Perkins 1106E Operation And Maintenance Manual
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Perkins 1106E Operation And Maintenance Manual

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SEBU7784
August 2003
Operation and
Maintenance
Manual
1106E Engine
VK (Engine )
This document has been printed from SPI². Not for Resale

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  • Page 1 SEBU7784 August 2003 Operation and Maintenance Manual 1106E Engine VK (Engine ) This document has been printed from SPI². Not for Resale...
  • Page 2 Obtain the complete and most current information before you s t ar t any jo b . Perkins dea le rs hav e t he m os t c ur r en t i nfo rm ati on a va il abl e.

  • Page 3: Table Of Contents

    Table of Contents Table of Contents Cooling System Specifications ......49 Refill Capacities ............ 51 Foreword ..............4 Maintenance Interval Schedule ......52 Safety Section Warranty Section Safety Signs and Labels ......... 6 Warranty Information ..........78 General Hazard Information ........6 Index Section Burn Prevention ............

  • Page 4: Foreword

    The illustrated, step-by-step instructions are grouped av ai lab le f r om yo ur Perkins de al er. C ons ul t w i t h by fuel consumption, service hours and/or calendar your dealer for information regarding these options.
  • Page 5 Foreword 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.

  • Page 6: Safety Section

    If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Perkins dealers or Perkins distributors can provide new warning signs. Do not work on the engine and do not operate the engine unless the instructions and warnings in the Operation and Maintenance Manual are understood.
  • Page 7 Safety Section General Hazard Information 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.

  • Page 8: Burn Prevention

    Oils If the application involves the presence of combustible gases, consult your Perkins dealer and/or your Hot oil and hot lubricating components can cause Perkins distributor for additional information about personal injury. Do not allow hot oil to contact the suitable protection devices.
  • Page 9 Safety Section Fire Prevention and Explosion Prevention Exhaust shields (if equipped) protect hot exhaust Use caution when you are refueling an engine. Do components from oil or fuel spray in case of a line, not smoke while you are refueling an engine. Do not a tube, or a seal failure.

  • Page 10: Crushing Prevention And Cutting Prevention

    Mounting and Dismounting Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Perkins dealer for repair or for replacement parts. Check lines, tubes and hoses carefully. Do not use Inspect the steps, the handholds, and the work area your bare hand to check for leaks.

  • Page 11: Engine Starting

    Safety Section Engine Starting All protective guards and all protective covers must Note: The engine is equipped with an automatic be installed if the engine must be started in order device for cold starting for normal conditions of to perform service procedures. To help prevent an operation.

  • Page 12: Engine Electronics

    Safety Section Engine Electronics To help prevent sparks from igniting combustible To ensure that the engine and the engine electrical gases that are produced by some batteries, the systems function properly, an engine-to-frame ground negative “−” jump start cable should be connected strap with a direct path to the battery must be used.
  • Page 13 Safety Section Engine Electronics 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.

  • Page 14: Product Information Section

    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 compo- nent.

  • Page 15: Model Views

    Product Information Section Model Views Model Views i01889425 Model View Illustrations 1106 Engine Views g00888100 Illustration 9 Left side view of the 1106 engine Typical example of the 1106 engine (1) Crankshaft pulley (4) Machine interface connector (MIC) (7) Electronic control module (ECM) (2) Engine coolant temperature sensor (5) Engine oil pressure sensor (8) Engine oil filter...
  • Page 16 Product Information Section Model Views g00888106 Illustration 10 Right side view of the 1106 engine Typical example of the 1106 engine (10) Boost pressure sensor (12) Electric starting motor (14) Flywheel (11) Inlet manifold temperature sensor (13) Flywheel housing (15) Turbocharger Engine Specifications i01889426 Engine Description...
  • Page 17 The cooling system consists of the following Electronic Engine Features components: The Perkins 1106 Electronic Engine is designed with • Gear-driven centrifugal water pump electronic controls. The integral on board computer controls the operation of the engine. Current •...
  • Page 18 Product Information Section Model Views The engine lubricating oil is supplied by a gear type pump. The engine lubricating oil is cooled and the engine lubricating oil is filtered. Bypass valves provide unrestricted flow of lubrication oil to the engine parts when oil viscosity is high. Bypass valves can also provide unrestricted flow of lubrication oil to the engine parts if the oil cooler should become plugged or if the oil filter element should become...

