precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3 Viton seals .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4 How to care for your engine .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4 Engine preservation . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5 POWERPART recommended consumable products . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6 Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8 Engine data ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9

2 Engine views
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11 Location of engine parts . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11 Sensor positions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 14

3 Operation instructions
How to start the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 17 How to stop the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 19 Adjustment of the engine speed range .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 19 Running-in ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 19 Turbocharged engines ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 19 Angle of tilt .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 19

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4 Preventive maintenance
Preventive maintenance periods ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 21 Preventive maintenance schedules ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22 How to drain the cooling system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23 How to fill the cooling system .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23 How to check the specific gravity of the coolant ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24 How to check the drive belt(s) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25 Fuel pre-filter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 26 How to renew the fuel filter element .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 26 How to eliminate air from the fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28 Atomiser faults . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29 How to remove and to fit an atomiser ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30 How to renew the closed crankcase breather filter element .. ... ... ... ... ... ... ... ... ... ... ... ... ... 33 How to renew the engine lubricating oil ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33 How to renew the canister type oil filter .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34 How to renew the element type oil filter .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35 Air filter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36 Restriction indicator ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37 How to check the valve tip clearances .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38

5 Engine fluids
Fuel specification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39 Lubricating oil specification .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 40 Coolant specification .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 40

6 Fault diagnosis
Problems and possible causes .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42 List of possible causes . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43

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1
General information
Introduction
The Perkins 1104 engines for industrial and agricultural applications are the latest developments from Perkins Engines Company Limited, a world leader in the design and manufacture of high performance diesel engines. The engine conforms with USA (EPA/CARB) stage 2 and EEC stage 2 emissions legislation for agricultural and industrial applications. To ensure that you use the relevant information for your specific engine type, refer to "Engine identification" on page 8. Danger is indicated in the text by two methods: Warning! This indicates that there is a possible danger to the person. Caution: This indicates that there is a possible danger to the engine. Note: Is used where the information is important, but there is not a danger.

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4 cylinder RE Model engine

1100 Series

A
4 cylinder RF Model engine

R1277/1

A
2

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1100 Series General safety precautions

These safety precautions are important. You must refer also to the local regulations in the country of use. Some items only refer to specific applications. ! Only use these engines in the type of application for which they have been designed. ! Do not change the specification of the engine. ! Do not smoke when you put fuel in the tank.

! Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a safe place. ! Do not put fuel in the tank while the engine runs (unless it is absolutely necessary). ! Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training; even then extreme care must be used to prevent injury). ! Do not make adjustments that you do not understand. ! Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions. ! Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation. ! Do not permit loose clothing or long hair near moving parts. ! Keep away from moving parts during engine operation. Warning! Some moving parts cannot be seen clearly while the engine runs. ! Do not operate the engine if a safety guard has been removed. ! Do not remove the filler cap or any component of the cooling system while the engine is hot and while the coolant is under pressure, because dangerous hot coolant can be discharged. ! Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially to the eyes. ! Disconnect the battery terminals before a repair is made to the electrical system. ! Only one person must control the engine. ! Ensure that the engine is operated only from the control panel or from the operators position. ! If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately. ! Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons. Protect your hands with gloves or a special solution to protect the skin. ! Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated with oil into the pockets of clothing. ! Discard used lubricating oil in accordance with local regulations to prevent contamination. ! Ensure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is started. ! Use extreme care if emergency repairs must be made in adverse conditions. ! The combustible material of some components of the engine (for example certain seals) can become extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with the eyes. ! Always use a safety cage to protect the operator when a component is to be pressure tested in a container of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to be pressure tested. ! Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help immediately. ! Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and debris away from the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces. ! Fit only genuine Perkins parts, failure to do so can damage the engine and may effect the warranty. Continued

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1100 Series

! Do not wash an engine while it runs or while it is hot. If cold cleaning fluids are applied to a hot engine, certain components on the engine could be damaged. ! Ensure that the starter switch is in the off position before servicing or repairs are made to the fuel system, because fuel will be released if the lift pump has power. ! If the fuel level in the tank is higher then the fuel lift pump the supply and return fuel line valves must be turned off before servicing or repairs are made to the fuel system, because fuel will flow through the system.

Viton seals
Viton is used by many manufacturers and is a safe material under normal conditions of operation. Some seals used in engines and in components fitted to these engines are made of Viton. If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this burnt material to come into contact with the skin or with the eyes. If it is necessary to come into contact with components which have been burnt, ensure that the precautions which follow are used: ! Ensure that the components have cooled. ! Use neoprene gloves and discard the gloves safely after use. ! Wash the area with calcium hydroxide solution and then with clean water. ! Disposal of components and gloves which are contaminated must be in accordance with local regulations. If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.

How to care for your engine

Warning! Read the "Safety precautions" and remember them. They are given for your protection and must be applied at all times. Caution: Do not wash an engine while it runs or while it is hot. If cold cleaning fluids are applied to a hot engine, certain components on the engine could be damaged. This handbook has been written to assist you to maintain and operate your engine correctly. To obtain the best performance and the longest life from your engine, you must ensure that the maintenance operations are done at the intervals indicated in "Preventive maintenance". If the engine is operated in a very dusty environment or other adverse conditions, certain maintenance intervals will have to be reduced. Ensure that all adjustments and repairs are done by personnel who have had the correct training. The "left side" and "right side" of the engine are as seen from the flywheel end.

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1100 Series Engine preservation

Introduction For advice on when to use the preservation procedure, contact you local authorized Perkins dealer.

