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Perkins 1103AA-33G, Operation And Maintenance Manual

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Summary of Contents for 1103AA-33G

Page 1: ...Operation and Maintenance Manual 1103AA 33G 1103AA 33TG and 1104AA 44TG Industrial Engines LN Engine LQ Engine LR Engine M0105633 01 en us December 2020...

Page 2: ...rmation 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...

Page 3: ...ine Starting 14 Engine Stopping 15 Electrical System 15 Product Information Section Model Views 16 Product Identification Information 21 Operation Section Lifting and Storage 23 Gauges and Indicators...

Page 4: ...manual Whenever a question arises regarding your engine or this manual please consult with your Perkins dealer or your Perkins distributor for the latest available information Safety This safety sect...

Page 5: ...the engine as a convenient reminder Perkins also recommends that a maintenance record be maintained as part of the permanent record of the engine Your authorized Perkins dealer or your Perkins distri...

Page 6: ...alers 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 und...

Page 7: ...t the front of the valve mechanism cover on the three cylinder engine The ether warning label 2 can be found at the rear of the valve mechanism cover on the three cylinder engine i08315730 General Haz...

Page 8: ...rovisions to stop the engine if an overspeed occurs The stopping of the engine may be accomplished by shutting off the fuel supply and or the air supply to the engine Ensure that only the fuel supply...

Page 9: ...e the tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids Only use the tools that are suitable for containing fluids and equipment that is suitable for c...

Page 10: ...s when handling the equipment or parts Perkins also recommends the following Wear appropriate Personal Protective Equipment PPE Wash your hands and face with soap and water prior to eating drinking or...

Page 11: ...part of an operating engine Operating engines exhaust gases could burn do not come in contact with hot gases Allow the engine to cool before any maintenance is performed on the engine Relieve all pres...

Page 12: ...t your Perkins dealer and or your Perkins distributor for additional information about suitable protection devices Remove all flammable combustible materials or conductive materials such as fuel oil a...

Page 13: ...liar with the operation of the fire extinguisher Inspect the fire extinguisher and service the fire extinguisher regularly Obey the recommendations on the instruction plate Ether Ether is flammable an...

Page 14: ...ell ventilated area and if in an enclosed area vent the exhaust to the outside Inspect the engine for potential hazards Do not start the engine or move any of the controls if there is a DO NOT OPERATE...

Page 15: ...as been overhauled This may be accomplished by shutting off the fuel supply to the engine and or shutting off the air supply to the engine i02176668 Electrical System Never disconnect any charging uni...

Page 16: ...al applications your engine may appear different from the illustrations 1104AA Engine Model Views Illustration 14 g06418073 Typical example 1 Coolant outlet 2 Primary fuel filter 3 Oil gauge Dipstick...

Page 17: ...mple 10 Belt 11 Front lifting eye 12 Alternator 13 Turbocharger 14 Starting motor 15 Oil drain plug 16 Flywheel housing 17 Flywheel 18 Coolant drain 19 Rear lifting eye M0105633 01 17 Product Informat...

Page 18: ...ample 1 Coolant out let 2 Fuel injector 3 Oil cooler 4 Primary fuel filter 5 Oil gauge Dipstick 6 Oil filler 7 Oil filter 8 Oil drain plug 9 Open breather 10 Coolant intake 11 Water pump 12 Belt 18 M0...

Page 19: ...spirated Engine Specifications Note The front end of the engine is opposite the flywheel end of the engine The left and the right sides of the engine are determined from the flywheel end The number 1...

Page 20: ...engine lubricating oil is filtered Bypass valves provide unrestricted flow of lubrication oil to the engine parts when oil viscosity is high Bypass valves can also provide unrestricted flow of lubric...

Page 21: ...er Plate Illustration 20 g06419087 Typical serial number plate 1 List number Temporary 2 Serial number The Serial Number Plate is on the left side of the cylinder block behind the high pressure pipes...

Page 22: ...l Filter Element Auxiliary Oil Filter Element Total Lubrication System Capacity Total Cooling System Capacity Air Cleaner Element Fan Drive Belt Alternator Belt i07748311 Emissions Certification Film...

Page 23: ...s than 90 degrees When it is necessary to remove a component at an angle only use a link bracket that is properly rated for the weight Use a hoist to remove heavy components Use an adjustable lifting...

Page 24: ...nutes in order to remove all biodiesel from the system 2 Drain any water from the primary filter water separator Ensure that the fuel tank is full 3 The engine oil will not need to be drained in order...

Page 25: ...allowable temperature with the pressurized cooling system at 48 kPa 7 psi is 110 C 230 F Higher temperatures may occur under certain conditions The water temperature reading may vary according to load...

Page 26: ...area and if in an enclosed area vent the exhaust to the outside 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 sta...

Page 27: ...HEAT position for 6 seconds until the glow plug indicator light illuminates This action will activate the glow plugs and aid in the starting of the engine NOTICE Do not crank the engine for more than...

