SEBU8387
May 2007
Operation and
Maintenance
Manual
1106C Genset
PK (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this product Perkins recommends using Perkins replacement parts.
Failure to heed this warning can lead to premature failures, product damage, personal injury or death.
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Table of Contents |
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Table of Contents |
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Foreword ................................................................. |
4 |
Safety Section |
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Safety Messages .................................................... |
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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 .......................................... |
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Engine Starting ..................................................... |
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Engine Stopping ................................................... |
14 |
Electrical System .................................................. |
14 |
Engine Electronics ................................................ |
15 |
Product Information Section |
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General Information .............................................. |
17 |
Model Views ......................................................... |
18 |
Product Identification Information ........................ |
22 |
Operation Section |
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Lifting and Storage ................................................ |
24 |
Gauges and Indicators .......................................... |
26 |
Features and Controls .......................................... |
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Engine Diagnostics ............................................... |
34 |
Engine Starting ..................................................... |
38 |
Engine Operation .................................................. |
41 |
Engine Stopping ................................................... |
42 |
Cold Weather Operation ....................................... |
44 |
Maintenance Section |
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Maintenance Interval Schedule ............................ |
53 |
Warranty Section |
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Warranty Information ............................................ |
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Index Section |
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Index ..................................................................... |
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Refill Capacities .................................................... |
48 |
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SEBU8387 |
Foreword |
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Foreword
Literature Information
This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literature holder or literature storage area. Read, 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 consistency.
Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this 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 section lists basic safety precautions. In addition, this section identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before
operating or performing lubrication, maintenance and repair on this product.
Operation
Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities.
The operation section is a reference for operators. Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information.
Maintenance
The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance intervals. Items in the maintenance schedule are referenced to detailed instructions that follow.
Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary.
The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of the original requirement. We recommend that the
maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of the engine’s permanent record.
Your authorized Perkins dealer or your Perkins distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment.
Overhaul
Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that
interval. Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer or your Perkins distributor offers a variety of options regarding overhaul programs. If you experience
a major engine failure, there are also numerous after failure overhaul options available. Consult with your Perkins dealer or your Perkins distributor for information regarding these options.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.
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Safety Section
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Safety Messages
There may be several specific warning signs on your engine. The exact location and a description of the warning signs are reviewed in this section. Please become familiar with all warning signs.
Ensure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the warning signs. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the warning signs. The warning signs that are loosened could drop off of the engine.
Replace any warning sign that is damaged or missing. If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Your Perkins dealer or your distributor can provide new warning signs.
(1) Universal Warning
Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death.
Illustration 1 |
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Typical example |
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5 Safety Section Safety Messages
The Universal Warning label (1) is located on both sides of the valve mechanism cover base.
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Safety Section |
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Safety Messages |
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Illustration 2 |
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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.
Illustration 3 |
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Typical example |
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The ether warning label (2) is located on the cover of the inlet manifold.
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Safety Section |
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General Hazard Information |
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Illustration 4 |
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Location of labels |
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(2) Ether |
(3) Hand (High Pressure) |
(3) Hand (High Pressure)
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.
The warning label for the Hand (High Pressure) (3) is located on the top of the fuel manifold.
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General Hazard Information
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Illustration 5 |
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Attach a “Do Not Operate” warning tag or a similar |
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Typical example |
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warning tag to the start switch or to the controls |
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before you service the equipment or before you |
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repair the equipment. |
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Safety Section |
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General Hazard Information |
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Illustration 7 |
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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 from foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, and from steps.
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.
When pressurized air and/or water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield.
The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly.
Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve the hydraulic pressure.
Illustration 8 |
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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.
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.
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Safety Section |
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Burn Prevention |
•Only use the tools that are suitable for containing fluids and equipment that is suitable for containing fluids.
Obey all local regulations for the disposal of liquids.
i02334785
Burn Prevention
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
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.
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 with a bare hand. Remove the filler 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.
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 and Explosion Prevention
Illustration 9 |
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All fuels, most lubricants, and some coolant mixtures are flammable.
Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause 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 removed.
Determine whether the engine will be operated in an environment that allows combustible gases to be drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, property damage, or engine damage could result.
If the application involves the presence of combustible gases, consult your Perkins dealer and/or your Perkins distributor for additional information about suitable protection devices.
