1100 series Vista Engines.

Nomenclature

1106 D - 66 TA
Family/No of Cylinders
Identifier
A = Tier 0
B = Tier 1
C = Tier 2
D = Tier 3
Capacity(Litres)
Aspiration type
 Product Range – as is
4000 Ö
2000
4006

2800C

2300C

1300

1006

1104C

1004

1103C

3.152
Prime Power (kVA)
50 Hz
400C
Ö
0 250 500 750 1000 1250 1500 2000
Product Range – to be (2005)
4000
Ö
2000
4006

2800C

2300C

1300D

1106D

1104C

1104A

1103C

1103A
Prime Power (kVA)
50 Hz
400C
Ö
0 250 500 750 1000 1250 1500 2000
New Platform Evolution
4.236
1004
Old Family
New 1004
Tier 0

Vista
Tier 1
New Family

“C”
“B” “D”
“A” “E”
Platform rationalisation Enhanced Products
 New Platform Evolution
Emissions
Tier A B C D E
0 1 2 3 4

Cylinders

3 2005 2004 2003 2007 2012

4 2005 As required 2002 2006 2012

6 2008? As required 2002 2005 2011

 1100 Series = Tier 0
Emissions
Rating
compliance 60/50Hz
Model 1800rpm TA Governing Switch
1500rpm EPA
Standby Luft
Prime kVa Tier 0 (<4000
kWe mg NOx)

1103A-33G 30.6 30   Mech/Elec 

1103A-33TG1 47.1 45   Mech/Elec 
1103A-33TG2 61 60   Mech/Elec 
1104A-44TG1 62 65   Mech/Elec 
1104A-44TG2 82.1 80   Mech/Elec 
 1100A Series = Tier 0
50Hz 60Hz 50Hz 60Hz
1500rpm 1800rpm 1500rpm 1800rpm
Prime Standby Prime Standby
Power Power Power Power
(kVA) (kWe) (kVA) (kWe)

3.1524 27.5 28 1103A-33G1 30 30.8

1004G 44.5 45.5 1103A-33TG1 45 46.2

1103A-33TG2 60 61.6
1004TG1 65 62
1104A-44TG1 65 66.7

1004TG2 76 77.5 1104A-44TG2 80 82.1

 1100A Benefits
z More power (c. 2-4 kVA across the range)
z Hits right power nodes
z Increased flexibility due to more models
z Smaller package size / improved £/$/€ per kVA.
z Uses technical improvements developed to help reach
Tier II emissions levels to enhance Tier 0 product
z Uses same platform across emissions levels. Minimises
installation costs, instant product recognition, reduced
manufacturing costs, increased manufacturing flexibility.
z Quieter !
 1100 Series = Tier 2
Emissions
Rating
compliance 60/50Hz
Model 1800rpm TA Governing Switch
1500rpm EPA
Standby Luft
Prime kVA Tier 2 (<4000 mg
kWe NOx)

1103C-33G1 30 -  - Mech/Elec -
1103C-33G2 30 30 -  Elec 
1104C-44G1 40 40 -  Elec 
1104C-44G2 45 -  - Mech/Elec -
1103C-33TG1 45 -  - Elec -
1103C-33TG2 45 40 -  Elec 
1104C-44TG1 60  - Mech/Elec -
1104C-44TG2 60 60 -  Elec 
1104C-44TAG1 80 80   Elec -
1104C-44TAG2 100 100   Elec -
 1100 Series = Tier 3
Emissions
Rating
compliance 60/50Hz
Model 1800rpm EU Governing Switch
1500rpm EPA
Standby St
Prime kVA Tier 3
kWe 2
1103D-33G 30 30   Elec 
1104D-E44G 45-50 40-50   ECM / Elec 
1104D-E44TAG1 61 60   ECM / Elec 
1104D-E44TAG2 62 80   ECM / Elec 
1104D-E44TAG3 82.1 100   ECM 

1106D-E66TAG1 125 125   ECM 

1106D-E66TAG2 140 135   ECM 
1106D-E66TAG3 150 150   ECM 
1106D-E66TAG4 175 180   ECM 
 Improved performance
z Improved performance over 1100C