Page 28: ...re produced by some batteries 4 Start the engine 5 Immediately after the stalled engine is started disconnect the jump start cables in reverse order After jump starting the alternator may not be able...

Page 29: ...ed Engine 1 Run the engine for 3 to 5 minutes More time may be necessary when the temperature is below 18 C 0 F 2 Check all of the gauges during the warm up period 3 Perform a walk around inspection C...

Page 30: ...emergency stop button For more information about the emergency stop button refer to the OEM information Ensure that any components for the external system that support the engine operation are secured...

Page 31: ...Cold Weather Operation If the engine will start operate the engine until a minimum operating temperature of 81 C 177 8 F is achieved Achieving operating temperature will help prevent the intake valve...

Page 32: ...ations for Coolant Warm Up Warm up an engine that has cooled below normal operating temperatures due to inactivity The warm up should be performed before the engine is returned to full operation Durin...

Page 33: ...y insulating the engine compartment i05927268 Fuel and the Effect from Cold Weather Note Only use grades of fuel that are recommended by Perkins Refer to this Operation and Maintenance Manual Fluid Re...

Page 34: ...l filter is installed between the fuel tank and the engine fuel inlet After you change the fuel filter always prime the fuel system in order to remove air bubbles from the fuel system Refer to the Ope...

Page 35: ...nown The approximate capacity for the engine cooling system is listed below External System capacities will vary among applications Refer to the OEM specifications for the External System capacity Thi...

Page 36: ...ystem prob lems can develop without water temperature regulators Many engine failures are related to the cooling system The following problems are related to cooling system failures Overheating leakag...

Page 37: ...transfer capability of propylene glycol Use ethyl ene glycol in conditions that require additional protec tion against boiling or freezing Table 10 Propylene Glycol Concentration Freeze Protection 50...

Page 38: ...spark ignited gas engines Heavy duty diesel engines Automotive applications The anti corrosion package for ELC is different from the anti corrosion package for other coolants ELC is an ethylene glycol...

Page 39: ...ICE Incorrect or incomplete flushing of the cooling system can result in damage to copper and other metal components To avoid damage to the cooling system make sure that the cooling system is complete...

Page 40: ...SCA that is required Table 13 is an example for using the equation that is in Table 12 Table 13 Example Of The Equation For Adding The SCA To The Heavy Duty Coolant At The Initial Fill Total Volume of...

Page 41: ...neral Lubricant Information Because of government regulations regarding the certification of exhaust emissions from the engine the lubricant recommendations must be followed API American Petroleum Ins...

Page 42: ...vide finished oils with performance characteristics that meet industry standards There are no industry standard tests that evaluate the performance or the compatibility of aftermarket additives in fin...

Page 43: ...Sulfur Diesel ULSD Ultra Low Sulfur Diesel MEP China s Ministry of Environmental Protection General Information NOTICE Every attempt is made to provide accurate up to date information By use of this...

Page 44: ...fuel with a higher cetane number is recommended to operate at a higher altitude or in cold weather 2 Density range allowed includes summer and winter diesel fuel grades and regional variations 3 The...

Page 45: ...and altitude performance Fuel with higher cetane number is desirable and recommended Fuel with higher cetane number is of particular importance for operations in cold weather and at high altitude Vis...

Page 46: ...h higher wear scar diameter than 0 46 mm 0 01811 inch will lead to reduced service life and premature failure of the fuel system If fuels do not meet specified lubricity requirement appropriate lubric...

Page 47: ...olute filter Beta 4 75 up to 200 to reach the recommended cleanliness level This filtration should be at the device that dispenses the fuel to the fuel tank In addition filtration at the dispensing po...

Page 48: ...ate 64 Every 250 Service Hours Engine Oil and Filter Change 62 Fuel Inlet Screen Clean Inspect Replace 66 Fuel System Primary Filter Water Separator Element Replace 70 Every 300 Service Hours Fuel Con...

Page 49: ...y 3000 Service Hours or 2 Years Cooling System Coolant Commercial Heavy Duty Change 53 Every 4000 Service Hours Aftercooler Core Clean Test 50 Every 6000 Service Hours or 3 Years Cooling System Coolan...

Page 50: ...can result without following prop er procedure When using pressure air wear a protective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cl...

Page 51: ...t periods the batteries may not fully charge A battery with a low charge will freeze more easily than a battery with a full charge i07748719 Alternator and Fan Belts Inspect Adjust Replace Inspection...

Page 52: ...osition Remove all electrical loads 2 Turn off any battery chargers Disconnect any battery chargers 3 The NEGATIVE cable connects the NEGATIVE battery terminal to the NEGATIVE terminal on the starting...

Page 53: ...ed two negative connection must be disconnected 3 Remove the positive connection 4 Clean all disconnected connection and battery terminals 5 Use a fine grade of sandpaper to clean the terminals and th...

