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Perkins Engine
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1106C  
Service Manual
92 pgs1.45 Mb2

Perkins Engine 1106C   Service Manual

Operation and Maintenance Manual
SEBU8387
May 2007
1106C Genset
(Engine)
PK
SEBU8387 3
Table of Contents
Table of Contents
Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 5
General Hazard Information ................................... 7
Burn Prevention ...................................................... 9
Fire Prevention and Explosion Prevention .............. 9
Crushing Prevention and Cutting Prevention ......... 11
Mounting and Dismounting .................................... 11
High Pressure Fuel Lines ..................................... 12
Before Starting Engine .......................................... 13
Engine Starting ..................................................... 13
Engine Stopping ................................................... 14
Maintenance In
Warranty Secti
Warranty Information ............................................ 87
terval Schedule ............................ 53
on
Index Section
Index ..................................................................... 88
Electrical System .................................................. 14
Engine Electronics ................................................ 15
Product Information Section
General Information .... .......................................... 17
Model Views ......................................................... 18
Product Identification Information ........................ 22
Operation Section
Lifting and Storage ................................................ 24
Gauges and Indic ators .......................................... 26
Features and Controls .......................................... 28
Engine Diagnostics ............................................... 34
Engine Starting ..................................................... 38
Engine Operation .................................................. 41
Engine Stopping ................................................... 42
Cold Weather Operation ....................................... 44
Maintenance Section
Refill Capacities .................................................... 48
4 SEBU8387 Foreword
Foreword
Literature Information
This manual con lubrication and maintenance information. This manual should be stored in or near the engine area in a literatur study and keep it with the literature and engine information.
English is the primary language for all Perkins publications. The English used facilitates translation and consiste
Some photographs or illustrations in this manual show details from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvemen may have caused changes to your engine which are not included in this manual. Whenever a question arises reg consult with your Perkins dealer or your Perkins distributor for the latest available information.
Safety
This safety section lists basic safety precautions. In addition, this section identifies hazardous, warning si precautions listed in the safety section before operating or performing lubrication, maintenance and repair on
this product.
tains safety, operation instructions,
e holder or literature storage area. Read,
ncy.
or attachments that may be different
t and advancement of product design
arding your engine, or this manual, please
tuations. Read and understand the basic
Recommended se appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine a Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequen specified in the Maintenance Interval Schedule may be necessary.
The maintenance schedule items are organized for a preventive maintenance management program. If the prevent periodic tune-up is not required. The implementation of a preventive maintenance management program should mini avoidances resulting from reductions in unscheduled downtime and failures.
ive maintenance program is followed, a
mize operating costs through cost
rvice should be performed at the
lso governs the Maintenance Interval
t lubrication and maintenance than is
Maintenance Intervals
Perform maintenance on items at multiples of the original requirement. We recommend that the maintenan near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of
Your authorized Perkins dealer or your Perkins distribu maintenance schedule to meet the needs of your operating environment.
ce schedules be reproduced and displayed
the engine’s permanent record.
tor can assist you in adjusting your
Overhaul
Operatio
Operating techniques outlined in this manual are basic. Th techniques required to operate the engine more efficiently and economically. Skill and techniques develop engine and its capabilities.
The oper Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and sto discussion of electronic diagnostic information.
n
ey assist with developing the skills and
as the operator gains knowledge of the
ation section is a reference for operators.
pping the engine. This section also includes a
Maintenance
The mai The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance interv referenced to detailed instructions that follow.
ntenance section is a guide to engine care.
als. Items in the maintenance schedule are
Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the i interval. Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer or your P regarding overhaul programs. If you experience a major engine failure, there are also numerous after f your Perkins dealer or your Perkins distributor for information regarding these options.
nterval and the maintenance items in that
erkins distributor offers a variety of options
ailure overhaul options available. Consult with
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer,
defects, and other reproductive harm. Battery
birth posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.
SEBU8387 5
Safety Section
Safety Messages
Safety Section
i02648377
Safety Messages
There may be s engine. The exact location and a description of the warning signs are reviewed in this section. Please become famil
Ensure that all of the warning signs are legible. Clean the warning s the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the warning other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the warning si could drop off of the engine.
Replace an missing.Ifawarningsignisattachedtoapartofthe engine that is replaced, install a new warning sign on the replac distributor can provide new warning signs.
everal specific warning signs on your
iar with all warning signs.
igns or replace the warning signs if
signs. Do not use solvents, gasoline, or
gns. The warning signs that are loosened
y warning sign that is damaged or
ement part. Your Perkins dealer or your
(1) Universal Warning
Do not operate or work on this equipment unless you have r and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the or death.
ead and understand the instructions
warnings could result in s erious injury
Illustration 1
lexample
Typica
The Universal Warning label (1) is located on both sides o
f the valve mechanism cover base.
g01154807
6 SEBU8387 Safety Section Safety Messages
Illustration 2
Location of label
(1) Universal warning
(2) Ether Warning
Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.
g01329365
Illustration 3
Typical exam ple
g01154809
The ether warning label (2) is located on the cover of the inlet manifold.
