Perkins Engine 1106D Maintenance Manual
Operation and
Maintenance
Manual
SEBU8119-00
August 2005
1106D Industrial Engine
(Engine)
PJ
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.
SEBU8119 3
Table of Contents
Table of Contents
Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 5
General Hazard Information ................................... 7
Burn Prevention ...................................................... 8
Fire Prevention and Explosion Prevention .............. 9
Crushing Prevention and Cutting Prevention ......... 11
Mounting and Dismounting .................................... 11
High Pressure Fuel Lines ...................................... 11
Before Starting Engine .......................................... 13
Engine Starting ..................................................... 13
Engine Stopping ................................................... 14
Maintenance In
Warranty S ecti
Warranty Information ............................................ 90
terval Schedule ............................ 59
on
Index Section
Index ..................................................................... 91
Electrical System .................................................. 14
Engine Electronics ................................................ 15
Product Information Section
General Information .............................................. 16
Model Views ......................................................... 17
Product Identification Information ........................ 20
Operation Section
Lifting and Storage ................................................ 23
Gauges and Indicators .......................................... 25
Features and Controls .......................................... 26
Engine Diagnostics ............................................... 32
Engine Starting ..................................................... 36
Engine Operation .................................................. 39
Engine Stopping ................................................... 40
Cold Weather Operation ....................................... 42
Maintenance Section
Refill Capacities .................................................... 46
4 SEBU8119
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
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
this product.
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
rvice should be performed at the
lso governs the Maintenance Interval
t lubrication and maintenance than is
mize operating costs through cost
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.
SEBU8119 5
Safety Section
Safety Messages
Safety Section
i02288680
Safety Me ssage s
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
coulddropoffoftheengine.
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 serious injury
Illustration 1
lexample
Typica
The Universal Warning label (1) is located on the left
hand si
de of the valve mechanism cover base.
g01154807
6 SEBU8119
Safety Section
Safety Messages
Illustration 2
Location o
(1) Universal warning (2) E ther (3) Hand (High P ressu re)
(2) Ether
Do not us
ether. Such use could result in an explosion and
personal injury.
f labels
e aerosol types of starting aids such as
(3) Hand (High Pressure)
Contact
penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow thes
with high pressure fuel may cause fluid
e inspection, maintenance and service in-
structions may c ause personal injury or death.
g01177669
Illustration 3
Typical example
The eth
er warning label (2) is located on the cover
of the inlet manifold.
g01154
809
Illustration 4
lexample
Typica
g01154858
SEBU8119 7
Safety Section
General Hazard Information
The warning lab
located on the top of the fuel manifold.
General Hazar
on 5
Illustrati
Attach a “Do Not Operate” warning tag or a similar
warning tag
before you service the equipment or before you
repair the equipment.
el for the Hand (High Pressure) (3) is
i02328435
d Information
g00104545
to the start switch or to the controls
Obey all local r
Use all cleaning solutions with care.
Report all necessary repairs.
Do not allow un
equipment.
Ensure that th
you w ork on the bus bar or the glow plugs.
Perform maint
equipment in the servicing position. Refer to the
OEM information for the procedure for placing the
equipment in
Pressure Air
Pressurized air and/or water can cause debris
and/or hot wa
personal injury.
The direct ap
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 prot
oraprotectivefaceshield.
egulations for the disposal of liquids.
authorized personnel on the
e power supply is disconnected before
enance on the engine with the
the servicing position.
and Water
tertobeblownout.Thiscouldresultin
plication of pressurized air or
ection. Eye protection includes goggles
ation 6
Illustr
Wear a hard hat, protective glasses, and other
ive equipment, as required.
protect
Do not wear loose clothing or jewelry that can snag
on contr
Make sure that all protective guards and all covers
are secu
Keep the engine free from foreign material. Remove
debris,
walkways, and from steps.
Never pu
Drain all liquids into a suitable container.
ols or on other parts of the engine.
red in place on the engine.
oil, tools, and other items from the deck, from
t maintenance fluids into glass containers.
g00702020
The maximum
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40
Fluid Pene
Pressure can be trapped in the hydraulic circuit long
after the e
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
components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
informa
relieve the hydraulic pressure.
tion for any procedures that are required to
air pressure for cleaning purposes
psi).
tration
ngine has been stopped. The pressure can
. Do not disassemble any hydraulic
8 SEBU8119
Safety Section
Burn Prevention
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 ma y 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.
