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

MANITOU BF

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

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

647016EN	1st DATE OF ISSUE

	16 / 06 / 2008

ISSUE

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

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

Speciﬁcations

1104D (Mech) Industrial Engine

NK (Engine)

NL (Engine)

NK (Engine)

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used,

you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available.

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

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

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

4	KENR6245
Speciﬁcations Section

Speciﬁcations Section

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

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

Engine Design

i02655068

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

i02656438

Fuel Injection Lines

Illustration 1	g01333480

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

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

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

Illustration 2	g01334606

Typical example

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

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

KENR6245	5
	Speciﬁcations Section

i02663071

Fuel Injection Pump

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

Illustration 3	g01352237

Typical example

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

(1)O-ring

(2)Locking screw

(3)Washer

Locking the shaft

Loosen locking screw (2) and move the washer

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

Unlocking the shaft

Loosen locking screw (2) and install the washer

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

Illustration 4	g01352239

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

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

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

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

6		KENR6245
Speciﬁcations Section
i02662510		i02661897
Fuel Injectors		Fuel Transfer Pump

Illustration 5	g00908211

Fuel injector clamp

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

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

Leakage in 10 seconds ……………………………

0 drops

Table 1

Service setting for the Fuel Injector

Injection Pressure

29.4 + 0.8 MPa (4264 + 116 psi)

(1)Retaining bolts

(2)Clip

(3)Spacer

(4)Fuel transfer pump

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

(5)Fuel ﬁlter element

(6)O ring

(7)Fuel ﬁlter bowl

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

KENR6245	7
	Speciﬁcations Section

i02677369

Lifter Group

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

Clearance of the lifter in the cylinder block

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

i02655105

Rocker Shaft

Table 2

Required Tools

	Part
Tool	Number	Part Description	Qty

A	27610227	Spacing Tool	4

Illustration 8	g01345401

The rocker shaft

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

(1)Snap ring

(2)Washer

(3)Rocker arm

(4)Rocker arm bore

Diameter of the rocker arm

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

Clearance between the rocker arm and the rocker

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

(5) Spring

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

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

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

8	KENR6245
Speciﬁcations Section

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

(9)Locknut

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

i02551219

Valve Mechanism Cover

i02662486

Cylinder Head Valves

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

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

Illustration 10	g01345407

Cross section of cylinder head

(1)Valve spring

Naturally aspirated engines

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

Turbocharged engines

The installed length of the inlet valve springs

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

The installed length of the inlet valve springs (low

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

The installed length of the exhaust valve springs

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

KENR6245	9
	Speciﬁcations Section

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

(2)Valve spring recess

(3)The ﬁnished valve guides

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

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

(4) Exhaust valve

Diameter of the exhaust valve

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

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

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

Service limit ………………………

2.06 mm (0.0811 inch)

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

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

(5) Inlet valve

Diameter of the inlet valve

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

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

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

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

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

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

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

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

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

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

10	KENR6245
Speciﬁcations Section

Illustration 11	g00809016

Recess for the valve seat insert

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

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

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

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

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

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

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

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

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

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

i02662502

Cylinder Head

Table 3

Required Tools

	Part
Tool	Number	Part Description	Qty

A	21825607	Angle gauge	1

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

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

Illustration 12	g00987480

The tightening sequence

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

Tighten the bolts in the sequence that is shown in


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

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

KENR6245	11
	Speciﬁcations Section

Illustration 13	g00905621

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

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

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

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

	Illustration 14	g01006568

	Table 4

	Dimension	Maximum Permissible
	Distortion

	Width (A)	0.03 mm (0.0012 inch)

	Length (B)	0.05 mm (0.0019 inch)

	Diagonal Line (C)	0.05 mm (0.0019 inch)

i02662519

Turbocharger

Illustration 15	g00991357

Typical turbocharger

(1)Actuator rod

(2)Actuator

(3)Turbocharger

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

12	KENR6245
Speciﬁcations Section

Table 5

The part number for	The pressure for the
the turbocharger		wastegate

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

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

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

i02662527

Exhaust Manifold

Illustration 16	g01337856

Typical example

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

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

Camshaft

Illustration 17	g01277351

Checking the end play of the camshaft

KENR6245	13
	Speciﬁcations Section

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

Illustration 18	g01277354

Typical camshaft

(2) Bolt

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

(3) Camshaft thrust washer

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

Depth of the recess in the cylinder block for the

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

Tolerance of the thrust washer in cylinder block

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

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

Table 6

Diameters of Camshaft Journals

	Camshaft Journals	Standard Diameter

	1	50.711 to 50.737 mm
	(1.9965 to 1.9975 inch)


	2	50.457 to 50.483 mm
	(1.9865 to 1.9875 inch)

	3	49.949 to 49.975 mm
	(1.9665 to 1.9675 inch)

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

Illustration 19	g01345411

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

(6)Camshaft lobe height

(7)Base circle

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

1.Mount the camshaft between centers.