SEBU8387 7
Safety Section
General Hazard Information
Illustration 4
Location o
(2) Ether (3) Hand (High Pressure)
f labels
(3) Hand (High Pressure)
Contact penetration and burn hazards. High pressure fu­el spray may cause a fire hazard. Failure to fol­low thes structions may cause personal injury or death.
with high pressure fuel may cause fluid
e inspection, maintenance and service in-
g01329366
The warning label for the Hand (High Pressure) (3) is located o
n the top of the fuel manifold.
i023284
General Hazard Information
35
Illustration 5
lexample
Typica
g01154858
Illustration 6
g0010
Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls
e you service the equipment or before you
befor repair the equipment.
4545
8 SEBU8387 Safety Section General Hazard Information
Illustration 7
Wear a hard hat, protective glasses, and other protective equipment, as required.
Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine.
Make sure that all protective guards and all covers are secured in place on the engine.
Keep the engine free f rom foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, and from steps.
g00702020
When pressuriz cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protectiv
The maximum air pressure for cleaning purposes must be below water pressure for cleaning purposes must be below 275 kPa (40 psi).
ed air and/or water is used for
efaceshield.
205 kPa (30 psi). The maximum
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydrau escape rapidly if the pressure is not relieved correctly.
Do not remove until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve th
lic fluid or items such as pipe plugs to
any hydraulic components or parts
or parts until pressure has been relieved
e hydraulic pressure.
Never put maintenance fluids into glass containers. Drain all liquids into a suitable container.
Obey all local regulations for the disposal of liquids.
Use all cleaning solutions with care.
Report all necessary repairs.
Do not allow unauthorized personnel on the equipment.
Ensure that the power supply is disconnected before you work on the bus bar or the glow plugs.
Perform maintenance on the engine with the equipment in the servicing position. Refer to the OEM information for the procedure for placing the equipment in the servicing position.
Pressure Air and Water
Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury.
The direct application of pressurized air or pressurized water to the body could result in personal injury.
Illustration 8
Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.
g00687600
Containing Fluid Spillage
Care must be taken in order to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the engine. Make provision to collect the fluid with a suitable container before any compartment is opened or before any component is disassembled.
Only use the tools that are suitable for collecting
•
fluids and equipment that is suitable for collecting fluids.
SEBU8387 9
Safety Section
Burn Prevention
Only use the too
•
fluids and equipment that is suitable for containing fluids.
Obey all local regulations for the disposal of liquids.
ls that are suitable for containing
i02334785
Burn Prevention
Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fu­el spray may cause a fire hazard. Failure to fol­low these inspection, maintenance and service in­structions may cause personal injury or death.
After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines.
Oils
Hot oil and hot lubricating components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not allow hot components to contact the skin.
Batteries
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended.
i02320721
Fire Prevention an d Explosion Prevention
Allow the pressure to be purged in the air system, in the hydraulic system, in the lubrication system, or in the cooling system before any lines, fittings or related items are disconnected.
Coolant
When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained.
Check the coolant level after the engine has stopped and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the filler cap. The filler cap must be cool enough to touch withabarehand.Removethefiller cap slowly in order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.
tion 9
Illustra
All fuels, most lubricants, and some coolant mixtures are flamma
Flammable fluids that are leaking or spilled onto hot surfaces a fire. Fire may cause personal injury and property damage.
After the emergency stop button is operated ensure that you allow 15 minutes, before the engine covers are remo
Determinewhethertheenginewillbeoperatedinan environ drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, proper
If the application involves the presence of combustible gases, Perkins distributor for additional information about suitable protection devices.
ble.
or onto electrical components can cause
ved.
ment that allows combustible gases to be
ty damage, or engine damage could result.
consult your Perkins dealer and/or your
g00704000
10 SEBU8387 Safety Section Fire Prevention and Explosion Prevention
Remove all flamm
able combustible materials or conductive materials such as fuel, oil, and debris from the engine. Do not allow any flammable combustible materials or c
onductive materials to accumulate on
the engine.
Store fuels a
nd lubricants in correctly marked containers away from unauthorized persons. Store oily rags and any flammable materials in protective containers.
Do not smoke in areas that are used for
storing flammable materials.
Do not expose
theenginetoanyflame.
Exhaust shields (if equipped) protect hot exhaust components f
rom oil or fuel spray in case of a line, a tube, or a seal failure. Exhaust shields must be installed correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain flammable fl
uid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting.
Wiring must be kept in good condition. All electrical wires must be correctly routed and securely attached. Check all e
lectrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all elect
rical connections.
Oil filters and f
uel filters must be correctly installed. The filter housings must be tightened to the correct torque. Refer to the Disassembly and Assembly manual for mor
Illustration 10
e information.
g00704059
Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open flames or sparks. Always stop the engine before refueling.
