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  M0105633-01 (en-us) December 2020 Operation and Maintenance Manual 1103AA-33G, 1103AA-33TG and 1104AA-44TG Industrial Engines (Engine) LQ (Engine) LR (Engine)
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  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 you are authorized to perform this work, and that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.

• Page 3: Table Of Contents

  M0105633-01 Table of Contents Table of Contents Warranty Section Warranty Information……..79 Foreword …………4 Index Section Safety Section Index…………..80 Safety Messages……….6 General Hazard Information……7 Burn Prevention……….11 Fire Prevention and Explosion Prevention..12 Crushing Prevention and Cutting Prevention.. 14 Mounting and Dismounting ……

• Page 4: Foreword

  State of arises regarding your engine, or this manual, please California to cause cancer, birth defects, consult with your Perkins dealer or your Perkins distributor for the latest available information. and other reproductive harm. WARNING – This product can…

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  Perkins distributor offers various 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.

• Page 6: Safety Section

  If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Perkins dealers or Perkins distributors can provide new warning signs. Do not work on the engine and do not operate the engine unless the instructions and warnings in the Operation and Maintenance Manual are understood.

• Page 7: General Hazard Information

  M0105633-01 Safety Section General Hazard Information Illustration 3 g01682820 The ether warning label (2) can be found at the rear of the valve mechanism cover on the four cylinder engine. Refer to illustration 4 . Illustration 5 g06417655 Typical example of a three cylinder engine (1) Universal Warning Label (2) Ether Warning Label The universal warning label (1) can be found at the…

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  If Perkins recommend that you do not stand next to an the engine is in an enclosed area, vent the engine exposed running engine unless it is necessary when exhaust to the outside.
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  M0105633-01 Safety Section General Hazard Information Do not remove any hydraulic components or parts Dispose of all fluids according to local regulations until pressure has been relieved or personal injury and mandates. may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved Static Electricity Hazard when or personal injury may occur.
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  (ULSD fuel) poses a greater good hygiene, and adhering to safe work practices static ignition hazard than earlier diesel formula- when handling the equipment or parts. Perkins also tions with a higher sulfur contents. Avoid death recommends the following: or serious injury from fire or explosion.

• Page 11: Burn Prevention

  M0105633-01 Safety Section Burn Prevention Coolant • Use exhaust ventilation on permanent machining jobs. When the engine is at operating temperature, the engine coolant is hot. The coolant is also under • Wear an approved respirator if there is no other pressure.

• Page 12: Fire Prevention And Explosion Prevention

  Diesel Fuel If the application involves the presence of combustible gases, consult your Perkins dealer and/ or your Perkins distributor for additional information Diesel may be irritating to the eyes, respiratory about suitable protection devices.

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  Do not clip any other items to the high- pressure lines. Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for repair or for replacement parts. Check lines, tubes, and hoses carefully. Do not use your bare hand to check for leaks.

• Page 14: Crushing Prevention And Cutting Prevention

  M0105633-01 Safety Section Crushing Prevention and Cutting Prevention • End fittings are displaced. Make sure that all clamps, guards, and heat shields Engine exhaust contains products of combustion are installed correctly. During engine operation, which may be harmful to your health. Always correct installation will help to prevent vibration, start and operate the engine in a well ventilated rubbing against other parts, and excessive heat.

• Page 15: Engine Stopping

  M0105633-01 Safety Section Engine Stopping Always start the engine according to the procedure i02176668 that is described in the Operation and Maintenance Electrical System 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 Never disconnect any charging unit circuit or battery personal injury.

• Page 16: Product Information Section

  M0105633-01 Product Information Section Model Views Product Information Section Model Views i07747192 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. 1104AA Engine Model Views Illustration 14 g06418073 Typical example…

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  M0105633-01 Product Information Section Model View Illustrations Illustration 15 g06418098 Typical example (10) Belt (14) Starting motor (18) Coolant drain (11) Front lifting eye (15) Oil drain plug (19) Rear lifting eye (12) Alternator (16) Flywheel housing (13) Turbocharger (17) Flywheel…
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  M0105633-01 Product Information Section Model View Illustrations 1103AA Engine Model Views Illustration 16 g06418216 Typical example (1) Coolant out let (5) Oil gauge (Dipstick) (9) Open breather (2) Fuel injector (6) Oil filler (10) Coolant intake (3) Oil cooler (7) Oil filter (11) Water pump (4) Primary fuel filter (8) Oil drain plug…
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  M0105633-01 Product Information Section Engine Description Illustration 17 g06418246 Typical example (13) Alternator (15) Starting motor (17) Flywheel housing (14) Turbocharger (16) Flywheel (18) Coolant drain plug i07748275 Engine Description • Turbocharged aftercooled • Turbocharged • Naturally aspirated Engine Specifications Note: The front end of the engine is opposite the flywheel end of the engine.
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  M0105633-01 Product Information Section Engine Description (Table 2, contd) Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) Valve Lash Setting (Exhaust) 0.45 mm (0.018 inch) Engine Cooling and Lubrication The cooling system consists of the following components: • Gear-driven centrifugal water pump •…