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

14	KENR6245
Speciﬁcations Section

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

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

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

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

Camshaft Bearings

i02663064

Engine Oil Filter

Illustration 20 Typical example

Illustration 21	g01338237

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

g01334592

(1) The diameter of the installed camshaft

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

KENR6245	15
	Speciﬁcations Section

Illustration 22	g01338238

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

i02657143

Engine Oil Cooler

Illustration 23	g00952614

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

Illustration 24	g01334858

Setscrews

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

Setscrews

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

16	KENR6245
Speciﬁcations Section

i02656269

Engine Oil Pump

Engines with Balancer Group

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

Illustration 25	g01334408

The oil pump for the balancer

(1) Clearance of the outer rotor to the

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

Illustration 26	g01334410

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

Illustration 27	g01334412

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

KENR6245	17
	Speciﬁcations Section

Illustration 28	g01334415

The end cover

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

Illustration 29	g01334416

Idler gear and pump gear

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

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

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

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

Illustration 30	g00938064

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

Illustration 31	g00938061

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

18	KENR6245
Speciﬁcations Section

Illustration 32	g00938799

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

Tighten the bolts that hold the front cover of the oil

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

Engine Oil Pressure

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

i02505676

Engine Oil Bypass Valve

Installed in the Oil Pump

Illustration 33	g00919893

Typical engine oil pump

Illustration 34	g00921377

Relief valve and spring

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

(2)Plunger

Diameter of the plunger ….. 19.186 to 19.211 mm

(0.7554 to 0.7563 inch)

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

(3)Spring

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

KENR6245	19
	Speciﬁcations Section

Installed in the Balancer

Illustration 35	g00919890

Plug

Illustration 36		g00921379

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

i02662550

Engine Oil Pan

Table 7

Required Tools

Tool	Part Number	Part Description	Qty

A	21826038	POWERPART	1
Retainer

Front sealant

Illustration 37	g01254690

Applying sealant

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

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

Rear sealant

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

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

Crankcase Breather

		Table 8
				Required Tools

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

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

Illustration 39	g01255016

Typical example

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

Illustration 40	g00926199

Breather valve

(1)Cover

(2)Cover plate

(3)Screws

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

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

(4)Diaphragm

(5)Cap

KENR6245	21
		Speciﬁcations Section
(6) Spring		Breather Canister

Illustration 41	g00926200

Typical example

(7) O-ring

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

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

(80 lb in)

Illustration 42	g01277902

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

(2) Tighten the clamps to the following

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

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

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

(8) Tighten the canister to the following

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

22	KENR6245
Speciﬁcations Section

i02504533

Water Temperature Regulator and Housing

Table 9

Required Tools

Tool	Part Number	Part Description	Qty

A	21820221	POWERPART Red	1
Rubber Grease

Illustration 43	g01253716

Typical example

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

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

(2)Water temperature regulator housing

(3)Water temperature regulator

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

i02363605

Water Pump

Illustration 44	g01183807

Tightening sequence

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

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

Cylinder Block

Table 10

Required Tools

Tool	Part Number	Part Description	Qty

A	21826038	POWERPART	1
Retainer

KENR6245	23
	Speciﬁcations Section

Illustration 45	g00924764

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

The maximum permissible wear for the cylinder bore

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

(3)Camshaft bearings

Diameter of the bore in the cylinder

block for the number 1 camshaft

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

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

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

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

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

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

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

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

(180 lb ft)

Illustration 46	g00938203

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

Note: Install the rear seal before sealant is applied.