The recommendations indicated below are designed to prevent damage to the engine when it is withdrawn from service for a prolonged period. Use these procedures after the engine is withdrawn from service. The instructions for the use of POWERPART products are given on the outside of each container. Procedure 1 Completely clean the outside of the engine. 2 When a preservative fuel is to be used, drain the fuel system and fill it with the preservative fuel. POWERPART Lay-Up 1 can be added to the normal fuel to change it to a preservative fuel. If preservative fuel is not used, the system can be kept full with normal fuel but the fuel must be drained and discarded at the end of the storage period together with the fuel filter element(s). 3 Operate the engine until it is warm. Then correct leakages of fuel, lubricating oil or air. Stop the engine and drain the lubricating oil from the sump. 4 Renew the lubricating oil filter. 5 Fill the sump to the full mark on the dipstick with new and clean lubricating oil and add POWERPART layUp 2 to the oil to protect the engine against corrosion. If POWERPART Lay-Up 2 is not available, use a correct preservative fluid instead of the lubricating oil. If a preservative fluid is used, this must be drained and the lubricating oil sump must be filled to the correct level with normal lubricating oil at the end of the storage period. 6 Drain the cooling system, see "How to drain the cooling system" on page 23. In order to protect the cooling system against corrosion, fill it with an approved antifreeze mixture because this gives a protection against corrosion, see "Coolant specification" on page 40. Caution: Certain corrosion inhibitor mixtures could cause damage to some engine components. It is recommended that you consult the Perkins Service Department, Peterborough. 7 Operate the engine for a short period in order to circulate the lubricating oil and the coolant in the engine. 8 Disconnect the battery. Then put the battery into safe storage in a fully charged condition. Before the battery is put into storage, protect its terminals against corrosion. POWERPART Lay-Up 3 can be used on the terminals. 9 Clean the engine breather pipe (if one is fitted) and seal the end of the pipe. 10 Remove the atomisers and spray POWERPART Lay-up 2 for one to two seconds into each cylinder bore with the piston at BDC. 11 Slowly turn the crankshaft one revolution and then fit the atomisers, refer to "How to remove and to fit an atomiser" on page 30. 12 Remove the air filter. Then, if necessary, remove the pipe(s) installed between the air filter and induction manifold or turbocharger. Spray POWERPART Lay-Up 2 into the intake manifold or turbocharger. It is recommended that the spray time for the turbocharger is 50% longer than the spray time for the manifold, which is indicated on the container label. Seal the manifold or the turbocharger with waterproof tape. 13 Remove the exhaust pipe. Spray POWERPART Lay-Up 2 into the exhaust manifold or the turbocharger. It is recommended that the spray time for the turbocharger is 50% longer than the spray time for the manifold, which is indicated on the container label. Seal the manifold or the turbocharger with waterproof tape. 14 If the lubricating oil filler is fitted onto the rocker cover, remove the filler cap. If the lubricating oil filler is not fitted onto the rocker cover, remove the rocker cover. Spray POWERPART Lay-Up 2 around the rocker shaft assembly. Fit the filler cap or rocker cover. 15 Seal the vent pipe of the fuel tank or the fuel filler cap with waterproof tape. 16 Remove the drive belts and put them into storage. 17 In order to prevent corrosion, spray the engine with POWERPART Lay-Up 3. Do not spray the area inside the alternator cooling fan. If the engine protection is done correctly according to the above recommendations, no corrosion damage will normally occur.

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POWERPART recommended consumable products

1100 Series

Perkins have made available the products recommended below in order to assist in the correct operation, service and maintenance of your engine and your machine. The instructions for the use of each product are given on the outside of each container. These products are available from your Perkins distributor. POWERPART Antifreeze Protects the cooling system against frost and corrosion. Part number 21825166. POWERPART Easy Flush Cleans the cooling system. Part number 21825001. POWERPART Gasket and flange sealant To seal flat faces of components where no joint is used. Especially suitable for aluminium components. Part number 21820518. POWERPART Gasket remover An aerosol for the removal of sealants and adhesives. Part number 21820116. POWERPART Griptite To improve the grip of worn tools and fasteners. Part number 21820129. POWERPART Hydraulic threadseal To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and pneumatic systems. Part number 21820121. POWERPART Industrial grade super glue Instant adhesive designed for metals, plastics and rubbers. Part number 21820125. POWERPART Lay-Up 1 A diesel fuel additive for protection against corrosion. Part number 1772204. POWERPART Lay-Up 2 Protects the inside of the engine and of other closed systems. Part number 1762811. POWERPART Lay-Up 3 Protects outside metal parts. Part number 1734115. POWERPART Metal repair putty Designed for external repair of metal and plastic. Part number 21820126. POWERPART Pipe sealant and sealant primer To retain and seal pipe connections with coarse threads. Pressure systems can be used immediately. Part number 21820122. Continued

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POWERPART Radiator stop leak For the repair of radiator leaks. Part number 21820127. POWERPART Retainer (high strength) To retain components which have an interference fit. Part number 21820638. POWERPART Retainer (oil tolerant) To retain components which have an interference fit, but is in contact with oil. Part number 21820608. POWERPART Safety cleaner General cleaner in an aerosol container. Part number 21820128. POWERPART Silicone adhesive

An RTV silicone adhesive for application where low pressure tests occur before the adhesive sets. Used for sealing flange where oil resistance is needed and movement of the joint occurs. Part number 21826038. POWERPART Silicone RTV sealing and jointing compound Silicone rubber sealant which prevents leakage through gaps. Part number 1861108. POWERPART Stud and bearing lock To provide a heavy duty seal to components that have a light interference fit. Part number 21820119 or 21820120. POWERPART Threadlock and nutlock To retain small fasteners where easy removal is necessary. Part number 21820117 or 21820118. POWERPART Universal jointing compound Universal jointing compound which seals joints. Part number 1861117.

