Perkins 1103 and 1104,2490/1500 manual collection

Perkins 1103 &1104 Series WORKSHOP MANUAL Disassembly and Assembly 3 and 4 cylinder, naturally aspirated, and turbocharged diesel engines for agricultural and industrial use Publication SENR9779-00 © Proprietary information of Perkins Engines Company Limited 2004, all rights reserved. The information is correct at the time of print. Published by Technical Publications. Perkins Engines Company Limited, Peterborough, PE1 5NA, England

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 prema- ture failures, product damage, personal injury or death.

3 Table of Contents Table of Contents Disassembly and Assembly Section Fuel Priming Pump - Remove and Install .............. 4 Fuel Filter Base - Remove and Install .................... 5 Fuel Injection Lines - Remove ............................... 6 Fuel Injection Lines - Install ................................... 7 Fuel Injector Cover - Remove and Install ................ 8 Fuel Injection Pump - Remove (Delphi DP210) ...... 8 Fuel Injection Pump - Remove (Bosch EPVE for the 1104 engines only) .............................................. 10 Fuel Injection Pump - Install (Delphi DP210) ........ 11 Fuel Injection Pump - Install (Bosch EPVE for the 1104 engines only) .............................................. 13 Fuel Injector - Remove ......................................... 14 Fuel Injector - Install ............................................ 15 Turbocharger - Remove ........................................ 16 Turbocharger - Install ............................................ 17 Exhaust Manifold - Remove and Install ............... 18 Exhaust Elbow - Remove and Install (Option for Four Cylinder Engines Only) ....................................... 20 Inlet and Exhaust Valve Springs - Remove and Install ................................................................... 21 Inlet and Exhaust Valves - Remove and Install ..... 23 Inlet and Exhaust Valve Guides - Remove and Install ................................................................... 26 Inlet and Exhaust Valve Seat Inserts - Remove and Install ................................................................... 28 Engine Oil Filter Base - Remove and Install ........ 30 Engine Oil Cooler - Remove ................................. 34 Engine Oil Cooler - Install ..................................... 36 Engine Oil Relief Valve - Remove and Install (Engine Oil Pump) ............................................................ 37 Engine Oil Relief Valve - Remove and Install (Balancer Unit for the 1104 engines only) ........... 39 Engine Oil Pump - Remove (Engines Without a Balancer) ............................................................. 40 Engine Oil Pump - Install (Engines Without a Balancer) ............................................................. 40 Water Pump - Remove ......................................... 41 Water Pump - Disassemble ................................. 42 Water Pump - Assemble ...................................... 43 Water Pump - Install ............................................. 45 Water Temperature Regulator - Remove and Install ............................................................................. 46 Flywheel - Remove ............................................... 48 Flywheel - Install ................................................... 49 Crankshaft Rear Seal - Remove ........................... 50 Crankshaft Rear Seal - Install ............................... 50 Crankshaft Wear Sleeve (Rear) - Remove ............ 52 Crankshaft Wear Sleeve (Rear) - Install ............... 53 Flywheel Housing - Remove and Install ............... 53 Crankshaft Pulley - Remove and Install ............... 55 Crankshaft Front Seal - Remove ........................... 55 Crankshaft Front Seal - Install .............................. 56 Crankshaft Wear Sleeve (Front) - Remove ........... 57 Crankshaft Wear Sleeve (Front) - Install ............... 58 Front Cover - Remove and Install ......................... 58 Gear Group (Front) - Remove ............................... 59 Gear Group (Front) - Install ................................... 61 Idler Gear - Remove and Install ............................ 63 Housing (Front) - Remove ..................................... 68 Housing (Front) - Install ........................................ 69 Accessory Drive - Remove and Install ................. 70 Crankcase Breather - Remove and Install ........... 72 Valve Mechanism Cover - Remove and Install ..... 74 Rocker Shaft and Pushrod - Remove ................... 76 Rocker Shaft - Disassemble ................................ 77 Rocker Shaft - Assemble ..................................... 77 Rocker Shaft and Pushrod - Install ....................... 78 Cylinder Head - Remove ....................................... 79 Cylinder Head - Install .......................................... 81 Lifter Group - Remove and Install ......................... 84 Camshaft - Remove and Install ............................ 85 Camshaft Gear - Remove and Install ................... 86 Camshaft Bearings - Remove and Install ............ 86 Engine Oil Pan - Remove and Install ................... 87 Balancer - Remove (Some 1104 Engines Only) ... 90 Balancer - Install (Some 1104 Engines Only) ....... 91 Piston Cooling Jets - Remove and Install ............. 92 Pistons and Connecting Rods - Remove .............. 93 Pistons and Connecting Rods - Disassemble ....... 94 Pistons and Connecting Rods - Assemble ........... 95 Pistons and Connecting Rods - Install .................. 96 Connecting Rod Bearings - Remove .................... 98 Connecting Rod Bearings - Install ........................ 98 Crankshaft Main Bearings - Remove .................... 99 Crankshaft Main Bearings - Install (Crankshaft in Position) ............................................................ 101 Crankshaft - Remove .......................................... 103 Crankshaft - Install .............................................. 105 Crankshaft Gear - Remove and Install ............... 108 Bearing Clearance - Check ................................. 109 Glow Plugs - Remove and Install ....................... 110 V-Belts - Remove and Install .............................. 111 Fan - Remove and Install ................................... 112 Fan Drive - Remove and Install .......................... 113 Alternator - Remove ............................................ 113 Alternator - Install ................................................ 114 Electric Starting Motor - Remove and Install ..... 114 Vacuum Pump - Remove and Install (Some 1104 engines only) ..................................................... 115 Hydraulic Pump (Steering) - Remove ................. 116 Hydraulic Pump (Steering) - Install ..................... 116 Index Section Index ................................................................... 117

