1106 Vista D series

Electronic 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

2000

4006

2800C
2300C
1300

1006
1104C
1004
1103C
3.152

Prime Power (kVA)

50 Hz

400C

250

500

750

1000

1250

15002000

Product Range to be (2005)

4000

2000

4006

2800C
2300C
1300D
1106D

1104C
1104A
1103C
1103A

Prime Power (kVA)

50 Hz

400C

250

500

750

1000

1250

15002000

New Platform Evolution

4.236

1004

Tier 0

Old Family
New 1004
Vista
Tier 1

B
A
Platform rationalisation

New Family
C
D
E
Enhanced Products

New Platform Evolution

A

2005

2004

2003

2007

2012

2005

As required

2002

2006

2012

2008?

As required

2002

2005

2011

Emissions
Tier

Cylinders

1100 Series = Tier 0

Emissions
compliance

Rating
Model

Governing

60/50Hz
Switch

Mech/Elec

1800rpm
Standby
kWe

1500rpm
Prime kVa

EPA
Tier 0

1103A-33G

30.6

30

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

TA
Luft
(<4000 mg
NOx)

1100A Series = Tier 0

50Hz
1500rpm
Prime
Power
(kVA)

60Hz
1800rpm
Standby
Power
(kWe)

3.1524

27.5

28

1004G

44.5

45.5

1004TG1

1004TG2

65

76

50Hz
1500rpm
Prime
Power
(kVA)

60Hz
1800rpm
Standby
Power
(kWe)

1103A-33G1

30

30.8

1103A-33TG1

45

46.2

1103A-33TG2

60

61.6

1104A-44TG1

65

66.7

1104A-44TG2

80

82.1

62

77.5

1100A Benefits

More power (c. 2-4 kVA across the range)

Hits right power nodes
Increased flexibility due to more models
Smaller package size / improved /$/ per kVA.
Uses technical improvements developed to help reach
Tier II emissions levels to enhance Tier 0 product
Uses same platform across emissions levels. Minimises
installation costs, instant product recognition, reduced
manufacturing costs, increased manufacturing flexibility.
Quieter !

1100 Series = Tier 2

Emissions
compliance

Rating

Governing

60/50Hz
Switch

Mech/Elec

Elec

40

Elec

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

Model

1800rpm
Standby
kWe

1500rpm
Prime kVA

EPA
Tier 2

1103C-33G1

30

1103C-33G2

30

30

1104C-44G1

40

1104C-44G2

TA
Luft
(<4000 mg
NOx)

1100 Series = Tier 3

Emissions
compliance

Rating
1800rpm
Standby
kWe

1500rpm
Prime kVA

EPA
Tier 3

EU
St
2

Governing

60/50Hz
Switch

30

30

Elec

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

Model

1103D-33G
1104D-E44G

Improved performance

Improved performance over 1100C

300

1200
1200

250

1000
1000

200

800
800
Stage 2

150

Stage 3a

600
600

100

400
400

50

200
200

0
0
Power (hp)

43% extra power

Torque
Torque

51% increase in
torque

1106 Progression to Stage 3

New For Stage 3

1100D front & rear

4 Valve Head

Valve Train

6 Cylinder version of 1104

Common Rail FIE

Standard Electronics

Mechanical Features
Cylinder Head

Head
Multi-Layered-Steel
(MLS) Head Gasket
Fourteen - 16mm
bolts
Single Use
Torque and Angle
Tightening Method

Mechanical Features
Rocker Assembly

Bridge can be installed

either way
Single Bolt per Rocker
Lever
Lash settings the same
for Inlet and Exhaust
Injectors can be
replaced without
removing Rockers

Inlet (Long)

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

Dimple

Connecting Rods
Fracture Split
Removal from the Top
Notches
Bearing Alignment
Not Interchangeable
Top to Bottom
3 Lengths for Piston
Protrusion
Always use New Bolts
Dimples for Orientation
Dimple

Notch

Mechanical Features
Crankshaft

Crankshaft
Balanced Steel Forging
Induction Hardened
Larger Mains Diameter
84mm, 8mm Increase
Larger Rod Diameter
72mm, 9mm Increase
15mm Bearing Overlap Increase
Withstands Higher Torsional
loads
Lead free Bearings
100% Front PTO

Mechanical Features
Timing pin

Pinning the Crank to #1 TDC

Notch in Crank

Remember to Remove Pin

TDC access point

Service Tool
Available

Mechanical Features
Timing case

Timing Case
Increased Clearance for
Idler Hub access
PTFE Crank Seal with
dust seal
New Seal
Recommended if Timing
Case is removed
Use dummy Sleeve
when front Pulley is
Removed

Camshaft locating
pin boss

Idler Hub Location

Integral front oil seal to

ensure seal to crank alignment

Mechanical Features
Oil Pump

Serviced as Assembly

Left Hand Servicing to Right Hand

Servicing requires additional piping

The oil flows to the cooler via

internal galleries.

