Perkins 1106C Genset User manual

KENR6931
May 2007
Systems Operation
Testing and Adjusting
1106C Genset
PK (Engine)

Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate everypossible circumstance that might involve apotential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specificallyrecommended byPerkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you startany job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.

KENR6931 3
Table of Contents
Table of Contents
Systems Operation Section
General Information
Introduction ............................................................ 4
Engine Operation
Basic Engine ........................................................... 6
Air Inlet and Exhaust System ............................... 10
Cooling System .................................................... 13
Lubrication System .............................................. 14
Electrical System ................................................. 15
Cleanliness of Fuel System Components ............. 16
Fuel Injection ....................................................... 18
Electronic Control System ................................... 25
Power Sources ..................................................... 33
Glossary of Electronic Control Terms ................... 36
Testing and Adjusting Section
Fuel System
Fuel System - Inspect ........................................... 42
Air in Fuel - Test .................................................... 42
Finding Top Center Position for No. 1 Piston ........ 45
Fuel Injection Timing - Check ............................... 45
Fuel Quality - Test ................................................. 46
Fuel System - Prime ............................................. 47
Gear Group (Front) - Time .................................... 48
Air Inlet and Exhaust System
Air Inlet and Exhaust System - Inspect ................. 50
Turbocharger - Inspect .......................................... 51
Compression - Test ............................................... 53
Engine Valve Lash - Inspect/Adjust ...................... 54
Valve Depth - Inspect ............................................ 56
Valve Guide - Inspect ............................................ 57
Lubrication System
Engine Oil Pressure - Test .................................... 59
Engine Oil Pump - Inspect .................................... 59
Excessive Bearing Wear - Inspect ........................ 60
Excessive Engine Oil Consumption - Inspect ....... 60
Increased Engine Oil Temperature - Inspect ........ 61
Cooling System
Cooling System - Check ....................................... 62
Cooling System - Inspect ...................................... 62
Cooling System - Test ........................................... 63
Engine Oil Cooler - Inspect ................................... 65
Water Temperature Regulator - Test ..................... 66
Water Pump - Inspect ........................................... 67
Basic Engine
Piston Ring Groove - Inspect ................................ 68
Connecting Rod - Inspect ..................................... 68
Cylinder Block - Inspect ........................................ 70
Cylinder Head - Inspect ........................................ 71
Piston Height - Inspect .......................................... 72
Flywheel - Inspect ................................................. 72
Flywheel Housing - Inspect ................................... 73
Gear Group - Inspect ............................................ 75
Vibration Damper - Check .................................... 75
Electrical System
Alternator-Te
st .................................................... 77
Battery - Test ......................................................... 78
Charging System - Test ........................................ 78
V-Belt - Test .......................................................... 78
Electric Starting System - Test .............................. 79
Glow Plugs - Test .................................................. 81
Index Section
Index ..................................................................... 82

4KENR6931
Systems Operation Section
Systems Operation Section
General Information
i02756359
Introduction
The following model views show a typical 1106C
Genset. Due to individual applications, your engine
may appear different from the illustrations.
g01329939
Illustration 1
Front left engine view
(1) Fuel manifold (Rail)
(2) Canister for the crankcase breather
(3) Electronic control module
(4) P2 connector
(5) Secondary fuel filter
(6) Hand primer
(7) Primary fuel filter
(8) Oil sampling valve
(9) Oil filter
(10) Fuel pump
(11) Water pump
(12) Damper
(13) Fan
(14) Fan pulley
(15) Belt tensioner

KENR6931 5
Systems Operation Section
g01329941
Illustration 2
Rear right engine view
(16) Oil gauge
(17) Air intake
(18) Oil filler
(19) Front lifting eye
(20) Alternator
(21) Exhaust manifold
(22) Exhaust elbow
(23) Turbocharger
(24) Wastegate solenoid
(25) Starting motor
(26) Oil pan
(27) Drain plug (oil)
(28) Drain plug or coolant sampling valve
(29) Breather
(30) Rear lifting eye
The 1106C genset is electronically controlled. The
1106C genset uses an Electronic Control Module
(ECM) that receives signals from the fuel injection
pump and other sensors in order to control the fuel
injectors. The pump supplies fuel to the fuel injectors.
The six cylinders are arranged in-line. The cylinder
head assembly has two inlet valves and two exhaust
valves for each cylinder. The ports for the exhaust
valves are on the right side of the cylinder head. The
ports for the inlet valves are on the left side of the
cylinder head. Each cylinder valve has a single valve
spring.
Each cylinder has a piston cooling jet that is installed
in the cylinder block. The piston cooling jet sprays
engine oil onto the inner surface of the piston in order
to cool the piston. The pistons have a Quiescent
combustion chamber in the top of the piston in order
to achieve clean exhaust emissions. The piston pin is
off-center in order to reduce the noise level.
The pistons have two compression rings and an oil
control ring. The groove for the top ring has a hard
metal insert in order to reduce wear of the groove.
Theskirthasacoatingofgraphiteinordertoreduce
wear when the engine is new. The correct piston
height is important in order to ensure that the piston
does not contact the cylinder head. The correct
piston height also ensures the efficient combustion
of fuel which is necessary in order to conform to
requirements for emissions.
Apistonandaconnectingrodarematchedto
each cylinder. The piston height is controlled by the
distance between the center of the big end bearing
and the center of the small end bearing of the
connecting rod. Three different lengths of connecting
rods are available in order to attain the correct piston
height. The three different lengths of connecting rods
are made by machining the blank small end bearing
of each rod at three fixed distances vertically above
the centerline of the big end bearing. .