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Engine identification

1100 Series

The 1104 engines consist of a range of four cylinder engines with and without electronic control. Each range has three basic engine types, naturally aspirated, turbocharged and turbocharged charge cooled. In this handbook, the different engine types are identified by their code letters, which are the first two letters of the engine number as shown below:
Code Letters RE RF RG RH RJ RK Engine type Four cylinder, naturally aspirated Four cylinder, naturally aspirated, electronic Four cylinder, turbocharged Four cylinder, turbocharged, electronic Four cylinder, turbocharged, charge cooled Four cylinder, turbocharged, charge cooled, electronic

A0043

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1100 Series Engine data

Number of cylinders. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4 Cylinder arrangement .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .In line Cycle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Four stroke Direction of rotation . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Clockwise from the front Induction system: - RE, RF... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Naturally aspirated - RG, RH.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Turbocharged - RJ, RK ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Turbocharged, charge cooled Combustion system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Direct injection Nominal bore ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 105 mm (4.134 in) Stroke .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 127 mm (5.00 in) Compression ratios: - Naturally aspirated ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19.3:1 - Turbocharged ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18.2:1 Cubic capacity . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..4,4 litres (268 in3) Firing order .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1, 3, 4, 2 Valve tip clearances cold: - Inlet ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,20 mm (0.008 in) - Exhaust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,45 mm (0.018 in) Lubricating oil pressure (1) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .300 kpa (43 lbf/in) 3.0 kg/cm
(1) Minimum pressure at maximum engine speed and normal engine temperature

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Engine views
Introduction
Perkins engines are built for specific applications and the views that follow do not necessarily match your engines specification.

Location of engine parts

Front and left side of the RE engine 1 Filler cap for the lubricating oil 2 Electric fuel lift pump 3 Fuel filter 4 Fuel injection pump 5 Starter motor 6 Lubricating oil dipstick 7 Lubricating oil sump 8 Drain plug for the lubricating oil 9 Crankshaft pulley 10 Fan 11 Coolant pump 12 Sender unit for the Start and advance (KSB) 13 Thermostat housing 14 Front lift bracket

14 13 12

1 2

11

5 10 6

9 7 8

R1277

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Front and right side of the RK engine 1 Coolant tempture sensor 2 Fan pulley 3 Alternator 4 Drive belts 5 Turbocharger lubricating oil pipe 6 Turbocharger 7 Exhaust manifold 8 Rocker cover

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8 1

2 3 6 4 5

R1278

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Rear and left side of the RK engine 9 Intake manifold temperature sensor 10 Intake manifold pressure sensor 11 Lubricating oil cooler 12 Engine speed and timing sensor 13 Lubricating oil filter 14 Engine oil pressure sensor 15 Machine interface connector (MIC) 16 Engine control module (ECM)

16 9 10

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15 14 12

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Sensor positions
Rear and left side of the RH engine 1 2 Intake manifold temperature sensor Speed and timing sensor 3 4 Oil pressure sensor Intake manifold pressure sensor

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B

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Front and right side of the RH engine 5 Coolant temperature sensor

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Operation instructions
How to start the engine
Warning! Ether type fuels must not be used in the 1100 series four cylinder engine. The 1104 electronic engines are fitted with an automatic glow plug cold starting system. The 1104 mechanical engines have a manual system. Refer to the equipment manual for the type of starting aid fitted. Several factors affect engine start, for example: ! The power of the batteries ! The performance of the starter motor ! The viscosity of the lubricating oil ! The installation of a cold starting system. The engine is fitted with a cold starting device for normal conditions of operation. Diesel engines need an extra cold starting aid if they are to start in very cold conditions. Normally, your vehicle or your machine will be fitted with the correct equipment for your region of operation. Glow Plug starting aid An electrically operated device fitted to each cylinder that heats the intake air. Continued

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How to start a cold electronic engine !

1100 Series

Cautions: ! Ensure that the engine and starter motor are stationary before the starter motor is engaged. For the electronic engine the engine speed on start up is controlled by the ECM. The speed control should not be adjusted.

1 Turn the start key to the R position (A) and keep it there for 20 seconds. 2 Turn the start key to the S position (A) to engage the starter motor. Allow the start key to return to the R position, when the engine starts. 3 If the engine does not start in 30 seconds, turn the start key to the 0 position (A). Wait for 90 seconds. Then turn the start key to the R position (A) and keep it there for 20 seconds. Then engage the starter motor for a maximum period of 30 seconds. How to start a warm electronic engine 1 Turn the start key to the S position (A) to engage starter motor for a maximum period of 30 seconds. 2 Allow the start key to return to the R position (A) as soon as the engine starts. 3 If the engine does not start in 30 seconds, turn the start key to the 0 position (A) and wait 90 seconds. Then engage the starter motor again for a maximum period of 30 seconds. How to start a cold mechanical engine with the glow plug starting aid 1 Turn the start key to the H position (B) and keep it there for 20 seconds. 2 Adjust the engine speed control to the maximum speed position. 3 Turn the start key to the HS position (B) to engage the starter motor. Allow the start key to return to the R position (B) when the engine starts. Then adjust the engine speed control to give an even idle speed. 4 If the engine does not start in 30 seconds, turn the start key to the 0 position (B) and wait 90 seconds. Turn the start key to the H position (B) and hold it there for 20 seconds. Then engage the starter motor again, for a maximum period of 30 seconds. How to start a warm mechanical engine 1 Adjust the engine speed control to one quarter of maximum speed. 2 Turn the start key to the "HS" position (B) to engage the starter motor. 3 If the engine does not start in 30 seconds, turn the start key to the 0 position (B) and wait 90 seconds. Then engage the starter motor again for a maximum period of 30 seconds.

R S

R H H S

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1100 Series How to stop the engine

Caution: It is recommended that a turbocharged engine is run at approximately 1000 rev/min at a reduced load for 2-3 minutes before it is shut down. This will allow the turbocharger to cool. Turn the engine start key to the "O" position (A or B on page 18).