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

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

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

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

Total height of the cylinder block between the top and

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

24	KENR6245
Speciﬁcations Section

Crankshaft

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

Illustration 47	g01338264

Typical example

(1) Crankshaft

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

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

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

KENR6245	25
	Speciﬁcations Section

Illustration 48	g01338265

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

Table 11

The undersize diameter of the Crankshaft Journals

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

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


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

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

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

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

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


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

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

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

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

26	KENR6245
Speciﬁcations Section

Table 12

Journal	Excessive run out

(1)	Mounting

(2)	0.08 mm (0.0031 inch)

(3)	0.15 mm (0.0059 inch)

(4)	0.08 mm (0.0031 inch)

(5)	Mounting

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

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

i02658811

Crankshaft Seals

Illustration 49	g01335894

Typical example

(1)Crankshaft

(2)Crankshaft seal

(3)Plastic sleeve

(4)Alignment tool

Illustration 50	g00915076

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

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

Tighten bolts 8 and 9 in the sequence that is shown

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

Connecting Rod Bearing

Journal

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

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

Maximum permissible wear of a bearing journal on a

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

KENR6245	27
	Speciﬁcations Section

Surface ﬁnish of radii ……………………

Ra 1.3 microns

i02656267

Main Bearing Journal

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

The original size of the main bearing

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

The shell for the main bearings

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

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

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

Clearance between the bearing shell and the main

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

i02662161

Connecting Rod

Illustration 51	g00907738

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

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

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

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

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

(2) The bearing shell for the connecting rod

28		KENR6245
Speciﬁcations Section

Illustration 52	g00995584

Alignment of the bearing shell

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

Table 13

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

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


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


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

Table 14

Undersized Connecting Rod Bearing

0.25 mm (0.010 inch)

0.51 mm (0.020 inch)

0.76 mm (0.030 inch)

Illustration 53	g00907744

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

Illustration 54	g00915056

KENR6245	29
	Speciﬁcations Section

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

Table 15

Length Grades for Connecting Rods

Grade Letter	Color Code	Length (Y)

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

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

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

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

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

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


		i02662142

Piston and Rings

Illustration 55	g01363510

Typical example

(1)Top compression ring

Naturally Aspirated

The shape of the top compression

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

Width of the top compression

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

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

(0.0035 to 0.0051 inch)

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

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

(2) Intermediate compression ring

The shape of the intermediate compression

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

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

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

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

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

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

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

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

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

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

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

Piston

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

The combustion bowl re-entrant angle for the

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

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

Piston Cooling Jet

Illustration 56	g00942652

(1) Installed piston cooling jets

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

Piston Cooling Jet Alignment

Illustration 57	g01006929

(2)Piston cooling jet

(3)Rod

(4)Cylinder block

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

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

KENR6245	31
	Speciﬁcations Section

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

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

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

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

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

i02662168

Front Housing and Covers

The front housing must be aligned to the cylinder

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

Illustration 59	g00918672

Front cover

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

(16 lb ft)

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

i02662183

Gear Group (Front)

Illustration 58	g01337594

Alignment

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

(16 lb ft)

Illustration 60	g00995886

Gear train

32	KENR6245
Speciﬁcations Section

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

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

(2) Camshaft gear

Tighten the bolt for the camshaft gear to the

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

Outside diameter of the camshaft

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

Clearance between the camshaft gear and the

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

Tighten the bolts for the idler gear to the following

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

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

Illustration 61	g00996214

The gear train for the oil pump

(4)Crankshaft gear

Bore diameter of crankshaft gear

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

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

KENR6245	33
	Speciﬁcations Section

Backlash between the oil pump idler gear (5) and

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

Backlash between the camshaft gear (2) and the

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

Backlash between the fuel injection pump gear

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

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

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

drive (if equipped) and the idler gear

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

Engines that have a Balancer

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

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

i02503254

Flywheel

Illustration 63	g00584712

Typical example

(1) Flywheel ring gear

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

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

(2)Flywheel

(3)Bolt

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

34		KENR6245
Speciﬁcations Section
i02663068		i02662798
Flywheel Housing		Crankshaft Pulley

Illustration 64	g01338247

Typical example

(1)Bolt

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

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

Illustration 65	g00915497

A standard pulley

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

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

(2) Thrust block

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

(3) Crankshaft pulley

KENR6245	35
	Speciﬁcations Section

Crankshaft Pulley for the Poly V-Belt

Illustration 66	g01337951

Typical example

(1)Bolt

(2)Thrust block

(3)Crankshaft adapter

(4)Crankshaft pulley

(5)Bolt

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

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

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

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

Non — Standard Pulley

Illustration 67	g01337945

(1)T Mark

(2)Alignment mark

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

i02663070

Fan Drive

Illustration 68	g01338248

Typical example

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

Fan drive housing

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

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

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

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

i02656398

Alternator

The 12 Volt and 24 Volt Denso

Alternators

Three types of alternator are available.