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

Cap all fuel passages Immediately after removal

Do Not Blow Out or Wash Out any fuel passages

Place removed parts in clean area

Do Not pre-fill filters

Remove packaging and protective caps immediately before

installation

Fuel Lines can not be reused

Fuel System overview

Fuel System using common rail technology

Low Pressure
300kPa (43 PSI)
20 Micron Primary Filter
2 Micron Secondary Filter
Fuel Cooler Required on some arrangements
High Pressure
Up to 160 MPa (1600bar - 23,200 PSI)
Fluid penetration safety hazard.
Hardened Fuel Lines
External Fuel Manifold

The Fuel system

Low Pressure Fuel

The Fuel system

Low Pressure Fuel

The Fuel system

Fuel pump

Two Pumps
High Pressure
Transfer
HP Pump Lubricated by
Engine Oil
Longer Life
Lube Oil Feed
Pump Speed/Position
Sensor
Transfer Pump

The Fuel system

Fuel system

Stroke in phase with Injection

Self Bleeding
Do Not Crack lines to bleed
Lock Pump BEFORE removal
Replace HP Fuel Line when Pump
is removed
Check Clips
Fuel Leak off to Tank
Fuel in to HP Pump From
Secondary Filter
To Fuel HP Manifold
To Secondary Filter
Pump Speed/Position Sensor
From Primary Filter

The Fuel system

Two Cams - 3 lobe
each
Solenoid adjusts rail
pressure and return to
tank
Needs to be Timed

Fuel system
High Pressure Pump

Rollers Ride on Cam

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

Solenoids covert electrical energy into mechanical movement.

This movement can be two positions or infinitely variable.

These Fuel Pump Solenoids have two positions.

Position of Solenoid Slug

dependant on Input Voltage

Slug

The Fuel system

High Pressure Fuel Control
Injector x 6

To Fuel Rail
Customer

Fuel
cooler
Single connector?
Air bleed on certain applications

Pressure
regulator
valve
High pressure
fuel pump
Confidential:
Yellow

Lift
pump

2o filter

ECM

Fuel Tank
1o filter w/ water
separator and hand
priming pump

The Fuel system

Transfer Pump

The transfer pump is driven from the

rear of the High Pressure Pump drive
shaft.
The pump has the capacity to create
both negative and positive pressures.
It draws the fuel (negative
pressure)into the pump, via a 20
micron primary fuel filter
The pump then delivers the fuel, at
between 43 to 85 PSI, to the
secondary filter.

The Fuel system

High Pressure Relief Valve

Protects System from

Over-Pressure
Opens at Constant
Pressure of 1600
Bar(23,000 PSI)
Withstands Spikes
to 1900 Bar(27,500
PSI)
Returns fuel to Tank
Replacement?

High Pressure Relief Valve

The Fuel system

Fuel return from Head

Excess Fuel Returned to

Transfer Pump
Not High Pressure

Fuel
Return
from
Head
LIne

High Pressure Fuel System

Dos & Donts

Fuel Manifold
Do Check for leaks
Do Not Loosen HP
Connection with Engine
Running
Do Replace HP Pipes After
they are Loosened
Do Replace ALL Hp Pipes if
new manifold is Installed
Do Not Force Pipes to Fit
Do Cap Manifold and
Injector Connections
Immediately when HP Pipe
is removed

Injector Lines

Feed From High Pressure Pump

High Pressure Fuel System

Dos & Donts

Do Remove HP Cap
just before installation
Do Keep your Work
Area Clean
Do Think about
Cleanliness when
working on HP System
Do Make Sure all Clips
and Clamps are tight
and in position

Fuel Manifold

Injector Lines

Feed From High Pressure Pump

Fuel Injection Serviceability

NEVER loosen high pressure pipes when engine

is running! 23,000 PSI
Use Electronic Service Tool to Troubleshoot
Injector Problems
Injectors have no serviceable parts.
Warranty will only be paid with evidence of the
correct tests.
Pump Solenoid is non serviceable.
If the solenoid is removed the whole pump
assembly must be replaced.
Transfer pump is a serviceable item, separate
from High Pressure pump.
Speed sensor is serviceable.