300 1200

250 1000

200 800

Stage 2
150 Stage 3a 600

100 400

50 200

0 0
Power (hp) Torque

9 43% extra power 9 51% increase in

torque
1106 Progression to Stage 3
New For Stage 3
z 4 Valve Head

z Valve Train

z 6 Cylinder version of
1104

z Common Rail FIE

z Standard Electronics

1100D front & rear

 Mechanical Features
Cylinder Head
z Head
z Multi-Layered-Steel
(MLS) Head Gasket
z Fourteen - 16mm
bolts
z Single Use
z Torque and Angle
Tightening Method
 Mechanical Features
Rocker Assembly
z Bridge can be installed Inlet (Short)
either way
z Single Bolt per Rocker
Lever
z Lash settings the same
for Inlet and Exhaust
z Injectors can be
replaced without
removing Rockers

Exhaust (Short)
Mechanical Features
Cylinder Block
These features give a more ridged
structure with lower noise attenuation
•New block Improved rib structure, give
it a more ridged structure with a lower
noise attenuation.
•Increased bore size, Now 105mm
•Enclosed top deck
•The production block is liner less
Mechanical Features
Piston
The piston is made of a low expansion
aluminium incorporating a Quiescent
bowl design
This design of combustion bowl allows
the use of multiple injections

The squared boss on the inside of the

piston is fitted facing towards the front
of the engine.
 Mechanical Features
Connecting rod
z Connecting Rods Dimple
z Fracture Split
z Removal from the Top
z Notches
z Bearing Alignment
z Not Interchangeable
Top to Bottom
z 3 Lengths for Piston
Protrusion
z Always use New Bolts
z Dimples for Orientation

Dimple Notch
 Mechanical Features
Crankshaft
z Crankshaft
z Balanced Steel Forging
z Induction Hardened
z Larger Mains Diameter
z 84mm, 8mm Increase
z Larger Rod Diameter
z 72mm, 9mm Increase
z 15mm Bearing Overlap Increase
z Withstands Higher Torsional
loads
z Lead free Bearings
z 100% Front PTO
 Mechanical Features
Timing pin
z Pinning the Crank to #1 TDC
z Notch in Crank
z Remember to Remove Pin

z TDC access point

z Service Tool
Available
 Mechanical Features
Timing case
Camshaft locating Idler Hub Location
z Timing Case pin boss

z Increased Clearance for

Idler Hub access
z PTFE Crank Seal with
dust seal
z New Seal
Recommended if Timing
Case is removed
z Use “dummy” Sleeve
when front Pulley is
Removed Integral front oil seal to
ensure seal to crank alignment
 Mechanical Features
Oil Pump
z Serviced as Assembly

z Left Hand Servicing to Right Hand

Servicing requires additional piping

z The oil flows to the cooler via

internal galleries.

z From the cooler the oil passes to

the lube oil filter and then on into
the oil feed galleries.
Pressure
Relief Valve
 Fuel System Handling
z Cap all fuel passages Immediately after removal
z Do Not “Blow Out” or “Wash Out” any fuel passages
z Place removed parts in clean area
z Do Not pre-fill filters
z Remove packaging and protective caps immediately before
installation
z Fuel Lines can not be reused
 Fuel System overview

z Fuel System using common rail technology

z Low Pressure
z 300kPa (43 PSI)
z 20 Micron Primary Filter
z 2 Micron Secondary Filter
z Fuel Cooler Required on some arrangements
z High Pressure
z Up to 160 MPa (1600bar - 23,200 PSI)
z Fluid penetration safety hazard.
z Hardened Fuel Lines
z External Fuel Manifold
 The Fuel system
Low Pressure Fuel
 The Fuel system
Low Pressure Fuel
 The Fuel system
Fuel pump
z Two Pumps
z High Pressure
z Transfer
z HP Pump Lubricated by
Engine Oil
z Longer Life
z Lube Oil Feed
z Pump Speed/Position
Sensor
z Transfer Pump
 The Fuel system
Fuel system
z Stroke in phase with Injection
z Self Bleeding
z Do Not Crack lines to bleed
z Lock Pump BEFORE removal
z Replace HP Fuel Line when Pump
is removed
z Check Clips
z Fuel Leak off to Tank
z Fuel in to HP Pump From
Secondary Filter
z To Fuel HP Manifold
z To Secondary Filter
z Pump Speed/Position Sensor
z From Primary Filter
 The Fuel system
Fuel system
Two Cams - 3 lobe
each High Pressure Pump

Solenoid adjusts rail

pressure and return to
tank Rollers ‘Ride’ on Cam

Needs to be Timed
Transfer Pump
Lock in Place BEFORE
Removal

Engine Lubrication Oil

The Fuel system
Fuel system
HP Pump Control Solenoid

Cam Rollers

Pump Clamp

Triple Cam Lobes

 The Fuel system
High Pressure Fuel Control
z Solenoids covert electrical energy into mechanical movement.
z This movement can be two positions or infinitely variable.

z These Fuel Pump Solenoids have two positions.