Eliminate all wiring that is unattached or unnecessary. Do not use
any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure connections, recommended wiring, and correctly maintai
ned battery cables will help to prevent arcing
or sparking.
Contact with high pressure fuel may cause fluid penetra
tion and burn hazards. High pressure fu­el spray may cause a fire hazard. Failure to fol­low these inspection, maintenance and service in-
ions may cause personal injury or death.
struct
After the engine has stopped, you must wait for 60 second
s in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines.
Ensure that the engine is stopped. Inspect all lines and hoses for wear or for deterioration. The hoses must be
correctly routed. The lines and hoses must
have adequate support and secure clamps.
Illustration 11
g00704135
Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery. Do not smoke in battery charging areas.
Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or ahydrometer.
SEBU8387 11
Safety Section
Crushing Prevention and Cutting Prevention
Incorrect jump an explosion that can result in injury. Refer to the Operation Section of this manual for specific instructions
Do not charge a frozen battery. This may cause an explosion.
The batteries must be kept clean. The covers (if equipped recommended cables, connections, and battery box covers when the engine is operated.
er cable connections can cause
.
)mustbekeptonthecells.Usethe
Fire Extinguisher
Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher. Inspect the fi extinguisher regularly. Obey the recommendations on the instruction plate.
re extinguisher and service the fire
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are damaged.
Leaks can cause fires. Consult your Perkins dealer or your Per
Replace the parts if any of the following conditions are presen
kins distributor for replacement parts.
t:
i02143194
Crushing Prevention and Cutting Preve
Support the component correctly when work beneath the component is performed.
Unless other maintenance instructions are provided, never attempt adjustments while the engine is running.
Stay clear of all rotating parts and of all moving parts. Leave is performed. After the maintenance is performed, reinstall the guards.
Keep objects away from moving fan blades. The fan blades will throw objects or cut objects.
When objects a re struck, wear protective glasses in order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure that no one will be i
the guards in place until maintenance
njured by flying debris.
ntion
i02235492
Mounting and Dismounting
High pressure fuel line or lines are removed.
•
End fittings are damaged or leaking.
•
Outer cove
•
Wires are exposed.
•
Outer coverings are ballooning.
•
Flexible p
•
Outer covers have embedded armoring.
•
End fittings are displaced.
•
Make sure t are installed correctly. During engine operation, this will help to prevent vibration, rubbing against other parts, an
rings are chafed or cut.
art of the hoses are kinked.
hat all clamps, guards, and heat shields
d excessive heat.
Inspect the steps, the handholds, and the work area before mounting the engine. Keep these items clean and keep these items in good repair.
Mount the engine and dismount the engine only at locations that have steps and/or handholds. Do not climb on the engine, and do not jump off the engine.
Face the engine in order to mount the engine or dismount the engine. Maintain a three-point contact with the steps and handholds. Use two feet and one hand or use one foot and two hands. Do not use any controls as handholds.
Do not stand on components which cannot support your weight. Use an adequate ladder or use a work platform. Secure the climbing equipment so that the equipment will not move.
Do not carry tools or supplies when you mount the engine or when you dismount the engine. Use a hand line to raise and lower tools or supplies.
12 SEBU8387 Safety Section High Pressure Fuel Lines
i02668808
High Pressure Fuel Lines
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fu­el spray may ca low these inspection, maintenance and service in­structions may cause personal injury or death.
use a fire hazard. Failure to fol-
Illustration 1 2
(1)Highpressureline (2)Highpressureline (3)Highpressureline
(4) High press u re line (5) High press u re line (6) High press u re line
The high pressure fuel lines are the fuel lines that are between the high pressure fuel pump and the high pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head. These fuel lines are different from fuel lines on other fuel systems.
This is because of the following differences:
g01341328
(7) High pressure fuel manifold (rail) (8) High pressure line
The high pressure fuel lines are constantly charged
•
with high pressure.
The internal pressures of the high pressure fuel
•
lines are higher than other types of fuel system.
The high pressure fuel lines are formed to shape
•
and then strengthened by a special process.
SEBU8387 13
Safety Section
Before Starting Engine
Donotsteponth deflect the high pressure fuel lines. Do not bend or strike the high pressure fuel lines. Deformation or damage of the h point of weakness and potential failure.
Do not check t engine or the starting motor in operation. After the engine has stopped allow 60 seconds to pass in order to allow the p or repair is performed on the engine fuel lines.
Do not loosen to remove air from the fuel system. This procedure is not required.
Visually inspect the high pressure fuel lines before the engine is started. This inspection should be each day.
If you inspect the engine in operation, always use the proper a fluid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”.
Inspect the high pressure fuel lines for damage,
•
deformation, a nick, a cut, a crease, or a dent.
