1100 Pres For Ediscovery

1100 Series
Designed to perform delivered with choice
Perkins 1100 Series Range Presentation 12/11/2002

Proprietary Information of Perkins Engines Company Limited 2002 - All Rights Reserved Perkins Confidential Green
1100 Series
1103C
1104C
1106C
1103 Mechanical
1103C-33 3 cylinder 3.3 Litre Naturally Aspirated 1103C-33T 3 cylinder 3.3 Litre Turbo Charged
1103C
1104 Mechanical
1104C
1104C-44 4 cylinder 4.4 Litre Naturally Aspirated 1104C-44T 4 cylinder 4.4 Litre Turbo Charged 1104C-44TA 4 cylinder 4.4 Litre Charge Air Cooled
1104 Electronic
1104C
1104C-E44 4 cylinder 4.4 Litre Naturally Aspirated 1104C-E44T 4 cylinder 4.4 Litre Turbo Charged 1104C-E44TA 4 cylinder 4.4 Litre Charge Air Cooled
1106 Electronic
1106C-60TA 6 cylinder 6.0 Litre Charge Air Cooled
1106C
1100 Series
EMISSIONS FROM EMISSIONS FROM
01/01/2004
01/01/2003
Bore (mm)
Stroke (mm)
Swe Volu (Lite
1103C-33 1103C-33T 1104C-(E)44 1104C-(E)44T 1104C-(E)44TA 1106C-E60TA

0kW
(0bhp)
37-42 (49-56) 48-55 (65-74) 48-64 (65-86)
105 105 105 105 105 100
127 127 127 127 127 127
3.3
3.3
4.4
60-85.7 (80-115) 75-104.4 (100-140) 75-129.5 (100-174) 75Kw

(110bhp)
4.4
4.4
5.9
130kW
(174bhp)

1103 / 1104 Mechanical Design Features

Cross Flow Cylinder Head Performance, Emissions Delphi DP200 Fuel Pump Peripheral Fixed, Isolated Top Cover Eliminated Leaks Integrated Closed Circuit Breather Electric Lift Pump Leak Free/Durability
High Contact Ratio / Gear Train Reduced Noise Stressed Block Reduced Noise Sump Edge Moulded Carrier Gasket, Leak Free
Integral Oil Cooler No Leak Paths

Integral Rear End Oil Seal Open Top Deck Block Reduced Noise, Improved Cooling
1104 Electronic Design Features

Cross Flow Cylinder Head Performance, Emissions Peripheral Fixed, Isolated Top Cover Eliminated Leaks Integrated Closed Circuit Breather Electric Lift Pump 12/24 Volt Bosch VP30 Performance, Emissions, Power Trim
Leak Free/Durability
Integral Oil Cooler

No Leak Paths
High Contact Ratio / Gear Train Reduced Noise
Integral Rear End Oil Seal Eliminated Oil Leaks Open Top Deck Block
Reduced Noise, Improved Cooling
Stressed Block Reduced Noise Sump Edge Moulded Carrier Gasket, Leak Free Electronic FIE
A4E1 ECM Power Set to + 3% on all Electronic Ratings

1103C
3 cylinder 37 - 55 kW (49 - 74 hp) Cross flow head Identical front and back-ends to 1104 Family concept key deliverables Mechanical FIE only NA / T models Options from 900 Series and 1104

1103C Product Highlights

22% 15%
increase in capacity to 3.3 litres increase in power to 55 kW (74 hp)
TBU increased to 25% turbocharged, 22% on naturally aspirated Torque at 1000 rpm increased 500 hour service intervals by 13%
True family installation and service with 1104

1104C
4 Cylinder 48 104.4 kW (65 - 140 hp) Mechanical and Electronic Choice of NA, T, TA aspirations Improved low speed torque and torque back up Cross flow cylinder head Noise / Quality / Service improvements


4.4 Litre New Architecture Performance improvements for example:

Power increased to TBU increased to
97 kWm (130 hp) 30%
Peak torque increased by
10%
37%
Torque at 1000 rpm increased by
3 dBA quieter
Installation envelope as New 1000

Full authority electronics an option 500 hour service intervals
1106C Design Features

Multi-Piece Exhaust Manifolds Improved reliability Optimised Swirl Combustion System Emissions / Performance 12/24 Volt Bosch VP30 Performance, Emissions, Power Trim
Peripheral Fixed Aluminium Top Cover Eliminated oil leaks
No Leak off Rail Injectors Eliminates Leak Off Rail
Carrier Joint Oil Cooler Cover Seal Eliminating oil leaks Integral Rear End Oil Seal Eliminated oil leaks A4E1 ECM Power Set to + 3% on all Electronic Ratings Tappet Chamber Barriers Oil Carryover
High Contact Ratio / Gear Train Reduced Noise
An evolution of previous 1006 Engine