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Safety Section |
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Fire Prevention and Explosion Prevention |
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Remove all flammable combustible materials or conductive materials such as fuel, oil, and debris from the engine. Do not allow any flammable combustible materials or conductive materials to accumulate on the engine.
Store fuels and 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 the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust components from 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 fluid. 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 electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all electrical connections.
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 maintained battery cables will help to prevent arcing or sparking.
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.
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.
Oil filters and fuel filters must be correctly installed. The filter housings must be tightened to the correct torque. Refer to the Disassembly and Assembly manual for more information.
Illustration 10 |
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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.
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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 a hydrometer.
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Safety Section |
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Crushing Prevention and Cutting Prevention |
Incorrect jumper cable connections can cause 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.
i02143194
Crushing Prevention and Cutting Prevention
The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the instruction plate.
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 the guards in place until maintenance 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.
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 Perkins distributor for replacement parts.
Replace the parts if any of the following conditions are present:
•High pressure fuel line or lines are removed.
•End fittings are damaged or leaking.
•Outer coverings are chafed or cut.
•Wires are exposed.
•Outer coverings are ballooning.
•Flexible part of the hoses are kinked.
•Outer covers have embedded armoring.
•End fittings are displaced.
Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, this will help to prevent vibration, rubbing against other parts, and excessive heat.
When objects are 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 injured by flying debris.
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Mounting and Dismounting
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.
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Safety Section |
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High Pressure Fuel Lines |
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i02668808
High Pressure Fuel Lines
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.
Illustration 12 |
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(1) High pressure line |
(4) High pressure line |
(7) High pressure fuel manifold (rail) |
(2) High pressure line |
(5) High pressure line |
(8) High pressure line |
(3) High pressure line |
(6) High pressure line |
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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:
•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.
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Safety Section |
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Before Starting Engine |
Do not step on the high pressure fuel lines. Do not deflect the high pressure fuel lines. Do not bend or strike the high pressure fuel lines. Deformation or damage of the high pressure fuel lines may cause a point of weakness and potential failure.
i02322199
Before Starting Engine
Do not check the high pressure fuel lines with the engine or the starting motor in operation. After the engine has stopped allow 60 seconds to pass in order to allow the pressure to be purged before any service or repair is performed on the engine fuel lines.
Do not loosen the high pressure fuel lines in order 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 inspection procedure in order to avoid 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 is a leak do not tighten the connection in order
to stop the leak. The connection must only be tightened to the recommended torque. Refer to Disassembly and Assembly, “Fuel injection lines - Remove and Fuel injection lines - Install”.
•If the high pressure fuel lines are torqued correctly and the high pressure fuel lines are leaking the high pressure fuel lines must be replaced.
•Ensure that all clips on the high pressure fuel lines 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 replaced. Refer to Disassembly and assembly manual, “ Fuel Injection Lines - Install”.
The initial start-up of an engine that is new, serviced or repaired make provision to shut the engine
off, in order to stop an overspeed. This may be accomplished by shutting off the air and/or fuel supply to the engine.
Overspeed shutdown should occur automatically for engines that are controlled electronically. If automatic shutdown does not occur, press the emergency stop button in order to cut the fuel and/or air to the engine.
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 of personnel.
If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work correctly, if equipped.
All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.
Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are provided in order to help prevent personal injury. The circuits are also provided in order to help prevent engine damage.
See the Service Manual for repairs and for adjustments.
i02251260
Engine Starting
Do not use aerosol types of starting aids such as ether. Such use could result in 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.
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Engine Stopping |
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All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.
Start the engine from the operator’s compartment or from the engine start switch.
Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Knowing the correct procedure will help to prevent major damage to the engine components. Knowing the procedure will also help to prevent personal injury.
To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is working correctly, check the water temperature gauge and/or the oil temperature gauge during the heater operation.
Engine exhaust contains products of combustion which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside.
Note: The engine is equipped with a device for cold starting. If the engine will be operated in very cold conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with the correct type of starting aid for your region of operation.
These engines are equipped with a glow plug starting aid in each individual cylinder that heats the intake air in order to improve starting.
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Engine Stopping
Stop the engine if an overspeed condition occurs 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.
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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 cable to the engine block.
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.
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.