Position of Solenoid ‘Slug’ Slug

dependant on Input Voltage
 The Fuel system
High Pressure Fuel Control
Injector x 6

To Fuel Rail
Customer
Fuel
cooler

Single connector?
Air bleed on certain applications

Pressure Fuel Tank

regulator
valve
1o filter w/ water
High pressure separator and hand
fuel pump priming pump
Lift
2o filter pump
Confidential:
Yellow

ECM
 The Fuel system
Transfer Pump
z The transfer pump is driven from the
rear of the High Pressure Pump drive
shaft.
z The pump has the capacity to create
both negative and positive pressures.
z It draws the fuel (negative
pressure)into the pump, via a 20
micron primary fuel filter
z The pump then delivers the fuel, at
between 43 to 85 PSI, to the
secondary filter.
 The Fuel system
High Pressure Relief Valve
High Pressure Relief Valve
z Protects System from
Over-Pressure
z Opens at Constant
Pressure of 1600
Bar(23,000 PSI)
z Withstands Spikes
to 1900 Bar(27,500
PSI)
z Returns fuel to Tank
z Replacement?
 The Fuel system
Fuel return from Head

Fuel
Return
from
z Excess Fuel Returned to Head
Transfer Pump LIne
z Not High Pressure
High Pressure Fuel System
z Do’s & Don’ts
z Do Check for leaks Fuel Manifold Injector Lines
z Do Not Loosen HP
Connection with Engine
Running
z Do Replace HP Pipes After
they are Loosened
z Do Replace ALL Hp Pipes if
new manifold is Installed
z Do Not Force Pipes to Fit
z Do Cap Manifold and
Injector Connections
Immediately when HP Pipe
is removed
Feed From High Pressure Pump
 High Pressure Fuel System
z Do’s & Don’ts
Fuel Manifold Injector Lines
z Do Remove HP Cap
just before installation
z Do Keep your Work
Area Clean
z Do Think about
Cleanliness when
working on HP System
z Do Make Sure all Clips
and Clamps are tight
and in position

Feed From High Pressure Pump

Fuel Injection Serviceability
z NEVER loosen high pressure pipes when engine
is running! 23,000 PSI
z Use Electronic Service Tool to Troubleshoot
Injector Problems
z Injectors have no serviceable parts.
z Warranty will only be paid with evidence of the
correct tests.
z Pump Solenoid is non serviceable.
z If the solenoid is removed the whole pump
assembly must be replaced.
z Transfer pump is a serviceable item, separate
from High Pressure pump.
z Speed sensor is serviceable.
 The Fuel system
Injectors Electronic Solenoid

Poppet Valve
z Electrical connections to the solenoid
operated injectors can be easily
damaged. Do not over-tighten. Use the
correct torque
z Re-new both the copper washer and
rubber ‘O’ ring when replacing the
injectors

Nozzle
Assembly
The Fuel system
Injectors

Constant
Fuel
pressure
 The Fuel system
Injectors
z Do’s and Don’ts
z Do Use Proper Torque on
Electrical Connection
z Service Tool Available
z Do Finger Tighten all Clamps
and HP Lines, First, then torque
properly
z Do Cap the Injector
Immediately After Removing
HP Fuel Line
z Do Make Sure the O-Ring and
Copper Washer are in place
z Do Not Re-use O-Ring or
Cooper Washer
 The Fuel system
Injectors
z Do’s and Don’ts
z Do Write down the Injector
Serial Number
and Confirmation Code
before you install the
Injector
z Do use Cat ET to Program
ECM with proper Injector
Trim File
z Do Look for the Trim File
CD in the Injector Box
 The Engine Management
System
z Improved fuel consumption through precise control of injection
z Machine protection under extreme operating conditions.
z Easy servicing and fault diagnostics, Electronic Service Tool, (EST)
z Exceeds emissions legislation and has a lower noise level.
z Better engine ‘responsiveness’.
z Improved reliability and engine monitoring
z Further cost savings through integration into machine design.(CAN)
z Improved torque, different torque curves available, torque ‘shaping’
z Configuration files, gives the customer flexibility,(L/idle, H/idle)
The Engine Management
Intake Air Intake Manifold
Temperature Pressure
Engine Coolant Fuel Manifold
Temperature Pressure