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

Illustration 69	g01332517

Typical example

(1) Terminal “W”

Tighten the terminal nut to the following

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

The 12 Volt and 24 Volt Iskra

Alternator

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

Illustration 70	g01332519

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

KENR6245	37
	Speciﬁcations Section

i02656404

Starter Motor

24 Volt Starting Motor

Illustration 71	g00974968

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

38	KENR6245
Speciﬁcations Section

12 Volt Starting Motor

Illustration 72

The 12 volt starting motor which shows the electrical connections

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

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

Rated voltage …………………………………………

12 volts

Glow Plugs

Illustration 73	g01334536

Typical example

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

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

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

40	KENR6245
Index Section

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

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

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

42	KENR6245
Index Section

KENR6245	43
	Index Section

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

Systems Operation

Testing and Adjusting

1104D (Mech) Industrial Engine

NK (Engine)

NL (Engine)

NM (Engine)

Important Safety Information

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

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

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

KENR6246	3
	Table of Contents

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

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

4	KENR6246
Systems Operation Section

Systems Operation Section

i02680003

Engine Design

Illustration 1	g01346235

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

1104D Engine Speciﬁcation

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

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

i02680006

General Information

Engine Description

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

Information” for the correct numbers for your engine.

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

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

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

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

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

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

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

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

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

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Источник

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

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

Автор: —
Издательство: Perkins Engines Ltd.
Год издания: 2002
Страниц: 440
Формат: PDF
Размер: 27,7 Mb

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

Автор: —
Издательство: Perkins Engines Ltd.
Год издания: 1983
Страниц: 114
Формат: PDF
Размер: 5,3 Mb

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

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Год издания: 1997
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Руководство на английском языке по техническому обслуживанию и ремонту автомобильных дизельных двигателей Perkins моделей 4.99M/4.107M/4.108M.

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Издательство: Perkins Engines Ltd.
Год издания: 1978
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Руководство по техническому обслуживанию и ремонту двигателя Perkins модели 1104D-E44TA.

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Manuals
Brands
Perkins Manuals
Engine
1104D

Manuals and User Guides for Perkins 1104D. We have 2 Perkins 1104D manuals available for free PDF download: Troubleshooting Manual, Operation And Maintenance Manual

Perkins 1104D Troubleshooting Manual (228 pages)