Full authority electronic control 75 to 129.5 kW (100 - 174 hp)
Improved
Reduced
quality
noise

1106 Product Highlights
Installation envelope as previous 1000 Series

TBU increased up to 35% by 20% Torque at 1000 rpm increased Noise reduction of 1 dba Air/Air charge cooling and electronics 500 hour service intervals Easy first step to electronics
Voice of the Customer

Importance Ranking Summary of Sub-Categories 1. 2. Reliability Quality 16. 17. PTO Speed
3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
1.Productivity 2.Reliability 3.Cost of Ownership

Cost of Engine Product Availability NVH Product Support Service Cost of Operation Rated Power Torque Curve On Time Delivery Durability Cooling System NPI Package Flexibility 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
Design Installation Electronics Cold Starting Low Speed / Idle Requirements Governing Fuel Tolerance Emissions Environmental / Green Issues Package Cost Image / Branding Weight Protection Safety and Integrity New Concept
1100 Series
Productivity:

Productivity
Improved Customer Productivity?

Capital Investments M Design Features, and Robust
Enhanced Flexibility of Products and Services

Expanded, Even More Flexible offering

Manufacturing Key Objectives

Maintain competitive product position

Deliver a step improvement in product quality and reliability 30 million investment programme, driven by... Customer value, Quality and Reliability

Quality Improvements
APQP - Advanced Product Quality Planning FMEAs (Failure Mode & Effect Analysis) Poke Yoke (Designed for assembly) Outsourced Sub-Assemblies Reduced routine Complexity Increased focus on customer specifications

Low Speed Torque

More Low Speed Torque Engine Torque
1000
Engine Speed (rpm)
2200

1100 Series
Refinement

Engine Noise Reduction
Significant Noise Reduction over speed and load range Charge Cooled 1104C Full load range, over 3.5 dB(A) reduction 90.8 dB(A) at 2200 rev/min previously 95.5 dB(A) Naturally Aspirated 1104C/E Full load range, over 2.5 dB(A) reduction 92.0 dB(A) at 2200 rev/min previously 94.5 dB(A)
1100 Series 34%
1100 Series 58%
(Numbers quoted being average Sound Pressure Level at 1m, dB(A) re. 20 Pa )
Engine Noise Reduction
At Idle - an important subjective condition Naturally Aspirated 1104, 3 dB(A) reduction 82 dB(A)
Reduction 50%
1100 Series 50%
Engine Noise Reduction In Vehicle
At Typical Vehicle Legislation test Conditions Naturally Aspirated 1104 3 dB(A) reduction 94 dB(A) 91 dB(A) Vehicle Noise Benefits already achieved
1100 Series 50%

Reduction 50%
Noise
Situation Comparison - Sound Pressure dBa
90.0 dBa
92.4 dBa
97.0 dBa
1104 Noise Refinement

Two piece pressed steel
Sound deadened material

Reduces noise
New Gear Tooth Profile Closer gear contact tighter helix Reduced noise
Open Top Deck Block Reduces noise & vibration transmission Prevents bore distortion
Peripherally Fixed Top Cover
Integral Seal in Top Cover (O Ring) = Leak Free design Reduced vibration and noise transmission
Inclusion of injector cover
1104 Peripherally Fixed Top Cover

1100 Series
Low Cost of Ownership

Reduced oil consumption
Extended Warranty
Extended service intervals
Fuel economy
Cost of Ownership
Ease of service
Parts support Durability and reliability


1100 Series focus is through
Improved fuel economy

Reduced oil consumption Ease of service / extended service periods Ease of installation Improved peace of mind - two year warranty

Low Fuel Consumption

1104C v New 1004 at FLRS
250
SFC (g/kWh)
SFC (g/kWh)
240
1104C v New 1004 at Max So far with Torque new head improvements 220 to come
230 210
230
220 4NA 4T 4TW/4TA
200 1104NA 1104T 4TW/4TA
New 1000
1104C
New 1000
1104C

Low Fuel Consumption

Cross Flow Cylinder Head
Increased air volume & flow

Lower fuel consumption Low cost of ownership
12/24 Volt Bosch VP30 Performance, Emissions, Power Trim High Contact Ratio / Gear Train More accurate FIE Reduced Noise
Cross Flow Cylinder Head Performance, Emissions
Electronic FIE Accurate Fuel injection