High Pressure Crank

Fuel Pump Speed/Position

Pump/Cam
Speed/Position Engine Oil Pressure
The Engine Management
Jack 1 ‘Customer’ Connection

A4-E2
Engine
Control
Module

Jack 2 ‘On Engine’ Wiring Connection

The Engine Management
The Engine Management
J1
Fuel Flow ‘in’
‘Customer’
Connector

J 2 ‘On
Engine’ Anti-Vibration
Connector Mounts

Electro Magnetic
Interference Fuel Flow ‘out’
(EMI) earth strap
The Engine Management
Engine Coolant Ground
Temperature Sensor Pin No 2

Signal
Pin No 1
Intake Manifold
Temperature Sensor
 The Engine Management

2,500
Ohms

1000

20 C

z Thermistor sensing devices

z Resistance (Ohms) varies with temperature

z The Sensor has a Negative Temperature Coefficient (NTC). As

temperature increases its resistance decreases
The Engine Management
Diagnostic Example
110-3 Signal shorted to a high voltage or Open Circuit
4.8
Very cold Temp

Warning Temp
VOLTS

Start Derate Temp

Shutdown
Temp

0.2
110-4 Signal shorted to a lower voltage

Temperature
The Engine Management
OIL PRESSURE INTAKE MANIFOLD
SENSOR PRESSURE SENSOR

FUEL RAIL PRESSURE SENSOR

 The Engine Management
z Fuel Rail Pressure Sensor
z Determines Fuel Rail Pressure
z Continuous Operating
Pressure 200 Mpa
z Maximum without damage,
260 Mpa
(burst at 320 Kpa)
z Temperature Range, -40º to
+160ºC
z Sensor has M12 x 1.5 Thread
z Requires Special ‘Crush’
Washer for Sealing
z Ensure there is no Rail
Pressure before removal
z Serviced as a Kit with ‘Crush’
Washer
The Engine Management

z Intake Manifold Air Pressure

Sensor
z Measures Manifold Air
Pressure
z Used to calculate air/fuel
ratio
z Used for smoke limiting
strategy
z Measures atmospheric
pressure on “key-on”
z Serviced as a Kit with O-
ring
The Engine Management
z Engine Oil Pressure
Sensor
z Used for engine
protection,
Warning/Shutdown
z Provides signal for
pressure gauge, via
the ECM
z Serviced as a Kit
with O-Ring
Crankshaft Speed/Position
Sensor

• Number 1 Speed/Timing Sensor

• ‘Target’ 60 Teeth (one wide)
• Two Wire ‘Hall Effect’
• Produces Conditioned Square Wave
Crankshaft Speed/Position
Sensor
z Two speed/position sensors on the 1106 Vista D
z Crankshaft - Primary
z High Pressure Fuel Pump - Secondary
z Two Wire ‘Hall Effect’
z Produce Conditioned Square Wave
z Engine will Run if the Primary sensor fails
z ‘Limp Home Mode’ - 1200 rpm Max
z Engine will Not Shutdown if Secondary sensor Fails
z Cannot be re-started if the engine is stopped.
Crankshaft Speed/Position
Sensor

Crank Speed/Position Target – 60 Teeth

Signal Output Waveform

HP Pump Speed/Position
Sensor

Speed / Timing Speed / Timing

Sensor Sensor ‘Target’
HP Pump Speed/Position
Sensor

Crank Speed/Position Target – 36 Teeth

Signal Output Waveform

 Service Tool Hardware Requirement
Unicable
PC Serial cable
@Pe
rkins cable
PC Based TIPSS Comms.
Adaptor
Electronic Unit
Service
Tool
Engine

Installation
EST software manual for
Comms Communications
+ Adaptor Adaptor Kit
Installation
Manual
Plastic carrying
User Manual case (with foam
for EST inside)
EST Service Tool Hardware Requirements
Communications Adaptor Kit

Part numbers:
Software; 650-406
Hardware; 650-407
 Electronic Service Tool - PC

Software part number:

 Installing EST Service Tool

z Recommended PC specification
• IBM® PC compatible with Pentium III 450 MHz processor
• 128-MB RAM
• 1-GB of available hard disk drive
• 24X speed CD-ROM drive
• 3.5” 1.44-MB floppy disk drive
• Super VGA colour monitor or display
• Microsoft Windows™ NT, 2000 or Windows 9x
• RS232 port with 16550AF UART
z Built in pointing device or mouse