Illustration 7
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.
Only use the tools that are suitable for containing
•
fluids and equipment that is suitable for containing
fluids.
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.
Obey all local regulations for the disposal of liquids.
i02334785
Burn Pre
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance is
perform
ed on the engine.
vention
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.
SEBU8119 9
Safety Section
Fire Prevention and Explosion Prevention
i02320721
Fire Prevention and Explosion
Prevention
on 8
Illustrati
All fuels, most lubricants, and some coolant mixtures
are flammab
Flammable fluids that are leaking or spilled onto hot
surfaces or
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 remove
Determine whether the engine will be operated in an
environme
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property
If the application involves the presence of combustible
gases, co
Perkins distributor for additional information about
suitable protection devices.
Remove all flammable combustible materials or
conductive materials such as fuel, oil, and debris from
the engi
materials or conductive materials to accumulate on
the engine.
le.
onto electrical components can cause
d.
nt that allows combustible gases to be
damage, or engine damage could result.
nsult your Perkins dealer and/or your
ne. Do not allow any flammable combustible
g00704000
Exhaust shield
components from oil or fuel spray in case of a line,
a tube, or a seal failure. Exhaust shields must be
installed cor
Do not weld on lines or tanks that contain flammable
fluids. Do no
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or fl
Wiring must be kept in good condition. All electrical
wires must be
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
engine. Cle
all electrical connections.
Eliminate a
Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or cir
Arcing or sparking could cause a fire. Secure
connectio
maintained battery cables will help to prevent arcing
or sparking.
Contact w
penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these
structions ma y cause personal injury or death.
After the
seconds in order to allow the fuel pressure to be
purged from the high pressure fuel lines before any
service
Ensure that the engine is stopped. Inspect all lines
and hose
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
manual for more information.
or repair is performed on the engine fuel lines.
. Refer to the Disassembly and Assembly
s (if equipped) protect hot exhaust
rectly.
t flame cut lines or tanks that contain
ame cutting.
correctly routed and securely attached.
an all electrical connections and tighten
ll wiring that is unattached or unnecessary.
cuit breakers.
ns, recommended wiring, and correctly
ith high pressure fuel may cause fluid
inspection, maintenance and service in-
engine has stopped, you must wait for 60
s for wear or for deterioration. The hoses
Store fuels and lubricants in correctly marked
containers away from unauthorized persons. Store
oily rag
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.
s and any flammable materials in protective
10 SEBU8119
Safety Section
Fire Prevention and Explosion Prevention
Illustration 9
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.
g00704059
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
.
) must be kept on the cells. Use the
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the f
extinguisher regularly. Obey the recommendations
on the instruction plate.
ire extinguisher and service the fire
Lines, Tubes and Hoses
Donotbendhighpressurelines.Donotstrikehigh
pressure lines. Do not install any lines that are
damaged.
Illustration 10
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.
g00704135
Leaks can cause fires. Consult your Perkins dealer
or your Per
Replace the parts if any of the following conditions
are presen
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
kins distributor for replacement parts.
t:
rings are chafed or cut.
artofthehosesarekinked.
hat all clamps, guards, and heat shields
d excessive heat.
SEBU8119 11
Safety Section
Crushing Prevention and Cutting Prevention
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 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 i
the guards in place until maintenance
njured by flying debris.
ntion
i02325622
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 ma y cause personal injury or death.
use a fire hazard. Failure to fol-
i02235492
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.
12 SEBU8119
Safety Section
High Pressure Fuel Lines
Illustration 11
(1) High p
(2) High p
(3) High pr
ressure line
ressure line
essure line
(4) Hig h p
(5) Hig h p
(6) Hig h pr
ressure line
ressure line
essure line
The high pressure fuel lines are the fuel lines that
are betwe
en 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
es are different from fuel lines on other fuel
fuel lin
systems.
This is b
•
•
•
ecause of the following differences:
The high pressure fuel lines are constantly charged
with hig
hpressure.
The internal pressures of the high pressure fuel
lines ar
e higher than other types of fuel system.
Thehighpressurefuellinesareformedtoshape
and then
strengthened by a special process.