Adjustment of the engine speed range

Caution: The engine speed settings should not be changed by the engine operator, because this can cause the exhaust emissions to become excessive and may also damage the engine or transmission. Note: For electronic engines the speed range is controlled by the ECM.

Running-in
Cautions: ! Do not operate the engine at high speeds without a load. ! Do not overload the engine. A gradual running-in of a new engine or an exchange engine is not necessary. Prolonged operation at light loads during the early life of the engine can cause lubricating oil to enter the exhaust system. Maximum load can be applied to a new engine as soon as the engine is put into service and when the coolant temperature has reached a minimum of 60 C (140 F). The engine will benefit if the load is applied as soon as possible after the engine is put into service.

Turbocharged engines
Because of the power characteristics of the turbocharged engines, when fitted in vehicles, it is necessary to maintain a high engine speed when you need full load. To ensure that the engine is not overloaded at low engine speeds engage a lower gear.

Angle of tilt
Warning! Do not operate the engine at an angle of tilt greater than the limit approved for the engine. Refer to the equipment handbook for details.

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Preventive maintenance
Preventive maintenance periods
Use the procedures in this chapter to maintain your engine in accordance with the preventive maintenance schedule. Check the periods given by the manufacturer of the equipment in which the engine is installed. It is good preventive maintenance to check for leakage and loose fasteners at each service. These maintenance periods apply only to engines that are operated with fuel, lubricating oil and coolant that conform to the specifications given in this handbook.

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Preventive maintenance schedules
A B A Every day or every 8 hours Every 500 hours or 12 months B C D C D Every 1000 hours Every 8000 hours Operation Check the amount of coolant in the header tank Check the engine for leakage of oil and coolant Check the specific gravity of the coolant (1) (4) Check the tension and condition of the drive belt(s) Check for water in the pre-filter bowl (or earlier if your fuel supply is contaminated)

1100 Series

The schedules which follow must be applied at the intervals (hours or months) which ever occur first.

! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! ! !

Renew the element(s) of the fuel filter(s) Check the amount of lubricating oil in the sump Check the lubricating oil pressure at the gauge Renew the engine lubricating oil (2) (3) (6) Renew the closed crankcase breather element (5) Renew the closed breather assembly Renew the canister or element of the lubricating oil filter (2) (3) (6) Empty the dust bowl of the air filter: - Normal conditions - In extremely dusty conditions (7) Renew the air filter element Check all hoses and connections Check all electrical cables and connections Check the valve tip clearances of the engine and adjust, if necessary (1)

(1) By a person who has had the correct training. (2) The oil service interval will change with the amount of sulphur in the fuel see, "Fuel specification" on page 39. The interval to change the canister or element of the lubricating oil filter is not affected. (3) See, "Lubricating oil specification" on page 40. (4) Renew the antifreeze every 2 years. If a coolant inhibitor is used instead of antifreeze, it should be renewed every 6 months. If combustion gases are released into the coolant circuit, the coolant must be renewed. (5) For turbocharged and charge cooled engines only see,"How to renew the closed crankcase breather filter element" on page 33. (6) Engines with high load factor or high oil temperature will require a 250 hour or 12 months service period, whichever occurs first. This would normally be determined between the customer and the Perkins applications engineer, but would typically be anything above 75% load factor (average) or 125 C oil temperature (more than 1 hour in 12). Load factors should be expressed in actual f uel used divided by fuel load rated speed used. For further information and advice, contact Perkins applications. (7) Check, and if necessary renew the air filter element.

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1100 Series How to drain the cooling system

Warning! Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged.

Caution: To prevent frost damage, ensure that all of the coolant is removed from the engine. This is important if the system is drained after it has been flushed with water, or if an antifreeze solution which is too weak to protect the system from frost has been used. 1 Ensure that the machine is on level ground. 2 Remove the filler cap of the coolant system. 3 Open the tap or remove the drain plug at the bottom of the radiator in order to drain the radiator. If the radiator does not have a tap or drain plug, disconnect the hose at the bottom of the radiator. 4 Remove the drain plug (A1) from the side of the cylinder block in order to drain the engine. Ensure that the drain hole is not restricted. 5 Flush the coolant system with clean water. 6 Fit the drain plug (A1) and tighten to 40 Nm (29,5 lbf ft) 4,1kgf m. 7 Fit the filler cap and close the radiator tap, or fit the bottom hose.

A How to fill the cooling system

R1188/1

Warning! Refer to your equipment supplier's handbook for the application to fill the cooling system. If coolant is to be added to the system during service, allow the engine to cool before the coolant is added. Do not add coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged. Caution: If coolant is added to the circuit during service, it must consist of the same original mixture as used to fill the system. For details of the correct coolant to be used in the system, see "Coolant specification" on page 40. 1 Ensure that the top and bottom hose connections are fitted correctly. 2 Check that the drain plug (A1) on the side of the cylinder block is fitted and tighten to 40 Nm (29,5 lbf ft) 4,1kgf m. Ensure that the radiator tap is closed, if one is fitted. 3 Remove filler cap. Fill the cooling system with coolant of the correct specification, see "Coolant specification" on page 40. 4 Continue to slowly fill the cooling system to the correct level, refer to the users handbook for the application. 5 Fit the filler cap, run the engine to normal operating temperature. Stop the engine. When the engine has cooled, check the coolant level. If necessary, fill again to the correct level.

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How to check the specific gravity of the coolant
For mixtures which contain inhibited ethylene glycol: 1 Ensure that the machine is on level ground.