• Page 21: Product Identification Information

  Serial Number Plate i07769156 Engine Identification Perkins engines are identified by a serial number. This number is shown on a serial number plate that is mounted on the left-hand side of the engine block. An example of an engine number is LR12345S090001E.

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  M0105633-01 Product Information Section Emissions Certification Film Record for Reference Engine Model Engine Serial number Engine Low Idle rpm Engine Full Load rpm Primary Fuel Filter Water Separator Element Secondary Fuel Filter Element Lubrication Oil Filter Element Auxiliary Oil Filter Element Total Lubrication System Capacity Total Cooling System Capacity Air Cleaner Element…

• Page 23: Operation Section

  If alterations are made, ensure that correct lifting devices are provided. Consult your Perkins dealer or your Perkins distributor for Illustration 23 g06418625 information regarding fixtures for correct engine Typical example of the three cylinder lifting eyes lifting.

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  Operation Section Engine Storage Sealed Coolant System i05876583 Engine Storage Ensure that the cooling system is filled with Perkins ELC, or an antifreeze that meets “ASTM D6210” specification. Perkins are not responsible for damage which may Open Cooling System occur when an engine is in storage after a period in service.

• Page 25: Gauges And Indicators

  Ammeter – This gauge indicates the Determine and correct the cause of any significant amount of charge or discharge in the change in the readings. Consult your Perkins dealer battery charging circuit. Operation of or your Perkins distributor for assistance.

• Page 26: Engine Starting

  M0105633-01 Operation Section Engine Starting Engine Starting • Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or i02194223 to the controls. Before Starting Engine •…

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  M0105633-01 Operation Section Cold Weather Starting 1. If equipped, move the throttle lever to the full NOTICE throttle position before you start the engine. Do not crank the engine for more than 30 seconds. Allow the electric starting motor to cool for two mi- NOTICE nutes before cranking the engine again.
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  M0105633-01 Operation Section After Starting Engine Note: If it is possible, first diagnose the reason for the i06791278 starting failure. Make any necessary repairs. If the After Starting Engine engine will not start only due to the condition of the battery, either charge the battery, or start the engine with jump start cables.

• Page 29: Engine Operation

  Maintenance Manual are followed, costs can be minimized and engine service life can be maximized. The efficiency of the engine can affect the fuel economy. Perkins design and technology in The engine can be operated at the rated rpm after manufacturing provides maximum fuel efficiency in the engine reaches operating temperature.

• Page 30: Engine Stopping

  M0105633-01 Operation Section Engine Stopping Engine Stopping i01903608 After Stopping Engine i01929389 Stopping the Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan. NOTICE •…

• Page 31: Cold Weather Operation

  Cold Weather Operation • Install the correct specification of engine lubricant before the beginning of cold weather. Perkins Diesel Engines can operate effectively in • Check all rubber parts (hoses, fan drive belts.) cold weather. During cold weather, the starting and weekly.

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  An electric block heater can be activated once the • Pushrods may become bent. engine is stopped. An effective block heater is typically a 1250/1500 W unit. Consult your Perkins • Other damage to valve train components can dealer or your Perkins distributor for more result.
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  Pour point is the last temperature before the fuel flow dissipation. stops and waxing of the fuel will start. Note: Perkins discourages the use of all air flow Be aware of these properties when diesel fuel is restriction devices such as radiator shutters.
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  M0105633-01 Operation Section Fuel Related Components in Cold Weather i01903588 Fuel Related Components in Cold Weather Fuel Tanks Condensation can form in partially filled fuel tanks. Top off the fuel tanks after you operate the engine. Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks.

• Page 35: Maintenance Section

  M0105633-01 Maintenance Section Refill Capacities Maintenance Section (Table 4, contd) These values are the approximate capacities for the crankcase oil sump which include the standard factory installed oil filters. Engines with auxiliary oil filters will require additional oil. Refer Refill Capacities to the OEM specifications for the capacity of the auxiliary oil filter.