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Safety Section |
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Engine Electronics |
Grounding Practices
Illustration 13 |
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Typical example |
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(1)Starting motor to engine block
(2)Ground to starting motor
(3)Ground to battery
Illustration 14 |
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Typical example |
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(4)Ground to engine
(5)Ground to battery
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.
Uncontrolled electrical 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 function 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 ground to the frame.
The connections for the grounds should be tight and free of corrosion. The engine alternator must be grounded to the negative “-” battery terminal with
a wire that is adequate to handle the full charging current of the alternator.
The power supply connections and the ground connections for the engine electronics should always be from the isolator to the battery.
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Engine Electronics
Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/or engine damage.
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
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Engine Electronics |
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Derate |
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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/Timing
•Intake Manifold Air Temperature
The Engine Monitoring package can vary for different engine models and different engine applications. However, the monitoring system and the engine monitoring control will be similar for all engines.
Note: Many of the engine control systems and display modules that are available for Perkins Engines will work in unison with the Engine Monitoring System. Together, the two controls will provide the engine monitoring function for the specific engine application. Refer to Troubleshooting for more information on the Engine Monitoring System.
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Product Information Section |
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General Information |
Product Information
Section
General Information
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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.
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.
Illustration 15 |
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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)Keyswitch in the OFF position
(4)Battery disconnect switch in the open position
(5)Disconnected battery cables
(6)Battery
(7)Electrical/Electronic component
(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 flow from the welder could severely damage the component.
5.Protect the wiring harness from welding debris and spatter.
6.Use standard welding practices to weld the materials.
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Model Views |
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Model Views
i02649396
Model View Illustrations
The following model views show typical features of the engine. Due to individual applications, your engine may appear different from the illustrations.
Note: Only major components are identified on the following illustrations.
Illustration 16 |
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Front left engine view |
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(1) |
Fuel manifold (Rail) |
(6) |
Hand primer |
(11) Water pump |
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(2) Canister for the crankcase breather |
(7) |
Primary fuel filter |
(12) |
Damper |
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(3) Electronic control module |
(8) |
Oil sampling valve |
(13) |
Fan |
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(4) |
P2 connector |
(9) Oil filter |
(14) |
Fan pulley |
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(5) |
Secondary fuel filter |
(10) Fuel pump |
(15) Belt tensioner |
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Model Views |
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Illustration 17 |
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Rear right engine view |
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(16) |
Oil gauge |
(21) |
Exhaust manifold |
(17) |
Air intake |
(22) |
Exhaust elbow |
(18) |
Oil filler |
(23) |
Turbocharger |
(19) |
Front lifting eye |
(24) |
Wastegate solenoid |
(20) |
Alternator |
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Starting motor |
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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)Rear 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.
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Model Views |
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Illustration 18 |
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1106 Electronic Engine model PK |
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(A) Exhaust valves |
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(B) Inlet valves |
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Table 1
1106 Electronic Engine Model PK Specifications
Operating Range (rpm) |
900 to 2800(1) |
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Number of Cylinders |
6 In-Line |
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Bore |
105 mm (4.13 inch) |
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Stroke |
127 mm (5.0 inch) |
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Aspiration |
Turbocharged aftercooled |
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Compression Ratio |
16.2:1 |
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Displacement |
6.6 L (403 in3) |
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Firing Order |
1-5-3-6-2-4 |
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Rotation (flywheel end) |
Counterclockwise |
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Valve Lash Setting (Inlet) |
0.35 mm (0.013 inch) |
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Valve Lash Setting |
0.35 mm (0.013 inch) |
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(Exhaust) |
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(1) The operating rpm is dependent on the engine rating, the application and the configuration of the throttle.
Electronic Engine Features
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
•Automatic air/fuel ratio control
•Torque rise shaping
•Injection timing control
•System diagnostics
For more information on electronic engine features, refer to the Operation and Maintenance Manual, “Features and Controls” topic (Operation Section).
Engine Diagnostics
The engine has built-in diagnostics in order to ensure that the engine systems are functioning correctly. The operator will be alerted to the condition by a “Stop or Warning” lamp. Under certain conditions, the engine horsepower and the vehicle speed may be limited.
The electronic service tool may be used to display the diagnostic codes.
There are three types of diagnostic codes: active, logged, and event.
Most of the diagnostic codes are logged and stored in the ECM. For additional information, refer to 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 engine rpm.