Industrial Engines

Brand: Perkins
|
Category: Engine
|
Size: 2.66 MB

Table of Contents

3
Troubleshooting Section

5
Electronic Troubleshooting

5
System Overview

5
Glossary

8
Electronic Service Tools

12
Indicator Lamps

14
Replacing the ECM

17
Self-Diagnostics

18
Sensors and Electrical Connectors

18
Engine Wiring Information

25
ECM Harness Connector Terminals

29
Programming Parameters

31
Test ECM Mode

31
ECM Snapshot

31
Factory Passwords

32
Factory Passwords Worksheet

33
Flash Programming

33
Injector Trim File

34
Mode Switch Setup

35
Throttle Setup

36
Multiposition Switch Setup

39
Customer Specified Parameters

41
Customer Specified Parameters Table

44
Customer Specified Parameters Worksheet

45
System Configuration Parameters

46
Troubleshooting Without a Diagnostic Code

47
Alternator Noise

47
Alternator will Not Charge

47
Battery

48
Can Not Reach Top Engine RPM

48
Coolant in Engine Oil

50
Coolant Temperature Is too High

51
ECM will Not Accept Factory Passwords

52
ECM will Not Communicate with Other Systems or Display Modules

52
Electronic Service Tool will Not Communicate with ECM

52
Engine Cranks but will Not Start

53
Engine Has Early Wear

56
Engine Misfires, Runs Rough or Is Unstable

56
Engine Oil in Cooling System

58
Engine Speed Does Not Change

59
Engine Stalls at Low RPM

60
Engine Vibration

61
Engine will Not Crank

62
Excessive Black Smoke

63
Excessive Engine Oil Consumption

65
Excessive Fuel Consumption

66
Excessive Valve Lash

68
Excessive White Smoke

68
Intake Air Temperature Is too High

69
Intermittent Engine Shutdown

71
Intermittent Low Power or Power Cutout

72
Low Engine Oil Pressure

73
Low Power/Poor or no Response to Throttle

74
Mechanical Noise (Knock) in Engine

76
Noise Coming from Cylinder

77
Troubleshooting with a Diagnostic Code

78
Diagnostic Code Cross Reference

78
No Diagnostic Codes Detected

80
CID 0001 Fmi 02

80
CID 0001 Fmi 05

81
CID 0001 Fmi 06

81
CID 0001 Fmi 07

82
CID 0002 Fmi 02

82
CID 0002 Fmi 05

83
CID 0002 Fmi 06

83
CID 0002 Fmi 07

84
CID 0003 Fmi 02

84
CID 0003 Fmi 05

84
CID 0003 Fmi 06

85
CID 0003 Fmi 07

85
CID 0004 Fmi 02

86
CID 0004 Fmi 05

86
CID 0004 Fmi 06

87
CID 0004 Fmi 07

87
CID 0005 Fmi 02

87
CID 0005 Fmi 05

88
CID 0005 Fmi 06

88
CID 0005 Fmi 07

89
CID 0006 Fmi 02

89
CID 0006 Fmi 05

90
CID 0006 Fmi 06

90
CID 0006 Fmi 07

91
CID 0041 Fmi 03

91
CID 0041 Fmi 04

92
CID 0091 Fmi 02

92
CID 0091 Fmi 03

93
CID 0091 Fmi 04

93
CID 0091 Fmi 08

94
CID 0100 Fmi 03

94
CID 0100 Fmi 04

95
CID 0100 Fmi 10

95
CID 0110 Fmi 03

96
CID 0110 Fmi 04

96
CID 0168 Fmi 00

96
CID 0168 Fmi 01

97
CID 0168 Fmi 02

97
CID 0172 Fmi 03

98
CID 0172 Fmi 04

98
CID 0190 Fmi 08

99
CID 0247 Fmi 09

99
CID 0247 Fmi 12

99
CID 0253 Fmi 02

100
CID 0261 Fmi 11

100
CID 0262 Fmi 03

100
CID 0262 Fmi 04

101
CID 0268 Fmi 02

101
CID 0342 Fmi 08

101
CID 0526 Fmi 05

102
CID 0526 Fmi 06

102
CID 0526 Fmi 07

102
CID 0774 Fmi 03

103
CID 0774 Fmi 02

103
CID 0774 Fmi 04

104
CID 0774 Fmi 08

105
CID 1639 Fmi 09

105
CID 1743 Fmi 02

105
CID 1779 Fmi 05

106
CID 1779 Fmi 06

106
CID 1785 Fmi 03

106
CID 1785 Fmi 04

107
CID 1785 Fmi 10

107
CID 1797 Fmi 03

108
CID 1797 Fmi 04

108
CID 1834 Fmi 02

108
CID 2246 Fmi 06

109
Troubleshooting with an Event Code

110
Event Codes

110
E172 High Air Filter Restriction

110
E194 High Exhaust Temperature

110
E232 High Fuel/Water Separator Water Level

111
E360 Low Engine Oil Pressure

111
E361 High Engine Coolant Temperature

113
E362 Engine Overspeed

114
E396 High Fuel Rail Pressure

115
E398 Low Fuel Rail Pressure

115
E539 High Intake Manifold Air Temperature

116
E2143 Low Engine Coolant Level

117
Diagnostic Functional Tests

118
Volt Sensor Supply Circuit — Test

118
Analog Throttle Position Sensor Circuit — Test

125
CAN Data Link Circuit — Test

130
Data Link Circuit — Test

133
Digital Throttle Position Sensor Circuit — Test

139
ECM Memory — Test

146
Electrical Connectors — Inspect

147
Engine Pressure Sensor Open or Short Circuit — Test

151
Engine Speed/Timing Sensor Circuit — Test

158
Engine Temperature Sensor Open or Short Circuit — Test

166
Fuel Rail Pump Solenoid — Test

171
Idle Validation Switch Circuit — Test

176
Ignition Keyswitch Circuit and Battery Supply Circuit — Test

181
Indicator Lamp Circuit — Test

187
Injector Data Incorrect — Test

190
Injector Solenoid Circuit — Test

192
Mode Selection Circuit — Test

202
PTO Switch Circuit — Test

206
Starting Aid (Glow Plug) Relay Circuit — Test

210
Throttle Switch Circuit — Test

213
Wastegate Solenoid — Test

217
Index

223

Perkins 1104D Operation And Maintenance Manual (112 pages)

Brand: Perkins
|
Category: Engine
|
Size: 3.89 MB

Perkins Categories

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More Perkins Manuals

Источник

Each Perkins engine has its own Operation and Maintenance Manual (RETO / OMM). This provides all the necessary information so that your engine runs normally day after day. It contains detailed
information on regular maintenance intervals along with technical data and instructions.