1100 Series

2 Operate the engine until it is warm enough to open the thermostat. Continue to run the engine until the coolant has circulated the cooling system. 3 Stop the engine. 4 Allow the engine to cool until the temperature of the coolant is below 60 C (140 F). Warning! Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged. 5 Remove the filler cap of the cooling system. 6 Drain some coolant from the cooling system into a suitable container. 7 Use a special coolant hydrometer that will check the temperature and the specific gravity of the coolant, follow the manufacturer's instructions. Note: If a special coolant hydrometer is not available, put a hydrometer and a separate thermometer into the antifreeze mixture and check the readings on both instruments. Compare the readings with the chart (A). 8 Adjust the strength of the mixture as necessary. Note: If it is necessary to fill or replenish the coolant system in service, mix the coolant to the correct strength before it is added to the coolant system. Perkins POWERPART antifreeze with a concentration of 50% will give protection against frost to a temperature of -35 C (-31 F). It will also give protection against corrosion. This is especially important when there are aluminium components in the coolant circuit.
40 45 50 55 60

A
140 122 104 86 68 50

60 50 40

30 20 10 0

1.04

1.05

1.06

1.07

1.08

1.09

1.10

1.11

A
Specific gravity chart

A = Percentage antifreeze by volume B = Mixture temperature in F C = Specific gravity D = Mixture temperature in C

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Users Handbook, TPD 1477E, issue 2

1100 Series How to check the drive belt(s)

Renew a belt if it is worn or damaged. If twin belts are fitted, they must be renewed together.

To ensure maximum belt life, it is recommended that a belt tensioner gauge is used to check the belt tension. Fit the gauge (A1) at the centre of the longest free length and check the tension. The correct tension is 535 N (120 lbf) 54 kgf. If the tension is 250 N (56 lbf) 25 kgf or below, adjust the belt to 535 N (120 lbf) 54 kgf as indicated below: If twin belts are fitted, check and if necessary adjust the tension on both the belts. How to adjust the belt tension 1 Loosen the pivot fastener (B1) of the alternator and the adjustment link fasteners (B2) and (C1). 2 Change the position of the alternator to give the correct tension. Tighten the pivot fastener of the alternator and the adjustment link fasteners to 22 Nm (16 lbf ft) 2,2 kgf m. 3 Check the belt tension again to ensure that it is still correct. If a new belt is fitted, the belt tension must be checked again after the first 20 hours of operation.

1
1

A1022

R1282

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Fuel pre-filter

1100 Series

A pre-filter, if fitted, is installed between the fuel tank and the engine. Check the pre-filter bowl for water at regular intervals and drain as necessary, see "Preventive maintenance schedules" on page 22.

How to renew the fuel filter element

Warnings! ! The combustible material of some components of the engine (for example certain seals) can become extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with the eyes. ! Discard the used element and fuel oil in a safe place and in accordance with local regulations. ! Ensure that the starter switch is in the off position before servicing or repairs are made to the fuel system, because fuel will be released if the lift pump has power. ! If the fuel level in the tank is higher than the fuel lift pump, all the fuel line valves must be closed before maintenance or repairs are made to the fuel system, if this is not done, the fuel system will drain. Cautions: ! It is important that only genuine Perkins parts are used. The use of an element that is not a genuine Perkins part may damage the fuel injection pump and the warranty. ! The pre-filter canister and main filter elements must be renewed at the same time. ! Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area around the connection. After a component has been disconnected, fit a suitable cover to all open connections. 1 Place a suitable container below the fuel filter assembly to retain spilt fuel oil. 2 Thoroughly clean the outside surfaces of the fuel filter assembly. Open the drain tap (A1) at the bottom of the filter casing to drain the fuel from the filter. 3 Loosen the filter casing. Remove the casing and element from the fuel filter head. Continued

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Users Handbook, TPD 1477E, issue 2

1100 Series
4 Remove the filter element from the casing. Press down on the filter element (B1), against the spring pressure, and rotate it to the left to release it from the filter casing (B4).

5 Put the new filter element inside the casing and press it down against the spring pressure, rotate it to the right to lock it into the casing. 6 Fit a new seal (B3) to the casing and lightly lubricate the seal face with clean fuel oil. 7 Check that the thread (B2) on the inside of the element is not damaged. 8 Fit the filter assembly to the fuel filter head and tighten by hand until it contacts the filter head. Tighten the assembly a further 1/4 of a turn by hand. Do not use a strap wrench. 9 Close the drain tap (A1) and remove the container. 10 Before the starter motor is engaged, operate the lift pump for one minute to eliminate air from the filter. 11 Start the engine and check for leaks.

1 2 3 4

1
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How to eliminate air from the fuel system
Cautions: ! Do not operate the engine until the air is eliminated from the fuel injection pump. ! After the air is eliminated, operate the engine at low idle for two minutes.

1100 Series

The Delphi DP210 fuel injection pump will vent automatically when the start key is turned to the (R) position for three minutes. The Bosch VE and the VP30 fuel injection pumps will not vent automatically. 1 Remove the atomiser cover, see "How to remove and to fit an atomiser" on page 30. 2 Turn the start key to (R) position for three minutes, then return the key to the (0) position. 3 loosen the high pressure pipes (A1) at the atomisers. 4 Operate the starter motor until fuel free from air comes from the connections. 5 Tighten the union nuts to 30 Nm (22 lbf ft) 3,0 kgf m. 6 Start the engine and check for leaks. 7 Fit the atomiser cover and tighten its setscrews.

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1100 Series Atomiser faults

Caution: A faulty atomiser must be renewed by a person who has had the correct training.

Regular maintenance of the atomisers is not necessary. The atomiser nozzles should be renewed and not cleaned, and renewed only if an atomiser fault occurs. Some of the problems that may indicate that new nozzles are needed are listed below: Engine will not start or is difficult to start Not enough power Engine misfires or runs erratically High fuel consumption Black exhaust smoke Engine knocks or vibrates excessively Excessive engine temperature. Warnings! ! If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately. ! Keep away from moving parts during engine operation. Some moving parts cannot be seen clearly while the engine runs. Remove the atomiser cover setscrews (A1) and remove the atomiser cover (A2). In order to find which atomiser is defective, operate the engine at fast idle speed. Loosen and tighten the union nuts (B1) of the highpressure fuel pipe at each atomiser. Do not loosen the union nut more than half a turn. When the union nut of the defective atomiser is released, it has little or no effect on the engine speed.