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  M0105633-01 Maintenance Section Fluid Recommendations Table 7 1103 Naturally Aspirated Engines and Turbocharged Many engine failures are related to the cooling Engines with an oil cooler system. The following problems are related to cooling system failures: Overheating, leakage of the water Compartment or System Liters Quarts…
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  Ethylene Glycol Concentration Freeze Protection Coolant Recommendations −36 °C (−33 °F) 50 Percent The following three glycol-based coolants are −51 °C (−60 °F) recommended for use in Perkins diesel engines: 60 Percent Preferred – Perkins ELC…
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  However, ELC contains organic corrosion inhibitors and antifoam NOTICE agents with low amounts of nitrite. Perkins ELC has Do not use a commercial coolant/antifreeze that only been formulated with the correct amount of these meets the ASTM D3306 specification. This type of…
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  8. Repeat Steps 6 and repeat steps 7 until the containers before opening any compartment or disas- system is completely clean. sembling any component containing fluids. 9. Fill the cooling system with the Perkins Premixed Dispose of all fluids according to local regulations ELC. and mandates.
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  Check the antifreeze (glycol concentration) to ensure adequate protection against boiling or freezing. Table 14 Perkins recommends the use of a refractometer for Equation for Adding the SCA to the Commercial Heavy-Duty checking the glycol concentration. Do not use a Coolant for Maintenance hydrometer.
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  “EMA Recommended Guideline on Diesel Engine 4. Run the engine for approximately 30 minutes, Oil”. In addition to Perkins definitions, there are other leave the engine to cool down, and drain the definitions that will be of assistance in purchasing system.
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  Engine Oil Specification Engines Operating on High Sulfur Fuel Aftermarket Oil Additives Perkins does not recommend the use of aftermarket Refer to this Manual Fluid Recommendations, “Fuel additives in oil. It is not necessary to use aftermarket Specification” for the required service interval for additives to achieve the engines maximum service operating with high sulfur fuel.
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  • The Oil Condition Analysis determines the loss of NOTICE the oils lubricating properties. An infrared analysis The footnotes are a key part of Perkins specification is used to compare the properties of new oil to the requirements for China distillate diesel fuel. Read properties of the used oil sample.
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  M0105633-01 Maintenance Section Fuel Recommendations Table 17 Specification for China Distillate Diesel Fuel Property UNITS Requirements “ASTM Test” “ISO Test” “China Test” %Weight 0.01% maximum “D482” “ISO 6245” “GB/T 508” Carbon Residue on %Weight 0.3% maximum “D524” “ISO 4262” “GB/T 268” 10% Bottoms Cetane Number 45 minimum…
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  NOTICE fuel. The common reference is to kinematic viscosity. Operating with fuels that do not meet the Perkins rec- Kinematic viscosity is the quotient of the dynamic ommendations can cause the following effects: Start- viscosity that is divided by the density.
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  80 hours. lubricity up to 0.46 mm (0.01811 inch) wear scar di- Perkins fuel cleaner can be used on an on-going ameter as tested by “ISO 12156-1”. Fuel with higher basis with no adverse impact on engine or fuel wear scar diameter than 0.46 mm (0.01811 inch) will…
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  200 ppm water or less. • Perkins recommends the use of bulk fuel filter / coalescer units which clean the fuel of both particulate contamination and water in a single pass.

• Page 48: Maintenance Interval Schedule

  M0105633-01 Maintenance Section Maintenance Interval Schedule “ Fuel System Primary Filter (Water Separator) i08323373 Element — Replace“ ……70 Maintenance Interval Schedule Every 300 Service Hours “…

• Page 49: Maintenance Interval Schedule

  M0105633-01 Maintenance Section Maintenance Interval Schedule “ Water Pump — Inspect“….. . 78 Every 3000 Service Hours “ Fuel Injector — Test/Change“ ….65 Every 3000 Service Hours or 2 Years “…

• Page 50: Aftercooler Core — Inspect

  M0105633-01 Maintenance Section Aftercooler Core — Clean/Test i02322260 Aftercooler Core — Clean/Test Personal injury can result from air pressure. Personal injury can result without following prop- er procedure. When using pressure air, wear a 1. Remove the core. Refer to the OEM information for protective face shield and protective clothing.

• Page 51: Replace

  Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps and seals. Make repairs, if necessary. i02322311 Alternator — Inspect Perkins recommends a scheduled inspection of the Illustration 27 g06420392 alternator. Inspect the alternator for loose Typical example connections and correct battery charging.