Perkins issues Operation and Maintenance Manuals (OMMs) for each engine type. Each manual is divided into four sections, which cover:

security,
product information,
exploitation,
maintenance — this part contains information on the capacity of refueling containers, recommendations for liquids, schedules for maintenance intervals and maintenance procedures

The first letters of the engine serial number are the engine family and type code. They can be found on the engine data plate or in the sales order confirmation.

Perkins is a subsidiary of Caterpillar and manufactures engines used in:

agricultural machinery
vehicles
building
electricity generation
industry.

Perkins engines can be both diesel and gas.

Example: 1206E-E66TA (G)

1206E-E66TA (G) 12 = Series. (12 = 1200 series)

1206E-E66TA (G) 06 = Number of cylinders

1206E-E66TA (G) (Emissions Compliancy) Emission Compliance

1206E-E66TA (G) (Electronic Fuel Injection) Electronic Injector

1206E-E66TA (G) Capacity in liters. (6.6 liter)

1206E-E66TA (G) Supercharging: T = Turbo, A = Air — air cooling, W = Water — water cooling.

1206E-E66TA (G) Generator Set Rating

Perkins 2806D-E18TA
Industrial Engine – PDF Service Manual

Perkins 2806F-E18TA
Industrial Engine – PDF Service Manual

PERKINS 4-108 SHOP
MANUAL

Perkins 400 Series
4016-E61TRS (Models 403C-11, 403C-15, 404C-22 and 404C-22T)

Perkins 4000 Series
(4006-23 TAG1A, TAG2A and TAG3A Inline diesel engine)

Perkins 4000 Series Diesel
Engine – PDF Service Manual

Perkins 4000 Series Inline
diesel engine – PDF Service Manual

Perkins 4006 and 4008
Diesel engine – PDF Service Manual

Perkins 4006 TRS Gas and
4008 TRS Gas Industrial Engines – PDF Service Manua

Perkins 4006 TRS Gas and
4008 TRS GasIndustrial Engines Workshop Manual

Perkins 4006-23 and 4008-30
Industrial Engine – PDF Service Manual

Perkins 400A and 400D Industrial Engine – PDF Service Manual

Perkins 4012-46A Industrial
Engine – PDF Service Manual

Perkins 4016-61 TRG
Industrial Engine – PDF Service Manual

Perkins 4016-61TRS1 and
4016-61TRS2 Gas Engines – PDF Service Manual

Perkins 402D-403D-404D
Industrial Engine Disassembly and Assembly Manual

Perkins 402D-403D-404D
Industrial Engine PDF Service manual

Perkins 402F-05, 403F-07,
403F-11, and 403F-15 Industrial Engines – PDF Service Manual

Perkins 403F-15T, 404F-22
and 404F-22T Industrial Engines – PDF Service Manual.

Perkins 404A-22SG1 Gas
Industrial Engine – PDF Service Manual

Perkins 404F-E22T,
404F-E22TA and 403F-E17T Industrial Engines – PDF Service Manual

Perkins 800D Series
Industrial Engines – PDF Service Manual

Perkins 854E-E34TA and
854F-E34T Industrial Engine – PDF Service Manual

Perkins 854F-E34TA
Industrial Engine – PDF Service Manual

Perkins DIAG1300 User
manual.

Perkins Diesel Engine 4-154
Workshop Manual.

Perkins Engine Fault
Finding Guide.

Perkins Engine Number
Guide.