Do not operate the engine with a fuel leak. If there
•
isaleakdonottightentheconnectioninorder to stop the tightened to the recommended torque. Refer to Disassembly and Assembly, “Fuel injection lines ­Remove an
If the high pressure fuel lines are torqued correctly
•
and the hi high pressure fuel lines must be replaced.
e high pressure fuel lines. Do not
igh pressure fuel lines may cause a
he high pressure fuel lines with the
ressure to be purged before any service
thehighpressurefuellinesinorder
inspection procedure in order to avoid
leak. The connection must only be
d Fuel injection lines - Install”.
gh pressure fuel lines are leaking the
i02322199
Before Starting Engine
The initial sta or repaired make provision to shut the engine off, in order to stop an overspeed. This may be accomplished supply to the engine.
Overspeed shu engines that are controlled electronically. If automatic shutdown does not occur, press the emergency stop button in ord
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free
If equipped, ensure that the lighting system for the engine is su lights work correctly, if equipped.
All protect be installed if the engine must be started in order to perform service procedures. To help prevent an accident t around the parts carefully.
Do not bypa disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits engine damage.
rt-up of an engine that is new, serviced
by shutting off the air and/or fuel
tdown should occur automatically for
er to cut the fuel and/or air to the engine.
of personnel.
itable for the conditions. Ensure that all
ive guards and all protective covers must
hat is caused by parts in rotation, work
ss the automatic shutoff circuits. Do not
are also provided in order to help prevent
Ensure th
•
are in place. Do not operate the engine with clips that are damaged, missing or loose.
Do not attach any other item to the high pressure
•
fuel lines.
Loosened high pressure fuel lines must be
•
replaced. Also removed high pressure fuel lines must be r assembly manual, “ Fuel Injection Lines - Install”.
at all clips on the high pressure fuel lines
eplaced. Refer to Disassembly and
See the Se adjustments.
rvice Manual for repairs and for
i02251260
Engine Starting
Do not use aerosol types of starting aids such as ether. Such use could result i n an explosion and personal injury.
If a warning tag is attached to the engine start switch or to the controls DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.
14 SEBU8387 Safety Section Engine Stopping
All protective be installed if the engine must be started in order to perform service procedures. To help prevent an accident that around the parts carefully.
Start the eng from the engine start switch.
Always start that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Kno prevent major damage to the engine components. Knowing the procedure will also help to prevent personal in
To ensure that the jacket water heater (if equipped) and/or the l correctly, check the water temperature gauge and/or the oil temperature gauge during the heater operation
Engine exhaust contains products of combustion which can b engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the e
Note: The engine is equipped with a device for cold starting conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with the corre operation.
guards and all protective covers must
is caused by parts in rotation, work
ine from the operator’s compartment or
the engine according to the procedure
wing the correct procedure will help to
jury.
ube oil heater (if equipped) is working
.
e harmful to your health. Always start the
ngine exhaust to the outside.
. If the engine will be operated in very cold
ct type of starting aid for your region of
Stop the engine during the initial start-up of a new engine or an engine that has been overhauled.
To stop an electronically controlled engine, cut the power to the engine and/or shutting off the air supply to the engine
if an overspeed condition occurs
.
i02234878
Electrical System
Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible gases that are produced by some batteries, the negative “−” cable should be connected last from the external power source to the negative “−” terminal of the starting motor. If the starting motor is not equipped with a negative “−” terminal, connect the cabletotheengineblock.
Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical connections before the engine is started. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for specific starting instructions.
These en aid in each individual cylinder that heats the intake air in order to improve starting.
ginesareequippedwithaglowplugstarting
i02234873
Engine Stopping
Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine components.
Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected.
SEBU8387 15
Safety Section
Engine Electronics
Grounding Practices
Illustration 13
Typical exam ple
(1) Starting motor to engine block (2) Ground to starting motor (3) Ground to battery
g01162916
Uncontrolled e
lectrical circuit paths can result in damage to the crankshaft bearing journal surfaces and to aluminum components.
Engines that are installed without engine-to-frame ground straps can be damaged by electrical discharge.
To ensure that the engine and the engine electrical systems func
tion correctly, an engine-to-frame ground strap with a direct path to the battery must be used. This path may be provided by way of a direct engine groun
d to the frame.
The connections for the grounds should be tight and free of corro
sion. The engine alternator must be grounded to the negative “-” battery terminal with a wire that is adequate to handle the full charging current of t
he alternator.
The power supply connections and the ground connectio
ns for the engine electronics should always
be from the isolator to the battery.
i02650954
Engine Electro nics
Illustration 14
Typical exam ple
(4) Ground to engine (5) Ground to battery
g01162918
Correct grounding for the engine electrical system is necessary for optimum engine performance and reliability. Incorrect grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths.
Tamper ing
with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/or engine da
mage.
Electrical Shock Hazard. The electronic unit injec­tors use DC voltage. The ECM sends this voltage to the electronic unit injectors. Do not come in contact with the harness connector for the elec­tronic unit injectors while the engine is operating. Failure to follow this instruction could result in personal injury or death.
This engine has a comprehensive, programmable Engine Monitoring System. The Electronic Control Module (ECM) has the ability to monitor the engine operating conditions. If any of the engine parameters extend outside an allowable range, the ECM will initiate an immediate action.