  • Page 19: Product Identification Information

    Information i01889962 Engine Identification Perkins engines are identified by a serial number. This number is shown on a serial number plate that is mounted on the left hand side of the engine block. An example of an engine number is VKU090001H.
  • Page 20 Product Information Section Product Identification Information Engine Full Load rpm _________ ____________________________ Primary Fuel Filter No. _________ ___________________________ Water Separator Element No. _________ __________________ Secondary Fuel Filter Element No. _________ ___________ Lubrication Oil Filter Element No. _________ _____________ Auxiliary Oil Filter Element No. _________ ________________ Total Lubrication System Capacity _________ ____________...

  • Page 21: Operation Section

    Consult your the correct level with normal lubricating oil. Perkins dealer for information regarding fixtures for proper engine lifting. This document has been printed from SPI². Not for Resale...
  • Page 22 Contact the coolant can be discharged. Service Department of Perkins for advice. If freezing temperatures are expected, check the 8. Operate the engine for a short period in order to...
  • Page 23 When the engine protection has been completed in accordance with these instructions, this ensures that no corrosion will occur. Perkins are not responsible for damage which may occur when an engine is in storage after a period in service.

  • Page 24: Gauges And Indicators

    Determine and correct the cause of any significant 2. Inspect the cooling system for leaks. change in the readings. Consult your Perkins dealer or your Perkins distributor for assistance. 3. Determine if the engine must be shut down...

  • Page 25: Features And Controls

    Indicator Lamps. For more information or assistance for repairs, consult If the Warning/Derate/Shutdown mode has been your Perkins dealer or your Perkins distributor. selected and the warning indicator activates, bring the engine to a stop whenever possible. De- pending on the application, special precautions should be taken to avoid personal injury.
  • Page 26 Operation Section Features and Controls i01902952 Sensors and Electrical Components Sensor Locations for the 1106 Engine g00894214 Illustration 16 Left side view of the 1106 engine Typical example of a 1106 engine (1) Engine coolant temperature sensor (3) Speed/timing sensor (2) Engine oil pressure sensor (4) Electronic control module (ECM) This document has been printed from SPI².
  • Page 27 Operation Section Features and Controls g00912351 Illustration 17 (5) Typical location of the voltage load protection module behind the ECM This document has been printed from SPI². Not for Resale...
  • Page 28 Operation Section Features and Controls g00912359 Illustration 18 Right side view of the 1106 engine (6) Boost pressure sensor (7) Inlet manifold temperature sensor Failure of Sensors Boost Pressure Sensor The boost pressure sensor provides a signal which All Sensors corresponds to boost pressure to the ECM.
  • Page 29 Operation Section Features and Controls Engine Oil Pressure Sensor i01902954 Overspeed The engine oil pressure sensor is an absolute pressure sensor that measures the engine oil pressure in the main oil gallery. The engine oil pressure sensor detects engine oil pressure for An overspeed condition is detected by the Electronic diagnostic purposes.

  • Page 30: Engine Diagnostics

    ECM. The codes Perkins Electronic Engines have the capability to that have been logged by the ECM can be identified perform a self-diagnostics test. When the system by the electronic service tool.
  • Page 31 Operation Section Engine Diagnostics i01902995 Engine Operation with Intermittent Diagnostic Codes If a diagnostic lamp illuminates during normal engine operation and the diagnostic lamp shuts off, an intermittent fault may have occurred. If a fault has occurred, the fault will be logged into the memory of the Electronic Control Module (ECM).

  • Page 32: Engine Starting

    Operation Section Engine Starting Engine Starting • Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls. i01903008 Before Starting Engine •...
  • Page 33 Operation Section Engine Starting 2. Turn the keyswitch to the RUN position. Leave the Startability will be improved at temperatures below keyswitch in the RUN position for 15 seconds. −18 °C (0 °F) from the use of a jacket water heater or extra battery capacity.
  • Page 34 Operation Section Engine Starting 3. Connect one negative end of the jump start cable i01903593 to the negative cable terminal of the electrical Starting with Jump Start source. Connect the other negative end of the Cables jump start cable to the engine block or to the chassis ground.

  • Page 35: Engine Operation

    Operation Section Engine Operation Engine Operation i01903587 Engine Operation Proper operation and maintenance are key factors in obtaining the maximum life and economy of the engine. If the directions in the Operation and Maintenance Manual are followed, costs can be minimized and engine service life can be maximized.

  • Page 36: Engine Stopping

    Operation Section Engine Stopping Engine Stopping i01903608 After Stopping Engine i01929389 Stopping the Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan. NOTICE •...

