Prognosis of Repair and Maintenance of Perkins Engine 1100 Series

Used For Power Generator

1
Afofu oluwafemi sulaimon 2 bajela gbenga gideon

Maintenance Department, Baolam Technical Nigeria Limited, P.M.B. Box, 6620 Shomolu Lagos.

Email: femex4sec@gmail.com

Abstract
Perkins engine are universally used for different application worldwide which include farm machineries,
power generation, transportation industrial application, water pump in rural areas etc. Repair and
costing comes in other to give the engine a new life which involves several processes and method.
Perkins engine are more durable due to the availability of parts and technicians available .This paper
discuss the analysis of part costing methods of repairs and results which include given the engine a new
life which will involve replacement of various parts including the piston, rings, bearings, complete
overhauling gasket, front and back seals, trust washer etc.

Keywords: Costing, Analysis Of Parts And Methods, Maintenance Processes.

I. Introduction
Generally Perkins engines are universally used as prime movers in other to attain various rotational
force desires e.g generators, water pumps, cranes, trucks, earth moving equipments etc. This after
various running hours due to heat and friction engine recondition is required.

Figure 1.0 Perkins 1100 Series Engine

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This paper mainly discuss Perkins engine used as generator wish serves as alternative to power supply in
our part of the country which entails constant running of the engine to meet the power requirement so
it is introduced that the generator is serviced after every 200 hours of operation for the first phase of
preventive maintenance and 600 hours for the second phase.

The power generator is said to be reconditioned after 30,000 operation hours which will be our major
concentration so when the engine is been discovered not to meet up with the power generation
requirement, then the corrective maintenance is been done to regulate the engine performance. Costs
of owning and operating including the preventive & corrective maintenance cost of diesel engine is very
important for deciding the appropriate time to replace the diesel engine on basis of repair &
maintenance cost.

The new engine failure are occurring rarely therefore less maintenance cost, but age increase the
maintenance cost is increase. Models for the repair and maintenance costs of Perkins engine provide
planner and policy makers and also owner an opportunity to evaluate performance of Perkins engine
economic.

II. collection
This repair is carried out at ihs lag 100 site which failure and maintenance analysis is collated and sorted
the parts needed is purchased and used in the reconditioning which method and analysis is noted.

Cost analysis of parts

Our part of the country the accepted currency is naira (₦) the costing analysis will be done on that
procedure. The required parts will be listed below which included no of parts, quantity required and
amount of various ones.

S/N Part Name Quantity Unit Price (₦) Total Price (₦)
1 Complete overhauling gasket 1 25,000 25,000
2 Engine crankshaft 1 150,000 150,000
3 Set of pistons 3 15,000 45,000
4 Set of rings 3 8000 24,000
5 Front and back oil seal 1 15,000 15,000
6 Main bearing 1 12,000 12,000
7 Connecting rod bearing 1 8000 8000
8 Oil pump 1 45,000 45,000
9 Trust washer 1 7000 7000
10 Connecting rod 2 13,000 26,000
11 Service parts 2 5000 5000
12 lubricants 2 3500 7000
13 Bottom tray 1 10,000 10,000
14 Set of valve seals 6 1500 9000

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 15 Washing materials 1 7000 7000
16 Service and calibration of 1 10,000 10,000
injector pump and nozzle
17 Labour and transport - 60,750 60,750
TOTAL - 465,750

Figure 1.2 Displays of Various Parts

Parts cost = ₦ 405,000

Labour cost = 15% of material cost I.e. 15% 405,000 = 15 × 405,000÷ 100

Labour cost = ₦ 60,750

Overhead cost = 20% of material cost = 20 × 405,000 ÷ 100

= ₦ 81,000

Maintenance cost = material cost + labour cost+ overhead cost = 405,000 + 60,750+ 81,000

= ₦ 546,750

Total amount in words: five hundred and fourty six thousand seven hundred and fifty naira only.