Improved Fuel Economy

Fuel Economy At specific conditions Across operating range of engine As in improved fuel economy by 1-6%
Through New cylinder heads (cross flow on 3, 4) New FIE
Electronics

1104 and 1104 Cylinder Head

Inlet Manifold
Cross Flow Head

Fuel Injection Equipment

Delphi DP200 Mechanical Fuel Pump
Bosch VP30 Electronic Fuel Pump


1100 Series focus is through Improved fuel economy
Reduced oil consumption

Ease of service / extended service periods Ease of installation Improved peace of mind - two year warranty

Reduced Oil Consumption

Oil Consumption
Halved 3 and 4 cylinder
Through
New block structure

New bore finish

1103 / 1104 Block Design

Cylinder Finish NEW 1000 Series
1100 Series
Open Top Desk Block

1104C Oil Consumption

2 Sigma (66%) 1104C 1004-40 0.06% 0.2% 3 Sigma (99%) 0.1% 0.31%
Reduced need to refill

Wider Max and Min Mark Larger sump


1106 (Stage 2) Target: 1006 (Stage 1) target :

Oil Used (Litres) 13.8 29.0 41.0
<0.2% <0.2%
Fuel Used (Litres) 13,850 30,450 43,752 Oil as % of Fuel 0.099 0.095 0.093
Engine 130 kW @ 500 hrs 130 kW @ 1,000 hrs 130 kW @ 1,500 hrs

Breather Oil Carry over The 1106 Solution
6 cylinder Tappet Chamber Barrier

Breather Oil Carry over The 1106 Solution
All models
Tappet chamber barriers - 50% reduction in oil carry over New high efficiency CCB system Reduces oil carry over to 2g/hour
Closed circuit breather option

No turbo, ATACC fouling or manifold leakage

Oil Consumption and Carry over Summary
How?

New honing process Open top deck Piston ring pack development with suppliers
Benefits Lower cost of ownership
Increased customer confidence


66% of engines
1103C & 1104C New 1000 Series 0.06% 0.2%
99% Of engines
0.1% 0.31%
Benefits Extended service intervals 500 hour oil change Low cost of ownership Increased productivity


1104 New Open Top Deck Block Structure
New 1000 Series
Finer honing
Improved Oil Flow

1100 Series
Lower Oil Consumption
Peripherally Fixed, Isolated Top Cover Eliminated Leaks
Integrated Closed Circuit Breather Electric Lift Pump Leak Free/Durability Integral Oil Cooler No Leak Paths Integral Rear End Oil Seal
Sump Edge Moulded Carrier Gasket, Leak Free

Stage 2 Product - Improved Open Breather Performance
New engine architecture
Stable open deck block design

Consistent bore geometry New piston design
New bore honing process
Reduced blow by and oil carry over
Evidence obtained via >100,000 test bed hours and >41,000 machine hours

Oil Carry Over Improved Performance

Approx. 90% of carry-over is oil vapour (visible smoke)
10% is liquid oil

Oil carry over is measured in grammes/hour
Oil Carry Over (gr/hour) New 1000 Series Full Load Rated Speed 70% Load Factor 15-20 1.5 1100C 2 0.24
1100C benefit:
Total oil content within the air mass has reduced by up to a factor of ten.

Blowby Gases Improved Performance

Blowby is measured in litres/minute Blowby is measured using conventional airflow measuring equipment
Blowby (litres/second) New 1000 Series 1100C
Full Load Rated Speed 70% Load Factor
0.8 2
0.6 0.8
1100C benefit:
Crankcase blowby gases reduced

Overall Result
1104C has ten times less oil carry over than New 1004 engine Crankcase blowby minimised

1100 Series focus is through Improved fuel economy Reduced oil consumption
Ease of service / extended service periods
Ease of installation Improved peace of mind - two year warranty

Ease of Service

Minimal Machine Downtime Service period doubled to 500 hours (oil/fuel filters) Not load dependent Oil/fuel filters 500 hours Valve train 1,000 hours No increase in sump capacity Single side servicing available Dipstick size

1100 Series focus is through Improved fuel economy Reduced oil consumption Ease of service / extended service periods
Ease of installation
Improved peace of mind - two year warranty

Ease of Installation
Flexible approach

Engine fits where Stage 1 fits Higher coolant temperature capability (more radiator flexibility) Range of fan options/configurations Range of component positions (PTO, filtration, fillers etc) Tailor installation to machine requirements for noise, serviceability, overall package size Electronics available for machine integration

1100 Series focus is through Improved fuel economy Reduced oil consumption Ease of service / extended service periods Ease of installation
Improved peace of mind - two year warranty

Peace of Mind

Increased warranty Standard two years warranty 1st year unlimited hours 2nd year 3,000 hour limit (from first use) Three years on majors

1100C Warranty
Improved warranty on Stage 2 engines
Standard two years warranty 1st year unlimited hours 2nd year 3,000 hour limit (from first use) Three years on majors

1100C Ease of Service
Minimal Machine Downtime Service period doubled to 500 hours at Stage 2 Not load dependent Oil filters 500 hours Fuel filters 500 hours Valve train 1,000 hours No increase in sump capacity Single side servicing

Low Cost of Ownership Example
What does this mean to the fleet owner/end user?