  • Page 37: Cold Weather Operation

    Cold Weather Operation • Check all electrical wiring and connections for any fraying or damaged insulation. Perkins Diesel Engines can operate effectively in • Keep all batteries fully charged and warm. cold weather. During cold weather, the starting and the operation of the diesel engine is dependent on •...
  • Page 38 An effective block heater is typically a 1250/1500 W unit. Consult your In addition, the engine must be thoroughly warmed in Perkins dealer or your Perkins distributor for more order to keep other engine parts in better condition information.
  • Page 39 Problems can result due to changes in temperature. Note: Group 3 fuels reduce the life of the engine. The use of Group 3 fuels is not covered by the Perkins Before troubleshooting for low power or for poor warranty.
  • Page 40 Operation Section Cold Weather Operation Low temperature fuels may be available for engine i01903588 operation at temperatures below 0 °C (32 °F). These Fuel Related Components in fuels limit the formation of wax in the fuel at low Cold Weather temperatures.

  • Page 41: Maintenance Section

    CF-2 CD-2 Lubricant Information The classifications CD-2 and American Petroleum Institute CF-2 are for two-cycle diesel engines. Perkins does not sell engines that utilize CD-2 and API CF-2 oils. Terminology General Information Certain abbreviations follow the nomenclature of Because of government regulations regarding “SAE J754”.
  • Page 42 API CH-4 oils may be the fuel sulfur level. For direct injection engines that used in Perkins engines that use API CG-4 and API use distillate fuel, the minimum TBN of the new oil CF-4 oils. API CH-4 oils will generally exceed the must be 10 times the fuel sulfur level.
  • Page 43 0.75 of normal characteristics that enhance the service life of the Greater than 1.0 0.50 of normal oil. Perkins does not recommend the automatic extending of the oil change intervals for any type of oil. Lubricant Viscosity Recommendations for Direct Injection (DI) Diesel Engines...
  • Page 44 Shortened engine service life could result if second choice oils are used. Re-refined base stock oils are acceptable for i01904027 use in Perkins engines if these oils meet the Aftermarket Oil Additives performance requirements that are specified by Perkins. Re-refined base stock oils can be used exclusively in finished oil or in a combination with new base stock oils.
  • Page 45 Maintenance Section Lubricant Specifications The S·O·S oil analysis is a diagnostic tool that is used to determine oil performance and component wear rates. Contamination can be identified and measured through the use of the S·O·S oil analysis. The S·O·S oil analysis includes the following tests: •...

  • Page 46: Fuel Specifications

    To get the correct power and performance from the engine, use a fuel of the correct quality. The • Other fuels recommended fuel specification for the Perkins 1106 engine is shown below: Group 1 (preferred fuels): Specification • Cetane number...
  • Page 47 Maintenance Section Fuel Specifications “JP5 MIL T5624 (Avcat FSII, NATO F44” Table 5 Perkins Specifications for Distillate Diesel Fuel “JP8 T83133 (Avtur FSII, NATO F34” Specifications Requirements ASTM Test “Jet A” Aromatics 35% maximum “D1319” “Jet A1, NATO F35, XF63”...
  • Page 48 To ensure optimum engine NOTICE performance, a complete fuel analysis should be Operating with fuels that do not meet the Perkins rec- obtained before engine operation. The fuel analysis ommendations can cause the following effects: Start- should include all of the properties that are listed in ing difficulty, poor combustion, deposits in the fuel in- Table 5.

  • Page 49: Cooling System Specifications

    Table 7. Table 7 NOTICE Perkins Minimum Acceptable Water Requirements If the engine is to be stored in, or shipped to an area with below freezing temperatures, the cooling system Property...
  • Page 50 • Cavitation of the water pump The manufacturers recommendations for the For optimum performance, Perkins recommends a maintenance of the coolant and the replacement of 1:1 mixture of a water/glycol solution. the coolant must be followed at all times.

  • Page 51: Refill Capacities

    Heat exchanger, or sump plus standard oil filters. Auxiliary oil filter aftercooler, and piping. Refer to Perkins specifications and/or the OEM specifications. Enter the value for the external cooling systems will require additional oil. Refer to the OEM system capacity in this row.

