GHADDAR MACHINERY CO.
- Training Manual
Contacts: Mohammed Shaat Trainer
Oussama Ghaddar Trainer
Contact Information
Ghaddar Machinery Co. Headquarters
Ghazieh, Sidon, Lebanon
Phone: +961 7 220 000
Fax: +961 7 223 322
P.O. Box: 110 Sidon
Email: info@ghaddar.com
Outline

Introduction 02

Training Center Overview 02

Course Description 03

Training Logistics 16

General Conditions for enrolment 16

 Introduction
Ghaddar Machinery Co. is the Appointed Perkins Distributor
for Lebanon with focusing on the distribution of Perkins En-
gines and their applications, Perkins Spare Parts and on Ser-
vicing Perkins Engines.

Ghaddar Machinery Co. builds on a 30 years experience in dis-

tribution, marketing and technical support of Perkins engines in the sectors of Electrical Power, Indus-
trial and Agricultural applications.

Training Center Overview

Ghaddar Machinery Co. is increasing the investment in its training capabilities by building a new train-
ing facility, acquiring new training tools and certifying its trainers for additional training courses.

Ghaddar Machinery Co. Trainers are Perkins Certified and they enjoy a strong experience in training
and technical capability that proved successful to many trainees and their companies by adding a lot
to their experience in troubleshooting and repairing Perkins engines.

Ghaddar Machinery Co. training Center offers the ultimate environment for effective training. It makes
available for the trainees a wide range of training equipment and constantly updated course material
specially prepared to suit their specific training needs.

02
 Course Description

Title Duration Pre-requisite

2000 Series Mechanical/Electrical 3 day Electronically Controlled Engines

400C/D Series 1 day

1100 A,B,C & D Series Mechanical engine 1 day
1300EDi Mechanical/Electrical 2 days Electronically Controlled Engines

1600EDi Mechanical/Electrical 3 days Electronically Controlled Engines

1100C Series - Mechanical/Electrical 2 days Electronically Controlled Engines

1100D Series - Mechanical/Electrical 2 days Electronically Controlled Engines

ECG & LCG Electronic Governors 1 day

Electronically Controlled Engines 3 days
4000 Series - Diesel 4.5 days
Applied failure analysis 3 days
1506 Series - Mechanical/Electrical 2 days Electronically Controlled Engines

Program 1- Welcome Note & Acquaintance

2- Agenda & Domestics
3- Course objective
4- Brief Description for the Company
5- Perkins range
6- Theoretical sessions
7- Practical implementation
8- Evaluation of acquired knowledge
9- Evaluation of the training Course

03
 2000 Series Mechanical/Electrical

Course Overview
With any engine there are always new skills which
need to be learnt and practiced and this is especially
true with the 2000 series. This course has be pre-
pared specifically for engine technicians and work-
shop staff to get to grips with the disassembly, re-
build and fault diagnosis techniques used on this
engine.

Pre-requisite
Persons wishing to attend this course should first attend PT62 or have covered the con-
tent in a previous course.

Course Objectives
Show technicians strip down techniques and the use of special tools
EST(Electronic Service Tool) and fault diagnosis procedures specific
to 2000

Course Outline
Engine Overview
Sensor operation
The function of the electronic control module
The wiring loom
Customer wiring
Diagnostics/re-programming
Operation of the electronic service tool relating to 2000 Familiarization
with mechanical features

Course Duration Course Location

Courses can be arranged to take place either at

3 Days
your premises or at our Training facility in Lebanon.

04
 400C/D Series

Course Overview
A hands on, engine teardown course, designed to
give an insight into the features and mechanical as-
pects of the engine. The course also covers service
points and is therefore aimed at those within a tech-
nical role. Persons in non-technical roles are wel-
come to attend also.

Pre-requisite
Persons with a sound diesel engine background, wishing to attain or grow their knowl-
edge of the 400C/D Series family.

Course Objectives
The aim of the course is to provide a technical understanding of the
400C/D Series range.