Do not step on the high pressure fuel lines. Do not
t the high pressure fuel lines. Do not bend or
deflec
strike the high pressure fuel lines. Deformation or
damage of the high pressure fuel lines may cause a
f weakness and potential failure.
point o
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
air is performed on the engine fuel lines.
or rep
g01162364
(7) High p
(8) Hig h p
ressure fuel manifold
ressure line
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 p
enetration 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 op
•
erate 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
ned to the recommended torque. Refer to
tighte
Disassembly and Assembly, “Fuel injection lines Remove and Fuel injection lines - Install”.
Ifthehighpressurefuellinesaretorquedcorrectly
•
and the high pressure fuel lines are leaking the
essure fuel lines must be replaced.
high pr
SEBU8119 13
Safety Section
Before Starting Engine
Ensure that all
•
areinplace.Donotoperatetheenginewithclips
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 repla
assembly manual, “ Fuel Injection Lines - Install”.
clips on the high pressure fuel lines
ced. Refer to Disassembly and
i02322199
Before Starting Engine
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. T o 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 inju
If a warning tag is attached to the engine start switch
or to the contr
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform se
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, “En
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing th
personal injury.
To ensure t
and/or the lube oil heater (if equipped) is working
correctly, check the water temperature gauge
and/or th
operation.
Engine ex
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If t
vent the engine exhaust to the outside.
Note: The
starting. If the engine will be operated in very cold
conditions, then an extra cold starting aid may be
require
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 o
d. Normally, the engine will be equipped with
rder to improve starting.
ry.
ols DO NOT start the engine or move
rvice procedures. To help prevent an
gine Starting” topic in the Operation
eprocedurewillalsohelptoprevent
hat the jacket water heater (if equipped)
e oil temperature gauge during the heater
haust contains products of combustion
he engine is started in an enclosed area,
engine is equipped with a device for cold
14 SEBU8119
Safety Section
Engine Stopping
i02234873
Engine Stopping
Stop the engine
the Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating o
the engine components.
Use the Emerge
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency st
problem that caused the emergency stop has been
corrected.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an engine
that has bee
To stop an electronically controlled engine, cut the
power to the
to the engine.
according to the procedure in
f the engine and accelerated wear of
ncy Stop Button (if equipped) ONLY
op, DO NOT start the engine until the
noverhauled.
engine and/or shutting off the air supply
i02234878
Grounding Practices
Illustration 12
Typical example
(1) Starting motor to engine block
(2) G ro und to startin g motor
(3) Ground to battery
g01162916
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 “í” cable should be connected last from the
external power source to the negative “í” terminal
of the starting motor. If the starting motor is not
equipped with a negative “í” 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.
Illustration 13
Typical example
(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.
SEBU8119 15
Safety Section
Engine Electronics
Uncontrolled e
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
ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct
engine groun
The connections for the grounds should be tight and
free of corro
grounded to the negative “-” battery terminal with
a wire that is adequate to handle the full charging
current of t
The power supply connections and the ground
connectio
be from the isolator to the battery.
lectrical circuit paths can result in
tion correctly, an engine-to-frame
dtotheframe.
sion. The engine alternator must be
he alternator.
ns for the engine electronics should always
i02321383
Engine Electron ics
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.
Together, t
monitoring function for the specific engine application.
Refer to the Electronic Troubleshooting Manual for
more inform
onitoring system and the engine
the engine control systems and display
he two controls will provide the engine
ation on the Engine Monitoring System.
Tamper ing
or the OEM wiring installation can be dangerous
and could result in personal injury or death and/or
engine da
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
•
with the electronic system installation
mage.
16 SEBU8119
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 14
Use th e example above. The current flow from the welder to
the ground clamp of the welder will not cause damage to any
associated com ponents.
(1) Engine
(2) Welding rod
(3) Keyswit ch in the OF F position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) M aximum distance between the component that is being
welded and any electrical/electronic c omponen t
(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.
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.
SEBU8119 17
Product Information Section
Model Views
Model Views
i02235118
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 5
Front left engine view
(1) Fuel pump
(2) Second ary fuel filter
(3) Air intake
(4) Hand primer
(5) Primary fuel filter
(6) Crankcase breather
(7) Fuel manifold
(8) J2 connector
(9) Electronic control module
(10) J1 connector
(11) Oil cooler
(12) Oil filter
(13) Oil gauge
(14) Damper
g01176033
(15) Timing case cover
(16) O il filler
(17) Fan
(18) Fan pulley
(19) Water pump
18 SEBU8119
Product Information Section
Model Views
Illustration 1 6
Rear right
(20) Rear lifting eye
(21) Valve mechanism cover
(22) Front lifting eye
(23) Exhaust elbow
(24) Alternator pulley
engine view
(25) Alternator
(26) Belt tensioner
(27) Timing case
(28) Crankshaft pulley
(29) Oil pan
i02235503
Engine Description
The1106El
for the following applications: machine and industrial
mobile equipment. The engine is available in the
followin
Turbocharged aftercooled
•
Engine Specifications
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right
sides of t
end. The number 1 cylinder is the front cylinder.