  • Page 52: Maintenance Interval Schedule

    Turbocharger - Inspect .......... 75 Note: For engine cooling systems that contain Water Pump - Inspect ........... 77 Perkins antifreeze, replace the coolant in the engine cooling system at 2 yearly intervals. For engine Every 2 Years cooling systems that contain an inhibitor, replace the coolant in the engine cooling system at 6 monthly Cooling System Coolant - Change .......

  • Page 53: Every 2000 Service Hours Aftercooler Core - Inspect

    Maintenance Section Aftercooler Core - Clean/Test Inspect the aftercooler for these items: damaged fins, i01853891 corrosion, dirt, grease, insects, leaves, oil, and other Aftercooler Core - Clean/Test debris. Clean the aftercooler, if necessary. For air-to-air aftercoolers, use the same methods that are used for cleaning radiators.

  • Page 54: Every 500 Service Hours Or 1 Year Air Compressor Filter - Clean/Replace

    Adjustment i01908658 Alternator - Inspect Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and proper battery charging. Inspect the ammeter (if equipped) during engine operation in order to ensure proper battery performance and/or proper performance of the electrical system.

  • Page 55: Battery - Replace

    Maintenance Section Battery - Replace i01915808 i01908638 Battery - Replace Battery Electrolyte Level - Check When the engine is not run for long periods of time or Batteries give off combustible gases which can when the engine is run for short periods, the batteries explode.

  • Page 56: Battery Or Battery Cable - Disconnect

    Note: The radiator may not have been provided by Perkins. The following is a general procedure for changing the coolant. Refer to the OEM information for the correct procedure.

  • Page 57: Cooling System Coolant Level - Check

    E = The temperature of the solution in °C Note: The cooling system may not have been provided by Perkins. The procedure that follows The following procedure must be used to measure is for a typical cooling system. Refer to the OEM coolant that contains antifreeze: information for the correct procedures.

  • Page 58: Cylinder Head Grounding Stud - Inspect/Clean/Tighten

    Maintenance Section Crankshaft Vibration Damper - Inspect i01196868 Crankshaft Vibration Damper - Inspect Damage to the crankshaft vibration damper or failure of the crankshaft vibration damper can increase torsional vibrations. This can result in damage to the crankshaft and to other engine components. A deteriorating damper can cause excessive gear train noise at variable points in the speed range.

  • Page 59: Engine - Clean

    “DO NOT OPERATE”. Note: The air filter system may not have been provided by Perkins. The procedure that follows is for a typical air filter system. Refer to the OEM NOTICE information for the correct procedure.
  • Page 60 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace • Operating conditions (dust, dirt and debris) may Note: Refer to “Cleaning the Primary Air Cleaner require more frequent service of the air cleaner Elements”. element. 3. Cover the air inlet with tape in order to keep dirt •...

  • Page 61: Engine Air Cleaner Service Indicator - Inspect

    Maintenance Section Engine Air Cleaner Service Indicator - Inspect Inspecting the Primary Air Cleaner There are two common methods that are used to clean primary air cleaner elements: Elements • Pressurized air • Vacuum cleaning Pressurized Air Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times.

  • Page 62: Every 8000 Service Hours Engine Crankcase Breather - Replace

    Maintenance Section Engine Crankcase Breather - Replace i01914584 Engine Crankcase Breather - Replace 1106 Engines g00103777 Illustration 30 Typical service indicator Observe the service indicator. The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur: •...

  • Page 63: Engine Crankcase Breather Element - Replace

    Engine Mounts - Inspect Note: The engine mounts may not have been supplied for this installation by Perkins. Refer to the OEM information for further information on the engine mounts and the correct bolt torque. Inspect the engine mounts for deterioration and for correct bolt torque.

  • Page 64: Engine Oil Sample - Obtain

    Perkins recommends using a sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when a sampling valve is used.

  • Page 65: Engine Oil And Filter - Change

    Use of an oil filter that is not recommended Do not drain the engine lubricating oil when the by Perkins could result in severe damage to the en- engine is cold. As the engine lubricating oil cools, gine bearings, crankshaft, etc., as a result of the larger...

  • Page 66: Engine Protective Devices - Check

    NOTICE To prevent damage to the engine, your authorized If equipped with an auxilliary oil filter system or a re- Perkins dealer or your Perkins distributor should mote filter system, follow the OEM or the filter manu- perform the tests.

  • Page 67: Fuel Injection Nozzles - Test/Exchange

    Only qualified service personel should perform this maintenance. Refer to the Service Manual or your au- Regular maintenance of the fuel injector nozzles thorized Perkins dealer or your Perkins distruibutor for is not necessary. The fuel injector nozzles should the complete valve lash adjustment procedure.