The following actions are available for engine monitoring control:
Warning
•
16 SEBU8387 Safety Section Engine Electronics
Derate
•
Shutdown
•
The following monitored engine operating conditions have the ability to limit engine speed and/or the engine power:
Engine Coolant Temperature
•
Engine Oil Pressure
•
Engine Speed/
•
Intake Manifold Air Temperature
•
The Engine Monitoring package can vary for different engine models and different engine applications. However, the m monitoring control will be similar for all engines.
Note: Many of modules that are available for Perkins Engines will work in unison with the Engine Monitoring System. Tog et he r, t monitoring function for the specific engine application. Refer to Troubleshooting for more information on the Engine Moni
Timing
onitoring system and the engine
the engine control systems and display
he two controls will provide the engine
toring System.
SEBU8387 17
Product Information Section
General Information
Product Information Section
General Information
i01889424
Welding on Engines with Electronic Controls
NOTICE Proper welding procedures are necessary in order to avoid damage to the engine’s ECM, sensors, and associated components. When possible, remove the component from the unit and then weld the compo­nent. If removal of the component is not possible, the following procedure must be followed when you weld with a unit that is equipped with an Electronic Engine. The following procedure is considered to be the safest procedure to weld a component. This pro­cedure should provide a minimum risk of damage to electronic components.
NOTICE Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can cause damage to the drive train bearings, hydraulic components, electrical components, and other com­ponents.
Clamp the ground cable from the welder to the com­ponent that will be welded. Place the clamp as close as possible to the weld. This will help reduce the pos­sibility of damage.
1. Stop the engine. Turn the switched power to the
OFF position.
2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is provided, open the switch.
Illustration 15
Use the example above. The current flow from the welder to the ground clamp of the welder will not cause damage to any associated components.
(1) Engine (2) Welding rod (3) Keysw itch in the OFF position (4) Battery disconnect switch in the open position (5) Disconnected battery cables (6) Battery (7) Electrical/Electronic com ponent (8) Maximum distance between the component that is being
welded and any electrical/electronic component (9) The component that is being welded (10) Current path of the welder (11) Ground clamp for the welder
4. Connect the welding ground cable directly to the
part that will be welded. Place the ground cable as close as possible to the weld in order to reduce the possibility of welding current damage to bearings, hydraulic components, electrical components, and ground straps.
Note: If electrical/electronic components are used as a ground for the welder, or electrical/electronic components are located between the welder ground and the weld, current fl ow from the welder could severely damage the component.
g00765012
3. Disconnect the J1/P1 connectors from the ECM. Move the harness to a position that will not allow the harness to accidentally move back and make contact with any of the ECM pins.
5. Protect the wiring harness from welding debris and spatter.
6. Use standard welding practices to weld the materials.
18 SEBU8387 Product Information Section Model Views
Model Views
i02649396
Model View Illustrations
The following model views show typical features of the engine. engine may appear different from the illustrations.
Due to individual applications, your
Note: Only maj
or components are identified on the
following illustrations.
Illustration 1 6
Front left engine view
(1) Fuel manifold ( Rail) (2) Canister for the crankcase breather (3) Electronic control module (4) P2 connector (5) Secondary fuel filter
(6) Hand primer (7) Pr imary f u el filter (8) Oil sampling valve (9) Oil fi lter (10) Fuel pump
g01329939
(11) Water p ump (12) Damper (13) Fan (14) Fan pulley (15) Belt tensioner
SEBU8387 19
Product Information Section
Model Views
Illustration 1 7
Rear right engine view
(16) Oil gauge (17) Air intake (18) O il filler (19) Front lifting eye (20) Alternator
(21) Exhaust manifold (22) Exhaust elbow (23) Turbocharger (24) Wastegate solenoid (25) Starting motor
i02715685
Engine Description
The 1106 Electronic Engine model PK is designed for the following applications: machine and industrial mobile equipment. The engine is available in the following type of aspiration:
Turbocharged aftercooled
•
Four stroke cycle
•
In-line 6 cylinder
•
g01329941
(26) Oil pan (27) Drain plug (oil) (28) Drain plug or coolant sampling valve (29) Breather (30) Rea r lifting eye
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 cylinder is the front cylinder.
20 SEBU8387 Product Information Section Model Views
Illustration 18
1106 Electronic Engine model PK
(A) Ex haust valves (B) Inlet valves
Table 1
1106 Electronic Engine Model PK Specifications
Operating Range (rpm)
Number of Cylinders 6 In-Line
Bore
Stroke 127 mm (5.0 inch)
Aspiration
Compression Ratio 16.2:1
Displacement 6.6 L (403 in3)
Firing Order 1-5-3-6-2-4
Rotation (fl
Valve Lash Setting (Inlet) 0.35 mm (0.013 inch)
Valve Lash Setting (Exhaust)
(1)
The o perating rpm is dependent on the engine rating, the
application and the configuration of the throttle.
ywheel end)
900 to 2800
105 mm (4.13 inch)
Turbocharged aftercooled
Counterclo
0.35 mm (0.013 inch)
g01127295
(1)
ckwise
Electronic Engine Features
Automatic air/
•
Torque rise shaping
•
Injection timing control
•
System diagno
•
fuel ratio control
stics
For more information on electronic engine features, refer to the Op
eration and Maintenance Manual,
“Features and Controls” topic (Operation Section).