Engine Cooling and Lubrication
The cooling system consists of the following components:
•Gear-driven centrifugal water pump
•Water temperature regulator which regulates the engine coolant temperature
•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 engine if the oil filter element should become plugged.
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Product Information Section |
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Model Views |
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Engine efficiency, efficiency of emission controls, and |
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engine performance depend on adherence to proper |
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operation and maintenance recommendations. |
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Engine performance and efficiency also depend on |
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the use of recommended fuels, lubrication oils, and |
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coolants. Refer to this Operation and Maintenance |
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Manual, “Maintenance Interval Schedule” for more |
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information on maintenance items. |
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Product Identification Information |
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Product Identification
Information
i02761892
Serial Number Plate (1)
The engine serial number plate is located on the left side of the cylinder block to the rear of the front engine mounting.
Plate Locations and Film
Locations
Illustration 19 |
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Location of the serial number plate |
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Perkins engines are identified by an engine serial number.
An example of an engine number is PK*****U000001J.
***** ____________________The list number for the engine
PK __________________________________________Type of engine
U ____________________________Built in the United Kingdom
000001 ___________________________Engine Serial Number
J _____________________________________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.
Illustration 20 |
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Serial number plate |
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Reference Numbers |
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Information for the following items may be needed to order parts. Locate the information for your engine. Record the information in the appropriate space. Make a copy of this list for a record. Keep the information for future reference.
Record for Reference
Engine Model _______________________________________________
Engine Serial number _____________________________________
Engine Low Idle rpm ______________________________________
Engine Full Load rpm _____________________________________
Primary Fuel Filter _________________________________________
Water Separator Element ________________________________
Secondary Fuel Filter Element __________________________
Lubrication Oil Filter Element ___________________________
Auxiliary Oil Filter Element _______________________________
Total Lubrication System Capacity _____________________
Total Cooling System Capacity _________________________
Air Cleaner Element _______________________________________
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Product Information Section |
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Product Identification Information |
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Fan Drive Belt ______________________________________________ |
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Alternator Belt ______________________________________________ |
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i02648170
Emissions Certification Film
Label for compliant engines
Typical examples of emissions labels
Illustration 21 |
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Operation Section |
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Lifting and Storage |
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Operation Section
Lifting and Storage
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Engine Lifting
Illustration 22 |
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NOTICE
Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less 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 beam to lift the engine. All supporting members (chains and cables) should be
parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted.
Some removals require lifting the fixtures in order to obtain correct balance and safety.
To remove the engine ONLY, use the lifting eyes that are on the engine.
Lifting eyes are designed and installed for specific engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting fixtures obsolete. If alterations are made, ensure that correct lifting devices are provided. Consult your Perkins dealer or your Perkins distributor for information regarding fixtures for correct engine lifting.
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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.
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 the system with preservative fuel. 1772204 POWERPART Lay-Up 1 can be mixed with 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.
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Operation Section |
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Lifting and Storage |
Personal injury can result from 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.
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.
Fill the oil pan to the Full Mark on the engine oil level gauge with new, clean lubricating oil. Add 1762811 POWERPART Lay-Up 2 to the oil in order to 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 POWERPART Lay-Up 3 can be used on the terminals. Put the battery into safe storage.
9.If equipped, replace the crankcase breather element. Seal the end of the breather pipe.
10.Remove the valve mechanism cover. Spray 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. Spray 1762811 POWERPART 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 filter assembly and the turbocharger. Spray 1762811 POWERPART Lay-Up 2 into the turbocharger. The duration of the spray is printed on the container. Seal the turbocharger with waterproof tape.
14.Remove the exhaust pipe from the output side of the turbocharger. Spray 1762811 POWERPART Lay-Up 2 into the turbocharger. The duration of the spray is printed on the container. Seal the turbocharger with waterproof tape.
15.Seal the vent of the fuel tank or the fuel filler cap with waterproof tape.
16.Remove the alternator drive belt and put the drive belt into storage.
17.In order to prevent corrosion to the outside
of the engine, spray the engine with 1734115 POWERPART Lay-Up 3. Do not spray the area inside the alternator.
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Gauges and Indicators |
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Gauges and Indicators
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Gauges and Indicators
Your engine may not have the same gauges or all of 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 the normal operating range by observing the gauges over a period of time.
1.Remove the load.
2.Stop the engine.
3.Check and maintain the oil level.