6KENR6931
Systems Operation Section
The crankshaft has seven main bearing journals. End
play is controlled by thrust washers which are located
on both sides of the number six main bearing.
The timing case is made of aluminum. The timing
gears are stamped with timing marks in order to
ensure the correct assembly of the gears. When the
number 1 piston is at the top center position on the
compression stroke, the marked teeth on the idler
gear will match with the marks that are on the fuel
injection pump, the camshaft, and the gear on the
crankshaft. There is no timing mark on the rear face
of the timing case.
The crankshaft gear turns the idler gear which then
turns the following gears:
•the camshaft gear
•the fuel injection pump
The camshaft and the fuel injection pump run at half
the rpm of the crankshaft. The cylinder bores are
machined into the cylinder block.
g01214399
Illustration 3
The fuel injection pump (1) that is installed on the
left side of the engine is gear-driven from the timing
case. The fuel transfer pump (33) is attached to the
fuel injection pump (1). The fuel transfer pump draws
low pressure fuel from the primary fuel filter. The
fuel transfer pump delivers the fuel to the secondary
filter at a pressure of 400 kPa (58 psi) to 500 kPa
(72.5200 psi). The fuel injection pump draws fuel
from the secondary filter. The fuel injection pump
increases the fuel to a maximum pressure of 130 MPa
(18855 psi). The fuel injection pump delivers the fuel
to the fuel manifold. The fuel injection pump is not
serviceable. Adjustments to the pump timing should
only be made by personnel that have had the correct
training. The fuel injection pump uses the engine
ECM to control the engine RPM.
The specifications for the 1106C refer to the
Specifications, “Engine Design”.
Engine Operation
i02756360
Basic Engine
Introduction (Basic Engine)
The eight major mechanical components of the basic
engine are the following parts:
•Cylinder block
•Cylinder head
•Pistons
•Connecting rods
•Crankshaft
•Vibration damper
•Timing gear case and gears
•Camshaft

KENR6931 7
Systems Operation Section
Cylinder Block and Cylinder Head
g01175307
Illustration 4
Typical Cylinder Block
The cast iron cylinder block for the 1106C genset
has six cylinders which are arranged in-line. The
cylinder block is made of cast iron in order to provide
support for the full length of the cylinder bores. Worn
cylinders may be rebored in order to accommodate
oversize pistons and rings.
The cylinder block has seven main bearings which
support the crankshaft. Thrust washers are installed
on both sides of number six main bearing in order to
control the end play of the crankshaft.
Passages supply the lubrication for the crankshaft
bearings. These passages are cast into the cylinder
block.
The cylinders are honed to a specially controlled
finish in order to ensure long life and low oil
consumption.
The cylinder block has a bush that is installed for the
front camshaft journal. The other camshaft journals
run directly in the cylinder block.
The engine has a cooling jet that is installed in the
cylinder block for each cylinder. The piston cooling
jet sprays lubricating oil onto the inner surface of the
piston in order to cool the piston.
A multi-layered steel (MLS) cylinder head gasket is
used between the engine block and the cylinder head
in order to seal combustion gases, water, and oil.
Cylinder head
g01201553
Illustration 5
The engine has a cast iron cylinder head. The inlet
manifold is integral within the cylinder head. There
are two inlet valves and two exhaust valve for each
cylinder. Each pair of valves are connected by a valve
bridge that is controlled by a pushrod valve system.
The ports for the inlet valves are on the left side of
the cylinder head. The ports for the exhaust valves
are on the right side of the cylinder head. The valve
stems move in valve guides that are machined into
the cylinder head. There is a renewable valve stem
seal that fits over the top of the valve guide.

