Perkins 403D-15 Generator Set

⚠ Reemplace las correas de impulsión múltiples en conjuntos

Tools: Medidor Burroughs

1. Afloje los pernos de montaje (2) y el perno de ajuste (1).
2. Mueva el alternador para aumentar o disminuir la tensión de la correa.
3. Apriete el perno de ajuste (1). Apriete los pernos de montaje (2).
4. Compruebe otra vez la tensión de las correas después de 20 horas de operación cuando se instalen correas nuevas.

⚠ Hot engine components can cause burns; allow the engine to cool.

⚠ Only qualified service personnel should perform this maintenance.

1. Ensure that the engine cannot be started while this maintenance is performed.
2. Ensure that the engine is stopped before measuring the valve lash.
3. Measure and adjust the valve lash clearance. The lash can be inspected and adjusted hot or cold.
4. Refer to Systems Operation, Testing and Adjusting, Engine Valve Lash - Inspect/Adjust for the complete procedure.

1. Remove the valve mechanism cover.
2. Remove the glow plugs.
3. Rotate the crankshaft until the No. 1 exhaust valve is nearly closed and the No. 1 inlet valve is starting to open.
4. Rotate the crankshaft approximately 360 degrees and align the timing mark on the crankshaft pulley with the TOP mark on the timing case.
5. Install the glow plugs.
6. Install the valve mechanism cover.

⚠ Old shims must not be reused.

1. Fuel injection timing is set at the factory and cannot change during operation.
2. If a fuel injection pump is removed, replace the old shims with new shims of the same thickness.
3. Select the correct combination of shims for the engine model from the shim tables.
4. If the original shim thickness cannot be determined, contact the Dealer Solution Network with the full engine number.

1. Align timing mark (X) on the idler gear with the timing mark on the crankshaft gear.
2. Align timing mark (X) on the idler gear with the timing mark on the camshaft gear.

⚠ The engine must be in running condition in order to carry out the governor adjustment procedure.

⚠ If the engine is fitted with a Boost Compensation Device contact an authorized Perkins distributor.

Tools: 21825617 Dial Indicator graduated in 0.01 mm (0.0004 inch), Extension 20 mm (0.787 inch) long, 27610331 Dial holder, 27610332 Adapter for the cylinder block, 27610333 Calibration spring, Allen head screw M4 x 20 mm x 0.70, Optical Tachometer

1. Operate the engine until the normal operating temperature is reached.
2. Use an optical tachometer to record the engine rpm at low idle.
3. Accelerate the engine to high idle; record the engine rpm as Speed A.
4. Remove tamper proof caps.
5. Record protrusion X of the high idle stop screw and protrusion Y of the low idle stop screw.
6. Release locknut (3); turn high idle trimmer screw (2) four turns counterclockwise and tighten locknut.
7. Accelerate the engine to high idle; record the engine rpm as Speed B.

⚠ Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operated.

Tools: multimeter, ammeter

1. Put the multimeter positive lead on the Bat terminal; negative lead on ground or frame.
2. Put an ammeter around the positive output wire of the alternator.
3. Turn off all electrical accessories; turn off the fuel to the engine.
4. Operate the starter motor for 30 seconds; wait two minutes to cool the starter motor.
5. Start the engine and run at high idle.
6. Check output current; initial charging current should equal or exceed minimum full load current.
7. After approximately ten minutes, output voltage should be 14.0 ± 0.5 volts.
8. After ten minutes the charging current should decrease to approximately 10 amperes.

⚠ Keep the engine rpm constant for all cylinders when taking a compression reading.

⚠ Measure the compression on all of the cylinders.

Tools: compression gauge

1. Remove the fuel injector from the cylinder to measure compression for that cylinder.
2. Connect a suitable compression gauge to the cylinder.
3. Disconnect the fuel shutoff solenoid.
4. Operate the starter motor and record the pressure on the compression gauge.
5. Repeat for each cylinder.
6. Repair procedures must be taken if the compression is lower than the repair limit.

Tools: suitable oil pressure gauge

1. Ensure the engine is filled to the correct oil level.
2. Connect a suitable gauge to a pressure tap location for engine oil.
3. Operate the engine and allow it to obtain normal operating temperature.
4. Keep the oil temperature constant with the engine at the rated rpm; read the pressure gauge.
5. Refer to the oil pressure table to determine if the oil pressure is in tolerance.

⚠ Always wear eye protection; test fluid under pressure can pierce the skin.

Tools: nozzle tester, adapter, tube assembly, extension, fuel collector, filter

1. Connect the fuel injector to suitable tooling with the spray directed into the extension and fuel collector.
2. Pump the pressure to about 2030 kPa (294 psi) below the opening pressure of the fuel injector.
3. Release the handle and note the time for pressure to decrease to approximately 0 kPa (0 psi).
4. If the time is less than 5 seconds or more than 45 seconds, the fuel injector is faulty.
5. Pump pressure to about 2030 kPa (294 psi) below opening pressure; fuel should not drip from the tip for at least ten seconds.
6. Replace the fuel injector if the results are not acceptable.

1. Run the engine at low idle.
2. Perform the test procedures to determine if a fuel injector does not work correctly.
3. Identify the suspect fuel injector.

1. Check fuel level in the fuel tank; ensure the fuel cap vent is not filled with dirt.
2. Check all fuel lines for leakage, restrictions, faulty bends; verify the return line is not collapsed.
3. Inspect the fuel filter for excessive contamination; install a new fuel filter if necessary.
4. Service the primary fuel filter, if equipped.
5. Operate the hand priming pump; inspect the fuel pressure regulating valve if resistance is felt.
6. Remove any air in the fuel system; refer to Fuel System - Prime.