1 1

R1283

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How to remove and to fit an atomiser
How to remove

1100 Series

Warning! The combustible material of some components of the engine (for example certain seals) can become extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with the eyes. Cautions: ! Atomisers must be removed and fitted by a person with the correct training. ! Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area around the connection. After a component has been disconnected, fit a suitable cover to all open connections. 1 If necessary remove the crossover pipe from the turbocharger to the intake manifold. Note: There are different types of breather pipe for naturally aspirated engine and turbocharged engine. An outlet hose may need to be removed from the breather pipe on the turbocharged engines. 2 Release the atomiser cover setscrews (A1) and remove the atomiser cover (A4). 3 If necessary on a turbocharged engine release the breather hose clip and remove the hose. 4 Release the fastener (A2) and remove the breather pipe (A3).

2 4 3

R1283/1

Continued

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1100 Series
Note: There are different types of atomiser fitted to 1104 engines. Not all are designed with leak-off connections. 5 If fitted, remove the fuel leak-off hose from the connection (B2).

6 Remove the union nuts of the high-pressure pipe from the atomiser (B1) and from the fuel injection pump. Do not bend the pipe. If necessary, remove the pipe clamps. Fit a plastic cap to cover all open connections. 7 Remove the setscrew (B3) and remove the clamp (B4) from the cylinder head. 8 Remove the atomiser and its seat washer (C1) from its recess in the cylinder head. Caution: Remove and discard the seat washer (C1). If the original seat washer remains in the recess, the nozzle protrusion will be incorrect when a new seat washer is added.

2 3 4

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4
How to fit 1 Remove all covers and caps from the component and connections. 2 Put a new seat washer into the seat recess in the cylinder head. Note: Some new atomisers have the seat washer (A3) fitted on the atomiser.

1100 Series

3 Ensure that the atomiser seal (A2) is not damaged. Apply a small amount of clean fuel oil to the seal. Cautions: ! The atomiser must be fitted so that the pin or the union (A1) faces away from the atomiser clamp (B4). ! If fitted the leak-off hose is a push fit and will need replacing if the hose leaks. 4 Put the atomiser (B1) into its recess in the cylinder head. 5 Fit the clamp (B4) and the setscrew (B3). Tighten the setscrew to 35 Nm (26 lbf ft) 3,5 kgf m. Caution: Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension. If there is a leakage from the union nut, ensure that the pipe is correctly aligned with the atomiser inlet. Do not tighten the atomiser union nut more, as this can cause a restriction at the end of the pipe. This can affect the fuel delivery. 6 Remove the plastic cap, fit the high-pressure fuel pipe and tighten the union nuts to 30 Nm (22 lbf ft) 3,0 kgf m. 7 If removed earlier, fit the clamps to the high pressure fuel pipes. 8 Where necessary, fit the fuel leak-off hose to the connectors (B2). 9 Check the O ring on the breather pipe and replace if necessary. Apply a small amount of clean engine oil to the O ring and fit the breather pipe into the rocker cover. Tighten the fastener to 9 Nm (7 lbf ft) 0,9 kgf m. Fit the breather hose and clip if fitted. 10 If removed, fit the crossover pipe. 11 Run the engine and check for leakage of fuel and air. Correct any leakage. 12 Stop the engine. 13 Refit the atomiser cover and tighten the setscrews to 6 Nm (4 lbf ft) 0,6 kgf m.

1 2

2 3 4

R1177/2

R1178/2

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Users Handbook, TPD 1477E, issue 2

1100 Series How to renew the closed crankcase breather filter element

Note: For details on how to change the closed crankcase breather element, contact Perkins applications for advice.

How to renew the engine lubricating oil

Warnings! ! Discard the used lubricating oil in a safe place and in accordance with local regulations. ! Do not exceed the correct level of lubricating oil in the sump. If there is too much lubricating oil, the excess must be drained to the correct level. An excess of lubricating oil could enter the breather valve. This could cause the engine speed to increase rapidly without control. Caution: Ensure that the machine is on a level surface to ensure an accurate reading on the dipstick. 1 Operate the engine until it is warm. Stop the engine. 2 Put a suitable container below the lubricating oil sump. 3 Remove the sump drain plug (A1) and its O ring and drain the lubricating oil from the sump into the container. 4 Ensure that the O ring is not damaged. Fit the drain plug and its O ring and tighten the plug to 34 Nm (25 lbf ft) 3,5 kgf m. 5 Fill the sump to the mark (A2) on the dipstick with new and clean lubricating oil of an approved grade, see "Lubricating oil specification" on page 40. 6 Remove the container and discard old lubricating oil.

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How to renew the canister type oil filter

1100 Series

Warning! Discard the used canister, and lubricating oil in a safe place and in accordance with local regulations. Cautions: ! Ensure that the machine is on a level surface to ensure an accurate reading on the dipstick ! It is important that only genuine Perkins parts are used. The use of an canister that is not a genuine Perkins part may damage the engine and the warranty. Note: The canister contains a valve and a special tube to ensure that lubricating oil does not drain from the filter, when the lubricating oil is changed. 1 Put a suitable container below the lubricating oil filter. 2 Remove the filter canister with a strap wrench. Ensure that the adaptor is secure in the filter head. Discard the canister. 3 Clean the filter head. Note: It is normally good procedure to fill the oil filter canister with clean engine lubricating oil. However this may not be possible on certain applications. 4 Lubricate the top of the canister seal (A1) with clean engine lubricating oil. 5 Fit the new canister and tighten it by hand only. Do not use a strap wrench. 6 Remove the container and discard the old lubricating oil. 7 Operate the engine and check for leakage from the filter. When the engine has cooled, check the oil level on the dipstick and add more oil into the sump, if necessary.