8KENR6931
Systems Operation Section
Pistons, Rings and Connecting
rods
g01205645
Illustration 6
The pistons have a Quiescent combustion chamber
inthetopofthepistoninordertoprovideanefficient
mix of fuel and air. The piston pin is off-center in
order to reduce the noise level.
The pistons have two compression rings and an oil
control ring. The groove for the top ring has a hard
metal insert in order to reduce wear of the groove.
The piston skirt has a coating of graphite in order to
reduce the risk of seizure when the engine is new.
The correct piston height is important in order to
ensure that the piston does not contact the cylinder
head. The correct piston height also ensures the
efficient combustion of fuel which is necessary in
order to conform to requirements for emissions.
The connecting rods are machined from forged
molybdenum steel. The connecting rods have
bearing caps that are fracture split. The bearing caps
on fracture split connecting rods are retained with
Torx screws. Connecting rods with bearing caps that
are fracture split have the following characteristics:
•The splitting produces an accurately matched
surface on each side of the fracture for improved
strength.
Crankshaft
g01196830
Illustration 7
The crankshaft is a chromium molybdenum forging.
The crankshaft has seven main journals. Thrust
washers are installed on both sides of number six
main bearing in order to control the end play of the
crankshaft.
The crankshaft changes the linear energy of the
pistons and connecting rods into rotary torque in
order to power external equipment.
A gear at the front of the crankshaft drives the timing
gears. The crankshaft gear turns the idler gear which
then turns the following gears:
•Camshaft gear
•Fuel injection pump and fuel transfer pump
•Lower idler gear which turns the gear of the
lubricating oil pump.
Lip type seals are used on both the front of the
crankshaft and the rear of the crankshaft.
A timing ring is installed to the crankshaft. The timing
ring is used by the ECM in order to measure the
engine speed and the engine position.

KENR6931 9
Systems Operation Section
g01205646
Illustration 8
Vibration Damper
g01180539
Illustration 9
Typical example
The force from combustion in the cylinders will
cause the crankshaft to twist. This is called torsional
vibration. If the vibration is too great, the crankshaft
will be damaged. The vibration damper is filled with
viscous fluid in order to limit the torsional vibration.
Gears and Timing Gear Case
g01194949
Illustration 10
The crankshaft oil seal is mounted in the aluminum
timing case. The timing case cover is made from
pressed steel.
The timing gears are made of steel.
The crankshaft gear drives an upper idler gear and
a lower idler gear. The upper idler gear drives the
camshaft and the fuel injection pump. The lower idler
gear drives the oil pump. The water pump drive gear
is driven by the fuel injection pump gear.
The camshaft and the fuel injection pump rotate at
half the engine speed.
Camshaft
The engine has a single camshaft. The camshaft
is made of cast iron. The camshaft lobes arechill
hardened.
The camshaft is driven at the front end. As the
camshaft turns, the camshaft lobes move the valve
system components. The valve system components
move the cylinder valves.
The camshaft gear must be timed to the crankshaft
gear. The relationship between the lobes and the
camshaft gear causes the valves in each cylinder to
open at the correct time. The relationship between
the lobes and the camshaft gear also causes the
valves in each cylinder to close at the correct time.

10 KENR6931
Systems Operation Section
i02656284
Air Inlet and Exhaust System
g01205681
Illustration 11
Air inlet and exhaust system
(1) Exhaust manifold
(2) Electronic unit injector
(3) Glow plug
(4) Inlet manifold
(5) Aftercooler core
(6) Exhaust outlet
(7) Turbine side of turbocharger
(8) Compressor side of turbocharger
(9) Air inlet from the air cleaner
(10) Inlet valve
(11) Exhaust valve
The components of the air inlet and exhaust system
control the quality of air and the amount of air that is
available for combustion. The air inlet and exhaust
system consists of the following components:
•Air cleaner
•Turbocharger
•Aftercooler
•Inlet manifold
•Cylinder head, injectors and glow plugs
•Valves and valve system components
•Piston and cylinder
•Exhaust manifold
Air is drawn in through the air cleaner into the air
inlet of the turbocharger (9) by the turbocharger
compressor wheel (8). The air is compressed and
heated to about 150 °C (300 °F) before the air is
forced to the aftercooler (5). As the air flows through
the aftercooler the temperature of the compressed
air lowers to about 50 °C (120 °F). Cooling of the
inlet air increases combustion efficiency. Increased
combustion efficiency helps achieve the following
benefits:
•Lower fuel consumption
•Increased horsepower output
•Reduced particulate emission
From the aftercooler, air is forced into the inlet
manifold (4). Air flow from the inlet manifold to the
cylinders is controlled by inlet valves (10). There are
two inlet valves and two exhaust valves for each
cylinder. The inlet valves open when the piston
moves down on the intake stroke. When the inlet
valves open, cooled compressed air from the inlet
port is forced into the cylinder. The complete cycle
consists of four strokes:
•Inlet