At the end of the course the delegates will be able to:

Use Perkins nomenclature to identify engine types

Use information in Perkins workshop manuals
Strip and re-assemble 400C/D Series engines
Carry out service operations

Course Duration Course Location

Courses can be arranged to take place either at

1 Day
your premises or at our Training facility in Lebanon.

05
 1100 A, B, C & D Series Mechanical engine

Course Overview
A hands on, engine teardown course, designed to
give an insight into the features and mechanical as-
pects of the engine. The course also covers service
points and is therefore aimed at those within a tech-
nical role. Persons in non-technical roles are wel-
come to attend also..

Pre-requisite
Persons with a sound diesel engine background, wishing to attain knowledge of the 1100
Series mechanical range.

Course Objectives
The course aim is to provide a technical understanding of the 1100
Series mechanical engine range.
At the end of the course the delegates will be able to:
Use Perkins nomenclature to identify engine types
Use information in Perkins workshop manual
Strip and re-assemble 1100 Series engines
Carry out service operations

Course Outline
Reception and registration
1100 Series history
Nomenclature
Technical presentation
Use of workshop manual
Strip and re-assembly
Service operations

Course Duration Course Location

Courses can be arranged to take place either at

1 Day
your premises or at our Training facility in Lebanon.

06
 1300EDi Mechanical/Electrical

Course Overview
The 1300 series engine was the first diesel engine
Perkins had in production that made use of electron-
ic controllers. This course is aimed directly at work-
shop and service personnel that come into contact
with the 1300 series engines..

Pre-requisite
Persons wishing to attend this course should first attend PT62 or have covered the con-
tent in a previous course.

Course Objectives
Upon completion of the course the participants will be able to:
Recognize the components associated with 1300EDi engines
Understand their operation and functions
Perform fault diagnostics, using a multimeter, flashing lights and the electronic
service tool
Wire up all industrial open power unit requirements and two gen-set functions.

Course Outline
Engine Overview
Injector operation
Oil system
Fuel system
The electronic control module
Sensor operation
Wiring the engine controls
Diagnostics/re-programming
Use and operation of the flashing fault codes
Use and operation of the electronic service tool - specific to these engines

Course Duration Course Location

Courses can be arranged to take place either at

2 Days
your premises or at our Training facility in Lebanon.

07
 1600 EDI Mechanical / Electrical

Course Overview
A hands on, engine mechanical overview and elec-
tronic troubleshooting course, designed to provide
confidence with mechanical repair and diagnosing
common faults relating to this range of engines. The
course content is aimed at those within a technical
role who have achieved the required prerequisites.
This course is not suitable for persons in non-tech-
nical roles.

Pre-requisite
This course is suitable for people with a sound diesel engine background and have
completed the Electronically Controlled Engines course, PT62 or equivalent.

Course Objectives
At the end of the course the delegates will be able to:
Answer basic questions relating to system components
Perform key service operations
Demonstrate the key functions of the 1600 Electronic Serve Tool
Diagnose faults with engine systems

Course Outline
Engine Overview
Injector operation
Oil system
Fuel system
The electronic control module
Sensor operation
Wiring the engine controls
Diagnostics/re-programming
Use and operation of the electronic service tool - specific to these engines

Course Duration Course Location

Courses can be arranged to take place either at

3 Days
your premises or at our Training facility in Lebanon.

08
 1100C Series - Mechanical/Electrical

Course Overview
This course covers the elements of the mechanical
course plus the electronic components and systems
that differ from the other products in the Perkins
range. Specific elements within EST relating to this
engine are also covered.

Pre-requisite
Persons wishing to attend this course should first attend PT62 or have covered the con-
tent in a previous course.