Engine Diagnostics
The engine has that the engine systems are functioning correctly. The operator will be alerted to the condition by a “Stop or Warning” lam horsepower and the vehicle speed may be limited. Theelectronicservicetoolmaybeusedtodisplay the diagnos
There are three types of diagnostic codes: active, logged, and
Most of the diagnostic codes are logged and stored in the ECM. F the Operation and Maintenance Manual, “Engine Diagnostics” topic (Operation Section).
The ECM provides an electronic governor that controls the injector output in order to maintain the desired en
Engine Coo
The cooling system consists of the following component
Gear-driven centrifugal water pump
•
Water temperature regulator which regulates the
•
engine coolant temperature
built-in diagnostics in order to ensure
p. Under certain conditions, the engine
tic codes.
event.
or additional information, refer to
gine rpm.
ling and Lubrication
s:
The engine operating conditions are monitored. The Electronic Control Module (ECM) controls the response of the engine to these conditions and to the demands of the operator. These conditions and operator demands determine the precise control of fuel injection by the ECM. The electronic engine control system provides the following features:
Engine monitoring
•
Engine speed governing
•
Control of the injection pressure
•
Cold start strategy
•
Gear-driven rotor type oil pump
•
Oil cooler
•
The engine lubricating oil is supplied by a rotor type oil pump.
The engine lubricating oil is cooled and the engine lubricating oil is filtered. The bypass valve can provide unrestricted flow of lubrication oil to the engin
e if the oil filter element should become
plugged.
SEBU8387 21
Product Information Section
Model Views
Engine efficien engine performance depend on adherence to proper operation and maintenance recommendations. Engine perfor the use of recommended fuels, lubrication oils, and coolants. Refer to this Operation and Maintenance Manual, “Mai information on maintenance items.
cy, e fficiency of emission controls, and
mance and efficiency also depend on
ntenance Interval Schedule” for more
22 SEBU8387 Product Information Section Product Identification Information
Product Identification Information
Plate Locations and Film Locations
i02761892
Serial Number Plate (1)
Theengineserialnumberplateislocatedonthe left side of the cylinder block to the rear of the front engine mounting.
on 20
Illustrati
Serial number plate
g01094203
i02164876
Reference Numbers
Illustration 19
Location of the serial number plate
g01331472
Perkins engines are identified by an engine serial number.
An example of an engine number is PK*****U000001J.
*****
____________________ The list number for the engine
__________________________________________ Type of engine
PK
____________________________Built in the United Kingdom
U
000001
J
___________________________ Engine Serial Number
_____________________________________ Year of Manufacture
Perkins dealers or Perkins distributors need all of these numbers in order to determine the components that were included with the engine. This permits accurate identification of replacement part numbers.
The numbers for fuel setting information for electronic engines are stored within the flash file. These numbers can be read by using the electronic service tool.
Informatio
n for the following items may be needed to order parts. Locate the information for your engine. Record the information in the appropriate space. Makeacopyo
f this list for a record. Keep the
information for future reference.
Record for Reference
_______________________________________________
Engine Mod
Engine Serial number _____________________________________
Engine Low Idle rpm ______________________________________
Engine Ful
Primary Fuel Filter _________________________________________
Water Separator Element ______ __________________________
Secondary
Lubrication Oil Filter Element ___________________________
Auxiliary Oil Filter Element _______________________________
Tot a l Lu br
Total Cooling System Capacity _________________________
el
l Load rpm
Fuel Filter Element
_____________________________________
__________________________
ication System Capacity
_____________________
Air Cleaner Element _______________________________________
SEBU8387 23
Product Information Section
Product Identification Information
Fan Drive Belt _
_____________________________________________
Alternator Belt ______________________________________________
i02648170
Emissions Certification Film
Label for compliant engines
Typical examp
les of emissions labels
Illustration 2 1
g01329012
24 SEBU8387 Operation Section Lifting and Storage
Operation Section
Lifting and Storage
Engine Lifting
i02164186
Some removals r obtain correct balance and safety.
To r em ov e t h e e are on the engine.
Lifting eyes a engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting fixtures obso that correct lifting devices are provided. Consult your Perkins dealer or your Perkins distributor for information lifting.
equire lifting the fixtures in order to
ngine ONLY, use the lifting eyes that
re designed and installed for specific
lete. If alterations are made, ensure
regarding fixtures for correct engine
i02308881
Engine Storage
If the engine is not started for a month or longer the lubricating oil will drain from the cylinder walls and from the piston rings. Rust can form on the cylinder walls. Rust on the cylinder walls will cause increased engine wear and a reduction in engine service life.