ectronic Engine model PJ is designed
gtypeofaspiration:
he engine are determined from the flywheel
(30) Starting motor
(31) Flywheel
(32) Flywheel housing
(33) Turbocharger
(34) Exhaust manifold
Illustration 17
1106 Electronic Engine model PJ
(A) Exhaus t valves
(B) Inlet valves
g01176963
g01127295
SEBU8119 19
Product Information Section
Model Views
Table 1
1106 Electronic Engine Model PJ Specifications
Operating Range (rpm) 900 to 2800
Number of Cylinders 6 In-Line
Bore
Stroke 127 mm (5.0 inch)
Aspiration
Compression Ratio
Displacement
Firing Order
Rotation (
Valve Lash Setting (Inlet) 0.35 mm (0.013 inch)
Valve Lash Setting
(Exhaust)
(1)
The operating rpm is dependent on the engine rating, the
application and the configuration of the throttle.
flywheel end)
105 mm (4.13 inch)
Turbocharged aftercooled
16.2:1
6.6 L (403 in3)
1-5-3-6-2-4
Countercl
0.35 mm (0.013 inch)
(1)
ockwise
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
•
Cold start strategy
•
Automatic air/fuel ratio control
•
Torque rise shaping
•
Injection timing control
•
There are three
types of diagnostic codes: active,
logged, and event.
Most of the dia
gnostic 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 Coo ling and Lubrication
The cooling s
components:
Gear-driven
•
Water temperature regulator which regulates the
•
engine cool
Gear-driven oil pump (gear type)
•
Oil cooler
•
The engine l
type pump. The engine lubricating oil is cooled and
the engine lubricating oil is filtered. Bypass valves
provide unr
engine parts when oil viscosity is high. Bypass valves
can also provide unrestricted flow of lubrication oil
to the engi
plugged or if the oil filter element should become
plugged.
Engine efficiency, efficiency of emission controls, and
engine performance depend on adherence to proper
operatio
Engine performance and efficiency also depend on
the use of recommended fuels, lubrication oils, and
coolants
Manual, “Maintenance Interval Schedule” for more
information on maintenance items.
ystem consists of the following
centrifugal water pump
ant temperature
ubricating oil is supplied by a gear
estricted flow of lubrication oil to the
ne parts if the oil cooler should become
n and maintenance recommendations.
. Refer to this Operation and Maintenance
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.
20 SEBU8119
Product Information Section
Product Identification Information
Product Identification
Information
Plate Locations and Film
Locations
i02285914
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.
on 19
Illustrati
Serial number plate
g01094203
i02164876
Reference Num bers
Illustration 18
Location of the se rial number plate
g01144128
Perkins engines are identified by an engine serial
number.
An example of an engine number is PJ*****U000001J.
*****
____________________The list number for the engine
__________________________________________ Type of engine
PJ
U
____________________________ Built in the United Kingdom
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 personality module.
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.
Make a copy o
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 b r
Total Cooling System Capacity _________________________
Air Cleaner Element _______________________________________
el
l Load rpm
Fuel Filter Element
_____________________________________
__________________________
ication System Capacity
_____________________
SEBU8119 21
Product Information Section
Product Identification Information
Fan Drive Belt _
_____________________________________________
Alternator Belt ______________________________________________
i02308954
Emissions Certification Film
Label for compliant engines
Typical examp
les of emissions labels
Illustration 2 0
This typical ex ample of a label is installed on engines that have electronic fuel injection systems and installed on engines that have electronic
fuel injection pumps.
Illustration 2 1
ical example of a label is installed on engines that have mechanical fuel injection pumps.
This typ
g01173630
g01156733
22 SEBU8119
Product Information Section
Product Identification Information
Label for engines that do not
comply with emissions
Illustration 2 2
This typical example o f a label is installed on engines that do not comply with emissions.
Illustration 2 3
This typical example of a label is installed on engines that are stationary engines.
g01156734
g01157127
SEBU8119 23
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage
Engine Lifting
i02164186
Some removals r
obtain correct balance and safety.