Eg fleet owner of Oil filter saving Fuel filter saving Oil savings (litres) Fuel savings (litres)
20 machines 320 filters 320 filters 2,720 litres 60,000 litres

Product Support
With a global production of over 15 Million engines, over 5 million still operating - Product Support has been a key factor in Perkins success Working in partnership with both our OEM customers and through Perkins distribution channel Perkins is now making significant advancements in Product Support

Perkins Worldwide Distribution
4,000 Distributors & dealers in 160 countries New Distributor Appointments from 2001 Existing Distributor Perkins 1100 Series Range Presentation 12/11/2002
Perkins North America Distribution
Long
Worldwide distributor index available on www.perkins.com

Applications Support
Perkins pride themselves on enabling custom designed and built diesel engines that go into multiple applications into over 800 customers. Perkins Application Engineers ensure all the key installation issues are optimised to ensure operator comfort, working efficiency and the maximum life for a Perkins Engine.
Perkins excellent electronic engine skills assist over one hundred OEMs with electronic architecture.

1100 Series
1103C
1104C
1106C

1100 Pres For Ediscovery

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1100 Series

Designed to perform delivered with choice

Perkins 1100 Series Range Presentation 12/11/2002

1106C-60TA 6 cylinder 6.0 Litre Charge Air Cooled

Swe Volu (Lite

1103C-33 1103C-33T 1104C-(E)44 1104C-(E)44T 1104C-(E)44TA 1106C-E60TA

37-42 (49-56) 48-55 (65-74) 48-64 (65-86)

105 105 105 105 105 100

127 127 127 127 127 127

60-85.7 (80-115) 75-104.4 (100-140) 75-129.5 (100-174) 75Kw

Perkins 1100 Series Range Presentation 12/11/2002

1103 / 1104 Mechanical Design Features

Integral Oil Cooler No Leak Paths

1104 Electronic Design Features

Integral Oil Cooler

High Contact Ratio / Gear Train Reduced Noise

A4E1 ECM Power Set to + 3% on all Electronic Ratings

Perkins 1100 Series Range Presentation 12/11/2002

1103C Product Highlights

increase in capacity to 3.3 litres increase in power to 55 kW (74 hp)

True family installation and service with 1104

Perkins 1100 Series Range Presentation 12/11/2002

Perkins 1100 Series Range Presentation 12/11/2002

1104C Product Highlights

4.4 Litre New Architecture Performance improvements for example:

Power increased to TBU increased to

97 kWm (130 hp) 30%

Peak torque increased by

Torque at 1000 rpm increased by

Installation envelope as New 1000

1106C Design Features

Peripheral Fixed Aluminium Top Cover Eliminated oil leaks

No Leak off Rail Injectors Eliminates Leak Off Rail

High Contact Ratio / Gear Train Reduced Noise

1106C Product Highlights

An evolution of previous 1006 Engine

Full authority electronic control 75 to 129.5 kW (100 - 174 hp)

Perkins 1100 Series Range Presentation 12/11/2002

1106 Product Highlights

Installation envelope as previous 1000 Series

Voice of the Customer

3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

1.Productivity 2.Reliability 3.Cost of Ownership

Perkins 1100 Series Range Presentation 12/11/2002

Improved Customer Productivity?

Capital Investments M Design Features, and Robust

Enhanced Flexibility of Products and Services

Perkins 1100 Series Range Presentation 12/11/2002

Manufacturing Key Objectives

Maintain competitive product position

Perkins 1100 Series Range Presentation 12/11/2002

Perkins 1100 Series Range Presentation 12/11/2002

Low Speed Torque

Engine Speed (rpm)

Perkins 1100 Series Range Presentation 12/11/2002

Perkins 1100 Series Range Presentation 12/11/2002

Engine Noise Reduction

1100 Series 34%

1100 Series 58%

Engine Noise Reduction

1100 Series 50%

Engine Noise Reduction In Vehicle

1100 Series 50%