R1186/1

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Users Handbook, TPD 1477E, issue 2

1100 Series How to renew the element type oil filter

Warning! Discard the used element and lubricating oil in a safe place and in accordance with local regulations. Cautions: ! Ensure that the machine is on a level surface to ensure an accurate reading on the dipstick. ! It is important that only genuine Perkins parts are used. The use of an element that is not a genuine Perkins part may damage the engine and the warranty. 1 Put a suitable container below the lubricating oil filter. 2 Remove the plug together with the seal (A2) and drain the lubricating oil. 3 Fit a 1/2 square drive ratchet into the recess (A1) and remove the filter casing (A3). Discard the old filter element. 4 Clean the filter casing and replace the seal (B2). 5 Fit the new filter element (B1) into the casing and rotate element to locate it into position. Note: It is normally good procedure to fill the oil filter casing with clean engine lubricating oil. However, this may not be possible on certain applications. 6 Lubricate the seal (B2) with clean engine lubricating oil. Fit the casing (A3) into the filter head (A4). 7 Tighten the casing (A3) to 25 Nm (18 lbf ft) 2,5 kgf m. 8 Fit a new seal to the drain plug and tighten the drain plug to 12 Nm (9 lbf ft) 1,2 kgf m. 9 Remove the container and discard the old lubricating oil. 10 Operate the engine and check for leakage from the filter. When the engine has cooled, check the oil level on the dipstick and add more lubricating oil into the sump, if necessary.

1
4

3 1

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Air filter

1100 Series

Caution: Do not operate the engine if there is a blockage in the air filter or the induction hose. This can cause lubricating oil to enter the cylinders through the breather valve. Environmental conditions have an important effect on the frequency at which the air filter needs service. Certain air filters have a separate dust bowl (A1) which must be cleaned at intervals. The amount of dust in the bowl shows if it has been removed at the correct time for the conditions of operation. Do not let dust completely fill the bowl, because this will reduce the life of the filter element (A2). Certain air filters have automatic dust valves (B1) through which dust is expelled from the filter. The rubber dust valve must be kept clean. Ensure that the sides of the valves close completely together and that they can separate freely. If a restriction indicator (C) is fitted, it will indicate precisely when the air filter element needs service. This prevents the premature removal of the filter element which causes extra cost or late removal of the element which can cause loss of engine power. The filter element must be cleaned or renewed according to the manufacturers recommendations.

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Users Handbook, TPD 1477E, issue 2

1100 Series Restriction indicator

The restriction indicator is fitted on the air filter outlet or between the air filter and the induction manifold.

When the red warning indicator (A1) is seen through the clear panel (A2) after the engine has stopped, the air filter element must be removed for service. After a clean element has been fitted, press the rubber bottom (A3) or the button (A4) of the restriction indicator to reset the red warning indicator.

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How to check the valve tip clearances

1100 Series

The valve tip clearances are checked between the top of the valve stem and the rocker lever (A), with the engine cold. The correct clearance for inlet valves is 0,20 mm (0.008 in) and 0,45 mm (0.018 in) for exhaust valves. The valve positions are shown at (B). The sequence of valves from number 1 cylinder is shown in the table below. Note: Number 1 cylinder is the furthest cylinder from the flywheel end of the engine. 1 Rotate the crankshaft in the normal direction of rotation until the inlet valve (B7) of number 4 cylinder has just opened and the exhaust valve (B8) of the same cylinder has not closed completely. Check the clearances of the valves (B1 and B2) of number 1 cylinder and adjust them, if necessary. 2 Set the valves (B3 and B4) of number 2 cylinder as indicated above for number 4 cylinder. Then check / adjust the clearances of the valves (B5 and B6) of number 3 cylinder. 3 Set the valves (B1 and B2) of number 1 cylinder. Then check / adjust the clearances of the valves (B7 and B8) of number 4 cylinder. 4 Set the valves (B5 and B6) of number 3 cylinder. Then check / adjust the clearances of the valves (B3 and B4) of number 2 cylinder.
Cylinder and valve number Valve I = Inlet E = Exhaust 1 1 2 3 2 4 5 3 6 7 4 8

R1180/1

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1100 Series

5
Engine fluids
Fuel specification
To get the correct power and performance from your engine, use good quality fuel. Recommended fuel specification ! EN590 Diesel Fuel Types - Auto/C0/C1/C2/C3/C4 ! BS2869 Class A2 ! ASTM D975-91 Class 2-2DA, US DF1, US DF2, US DFA ! JIS K2204 (1992) Grades 1, 2 ,3, and Special Grade 3. Note: Where low sulphur / low aromatic fuels are used it is important that lubricity additives are used. Acceptable fuel specification Caution: The fuel specification below is acceptable, however this fuel may reduce the life of the fuel injection equipment. The use of this fuel may also effect the engine performance. ! ASTM D975-91 Class 1-1DA ! JP7, MIL T38219 XF63 ! NATO F63. Low sulphur fuel
Percentage of sulphur in the fuel (%) < 0.5 0.5 to 1.0 > 1.0 Oil change interval Normal 0.75 of normal 0.50 of normal

Low temperature fuels Special winter fuels may be available for engine operation at temperatures below 0 C. T hese fuels have a lower viscosity and also limit the wax formation in the fuel at low temperatures. If wax formation occurs, this could stop the fuel flow through the filter. Aviation kerosene fuels Note: Aviation kerosine fuels have not been approved for the 1100 series engine.

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5
Lubricating oil specification
Use only a good quality lubricating oil to the minimum specification of: ! API CG-4 ! API CH-4 ! ACEA E3 ! ACEA E5.