To r e mov 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 obs
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
olete. 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 24
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
the system with preservative fuel. 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.
24 SEBU8119
Operation Section
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.
9. If equipped, re
place the crankcase breather
element. Seal the end of the breather pipe.
10. Remove the val
ve 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 filt
er 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 i
s printed on the container. Seal the
turbocharger with waterproof tape.
15. Seal the ve
nt 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 t
o prevent corrosion to the outside of
the engine, spray the engine with 1734115
POWERPART Lay-Up 3. Do not spray the area
inside th
e alternator.
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.
SEBU8119 25
Operation Section
Gauges and Indicators
Gauges and Ind icators
i02322200
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.
SAE10W40 is 350 to 450 kPa ( 50 to 65 psi) at rated
rpm.
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
tor lamps can be used to identify the
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
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 th
3. Inspect the cooling system for leaks.
load, the engine is running at high idle. The engine is
running at the full load rpm when the throttle control
lever is at
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). When the throttle control lever
ismovedtot
the full throttle position with maximum
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
Service Hour Meter – The gauge indicates
total operating hours of the engine.
.
oolant Temperature –
t sea level with the pressurized cooling
perature reading may vary according
e load.
he full throttle position without
NOTICE
A lower oil pressure is normal at low idle. If the load
is stable and the gauge reading changes, perform
the following procedure:
26 SEBU8119
Operation Section
Features and Controls
Features and Controls
i02308958
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 manifold air temperature
•
Intake manifold air pressure
•
Oil pressure
•
Engine speed/timing
•
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
begintoflashwhenthederatingoccurs.
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.
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. D epending on the a pplication, 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 Guide, “Indicator Lamps” for more
information or assistance for repairs, consult
SEBU8119 27
Operation Section
Features and Controls
i02296746
Monitoring System
Table 2
Warning
Lamp
ON ON
OFF OFF
ON OFF
ON FLASHING
FLASHING OFF
FLASHING FLASHING
ON ON
Shutdown
Lamp
Lamp Status Description of lamp status Engine Status
Lamp check When the engine start switch is turned to the
No faults There are no active diagnostic faults.
Active
diagnostic
fault
Active
diagnostic
fault
Warning
Derate and
warning
Engine
shutdown
“ON” position both lamps will illuminate for 2
seconds only.
An active diagnostic fault has been detected.
A serious active diagnostic fault has been
detected and an engine derate has been
invoked.
One or more of the engine protection values
has been exceeded.
One or more of the engine protection values
has been exceeded.
One or more of the engine protection values has
been exceeded or a serious active diagnostic
fault has been detected.
The engine has not been
started.
The engine is running
normally.
The engine is running
normally.
The engine is running
but the engine has been
derated.
The engine is running
normally.
The engine is running
but the engine has been
derated.
The engine is shutdown or
shutdown is imminent.
i02330154
Sensors and Electrical
Components
Sensor Locations
Illustration 25 shows the typical locations of the
sensors on the engine. Specific engines may appear
different from the illustration due to differences in
applications. The location of the electronic control
module is illustrated.
28 SEBU8119
Operation Section
Features and Controls
Illustration 2 5
(1) Coolant temperature sensor
(2) Inlet air temperature sens or
(3) Inlet air pressu re sensor
(4) Fuel pressure sensor
g01158591
(5) Electronic control module (ECM)
(6) Oil pressure sensor
(7) Crankshaft position sensor
(8) Secondary position sensor
SEBU8119 29
Operation Section
Features and Controls
Illustration 2 6
Illustration 26 shows the sensors in position on the
engine.
Failure of Sensors
All Sensors
A failure of any of the sensors may be caused by one
of the following malfunctions:
Sensor output is open.
•
Sensor output is shorted to “- battery” or “+ battery”.
•
Measured reading of the sensor is out of the
•
specification.
g01158681
Programmable Monitoring System
(PMS)
The Programmable Monitoring System determines
the level of action that is taken by the Engine Control
Module (ECM) (5) in response to a condition that can
damage the engine. These conditions are identified
by the ECM from the signals that are produced from
the following sensors. Refer to illustration 25 for the
ECM.
Inlet Air Temperature Sensor
•
Engine Coolant Temperature Sensor
•
Engine Oil Pressure Sensor
•
Engine Speed/Timing Sensors
•
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