Perkins 1106 Generator Set

Tools: Feeler gauge

1. Remove valve mechanism cover.
2. Rotate crankshaft until No. 6 cylinder inlet valve opened and exhaust valve not fully closed (TC compression).
3. Measure valve lash for valves according to Table 5.
4. Adjust if necessary: loosen locknut, place feeler gauge, turn adjustment screw.
5. Rotate crankshaft to TC exhaust stroke (360 from TC compression).
6. Measure valve lash for valves according to Table 6.
7. Adjust if necessary.
8. Install valve mechanism cover.

1. Fasten temporary pointer to front cover.
2. Remove fuel injection nozzles and valve mechanism cover.
3. Rotate crankshaft clockwise until inlet valve pushrod of rear cylinder tightens.
4. Rotate crankshaft 1/8 turn clockwise; open No. 1 inlet valve with spacer.
5. Rotate crankshaft counterclockwise until piston contacts open valve; mark damper.
6. Rotate crankshaft clockwise one or two degrees; remove spacer.
7. Rotate crankshaft 1/4 turn counterclockwise; install spacer.
8. Rotate crankshaft clockwise until piston contacts open valve; mark damper.
9. Mark center point between two marks; remove other marks.
10. Rotate crankshaft 1/8 turn counterclockwise; remove spacer.
11. Rotate crankshaft clockwise until center mark aligns with pointer; No. 1 piston at top center.
12. Install valve mechanism cover and fuel injection nozzles.
13. Remove temporary pointer.

Tools: 27610032 Timing Pin (Bosch), 27610218 Tool (piston displacement)

1. Set No. 1 piston at top center compression stroke.
2. Remove No. 2 fuel injection nozzle.
3. Ensure seat washer for nozzle is removed.
4. Check bore and seat of fuel injection nozzle.
5. Align alignment pin of main body to slot in nozzle hole.
6. Place main body into nozzle hole and install gland nut.
7. Apply clean engine oil to probe.
8. Insert probe into main body; lower onto piston crown.
9. Rotate crankshaft clockwise until machined face of probe aligns with top of main body.
10. No. 1 piston is at four degrees after top center compression stroke.
11. Remove probe, gland nut, and main body.
12. Replace fuel injection nozzle.

Tools: Electronic Service Tool

1. From the menu select Services.
2. On the Services screen select Throttle Configuration.
3. Select the type of input: Analog throttle, PWM throttle, or Communications port throttle (J1939 TSC1).
4. If analog input is selected, program the analog parameters into the ECM.

1. Disconnect fuel supply line and electrical connection; remove heater from manifold.
2. Connect fuel supply line to heater; prime until fuel free of air; tighten fitting.
3. Start engine at low speed; check for fuel leakage from valve.
4. If leakage, replace heater; if not, reinstall and connect.

1. Examine fuel system for leaks; ensure fittings tight.
2. Install fuel flow tube with sight gauge in fuel return line.
3. Observe fuel flow during cranking for air bubbles.
4. If excessive air, install second sight gauge at inlet to fuel transfer pump.
5. Pressurize fuel tank to 35 kPa (5 psi); check for leaks.

Tools: Multimeter, Ammeter

1. Put multimeter positive lead on 'Bat' terminal, negative on ground; put ammeter around positive output wire.
2. Turn off accessories and fuel; crank engine 30 seconds; wait two minutes.
3. Start engine and run at full throttle.
4. Check output current; initial charging current should equal minimum full load current.
5. After ten minutes at full throttle, output voltage should be 14.0 ± 0.5 V for 12 V system or 28.0 ± 1 V for 24 V system.
6. After ten minutes, charging current should decrease to approximately 10 A.

⚠ Test ECM Mode must be activated before the engine serial number is programmed into the ECM.

Tools: Electronic Service Tool

1. Search for the latest flash file for the engine.
2. Use Copy Configuration to copy parameters from the suspect ECM.
3. Disconnect the suspect ECM and temporarily connect the test ECM.
4. Flash program the test ECM with the newest software.
5. Start Test ECM Mode through the Service menu.
6. Program the test ECM with the copied configuration.
7. Program the engine serial number into the test ECM.
8. Verify that the test ECM rectifies the fault.

⚠ Personal injury can result from hot coolant, steam and alkali.

Tools: Pressurizing pump

1. Loosen filler cap to first stop; release pressure; remove cap.
2. Ensure coolant covers top of radiator core.
3. Put pressurizing pump onto radiator.
4. Increase pressure to 20 kPa (3 psi) more than filler cap operating pressure.
5. Check radiator for leakage on outside.
6. Check all connections and hoses for leaks.

1. Remove water temperature regulator from engine.
2. Heat water in pan to fully open temperature of regulator.
3. Hang regulator in pan, below surface, away from sides and bottom.
4. Keep water at correct temperature for ten minutes.
5. Remove regulator; immediately measure opening.
6. Replace if distance less than specification.

⚠ Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension.

Tools: Hoist, Adjustable lifting beam

1. Use a hoist and an adjustable lifting beam to lift the engine.
2. Keep all supporting members (chains and cables) parallel and perpendicular to the top of the load.
3. Use only the lifting eyes that are on the engine to remove the engine.

⚠ Personal injury can result from air pressure.

1. Remove the core.
2. Turn the aftercooler core upside-down to remove debris.
3. Use pressurized air opposite the fan air flow to remove loose debris.
4. Pressurized water may be used to soften mud; clean the core from both sides.
5. Back flush the core with a suitable cleaner.
6. Steam clean the core and flush the fins; remove any other trapped debris.
7. Wash the core with hot, soapy water and rinse thoroughly with clean water.
8. Dry the core with compressed air in the reverse direction of normal flow.
9. Inspect the core for cleanliness and pressure test it; repair if necessary.
10. Install the core.
11. Start the engine and accelerate to high idle to remove debris and dry the core, then stop the engine.