Jacket Water Coolant Temperature –
Typical temperature range is 83° to 95°C (181.4° to 171°F). The maximum allowable
temperature at sea level with the pressurized cooling system at 48 kPa (7 psi) is 103 °C (217.4 °F). Higher temperatures may occur under certain conditions.
The water temperature reading may vary according to load. The temperature reading should never exceed 7 °C (44.6 °F) below the boiling point for the pressurized system that is being used.
Noticeable changes in gauge readings indicate potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the readings are within specifications. Determine and correct the cause of any significant change in the readings. Consult your Perkins dealer or your Perkins distributor for assistance.
Some engine applications are equipped with Indicator Lamps. Indicator lamps can be used as a diagnostic 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 indicator lamps can be used to identify the current operational status of the engine. The indicator lamps can also indicate that the engine has a fault. This system is automatically operated via the ignition switch.
•The indicator lamps can be used to identify active diagnostic codes. This system is activated by pressing the Flash Code button.
Refer to the Troubleshooting Guide, “Indicator Lamps” for further information.
NOTICE
If no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded, STOP the engine. Engine damage can result.
Engine Oil Pressure – The oil pressure should be greatest after a cold engine is started. The typical engine oil pressure with
SAE10W40 is 350 to 450 kPa ( 50 to 65 psi) at rated rpm.
A lower oil pressure is normal at low idle. If the load is stable and the gauge reading changes, perform the following procedure:
A 100 kPa (14.5 psi) radiator cap may be installed on the cooling system. The temperature of this cooling system must not exceed 112 °C (233.6 °F).
If the engine is operating above the normal range and steam becomes apparent, perform the following procedure:
1.Reduce the load and the engine rpm.
2.Determine if the engine must be shut down immediately or if the engine can be cooled by reducing the load.
3.Inspect the cooling system for leaks.
Tachometer – This gauge indicates engine speed (rpm). When the throttle control lever is moved to the full throttle position without
load, the engine is running at high idle. The engine is running at the full load rpm when the throttle control lever is at the full throttle position with maximum rated load.
NOTICE
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.
Ammeter – This gauge indicates the amount of charge or discharge in the battery charging circuit. Operation of the
indicator should be to the “+” side of “0” (zero).
Fuel Level – This gauge indicates the fuel level in the fuel tank. The fuel level gauge operates when the “START/STOP” switch
is in the “on” position.
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Operation Section |
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Gauges and Indicators |
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Service Hour Meter – The gauge indicates total operating hours of the engine.
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Features and Controls |
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Features and Controls |
“Warning” |
Monitoring System
The “Warning” lamp and the warning signal (orange i02651062 lamp) turn “ON” and the warning signal is activated continuously in order to alert the operator that one or
more of the engine parameters is not within normal operating range.
If the Shutdown mode has been selected and the warning indicator activates, engine shutdown may take as little as 20 seconds from the time the warning indicator is activated. Depending on the application, special precautions should be taken to avoid personal injury. The engine can be restarted following shutdown for emergency maneuvers, if necessary.
NOTICE
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
•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:
“Warning/Derate”
The “Diagnostic” lamp turns “ON” and the warning signal (red lamp) is activated. After the warning, the engine power will be derated. The warning lamp will begin to flash when the derating occurs.
The engine will be derated if the engine exceeds preset operational limits. The engine derate is achieved by restricting the amount of fuel that is available for each injection. The amount of this reduction of fuel is dependent on the severity of the fault that has caused the engine derate, typically up to a limit of 50%. This reduction in fuel results in a predetermined reduction in engine power.
“Warning/Derate/Shutdown”
The “Diagnostic” lamp turns “ON” and the warning signal (red lamp) is activated. After the warning, the engine power will be derated. The engine will
continue at the rpm of the set derate until a shutdown of the engine occurs. The engine can be restarted after a shutdown for use in an emergency.
A shutdown of the engine may occur in as little as 20 seconds. The engine can be restarted after a shutdown for use in an emergency. However, the cause of the initial shutdown may still exist. The engine may shut down again in as little as 20 seconds.
If there is a signal for low oil pressure or for coolant temperature, there will be a two second delay in order to verify the condition.
For each of the programmed modes, refer to Troubleshooting , “Indicator Lamps” for more information on Indicator Lamps.
For more information or assistance for repairs, consult your Perkins dealer or your Perkins distributor.
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