Illustration 22
NOTICE Never bend the eyebolts and the brackets. Only load the eyeb ber that the capacity of an eyebolt is less as the angle between the supporting members and the object be­comes le
When it is necessary to remove a component at an angle, o the weight.
Use a ho an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be parall be perpendicular to the top of the object that is being lifted.
olts and the brackets under tension. Remem-
ss than 90 degrees.
nly use a link bracket that is properly rated for
ist to remove heavy components. Use
el to each other. The chains and cables should
g01097527
Perkins are not responsible for damage which may occur when an engine is in storage after a period in service.
Your Perkins dealer or your Perkins distributor can assist in preparing the engine for extended storage periods.
If an engine is out of operation and if use of the engine is not planned for more than one month, a complete protection procedure is recommended.
To help prevent excessive engine wear and corrosion to the engine, use the following guidelines:
1. Completely clean the outside of the engine.
2. Ensure that the vehicle is on level ground.
3. Drain the fuel system completely and refill
thesystemwithpreservativefuel.1772204 POWERPARTLay-Up1canbemixedwith the normal fuel in order to change the fuel into preservative fuel.
If preservative fuel is not available, the fuel system can be filled with normal fuel. This fuel must be discarded at the end of the storage period together with the fuel filter elements.
SEBU8387 25
Operation Section
Lifting and Storage
Personal injury can result from hot coolant. Any contact with hot coolan t or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained.
4. Drain and refill the cooling system. Refer to this
Operation and Maintenance Manual, “Cooling System coolant (Commercial Heavy Duty ­Change or Cooling System coolant (ELC) ­Change” for information on draining, flushing and refilling the cooling system.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fu­el spray may cause a fire hazard. Failure to fol­low these inspection, maintenance and service in­structions may cause personal injury or death.
5. Operate the engine until the engine reaches
normal operating temperature. Stop the engine. After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual, “Fuel Injection Lines - Install”.
6. Drain the lubricating oil from the oil pan.
Renew the canister(s) of the lubricating oil filter.
9. If equipped, re element. Seal the end of the breather pipe.
10. Remove the val 1762811 POWERPART Lay-Up 2 around the rocker shaft assembly.
11. Remove the glow plugs. Slowly rotate the crankshaft. By checking the valves, position the piston at BDC Lay-Up 2 for two seconds into the cylinder bore. This procedure must be carried out on each cylinder.
12. Install the glow plugs. Install the valve mechanism cover.
13. Remove the pipes that are installed between the air filte Spray 1762811 POWERPART Lay-Up 2 into the turbocharger. The duration of the spray is printed on with waterproof tape.
14. Remove the the turbocharger. Spray 1762811 POWERPART Lay-Up 2 into the turbocharger. The duration of the spray i turbocharger with waterproof tape.
15. Seal the ve with waterproof tape.
16. Remove the belt into storage.
17. In order t of the engine, spray the engine with 1734115 POWERPART Lay-Up 3. Do not spray the area inside th
e alternator.
place the crankcase breather
ve mechanism cover. Spray
.Spray1762811 POWERPART
r assembly and the turbocharger.
the container. Seal the turbocharger
exhaust pipe from the output side of
s printed on the container. Seal the
nt of the fuel tank or the fuel filler cap
alternator drive belt and put the drive
o prevent corrosion to the outside
Fill the oil pan to the Full Mark on the engine oil level gauge with new, clean lubricating oil. Add 1762811 POWERPARTLay-Up2totheoilin order t o protect the engine against corrosion. If 1762811 POWERPART Lay-Up 2 is not available, use a preservative of the correct specification instead of the lubricating oil. If a preservative is used, this must be drained completely at the end of the storage period and the oil pan must be refilled to the correct level with normal lubricating oil.
7. Operate the engine in order to circulate engine oil.
8. Disconnect the battery. Ensure that the battery is
in a fully charged condition. Protect the terminals against corrosion. 1734115 POWERP ART Lay-Up 3 can be used on the terminals. Put the battery into safe storage.
26 SEBU8387 Operation Section Gauges and Indicators
Gauges and Indicators
i02717240
Gauges and Indicators
Your engine m the gauges that are described. For more information about the gauge package, see the OEM information.
Gauges provide indications of engine performance. Ensure that the gauges are in good working order. Determine th the gauges over a period of time.
Noticeable c potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the r Determine and correct the cause of any significant change in the readings. Consult your Perkins dealer or your Per
Some engine applications are equipped with Indicator Lamps. Ind aid. There are two lamps. One lamp has an orange lens and the other lamp has a red lens.
These indicator lamps can be used in two ways:
The indica
•
current operational status of the engine. The indicator lamps can also indicate that the engine has a faul via the ignition switch.
The indic
•
diagnostic codes. This system is activated by pressing the Flash Code button.
Refer to the Troubleshooting Guide, “Indicator Lamps” for further information.
If no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded, STOP the engine. Engine damage can result.
SAE10W40is350to450kPa(50to65psi)atrated rpm.