The Fuel system

Injectors

Electronic Solenoid
Poppet Valve

Electrical connections to the solenoid

operated injectors can be easily
damaged. Do not over-tighten. Use the
correct torque

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

Dos and Donts

Do Use Proper Torque on
Electrical Connection
Service Tool Available
Do Finger Tighten all Clamps
and HP Lines, First, then torque
properly
Do Cap the Injector
Immediately After Removing HP
Fuel Line
Do Make Sure the O-Ring and
Copper Washer are in place
Do Not Re-use O-Ring or
Cooper Washer

The Fuel system

Injectors

Dos and Donts

Do Write down the Injector
Serial Number
and Confirmation
Code before you install
the Injector
Do use Cat ET to Program
ECM with proper Injector
Trim File
Do Look for the Trim File
CD in the Injector Box

The Engine Management

System

Improved fuel consumption through precise control of injection

Machine protection under extreme operating conditions.
Easy servicing and fault diagnostics, Electronic Service Tool, (EST)
Exceeds emissions legislation and has a lower noise level.
Better engine responsiveness.
Improved reliability and engine monitoring
Further cost savings through integration into machine design.(CAN)
Improved torque, different torque curves available, torque shaping
Configuration files, gives the customer flexibility,(L/idle, H/idle)

The Engine Management

Intake Air
Temperature

Intake Manifold
Pressure

Engine Coolant
Temperature

Fuel Manifold
Pressure

High Pressure
Fuel Pump

Crank
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
Customer
Connector

J 2 On
Engine
Connector

Electro Magnetic
Interference
(EMI) earth strap

Fuel Flow in

Anti-Vibration
Mounts

Fuel Flow out

The Engine Management

Engine Coolant
Temperature Sensor

Intake Manifold
Temperature Sensor

Ground
Pin No 2

Signal
Pin No 1

The Engine Management

2,500

Ohms

1000
20 C

Thermistor sensing devices

Resistance (Ohms) varies with temperature

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

temperature increases its resistance decreases

The Engine Management

Diagnostic Example
4.8

110-3 Signal shorted to a high voltage or Open Circuit

VOLTS

Very cold Temp

Warning Temp
Start Derate Temp
Shutdown
Temp

0.2

110-4 Signal shorted to a lower voltage

Temperature

The Engine Management

OIL PRESSURE
SENSOR

FUEL RAIL PRESSURE

INTAKE MANIFOLD
PRESSURE SENSOR

SENSOR

The Engine Management

Fuel Rail Pressure Sensor

Determines Fuel Rail Pressure
Continuous Operating Pressure
200 MPa
Maximum without damage, 260
MPa
(burst at 320 MPa)
Temperature Range, -40 to
+160C
Sensor has M12 x 1.5 Thread
Requires Special Crush
Washer for Sealing
Ensure there is no Rail
Pressure before removal
Serviced as a Kit with Crush
Washer

The Engine Management

Intake Manifold Air Pressure

Sensor
Measures Manifold Air
Pressure
Used to calculate air/fuel
ratio
Used for smoke limiting
strategy
Measures atmospheric
pressure on key-on
Serviced as a Kit with Oring

The Engine Management

Engine Oil Pressure

Sensor
Used for engine
protection,
Warning/Shutdown
Provides signal for
pressure gauge, via
the ECM
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

Two speed/position sensors on the 1106 Vista D

Crankshaft - Primary
High Pressure Fuel Pump - Secondary
Two Wire Hall Effect
Produce Conditioned Square Wave
Engine will Run if the Primary sensor fails
Limp Home Mode - 1200 rpm Max
Engine will Not Shutdown if Secondary sensor Fails
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
Sensor

Speed / Timing
Sensor Target

HP Pump Speed/Position
Sensor
Crank Speed/Position Target 36 Teeth

Signal Output Waveform

Service Tool Hardware Requirement

PC Based

kins
@Per

TIPSS

PC Serial
cable

Electronic
Service
Tool

Unicable
cable
Comms.
Adaptor
Unit

Engine

EST software
+
Installation
Manual
User Manual
for EST

Installation
manual for
Comms
Adaptor

Plastic carrying
case (with foam
inside)

Communications
Adaptor Kit

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

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

RS232 port with 16550AF UART

Built in pointing device or mouse

Windows NT, 2000 or Windows 9x