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 III. Procedure
Various stages and methods employed in carrying out the repairs of Perkins 1100 engine in achieving the
aim of given the engine a new life is met.

Pictures below show the work procedures during the repairs and completion.

Figure 1.3 Dismantling Of Engine

 At this stage all the worn out parts are been removed several components are been checked
gauged and been set for assembly.

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 Figure 1.4 crankshaft installation

 At this stage new parts are been fixed which include the installation of crankshaft and it is locked
with torque wrench one at a time using the manufactures provided sequence.

Figure 1.6 installation of back oil seal

 At the stage the back oil seal is been fixed with various bolts to the engine block.

Figure 1.7 installation of flange

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  At this stage the flange is been mounted to the engine block to house the fly wheel and aid
connection to the alternator.

Figure 1.8 installations of timing housing and gears

 At this stage the housing is been mounted with various bolt to the enginge block and the timing
gear are been fixed as marked.

Figure 1.9 Installations of Timing Cove And Front Oil Seal

 After completion of the timing the front cover if fixed alongside with the front seal.

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 Figure 2.0 installations of piston and ring
 At this stage piston and rings are been fixed with the use of a piston cramp via the connecting
rod to the crankshaft.

Figure 2.1 installations of oil pump and bottom tray

 At this stage the oil pump is been fixed with the gear messed with the crankshaft to aid rotation
for proper lubrication.
 The bottom tray is also fixed with various bolts to the engine block

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 Figure 2.2 mounting of engine seating

 At this state the engine seating is been mounted and cross checked

Figure 2.3 mounting of the engine to the alternator in the sound proof

 At this stage the engine is carried into the sound proof with the flywheel fixed and connected to
the alternator.
 The engine will be mounted with the engine seat well aligned and tightened

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 Figure 2.4 final engine installations

 At this stage the engine and the alternator are been mounted together firmly so as to have
equal rotational speed to produce accurate voltage required.

Figure 2.4 installations of cylinder head, rocker arms, valve cover, radiator and exhaust.

 At this stage the cylinder head is been mounted

 The push rods and the rocker arms are been fixed too
 The valve cover is been fixed
 The radiator is been fixed to aid cooling
 The exhaust connector is also fixed
 The valve setting also been done.

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 IV. Sequel and Discussions
Generally engine play a vital role in power generation and all other parts of applications were by
rotation force is required. The major objective of this paper to calculate the cost at which Perkins 1100
series will be overhauled and procedure followed in reconditioning process.

The reconditioning been done with all standards met the generator was tested on full load for about 2
hours and it work perfectly. The following are noted and recorded after the test run;

 Less oil consumption

 Less fuel consumption
 No smoke from the exhaust (CONTROLLED EMISSION)
 Smooth sound
 Cooling system working perfectly temperature at 70 0

V. Conclusion
The essence of this paper is to show case the procedure followed in Perkins engine 1100 reconditioning
and to clarify the parts and labour cost of the recondition which will help eliminate low engine
performance and engine oil excess consumption. The paper also creates concept on maintenance time
and cost implications

VI. Acknowledgment
Praise be to almighty Allah for his guidance , protection, loving and kindness over a successful
completion of this research work.

Reference
I. Afofu Oluwafemi Sulaimon , Olojo Tayo Ayopo,(2018) “Overhauling a Perkins Engine {400
Series} To Increase Engine Performance to Attain Perfect Combustion” Indo-Iranian Journal
of Scientific Research (IIJSR) (Peer Reviewed International Journal), Volume 2, Issue 3, Pages
19-22.
II. D.R.Dolas1, M.D. Jaybhaye2, Sudhir. D. Deshmukh, Prediction of Repair & Maintenance
Costs of Diesel Engine
III. Donca Gh., (2011) “Maintenance cost model for U683DT Tractor, “ Analele Universita Nii din
Oradea , Fascicula: Ecotoxicologie, Zootehnie i Tehnologii de Industrie Alimentara, pp 131-
136

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