A lower oil pressure is normal at low idle. If the load is stable and the gauge reading changes, perform the following procedure:
ay not have the same gauges or all of
e normal operating range by observing
hanges in gauge readings indicate
eadings are within specifications.
kins distributor for assistance.
icator lamps can be used as a diagnostic
torlampscanbeusedtoidentifythe
t. This system is automatically operated
ator lamps can be used to identify active
NOTICE
Engine Oil Pressure – The oil pressure should be greatest after a cold engine is started. The typical engine oil pressure with
1. Remove the load
2. Stop the engine.
3. Check and maintain the oil level.
Jacket Water C
Typical temperature range is 83° to 95°C
(181.4° to 171°F). The maximum allowable temperature a system at 48 kPa (7 psi) is 103 °C (217.4 °F). Higher temperatures may occur under certain conditions. The water tem to load. The temperature reading should never exceed 7 °C (44.6 °F) below the boiling point for the pressurized
A 100 kPa (14.5 psi) radiator cap may be installed on the cooling system. The temperature of this cooling system must n
If the engine is operating above the normal range and steam be procedure:
1. Reduce the l
2. Determine if the engine must be shut down
immediatel reducing the load.
3. Inspect the
load, the engine is running at high idle. The engine is running at lever is at the full throttle position with maximum rated load.
To help prevent engine damage, never exceed the high idle rpm. Overspeeding can result in serious damage to the engine. Operation at speeds exceed­ing high idle rpm should be kept to a minimum.
indicator should be to the “+” side of “0” (zero).
is in the “on” position.
system that is being used.
Tachometer – This gauge indicates engine
speed (rpm
ismovedtothefullthrottlepositionwithout
thefullloadrpmwhenthethrottlecontrol
Ammeter – This gauge indicates the
amount of charge or discharge in the
battery charging circuit. Operation of the
Fuel Level – This gauge indicates the fuel
level in the fuel tank. The fuel level gauge
operates when the “START/STOP” switch
.
oolant Temperature –
t sea level with the pressurized cooling
perature reading may vary according
ot exceed 112 °C (233.6 °F).
comes apparent, perform the following
oad and the engine rpm.
y or if the engine can be cooled by
cooling system for leaks.
). When the throttle control lever
NOTICE
SEBU8387 27
Operation Section
Gauges and Indicators
Service Hour M eter – The gauge indicates total operating hours of the engine.
28 SEBU8387 Operation Section Features and Controls
Features and Controls
i02651062
Monitoring System
If the Shutdown mode has been selected and the warning indi take as little as 20 seconds from the time the warn­ing indicator is activated. Depending on the ap­plication, s avoid personal injury. The engine can be restarted following shutdown for emergency maneuvers, if necessary.
The Engine Monitoring System is not a guarantee against catastrophic failures. Programmed delays and derate schedules are designed to minimize false alarms and provide time for the operator to stop the engine.
The following parameters are monitored:
Coolant temperature
•
Intake air temperature
•
Engine intake manifold pressure
•
Engine Oil pressure
•
Pressure in the fuel rail
•
cator activates, engine shutdown may
pecial precautions should be taken to
NOTICE
“Warning”
The “Warning” lamp and the warning signal (orange lamp) turn “ON continuously in order to alert the operator that one or more of the engine parameters is not within normal operating ra
” and the warning signal is activated
nge.
“Warning/Derate”
The “Diagnostic” lamp turns “ON” and the warning signal (red lamp) is activated. After the warning, the engine power begin to flash when the derating occurs.
Theenginewi preset operational limits. The engine derate is achieved by restricting the amount of fuel that is available f reduction of fuel is dependent on the severity of the fault that has caused the engine derate, typically up to a limit o predetermined reduction in engine power.
“Warning/
The “Diagnostic” lamp turns “ON” and the warning signal (re the engine power will be derated. The engine will continue at the rpm of the set derate until a shutdown of the engi after a shutdown for use in an emergency.
A shutdow as 20 seconds. The engine can be restarted after a shutdown for use in an emergency. However, the cause Theenginemayshutdownagaininaslittleas20 seconds.
will be derated. The warning lamp will
ll be derated if the engine exceeds
or each injection. The amount of this
f 50%. This reduction in fuel results in a
Derate/Shutdown”
d lamp) is activated. After the warning,
ne occurs. The engine can be restarted
n of the engine may occur in as little
of the initial shutdown may still exist.
Engine speed/timing
•
Programmable Options and Systems Operation
If the Warning/Derate/Shutdown mode has been selected and the warning indicator activates, bring the engine to a stop whenever possible. De­pending on the application, special precautions should be taken to avoid personal injury.
The engine can be programmed to the following modes:
If there is a signal for low oil pressure or for coolant temperature, there will be a two second delay in order to
For each of the programmed modes, refer to Trouble information on Indicator Lamps.
For more your Perkins dealer or your Perkins distributor.
verify the condition.
shooting , “Indicator Lamps” for more
information or assistance for repairs, consult
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