Course Objectives
Upon completion of the course the participants will be able to:
Recognize the components associated with 1100C electronic engines
Understand their operation and functions
Appreciate the reasons behind the migration to electronic engines
Perform operations within the electronic service tool relating to 1100C Series

Course Outline
Engine Overview
Sensor operation - pressure-temperature speed
The function of the electronic control module
The wiring loom
Customer wiring
Diagnostics/re-programming
Use and operation of the electronic service tool
Familiarization with new mechanical features of 1100 series engines

Course Duration Course Location

Courses can be arranged to take place either at

2 Days
your premises or at our Training facility in Lebanon.

09
 1100D Series - Mechanical/Electrical

Course Overview
The course focuses on both mechanical and elec-
trical aspects of the engine. It includes a mixture of
partial tear-down and running engine diagnostics,
covering fuel system operation, key service pro-
cedures, and electrical systems knowledge and
troubleshooting. It is especially suited to technical
staff involved with service and repair.

Pre-requisite
Persons wishing to attend this course should first attend PT62 or have covered the con-
tent in a previous course..

Course Objectives
Upon completion of the course the participants will be able to:
Recognize the components associated with 1100C&D Common Rail engines
Perform strip, rebuild and service operations
Perform systematic electrical fault diagnostics.

Course Outline
Mechanical overview
Service operations
Electrical/Electronic overview
Electronic Troubleshooting.

Course Duration Course Location

Courses can be arranged to take place either at

2 Days
your premises or at our Training facility in Lebanon.

10
 ECG & LCG Electronic Governors

Course Overview
This course not only provides information on the
workings of the ECG & LCG governors but also in-
cludes installation, programming and troubleshooting.
Anyone involved with the installation, service and
repair of a Perkins engine using these types of gov-
ernor should attend this course. It will also benefit
those who may not have contact with the engines
but want an understanding of the governors.

Pre-requisite
Persons wishing to attend this course need to have a good understanding of diesel en-
gines, a basic understanding of electrics including using a multi-meter and electronic
engine control.

Course Objectives
Upon completion of the course the participants will be able to:
Install governors in accordance with the installation literature.
Use the appropriate service tools.
Program the governor with the required software.
Perform systematic electrical/electronic fault diagnostics.

Course Outline
Product overview.
Product specifications.
Inputs and outputs.
Speed control features
Service tool.

Course Duration Course Location

Courses can be arranged to take place either at

1 Day
your premises or at our Training facility in Lebanon.

11
 Electronically Controlled Engines

Course Overview
A course, aimed primarily at the technician, covering
generic subjects relating to electronically controlled
Perkins Engines. The course covers subjects from
basic circuits to speed control, sensors, engine &
application wiring. Fault finding and use of diagnostic
equipment such as multimeters and the Electronic
Service Tool (EST), are a key part of this course.

Pre-requisite
A basic understanding of electricity is desirable.

Course Objectives
Upon completion of the course the participants will be able to:
Describe the benefits of electronically controlled engines
Answer basic questions relating to system components
Use a multi-meter to fault find using resistance and volts
Demonstrate the key functions of the Electronic Service Tool (EST)
Diagnose faults with engine electrical systems
Reprogram ECM software and configuration files
Reprogram throttle settings and understand the configuration process

Course Outline
Basic circuit building including the use of the multimeter basic fault diagnostics
The operation of the Electronic Control Module
Engine mounted sensors
Engine speed control
Electronic Service Tool (EST)
Electronic Component Fault Finding and Repair
Re-flashing and Configuration
Practical examples and exercises throughout the course.

Course Duration Course Location

Courses can be arranged to take place either at

3 Days
your premises or at our Training facility in Lebanon.

12
 4000 Series - Diesel

Course Overview
The 4000 Series engine is one of Perkins most suc-
cessful engines finding use in many applications
around the world. This course covers all aspects of
the engine and is particularly suited to workshop
personnel.

Pre-requisite
This syllabus shows the course content presented during classroom presentations and
in the workshop training facilities. The information given is to the Must know standard,
i.e. which required to effectively maintain, fault diagnose and repair the engine and its
systems. Delegates must be technically aware of diesel engine generic technology.