4 Disassembly and Assembly Section Disassembly and Assembly Section i01939024 Fuel Priming Pump - Remove and Install Removal Procedure Start By: a. Remove the assembly of the filter case and the fuel filter element. Refer to this Disassembly and Assembly Manual, “Fuel Filter Base - Remove and Install”. Note: There is an option for the three cylinder engine. The fuel priming pump and the fuel filter can be installed onto the application rather than onto the engine. If this is the case, refer to the appropriate OEM information as well as this text. Note: Put identification marks on all fuel hose assemblies and on all tube assemblies for installation purposes. After being disconnected, plug all fuel hose assemblies and plug all tube assemblies. This helps prevent fluid loss, and this helps to keep contaminants from entering the system. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. g00952432 Illustration 1 Typical example 1. Disconnect the tube assembly (5). Disconnect the tube assembly (6). Install dust covers onto the connectors for the fuel priming pump. 2. Disconnect the fuel return line from the connector (3). Install a dust cover to the connector (3). 3. Disconnect the harness assembly from the connector (2). 4. Support the fuel priming pump. Remove the three setscrews (1) and discard the rubber washers. Remove the fuel priming pump (4). Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. g00952432 Illustration 2 Typical example 1. Clean the external surfaces of the fuel priming pump (4). Position the fuel priming pump (4) and install the setscrews (1) and new rubber washers.

5 Disassembly and Assembly Section 2. Remove the dust covers from the fuel priming pump. Remove the plugs from the tube assemblies. Connect the tube assembly (5). Connect the tube assembly (6). 3. Connect the fuel return line to the connector (3). 4. Connect the harness assembly to the connector (2). 5. Remove the air from the fuel system. Refer to the Operations and Maintenance Manual, “Fuel System - Prime”. i01939067 Fuel Filter Base - Remove and Install Removal Procedure Note: There is an option for the three cylinder engine. The fuel filter and the fuel priming pump can be installed onto the application rather than onto the engine. If this is the case, refer to the appropriate OEM information as well to this text. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Note: The removal procedure is identical for the four cylinder and the three cylinder engines. The illustrations show the four cylinder engine. g01010637 Illustration 3 Typical example g01010595 Illustration 4 Typical example 1. Place a suitable container below the filter in order to collect the spilled fuel. Thoroughly clean the outside surfaces of the fuel filter. Open the drain (1) in order to drain the fuel from the filter. 2. Use a suitable strap wrench to loosen the filter case (2). Remove the filter case (2) from the filter head (5). 3. Push down against the spring pressure that is applied to the filter element (4). Rotate the filter element (4) counterclockwise in order to release the filter element from the filter case (2). 4. Discard the filter element (4) and the O-ring (3).

