Perkins 403C-11 Generator Set

⚠ The maximum no load speed must be set by an approved Perkins distributor.

Tools: Spill pipe 21825680

1. Set the piston for number one cylinder to TDC on the compression stroke. Turn the crankshaft counter clockwise a quarter of a revolution.
2. Remove the ESOS, high pressure fuel pipes and low pressure fuel pipes from the fuel injection pump.
3. Ensure that the fuel pump rack is in the maximum fuel position.
4. Remove the delivery valve holder for number 1 cylinder and remove the delivery valve; store in clean fuel until assembly.
5. Connect the fuel pump spill pipe to the delivery valve holder for number 1 cylinder.
6. Connect a clean fuel reservoir (approx. 0.2 litres clean fuel) to the fuel injection pump inlet.
7. Put a waste fuel container below the pipe neck and open the tap.
8. Turn the crankshaft slowly until the fuel flow reduces to a drop which falls every 7 - 10 seconds; this is the timing point.
9. Use the value shown by the timing mark with the injection timing tables.
10. If the engine timing is incorrect adjust the thickness of the fuel injection pump shim.
11. Fit the delivery valve and tighten the delivery valve holder.
12. The engine must be tested on an engine test brake to check the maximum no load speed and engine settings after assembly.

⚠ If the correct piston height above or below the cylinder block is not obtained, damage to the engine can occur.

Tools: Piston height tool

1. Put the piston height tool (A) on the face of the cylinder block and rotate the gauge dial to the zero position.
2. Rotate the crankshaft until the piston crown is approximately at top dead centre (TDC).
3. Carefully put the tool over the top of the piston with the plunger of the gauge in contact with the piston above the axis of the gudgeon pin.
4. Rotate the crankshaft to ensure that the piston is at the highest position and make a note of the gauge indication.

⚠ Do not remove the stop solenoid as this will allow the engine to start.

Tools: Compression gauge

1. Ensure that the valve tip clearances are set correctly.
2. Remove the atomisers.
3. Fit a suitable gauge into the atomiser hole of the cylinder to be tested.
4. Disconnect the stop solenoid or put the stop solenoid in the no fuel position. Operate the starter motor and record the pressure indicated on the gauge.
5. Repeat for each cylinder.

1. Put the thermostat into the water.
2. Raise the temperature of the water gradually.
3. Record the valve opening temperature and the valve lift.

⚠ Ensure components are fitted in their correct position; incorrect fitting may damage the engine.

⚠ It is important that the area around the vent hole is clean.

1. Release the four setscrews and remove the breather cover, the spring and the diaphragm assembly.
2. Clean the breather cavity in the rocker cover.
3. Clean the breather in clean diesel fuel.
4. Fit the breather assembly into the cavity in the rocker cover, ensuring the breather cover, diaphragm and spring are assembled correctly and the vent hole faces towards the flywheel.
5. Tighten the four setscrews.

Tools: Plastigauge

1. Clean the bearing surfaces and the exposed half of the crankshaft journal.
2. Fit the bearing caps and tighten the bearing cap to torque.
3. Remove the bearing cap of the clearance to be checked.
4. Place a piece of Plastigauge across the full width of the bearing surface on the crankshaft journal, fit the bearing cap and tighten the bearing cap setscrew to the specified torque.
5. Remove the bearing cap but do not move the Plastigauge.
6. Use the Plastigauge envelope to measure the widest point of the Plastigauge; this reading indicates the bearing clearance.
7. If the bearing clearance is not within the specifications the crankshaft must be reground and undersize bearings fitted.

⚠ Connections should be blanked off until assembly.

1. Loosen the vent screw on the fuel filter.
2. Operate the hand primer until fuel, free of air, flows from the vent screw. Tighten the vent screw.
3. Loosen the vent screw on the fuel injection pump. Operate the hand primer until fuel, free of air, flows. Tighten the vent screw.
4. Attempt to start the engine using the starter motor for a maximum of 15 seconds, wait for 30 seconds before trying again.