Perkins 1103 Generator Set

⚠ To prevent possible injury, do not use the starter to turn the flywheel.

⚠ Hot engine components can cause burns; allow the engine to cool before measuring valve clearance.

⚠ To prevent accidental starting, turn the ignition switch to OFF, place a do not operate tag and disconnect and tape the stop solenoid electrical connection.

Tools: Feeler gauge, Soft mallet

1. Put No. 1 piston at top center on the compression stroke.
2. 1104: with TC compression stroke adjust inlet valves 1,2 and exhaust valves 1,3 to 0.20 mm and 0.45 mm.
3. Lightly tap the rocker arm at the adjustment screw with a soft mallet; loosen the adjustment locknut.
4. Place the correct feeler gauge between the rocker arm and valve stem and turn the adjustment screw clockwise until slight drag is felt.
5. Tighten the adjustment locknut to 27 N·m (20 lb ft) without turning the adjustment screw; recheck valve lash.
6. Rotate the engine 360 degrees to TC exhaust stroke for cylinder 4.
7. 1104: adjust inlet valves 3,4 and exhaust valves 2,4. 1103: adjust the number 1, 5, 2 and 4 valves.

⚠ To prevent possible injury, do not use the starter to turn the flywheel.

⚠ Hot engine components can cause burns.

Tools: feeler gauge

1. Remove the valve mechanism cover.
2. Rotate crankshaft clockwise; when No. 4 inlet opened and No. 4 exhaust not closed, measure No. 1 valves.
3. Loosen the valve adjustment screw locknut on adjustment screw.
4. Place the appropriate feeler gauge between the rocker arm and valve.
5. Turn the adjustment screw until correct valve lash is achieved.
6. Tighten the locknut while holding the adjustment screw from turning.
7. Repeat for No. 3, No. 4 and No. 2 cylinders per engine sequence.
8. Install the valve mechanism cover.

Tools: 27610211 Crankshaft timing pin, 27610212 Camshaft timing pin

1. Remove the valve mechanism cover, glow plugs and front housing cover.
2. Rotate the crankshaft in the normal direction until the inlet valve of No. 4 cylinder has just opened and the exhaust valve has not completely closed.
3. Align the hole in the crankshaft with the hole in the cylinder block and timing case and insert the 27610211 Crankshaft Timing Pin fully.
4. Insert the 27610212 Camshaft Timing Pin through the camshaft gear into the timing case body.
5. Remove the timing pins from the camshaft gear and crankshaft web.

⚠ This procedure must only be carried out by a person with the correct training.

⚠ Do not rotate the fuel injection pump if the fuel injection pump shaft is locked.

Tools: 27610248 Bosch EPVE fuel injection pump timing adapter, Dial indicator

1. Set No. 1 piston at top center on the compression stroke and remove the rocker shaft.
2. Remove the high pressure fuel lines. Remove plug and washer and install 27610248 adapter with dial indicator.
3. Rotate the crankshaft counterclockwise until the plunger is at the bottom. Set dial indicator to zero.
4. Rotate the crankshaft clockwise until the required plunger lift is achieved.
5. Lock the pump shaft: loosen locking screw, remove washer, tighten locking screw to 31 N·m (23 lb ft).
6. Remove the water pump, front cover and fuel injection pump gear.
7. Set No. 1 piston at top center and install the fuel injection pump gear, front cover and water pump.
8. Install a new washer to the plug and install the plug. Install the rocker shaft and high pressure fuel lines and eliminate air.

Tools: 27610227 Rocker Assembly Tool

1. Lubricate both ends of pushrods with clean engine oil; install.
2. Loosen adjustment screw and nut on each rocker arm.
3. Position rocker shaft assembly onto cylinder head.
4. Install torx screws; longest screw at front of cylinder head.
5. Tighten torx screws from center outward to 35 N·m.
6. Remove rocker assembly tool.
7. Adjust inlet valve lash to 0.20 mm, exhaust to 0.45 mm.

⚠ Work carefully around a running engine; hot or moving parts can cause personal injury.

⚠ Always wear eye and face protection when using pressurized air.