6 Disassembly and Assembly Section Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: The installation procedure is identical for the four cylinder and the three cylinder engines. The illustrations show the four cylinder engine. g01010637 Illustration 5 Typical example g01010595 Illustration 6 Typical example 1. Thoroughly clean the inside of the filter case (2) and thoroughly clean the lower face of the filter head (5). 2. Inspect the thread of a new filter element (4) in order to ensure that the thread is not damaged. Inspect the thread of the adapter in the filter head (5) in order to ensure that the thread is not damaged. 3. Inspect the condition of the spring and ensure that the spring is correctly located within the filter case (2). 4. Install the new filter element (4) into the filter case (2). Push the filter element against the spring pressure and rotate the filter element in a clockwise direction in order to secure the filter element within the filter case (2). 5. Lightly lubricate a new O-ring (3) with clean fuel oil. Install the new O-ring (3) into the recess within the filter case (2). 6. Close the drain (1). 7. Remove the air from the fuel system. Refer to the Operations and Maintenance Manual, “Fuel System - Prime”. Remove the suitable container and dispose of the fuel that has drained as waste. i01939856 Fuel Injection Lines - Remove Removal Procedure Start By: a. Remove the cover for the fuel injectors. Refer to this Disassembly and Assembly Manual, “Fuel Injector Cover - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

7 Disassembly and Assembly Section NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Note: The removal procedure is identical for four cylinder and three cylinder engines. The illustration shows the four cylinder engine. g00955826 Illustration 7 Typical example 1. Disconnect the fuel injection lines (1) at the fuel injectors (2). 2. Disconnect the fuel injection lines (1) at the fuel injection pump (3). 3. If it is necessary remove the clamps for the fuel injection lines or loosen the clamps for the fuel injection lines. Remove the fuel injection lines (1). 4. Install dust caps onto the ports of the fuel injectors and onto the ports of the fuel injection pump. Install dust caps onto both ends of the fuel injection lines. i01939857 Fuel Injection Lines - Install Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. Note: The installation procedure is identical for the four cylinder and the three cylinder engines. The illustration shows the four cylinder engine. g00955826 Illustration 8 Typical example 1. Inspect the fuel injection lines (1) for wear and for damage. Replace any fuel injection line (1) that is worn or any fuel injection line that is damaged. 2. Loosely install the clamps for the fuel injection lines (1). 3. Remove the dust caps from the fuel injection pump (3) and from the fuel injectors (2). Remove the dust caps from the fuel injection lines (1). 4. Loosely connect the nuts at both ends of the fuel injection lines (1). 5. Ensure that each fuel injection line (1) does not contact any other fuel injection line or any other engine component. Tighten the fasteners for the clamps for the fuel injection lines (1). Check that the fuel injection lines (1) are still clear of other components. 6. Tighten the fuel injection lines (1) at the fuel injectors (2) to a torque of 30 N·m (22 lb ft). 7. Tighten the fuel injection lines (1) at the fuel injection pump (3) to 30 N·m (22 lb ft).

8 Disassembly and Assembly Section 8. Remove the air from the fuel system. Refer to the Operations and Maintenance Manual, “Fuel System - Prime”. End By: a. Install the cover for the fuel injectors. Refer to this Disassembly and Assembly Manual, “Fuel Injector Cover - Remove and Install”. i01940979 Fuel Injector Cover - Remove and Install Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: The removal procedure is identical for the four cylinder and the three cylinder engines. The illustration shows the four cylinder engine. g01011111 Illustration 9 Typical example 1. Thoroughly clean all of the outer surfaces of the cover (1) for the fuel injectors. 2. Remove the setscrews (2) from the cover (1). 3. Remove the cover (1). Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: The installation procedure is identical for the four cylinder and the three cylinder engines. The illustration shows the four cylinder engine. g01011111 Illustration 10 Typical example 1. Thoroughly clean all of the inner surfaces of the cover (1) for the fuel injectors. 2. Install the cover (1). 3. Install the setscrews (2) for the cover (1). Tighten the setscrews (2) to a torque of 9 N·m (7 lb ft). i01940997 Fuel Injection Pump - Remove (Delphi DP210) Removal Procedure Start By: a. Remove the fuel injection lines. Refer to this Disassembly and Assembly Manual, “Fuel Injection Lines - Remove”. b. Remove the crankshaft pulley. Refer to this Disassembly and Assembly Manual, “Crankshaft Pulley - Remove and Install”.