• Page 52: Battery — Replace

  M0105633-01 Maintenance Section Battery — Replace The battery cables or the batteries should not be removed with the battery cover in place. The bat- tery cover should be removed before any servic- ing is attempted. Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.

• Page 53: Battery Or Battery Cable — Disconnect

  M0105633-01 Maintenance Section Battery or Battery Cable — Disconnect 4. Clean all disconnected connection and battery terminals. All lead-acid batteries contain sulfuric acid which 5. Use a fine grade of sandpaper to clean the can burn the skin and clothing. Always wear a terminals and the cable clamps.

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  Note: When the cooling system is cleaned, only For information regarding the disposal and the clean water is needed. recycling of used coolant, consult your Perkins dealer or your Perkins distributor. Note: Inspect the water pump and the water temperature regulator after the cooling system has Flush been drained.
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  M0105633-01 Maintenance Section Cooling System Coolant (ELC) — Change 5. Stop the engine and allow the engine to cool. 5. Start the engine. Inspect the cooling system for Loosen the cooling system filler cap slowly to leaks and for correct operating temperature. relieve any pressure.
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  For information regarding the disposal and the 2. Start and run the engine. The engine rpm will recycling of used coolant, consult your Perkins dealer increase to the operating speed of the engine. Run or your Perkins distributor.

• Page 57: Cooling System Coolant Level — Check

  — Check Engines With a Coolant Recovery Tank Note: The cooling system may not have been provided by Perkins. The procedure that follows is for typical cooling systems. Refer to the OEM information for the correct procedures. Illustration 32 g02590196…

• Page 58: Engine — Clean

  M0105633-01 Maintenance Section Driven Equipment — Check • Other maintenance recommendations Perform any maintenance for the driven equipment which is recommended by the OEM. i07766787 Engine — Clean Personal injury or death can result from high voltage. Illustration 33 g00285520 Moisture create paths…

• Page 59: Engine Air Cleaner Element — Replace

  Servicing the Air Cleaner Elements Note: The air filter system may not have been provided by Perkins. The procedure that follows, is for a typical air filter system. Refer to the OEM information for the correct procedure.

• Page 60: Engine Air Cleaner Service Indicator — Inspect

  Perkins use the starter motor in order to ground the element. As the air cleaner element becomes dirty, engine. Check the connection on the starter motor at the pressure differential rises.

• Page 61: Engine Oil Sample — Obtain

  M0105633-01 Maintenance Section Engine Oil Level — Check When the engine mounts are supplied by Perkins the Note: After the engine has been switched OFF, wait maintenance procedure will be supplied in the for 10 minutes in order to allow the engine oil to drain Disassembly and Assembly manual for your engine.

• Page 62: Engine Oil And Filter — Change

  Use of an oil filter that is not recommended by Perkins could result in severe damage to the en- gine bearings, crankshaft, etc., as a result of the larg- er waste particles from unfiltered oil entering the engine lubricating system.

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  M0105633-01 Maintenance Section Engine Oil and Filter — Change NOTICE To prevent crankshaft bearing damage, crank the en- gine with the fuel OFF. This will fill the oil filters before starting the engine. Do not crank the engine for more than 30 seconds.

• Page 64: Fuel Control Linkage — Check/Lubricate

  (−) battery ter- maintenance. Refer to the Service Manual or your au- minal. Completely tape all metal surfaces of the thorized Perkins dealer or your Perkins distributor for disconnected battery cable end in order to pre- the complete valve lash adjustment procedure.

• Page 65: Fuel Injector — Test/Change

  M0105633-01 Maintenance Section Fuel Injector — Test/Change 2. Check the stop lever bracket retaining bolts (8) are Lubricate the solenoid ball joint plunger (4) and plunger seal with clean engine oil at a service interval securely tightened. of every 6 months. 3.

• Page 66: Fuel Inlet Screen — Clean/Inspect/Replace

  Refer to the Disassembly and Assembly Manual for more information. Consult your authorized Illustration 44 g06421506 Perkins dealer or your Perkins distributor for Typical example of a fuel Injector assistance. The fuel injector will need to be removed and the i07755806 injector will need to be checked for performance.

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  M0105633-01 Maintenance Section Fuel Inlet Screen — Clean/Inspect/Replace NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over any disconnected fuel system components. Before starting this procedure, the Fuel Injection Pump (FIP) driveshaft should be locked by reversing the lock pin.