Page 54: ...ntainer NOTICE Dispose of used engine coolant or recycle Various methods have been proposed to reclaim used cool ant for reuse in engine cooling systems The full distil lation procedure is the only me...

Page 55: ...mp to pressure test the cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does n...

Page 56: ...L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 3 Fill the cooling system with clean water Install the cooling system filler cap 4 Start and run the eng...

Page 57: ...k of introducing an air lock into the coolant system 1 Observe the coolant level in the coolant recovery tank Maintain the coolant level to COLD FULL mark on the coolant recovery tank Pressurized Syst...

Page 58: ...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 Moisture can...

Page 59: ...lements Before installation the new air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage...

Page 60: ...ted speed The yellow core should latch approximately at the greatest vacuum that is attained If the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum...

Page 61: ...ces the oil s lubricating char acteristics and could result in the loss of power 2 Remove the oil filler cap and add oil if necessary Clean the oil filler cap Install the oil filler cap i02202699 Engi...

Page 62: ...gh the engine lubrication system with the new oil Drain the Engine Oil Note Ensure that the container that will be used is large enough to collect the waste oil Illustration 38 g06420879 Typical examp...

Page 63: ...Refer to the Operation and Maintenance Manual for more information on refill capacities NOTICE If equipped with an auxiliary oil filter system or a re mote oil filter system follow the OEM or filter m...

Page 64: ...6418 Fuel Control Linkage Check Lubricate Do not work on the engine unless the instructions and warnings are understood Refer to the safety section in this Operation and Maintenance Manual for more in...

Page 65: ...e the solenoid ball joint stud 2 with suitable grease at a service interval of every 6 months Lubricate with Engine Oil The stop lever on the fuel injection pump and the actuating mechanism on the sol...

Page 66: ...e nozzle tip with high pressure Under this amount of pressure the test fluid can pierce the skin and cause serious injury to the operator Al ways keep the tip of the fuel injection nozzle pointed away...

Page 67: ...r from inside out Ensure that the diesel fuel used meets the required specification Refer to the Operation and Maintenance Manual Fluid Recommendations for more information Screen Remove Illustration...

Page 68: ...d nut 1 is central to the aluminum bowl 2 Tighten the knurled nut 1 until the aluminum bowl 2 is securely in place 6 Using a suitable wrench tighten the knurled nut 1 to a torque of 6 1 N m 53 8 9 lb...

Page 69: ...pwards 2 Loosen the vent screw 3 on the fuel filter 3 Push down and pull up the fuel priming pump handle for approximately 30 seconds 4 Continue to operate the fuel pump handle until strong pressure c...

Page 70: ...any servic ing or repair is performed Fuel Filter Remove 1 Turn the fuel supply valve if equipped to the OFF position before performing this maintenance 2 Clean the outside of the fuel filter assembl...

Page 71: ...d 7 Unscrew the bowl 3 from the filter canister 2 Remove O ring 6 and discard 8 Discard the filter canister 2 in accordance with local regulations 9 Ensure that the bowl 3 is clean and free from dirt...

Page 72: ...ter 6 Remove the container below the filter assembly and dispose any diesel fuel spillages in accordance with local regulations i07756868 Fuel System Primary Filter Water Separator Drain Fuel leaked o...

Page 73: ...Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system Water can be introduced into the fuel tank wh...

Page 74: ...Outer covering that is ballooning locally Flexible part of the hose that is kinked or crushed Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any...

Page 75: ...sure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean bo...

Page 76: ...may not start in an emergency situation Check the starting motor for correct operation Check the electrical connections and clean the electrical connections Refer to the Systems Operation Testing and...

Page 77: ...d plugs before the engine is serviced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source a...

Page 78: ...ce any gauges that are cracked Replace any gauge that can not be calibrated i01907756 Water Pump Inspect A failed water pump may cause severe engine overheating problems that could result in the follo...

Page 79: ...eous emission standards that are prescribed by the law at the time of manufacture This engine may be covered by an Emissions Warranty Consult your authorized Perkins dealer or distributor to determine...

Page 80: ...n 14 D Driven Equipment Check 58 E Electrical System 15 Grounding Practices 15 Emergency Stopping 30 Emissions Certification Film 22 Emissions Warranty Information 79 Engine Clean 58 Engine Air Cleane...

Page 81: ...Tank Water and Sediment Drain 73 Drain the Water and the Sediment 73 Fuel Storage Tanks 74 Fuel Tank 73 G Gauges and Indicators 25 General Hazard Information 7 Containing Fluid Spillage 9 Fluid Penet...

Page 82: ...Factors 76 Incorrect Maintenance Procedures 76 Incorrect Operating Procedures 76 Starting Motor Inspect 76 Starting the Engine 26 Starting with Jump Start Cables 27 Stopping the Engine 30 T Table of C...

Page 83: ...aintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Inf...

Page 84: ...M0105633 2020 Perkins Engines Company Limited All Rights Reserved 84 December 2020...

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