Perkins Phaser 4 – and
6-cylinder Workshop Manual

Perkins TIER2 DIESEL
ENGINES 1100 (VK) Workshop Manual

Perkins TPD1352 – PDF
Service Manual

The codes refer to the
model range of engines Perkins

Workshop Manual for Perkins
4.108, 4.107 and 4.99 diesel engines

Workshop Manual for Perkins
4.108M, 4.107M and 4.99M diesel engines

Источник

В настоящем издании описаны двигатели Perkins 1104D-E44TA, которые устанавливаются на тракторы (Massey Ferguson), экскаваторы-погрузчики (Terex), экскаваторы (Тверской экскаватор), асфальтоукладчики (Vogele), вилочные телескопические погрузчики (Manitou, Merlo), траншеекопатели, электрогенераторы и другую спецтехнику. Двигатели Perkins 1104D-E44TA – четырехцилиндровые дизельные двигатели с рабочим объемом 4,4 л, с четырьмя клапанами на цилиндр, с топливным коллектором Common Rail, с электронным управлением впрыском.

Содержание

Спецификации
Топливопроводы высокого давления
Топливный насос высокого давления
Форсунка
Головка топливного фильтра (двойной фильтр)
Подкачивающий топливный насос (механический)
Подкачивающий топливный насос (электрический)
Топливный коллектор COMMON RAIL
Толкатель клапана
Вал коромысел
Клапанная крышка
Клапаны
Головка блока цилиндров
Турбонагнетатель
Выпускной коллектор
Распредвал
Подшипник распредвала
Головка масляного фильтра
Маслоохладитель
Масляный насос, двигатели с блоком балансиров
Масляный насос, двигатели без блока балансиров
Давление моторного масла
Перепускной клапан моторного масла (на масляном насосе)
Перепускной клапан моторного масла (на блоке балансиров)
Масляный поддон
Сапун картера (без фильтра)
Сапун картера (с фильтром)
Термостат
Насос охлаждающей жидкости
Блок цилиндров
Коленвал из чугуна с шаровидным графитом (SGI)
Сальник коленвала
Шейки подшипников шатунов
Шатунные подшипники (стандарт)
Коренные подшипники (стандарт)
Шатун
Поршни и поршневые кольца
Поршень
Маслораспылитель охлаждения поршня
Блок балансиров
Передний картер и крышки
Передняя группа шестерен
Маховик.
Картер маховика
Шкив коленвала
Шкив коленвала для многоручьевого ремня
Натяжитель ремня
Компрессор кондиционера
Привод вентилятора
Подъемные кронштейны
Генератор (12 В и 24 В, тип 1)
Кронштейн генератора
Стартер
Датчик температуры охлаждающей жидкости
Датчик температуры моторного масла
Датчик давления воздуха наддува
Датчик температуры во впускном коллекторе
Датчик оборотов/момента газораспределения
Блок управления двигателя
Свечи предпускового подогрева
Снятие и установка компонентов Топливоподкачивающий насос (электрический), топливный фильтр и водоотделитель
Топливоподкачивающий насос (механический)
Регулятор расхода топлива
Головка топливного фильтра
Топливный коллектор COMMON RAIL
Топливопроводы высокого давления
Один топливопровод высокого давления между топливным коллектором и форсункой
Все топливопроводы высокого давления между топливным коллектором И форсунками и топливным насосом высокого давления
Топливный насос высокого давления
Шестерня топливного насоса высокого давления
Форсунки
Турбокомпрессор, боковое расположение
Турбокомпрессор, верхнее расположение
Выпускной коллектор с верхним расположением фланца
Выпускной коллектор с боковым расположением фланца
Выпускное колено турбокомпрессора
Клапанные пружины
Клапаны
Головка масляного фильтра
Маслоохладитель
Редукционный клапан системы смазки
Конструкция двигателя без блока балансиров
Конструкция двигателя с блоком балансиров
Масляный насос системы смазки
Насос охлаждающей жидкости
Термостат
Маховик
Задний сальник коленвала
Картер маховика
Шкив коленвала
Передний сальник коленвала
Передняя крышка
Передняя группа шестерен
Промежуточная шестерня
Передний картер
Привод вспомогательных агрегатов (SAE «B»)
Привод вспомогательных агрегатов (SAE «А»)
Сапун картера (без фильтра)
Сапун картера (с фильтром)
Клапанная крышка
Основание клапанной крышки
Ось коромысел и штоки толкателей клапанов
Головка блока цилиндров
Толкатели клапанов
Распределительный вал
Шестерня распределительного вала
Подшипник распределительного вала
Поддон картера (из чугуна)
Поддон картера (из алюминия или штампованной стали)
Блок балансиров
Маслораспылитель охлаждения поршня
Шатуны и поршни
Коленчатый вал
Кольцо синхронизации коленчатого вала
Шестерня коленчатого вала
Компрессор кондиционера
Датчик положения коленчатого вала
Вспомогательный датчик оборотов коленчатого вала/положения Коленчатого вала
Датчик температуры охлаждающей жидкости
Датчик давления моторного масла
Датчик давления топлива
Датчик температуры воздуха на входе
Свечи предпускового подогрева
Ремень привода генератора и натяжитель
Вентилятор
Привод вентилятора
Электронный блок управления
Монтажный кронштейн электронного блока управления
Генератор
Стартер
Воздушный компрессор
Проверки и регулировки Наличие воздуха в топливе, проверка
Установка поршня цилиндра № 1 в ВМТ
Синхронизация впрыска топлива, проверка
Компрессия, проверка
Клапанные зазоры, проверка и регулировка
Заглубление клапана
Направляющая клапана, осмотр
Масляный насос, измерение зазоров
Поршневое кольцо, измерение зазоров
Биение лицевой поверхности маховика
Биение боковой поверхности маховика
Биение картера маховика
Центровка картера маховика
Генератор, проверка
Генератор, проверка зарядки аккумулятора
Электрическая система пуска, проверка
Коды неисправностей
Самодиагностика
Мигающие коды
Коды неисправностей J1939
Коды неисправностей PDL (PERKINS DIAGNOSTIC LINK)
Таблица взаимного соответствия кодов PDL, кодов J1939 и мигающих кодов
Техническое обслуживание
Регламент технического обслуживания
По мере необходимости
Ежедневно
Еженедельно
Каждые 50 моточасов или еженедельно
Каждые 400 моточасов
Начальные 500 моточасов
Каждые 500 моточасов
Каждые 500 моточасов или ежегодно
Каждые 1000 моточасов
Каждые 2000 моточасов
Каждые 3000 моточасов
Каждые 3000 моточасов или каждые 2 года
Каждые 4000 моточасов
Каждые 6000 моточасов или каждые 3 года
Каждые 12 000 моточасов или каждые 6 лет
Приемка
Описание некоторых процедур технического обслуживания
Замена охлаждающей жидкости
Сливная пробка охлаждающей жидкости блока цилиндров
Замена моторного масла и масляного фильтра
Зазор кожух/вентилятор
Топливная система – прокачка
Ручной подкачивающий насос
Электрический подкачивающий насос