9 Disassembly and Assembly Section c. Remove the front cover. Refer to this Disassembly and Assembly Manual, “Front Cover - Remove and Install”. Note: The removal procedure is identical for the four cylinder and the three cylinder engines. The illustrations show the four cylinder engine. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the No. 1 cylinder is at top dead center on the compression stroke. Refer to the Testing and Adjusting Manual, “Finding Top Center Position for No. 1 Piston”. g00956204 Illustration 11 Typical example 2. Loosen the locking screw (5). Rotate the spacer (6) in order to allow the locking screw (5) to tighten against the shaft of the fuel injection pump. Rotate the fuel injection pump gear in a counterclockwise direction in order to remove the backlash. Tighten the locking screw (5) to a torque of 17 N·m (13 lb ft). Note: The locking screw (5) must be tightened in order to prevent the shaft of the fuel injection pump from rotating. The shaft of the fuel injection pump must not be rotated after the fuel injection pump has been removed from the engine. Note: Put identification marks on all fuel hose assemblies and on all tube assemblies for installation purposes. After being disconnected, plug all fuel hose assemblies and plug all tube assemblies with suitable plastic plugs. Also install dust caps on all of the connectors on the fuel injection pump. This helps prevent fluid loss, and this helps to keep contaminants from entering the system. 3. Disconnect the fuel return line (1). Disconnect the tube assembly (4) from the fuel injection pump. 4. Disconnect the fuel line (3). 5. Disconnect the harness assembly (2) from the timing advance solenoid (7). g01011369 Illustration 12 Typical example 6. Remove the nut (8) and the washer from the shaft of the fuel injection pump. 7. Use a suitable puller in order to remove the fuel injection pump gear (9). Note: Do not pry the fuel injection pump gear (9) from the shaft of the fuel injection pump. g00956267 Illustration 13 8. Remove the nut (14). Remove the bolt (12). 9. If necessary, remove the setscrew (15) and the bracket (11) from the cylinder block. 10. Remove the setscrews (13) in order to remove the fuel injection pump. 11. Remove the fuel injection pump from the front housing. Remove the O-ring (10) and discard the O-ring from the fuel injection pump.

10 Disassembly and Assembly Section i01941022 Fuel Injection Pump - Remove (Bosch EPVE for the 1104 engines only) Removal Procedure Start By: a. Remove the fuel injection lines. Refer to this Disassembly and Assembly Manual, “Fuel Injection Lines - Remove and Install”. b. Remove the crankshaft pulley. Refer to this Disassembly and Assembly Manual, “Crankshaft Pulley - Remove and Install”. c. Remove the front cover. Refer to this Disassembly and Assembly Manual, “Front Cover - Remove and Install”. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Ensure that the No. 1 cylinder is at top dead center on the compression stroke. Refer to the Testing and Adjusting Manual, “Finding Top Center Position for No. 1 Piston”. g00996409 Illustration 14 Note: Put identification marks on all fuel hose assemblies and on all tube assemblies for installation purposes. After being disconnected, plug all fuel hose assemblies and plug all tube assemblies with suitable plastic plugs. Also install dust caps on all of the connectors on the fuel injection pump. This helps prevent fluid loss, and this helps to keep contaminants from entering the system. 2. Disconnect the tube assembly (1) from the fuel injection pump. Disconnect the tube assembly (2) from the fuel injection pump. 3. Disconnect the wiring harness assembly from the cold start advance unit (3). Disconnect the wiring harness assembly from the engine shutoff solenoid (4). g00996410 Illustration 15

Perkins 1103 and 1104,2490/1500 manual collection

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