1100 Series

Always ensure that the correct viscosity grade of lubricating oil is used for the ambient temperature range in which the engine will run as shown in the chart (A).

Recommended viscosity grades

0W 5W20 10W30 15W40 20W50 20 30 40 -30 -22 -20 -4 -10 14 0 32 10 50 20 68 30 86 40 104 50oC 122oF

Ambient temperature

Coolant specification
The quality of the coolant that is used can have a great effect on the efficiency and life of the cooling system. The recommendations indicated below can help to maintain a good cooling system and to protect it against frost and/or corrosion. If the correct procedures are not used, Perkins cannot be held responsible for damage caused by frost or corrosion. Cautions: ! An antifreeze which contains the correct inhibitor must be used at all times to prevent damage to the engine by corrosion, because of the use of aluminium in the coolant circuit, ! If frost protection is not necessary, it is still extremely important to use an approved antifreeze mixture because this gives a protection against corrosion and also raises the boiling point of the coolant. Note: If combustion gases are released into the coolant circuit, the coolant must be renewed after repair of the fault. The antifreeze that is recommended for this engine is the latest POWERPART Antifreeze, see "POWERPART Antifreeze" on page 6. This antifreeze contains the correct corrosion inhibitor that is especially suitable for this engine. If it is possible, use clean soft water in the coolant. The quality of the antifreeze coolant must be checked at least once a year, for example, at the beginning of the cold period. The coolant must be renewed every two years. The antifreeze mixture must consist of equal quantities of antifreeze and water. The corrosion inhibitor in the antifreeze will be diluted if a concentration of less than 50% of antifreeze is used. Concentrations of more than 50% of antifreeze may have an adverse effect on the performance of the coolant.

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1100 Series

6
Fault diagnosis 6
Continued

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6
Problems and possible causes
Possible causes Problem The starter motor turns the engine too slowly The engine does not start The engine is difficult to start Not enough power Misfire High fuel consumption Black exhaust smoke Blue or white exhaust smoke The pressure of the lubricating oil system is too low The engine knocks The engine runs erratically Vibration The pressure of the lubricating oil system is too high The engine oil temperature is too high Crankcase pressure Bad compression The engine starts and stops Checks by the user 1, 2, 3, 4 2,5, 6, 8, 9, 10, 12, 13, 14, 15, 17 5, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 19 8, 9, 10, 11, 12, 13, 16, 18, 19, 20, 21 8, 9, 10, 12, 13, 15, 20, 22 11, 13, 15, 17, 18, 19, 22, 23 11, 13, 17, 19, 21, 22 4, 15, 21, 23 4, 24, 25, 26 9, 13, 15, 17, 20, 22, 23 8, 9, 10, 11, 12, 13, 15, 16, 18, 20, 22, 23 13, 18, 20, 27, 28 4, 25 11, 13, 15, 19, 27, 29, 30, 32, 64 31, 33 11, 22 10, 11, 12

1100 Series

Checks by the workshop personnel

34, 35, 36, 37, 38, 42, 43, 63 34, 36, 37, 38, 40, 42, 43, 44, 63 34, 36, 37, 38, 39, 42, 43, 44, 62, 63, 64 34, 36, 37, 38, 39, 40, 41, 43, 63 34, 36, 37, 38, 39, 40, 42, 43, 44, 62 34, 36, 37, 38, 39, 40, 42, 43, 44, 62, 63 36, 37, 38, 39, 42, 44, 45, 52, 58, 61 46, 47, 48, 50, 51, 59, 36, 37, 40, 42, 44, 46, 52, 53, 60 34, 38, 40, 41, 44, 52, 60, 63 34, 38, 39, 40, 41, 44, 52, 54, 63 49 34, 36, 37, 39, 52, 55, 56, 57, 64 39, 42, 44, 45, 52, 37, 39, 40, 42, 43, 44, 45, 53, 60 63

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1100 Series List of possible causes

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Battery capacity low Bad electrical connections Fault in starter motor Wrong grade of lubricating oil Starter motor turns engine too slowly Fuel tank empty Fault in stop control Restriction in a fuel pipe Fault in fuel lift pump Dirty fuel filter element Restriction in air induction system Air in fuel system Fault in atomisers or atomisers of an incorrect type Cold start system used incorrectly Fault in cold start system Restriction in fuel tank vent Wrong type or grade of fuel used Restricted movement of engine speed control Restriction in exhaust pipe Engine temperature is too high Engine temperature is too low Incorrect valve tip clearances Too much oil or oil of the wrong type is used in wet type air cleaner, if one is fitted Not enough lubricating oil in sump Defective gauge Dirty lubricating oil filter element Fan damaged Fault in engine mounting or flywheel housing Too much lubricating oil in sump Restriction in air or water passages of radiator Restriction in breather pipe Insufficient coolant in system Vacuum pipe leak or fault in exhauster Fault in fuel injection pump Broken drive on fuel injection pump Timing of fuel injection pump incorrect Valve timing is incorrect Bad compression Cylinder head gasket leaks Valves are not free Wrong high-pressure pipes Worn cylinder bores 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 Leakage between valves and seats Piston rings are not free or they are worn or broken Valve stems and/or guides are worn Crankshaft bearings are worn or damaged Lubricating oil pump is worn Relief valve does not close Relief valve does not open Relief valve spring is broken Fault in suction pipe of lubricating oil pump Piston is damaged Piston height is incorrect

Flywheel housing or flywheel is not aligned correctly Fault in thermostat or thermostat is of an incorrect type Restriction in coolant passages Fault in coolant pump Valve stem seal is damaged Restriction in sump strainer Valve spring is broken Lubricating oil seal of turbocharger leaks Air leak in Induction system (turbocharged engine) Faulty engine management system Induction system leaks (turbocharged engines)

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