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Снятие и установка компонентов

Масляный насос системы смазки

Снимите масляный поддон.
Если линия всасывания (5) оборудована опорным кронштейном, выверните болт (7) из кронштейна (8). Момент затяжки болта (7) при установке 44 Нм (32 фунт-фута).
Ослабьте затяжку болта (6) стопорного зажима. Момент затяжки при установке 22 Нм (16 фунт-футов).
Снимите кронштейн (8).

Внимание!
Отметьте положение и ориентацию деталей опорного кронштейна.

Снимите болты (4) с линии всасывания (1). Момент затяжки при установке 22 Нм (16 фунт-футов).
Снимите линию всасывания (5) с масляного насоса (2).

Снимите прокладку (3) (не показана).
Выверните болты (1). Момент затяжки при установке 22 Нм (16 фунт-футов). Снимите узел.
Выверните болты (11). Момент затяжки при установке 22 Нм (16 фунт-футов).
Снимите узел передней крышки (12) с узла масляного насоса двигателя (2).
Нанесите временную метку на наружный ротор (13) для последующей сборки.
Снимите наружный ротор с масляного насоса двигателя (2).
Не снимайте штифты (9) и (10) с корпуса масляного насоса двигателя, если они не повреждены.
Установка производится в последовательности, обратной снятию. После сборки проверьте люфты и зазоры в зацеплении шестерен, см. раздел «Спецификации».

Другие книги по ремонту и обслуживанию двигателей:

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книги по ремонту двигателей Cummins ISF 2.8
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Автомобильная литература

Источник

Testing and Adjusting

Скидки от справочной

Manuals and User Guides for Perkins 1104D. We have 2 Perkins 1104D manuals available for free PDF download: Troubleshooting Manual, Operation And Maintenance Manual

Perkins 1104D Troubleshooting Manual (228 pages)

Table of Contents

Perkins 1104D Operation And Maintenance Manual (112 pages)

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Perkins Categories

Содержание

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Снятие и установка компонентов

Масляный насос системы смазки