  • Page 68: Fuel System - Prime

    Refer to the Disassembly and Assembly Manual for more information. Consult your authorized Perkins dealer or your Perkins distributor for assistance. i01907679 Fuel System - Prime...

  • Page 69: Fuel System Primary Filter/Water Separator

    Illustration 40 The fuel filter/water separator (if equipped) is not High pressure pipes usually supplied by Perkins. The following text Note: Damage to the fuel injection pump, to the describes a typical fuel filter/water separator. Refer battery, and to the starter motor can occur if the...

  • Page 70: Replace

    Hand tightening is the only method that should be used. The fuel filter/water separator (if equipped) is not usually supplied by Perkins. The following text NOTICE describes a typical fuel filter/water separator. Refer Do not fill fuel filters with fuel before installing them.

  • Page 71: Fuel System Secondary Filter - Replace

    Maintenance Section Fuel System Secondary Filter - Replace i01907683 NOTICE Fuel System Secondary Filter - Do not use a tool in order to remove the fuel filter. Replace Attempting to remove the fuel filter with a filter wrench or a filter strap could damage the locking ring. 3.

  • Page 72: Hoses And Clamps - Inspect/Replace

    Maintenance Section Hoses and Clamps - Inspect/Replace Cleaning the Strainer and the • Softness Sediment Chamber for the Fuel • Loose clamps Transfer Pump Replace hoses that are cracked or soft. Tighten any Turn the fuel supply valve (if equipped) to the OFF loose clamps.

  • Page 73: Radiator - Clean

    Perkins. The following text describes a typical method of replacing The radiator is not usually supplied by Perkins. The coolant hoses. Refer to the OEM information for following text describes a typical cleaning procedure further information on the coolant system and the for the radiator.

  • Page 74: Severe Service Application - Check

    Operating at excessive speeds Refer to the standards for the engine or consult your • Operating outside the intended application Perkins dealer or your Perkins distributor in order to determine if the engine is operating within the defined Improper Maintenance Procedures parameters.

  • Page 75: Turbocharger - Inspect

    Severe Service Applications Test” for more information on the checking procedure can accelerate component wear. Severe Service and for specifications or consult your Perkins dealer Applications require more frequent inspections of the or your Perkins distributor for assistance.

  • Page 76: Walk-Around Inspection

    Disassembly and Assembly Manual, “Water Pump - Remove and Install” for more information or consult your Perkins dealer or your Perkins distributor. This document has been printed from SPI². Not for Resale...

  • Page 77: Water Pump - Inspect

    Maintenance Section Water Pump - Inspect • Inspect the lubrication system for leaks at the front Note: The water pump seal is lubricated by the crankshaft seal, the rear crankshaft seal, the oil coolant in the cooling system. It is normal for a small pan, the oil filters and the rocker cover.

  • Page 78: Warranty Section

    Emissions Warranty. Consult your authorized Perkins dealer or your authorized Perkins distributor in order to determine if your engine is emissions certified and if your engine is subject to an Emissions Warranty.

  • Page 79: Index

    Index Section Index Electrical System ............ 11 After Starting Engine ..........34 After Stopping Engine..........36 Grounding Practices .......... 12 Aftercooler Core - Clean/Test ........ 53 Emergency Stopping ..........36 Aftercooler Core - Inspect........53 Emissions Certification Film ........20 Aftermarket Oil Additives ........
  • Page 80 Index Section Fault Logging............30 Lifting and Storage ..........21 Features and Controls ........... 25 Lubricant Information..........41 Fire Prevention and Explosion Prevention ....8 API Oils .............. 41 Fire Extinguisher ..........9 Engine Manufacturers Association (EMA) Oils .. 41 Lines, Tubes and Hoses ........
  • Page 81 Index Section Serial Number Plate ..........19 Severe Service Application - Check ...... 74 Environmental Factors ........74 Improper Maintenance Procedures....74 Improper Operating Procedures ......74 Starting Motor - Inspect ......... 74 Starting the Engine ..........32 Starting a Cold Engine ........32 Starting a Warm Engine........
  • Page 82 Index Section This document has been printed from SPI². Not for Resale...
  • Page 83 Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number:...
  • Page 84 ©2003 Perkins Engines Company Limited This document has been printed from SPI². Not for Resale A ll R i ght s R es er ve d Printed in U.K.

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