• Page 68: Fuel System — Prime

  M0105633-01 Maintenance Section Fuel System — Prime 7. If the accumulation of particles found in the 5. Swing the tension bracket (4) into position so that aluminum bowl is found to be acceptable, the the knurled nut (1) is central to the aluminum bowl screen can be cleaned.

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  M0105633-01 Maintenance Section Fuel System — Prime Illustration 48 g06421659 Illustration 50 g06422143 Typical example of the fuel injection pump Typical example 1. Unlock the fuel priming pump handle (1). Turn handle counter clockwise. Pull the fuel priming pump handle upwards. 2.

• Page 70: Fuel System Primary Filter (Water Separator) Element — Replace

  M0105633-01 Maintenance Section Fuel System Primary Filter (Water Separator) Element — Replace i07756290 Fuel System Primary Filter (Water Separator) Element — Replace Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.

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  M0105633-01 Maintenance Section Fuel System Primary Filter (Water Separator) Element — Replace Illustration 51 g06423641 Typical example 4. Support filter canister (2) and rotate the clamp ring (1) to the left. 5. Remove the filter canister (2) from the fuel filter base (4) by a direct pull downwards.

• Page 72: Fuel System Primary Filter/Water Separator — Drain

  M0105633-01 Maintenance Section Fuel System Primary Filter/Water Separator — Drain Illustration 52 g06423641 Typical example 1. Install new O ring seal (5) onto new filter canister 6. Remove the container below the filter assembly (2). and dispose any diesel fuel spillages in accordance with local regulations.

• Page 73: Fuel Tank Water And Sediment — Drain

  M0105633-01 Maintenance Section Fuel Tank Water and Sediment — Drain i02335436 NOTICE The water separator is under suction during normal Fuel Tank Water and Sediment engine operation. Ensure that the drain valve is tight- ened securely to help prevent air from entering the — Drain fuel system.

• Page 74: Hoses And Clamps — Inspect/Replace

  (if equipped). The coolant system and the hoses for the coolant system are not usually supplied by Perkins. The Inspect all hoses for leaks that are caused by the following text describes a typical method of replacing following conditions: coolant hoses.

• Page 75: Severe Service Application — Check

  Severe Service Application — Radiator — Clean Check The radiator is not usually supplied by Perkins. The following text describes a typical cleaning procedure Severe service is the application of an engine that for the radiator. Refer to the OEM information for exceeds the current published standards for that further information on cleaning the radiator.

• Page 76: Starting Motor — Inspect

  Refer to the Systems Operation, Testing severe service operation. Consult your Perkins and Adjusting Manual, “Electric Starting System — dealer or your Perkins distributor for the unique Test” for more information on the checking procedure maintenance that is necessary for the engine.

• Page 77: Walk-Around Inspection

  Disassembly and Assembly Manual, 4. Fasten the air intake pipe and the exhaust outlet “Water Pump — Remove and Install” for more information or consult your Perkins dealer or your pipe to the turbocharger housing. Perkins distributor.

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  M0105633-01 Maintenance Section Water Pump — Inspect • Drain the water and the sediment from the fuel tank on a daily basis in order to ensure that only clean fuel enters the fuel system. • Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires.

• Page 79: Warranty Section

  This engine may be covered by an Emissions Warranty. Consult your authorized Perkins dealer or distributor to determine if your engine is emissions certified and if your engine is subject to an Emissions…

• Page 80: Index

  M0105633-01 Index Section Index After Starting Engine ……..28 Driven Equipment — Check ……58 After Stopping Engine ……..30 Aftercooler Core — Clean/Test……50 Aftercooler Core — Inspect ……. 50 Electrical System……….15 Alternator — Inspect ………. 51 Grounding Practices ……..15 Alternator and Fan Belts — Inspect/Adjust/ Emergency Stopping……..

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  M0105633-01 Index Section Fluid Recommendations (Engine Oil Pressurized Air and Water……8 Specification) ……….41 Static Electricity Hazard when Fueling with Engine Oil ………… 41 Ultra-low Sulfur Diesel Fuel ……9 General Lubricant Information….. 41 Fluid Recommendations (Fuel Recommendations) ……..43 Hoses and Clamps — Inspect/Replace…..
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  M0105633-01 Index Section Radiator — Clean ……….75 Reference Numbers ……..21 Record for Reference ……..22 Refill Capacities……….35 Cooling System……….35 Lubrication System ……..35 Safety Messages……….6 (1) Universal Warning ……..6 (2) Ether …………6 Safety Section ……….. 6 Serial Number Plate ……..
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  Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number:…
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  M0105633 ©2020 Perkins Engines Company Limited All Rights Reserved December 2020…

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