Course Objectives
Course Objectives
Introduction To The Course
External features of the engines
Engine strip and use of special workshop tools
Lubrication system
Fuel system
Governors
Engine rebuild and use of special workshop tools
Failed component analysis
Cooling system
Turbocharger and induction system

Course Duration Course Location

Courses can be arranged to take place either at

4.5 Days
your premises or at our Training facility in Lebanon.

13
 Applied Failure Analysis

Course Overview
However well an engine is designed and manufac-
tured there will always the time when some event oc-
curs causing a part to fail. This course is designed to
help people understand why the failure happened,
what caused it to happen and be able to report back
to customers, managers and manufacturer the most
probable root cause of the failure.

Pre-requisite
Persons who are competent with engine assembly, wishing to expand their knowledge. Per-
sons who already carry out failure analysis wishing to enhance their knowledge/experience

Course Objectives
The course aim is to provide a logical approach to failure analysis on a
diesel engine. The delegates will be shown through practical demon-
stration how different failure modes evidence themselves.
At the end of the course the delegates will be able to identify:
Common parts failures
Describe the evidence of common failure modes
Ascribe the most probable root cause of a failure

Course Outline
Reception and registration
Group Workshop - Failed Parts Reporting
Introduction to the Perkins Failure Analysis Techniques
Collecting failure data
Analyzing failure data
Determine probable root causes
Report compilation
Allocation of blame

Course Duration Course Location

Courses can be arranged to take place either at

3 Days
your premises or at our Training facility in Lebanon.

14
 1506 Series - Mechanical/Electrical

Description
The course focuses on both mechanical/electrical aspects
of the engine. It includes a mixture of partial tear-down/run-
ning engine diagnostics, covering fuel system operation, key
service procedures, electrical systems
knowledge/ troubleshooting. It is specially suited to techni-
cal staff involved with service and repair.

Pre-requisite
Persons wishing to attend this course should first attend PT62 or have covered the
content in a previous course.

Course Objectives
Upon completion of the course the participants will be able to:

Recognize the components associated with the 1506 HEUI fuel systems.
Perform strip, rebuild and service operations.
Perform systematic electrical fault diagnostics.

Course Outline

Engine Overview
Injector operation
Oil system
Fuel system
The electronic control module
Sensor operation
Wiring the engine controls

Course Duration Course Location

Courses can be arranged to take place either at

2 Days
your premises or at our Training facility in Lebanon.

15
Training Logistics
Number of participants: 4 to 8 trainees (except for PT62; max is 5)
Customized collection of courses can be done for at least 5 trainees
(Pre-requisites and durations are fixed)
Training fee will include besides to training course, issuance of
certificate, training literature, usage of training equipment in addition
to lunch meal & refreshers. It excludes charges for visa, tickets, hotel,
transportation, medications and others.
CD containing Presentation Material (Optional).
Payment should be settled upon receipt of invoice
Our secretarial services can be put at your disposal to help you book
Hotel rooms, however, accommodation and transportation charges
remain at the expense of the participants.

General Conditions for Enrolment

How to Register
Please send your enquiry by mail or by Fax.
Phone: +961 (0) 7 220 000
Fax: + 961(0) 7 223 322
e-mail: mshaat@ghaddar.com

Cancellation of registration
Any cancellation must be notified at least 14 days prior to the start of
the course. Ghaddar Machinery Co. Training reserves the right to can-
cel or reschedule the course in case of Force Majeur or any reason
that is out of our control.

Practical information
Upon registration, an agreement and a training program will be sent.
Registration will be confirmed upon receipt of the training agreement
signed. An attendance certificate will be attached to the invoice

Training Venue
Training is given at Ghaddar Machinery Co. training facility in Ghaddar
Machinery Co. Head office- Sidon-Lebanon.

16
This document can be electronically downloaded from
http://www.ghaddar.com/english/wp-content/uploads/2016/11/Perkins-Courses-Training-Manual-2016.pdf

November 2016
- Edition V.1.2 -