Tools: Fuel flow tube with visual sight gauge, Pressure gauge 0 to 80 kPa (0 to 12 psi)

1. Examine the fuel system for leaks. Check fuel line fittings and fuel level.
2. Install a fuel flow tube with sight gauge in the fuel return line, in a straight section at least 304.8 mm (12 inches) long. Observe flow during cranking.
3. If excessive air is seen, install a second sight gauge at the inlet to the fuel transfer pump and observe.
4. Pressurize the fuel tank to 35 kPa (5 psi), maximum 55 kPa (8 psi). Check for leaks between tank and transfer pump.
5. If the source is not found, disconnect the supply line from the tank and connect an external fuel supply to the transfer pump inlet.

Tools: Multimeter

1. Warning lamp does not illuminate: check the light bulb and replace if broken.
2. Check battery voltage with the ignition switch OFF.
3. Check voltage between terminal A and ground; it should equal battery voltage.
4. Turn ignition switch ON and check voltage between terminal B and ground; if more than 2 volts the alternator needs replacement.
5. Warning light on while running: run the engine at fast idle and measure voltage at terminals A and B.
6. Voltages should be 13 to 15 volts (12 volt system) or 26 to 30 volts (24 volt system); if not, replace the alternator.
7. Increase to high idle with an electrical load ON and repeat voltage measurement; replace the alternator if voltages do not match.

Tools: compression gauge

1. Ensure the battery is in good condition and fully charged and the starting motor operates correctly.
2. Set the valve lash correctly; remove all fuel injectors; disconnect the fuel supply.
3. Install a gauge for measuring cylinder compression in the hole for a fuel injector.
4. Operate the starting motor to turn the engine and record the maximum pressure indicated.
5. Repeat for all cylinders.
6. Compare cylinders; if one or more vary by more than 350 kPa (51 psi) repair may be needed.

1. Check the coolant level in the cooling system; low level allows air into the system.
2. Check the antifreeze and water mixture; should be 50 percent water and 50 percent 21825166 POWERPART antifreeze.
3. Check for air in the cooling system from incorrect filling or combustion gas leakage.
4. Check the sending unit, the radiator for restrictions, the filler cap, and the hoses and clamps.
5. Check for restrictions in the air inlet and exhaust systems.
6. Check the water temperature regulator and the water pump impeller.
7. Consider high outside temperatures; maximum ambient air should not exceed 50 °C (120 °F).
8. Consider excessive load applied to the engine causing reduced coolant flow.

⚠ Do not crank the engine for more than 30 seconds. Allow the starter to cool for two minutes before cranking again.

Tools: Multimeter, Ammeter

1. Measure the battery voltage across the battery posts while cranking. Compare with expected cranking voltage table.
2. Measure the current sent to the starting motor solenoid from the positive battery post with an ammeter.
3. Measure the voltage of the starting motor while cranking and compare with the temperature range table.
4. Measure voltage drops in the cranking circuits and compare with the maximum acceptable voltage drop table.
5. Rotate the crankshaft by hand to ensure it is not stuck; check oil viscosity and external loads.
6. Attempt to crank the starting motor; if it cranks slowly remove for repair or replacement.
7. If the starting motor does not crank, check for blocked engagement of the pinion gear and flywheel ring gear.

Tools: Suitable pressure gauge

1. Use a suitable pressure gauge to test the pressure of the lubrication system.
2. Run the engine at normal operating temperature and high idle.
3. Oil pressure must be a minimum of 280 kPa (40 psi); a lower pressure is normal at low idle.

Tools: 27610248 Bosch EPVE fuel injection pump timing adapter, Dial indicator

1. Set No. 1 piston at top center on the compression stroke.
2. Remove the high pressure fuel lines from the fuel injection pump.
3. Remove the plug and washer and install 27610248 timing adapter with a dial indicator set to approximately 3 mm (0.1181 inch).
4. Rotate the crankshaft counterclockwise until the plunger is at the bottom of the stroke. Set the dial indicator to zero.
5. Rotate the crankshaft clockwise until the crankshaft timing pin can be pushed into the crankshaft web.
6. Check the dial indicator reading at top center and compare to Specifications, Fuel Injection Pump.