Perkins 403F-11 Generator Set

⚠ Do not use the starter to turn the flywheel.

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

⚠ Turn ignition switch OFF and disconnect stop solenoid connection to prevent accidental starting.

Tools: feeler gauge

1. Remove valve mechanism cover with front housing installed.
2. Rotate crankshaft clockwise viewed from front; when inlet valve of one cylinder starts to open and exhaust valve not fully closed, check the paired valves.
3. Loosen valve adjustment screw locknut on adjustment screw.
4. Place feeler gauge between rocker arm and valve; turn adjustment screw to achieve specification.
5. Tighten locknut while holding adjustment screw from turning.

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

1. Note that fuel injection timing is set at the factory and cannot change during operation.
2. If pump is removed, replace old shims with new shims of the same thickness.
3. Select correct shim combination from the applicable model table.
4. Contact Dealer Solution Network if original shim thickness cannot be determined.

⚠ The engine must be in running condition 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, 27610331 Dial holder, 27610332 Adapter for cylinder block, 27610333 Calibration spring, Allen head screw (M4 x 20 mm x 0.70), Optical Tachometer

1. Operate engine to normal operating temperature and record low idle rpm.
2. Accelerate to high idle and record rpm as Speed A.
3. Remove tamper proof caps; record protrusion X of high idle stop screw and protrusion Y of low idle stop screw.
4. Release locknut, turn high idle trimmer screw four turns counterclockwise, tighten locknut.
5. Accelerate to high idle and record rpm as Speed B.
6. Set fuel screw using Tooling (A) to 2.00 ± 0.01 mm and tighten locknut to 6 N·m.
7. Set stop screw protrusions to original dimensions and set high idle trimmer screw two turns clockwise from fully out.
8. Run at low idle and adjust low idle stop screw to previously recorded speed.
9. Run at high idle and adjust high idle stop screw to Speed B.
10. Adjust high idle trimmer screw to Speed A and tighten locknut.
11. Install tamper proof caps.

⚠ Work carefully around a running engine.

⚠ Wear eye and face protection when using pressurized air.

Tools: fuel flow tube with visual sight gauge

1. Examine fuel system for leaks and check fuel level.
2. Install fuel flow tube with sight gauge in return line; observe flow during cranking.
3. If excessive air seen, install second sight gauge at inlet to fuel priming pump.
4. Pressurize fuel tank to 35 kPa (5 psi), not exceeding 55 kPa (8 psi), and check for leaks.
5. If source not found, connect external fuel supply to inlet of priming pump.

⚠ Never operate the alternator without the battery in the circuit.

Tools: multimeter, ammeter

1. Connect multimeter positive lead to Bat terminal and negative to ground; put ammeter around positive output wire.
2. Turn off accessories and fuel; operate starter motor 30 seconds, wait 2 minutes.
3. Start engine and run at high idle.
4. Check output current equals or exceeds minimum full load current.
5. After ten minutes at high idle, output voltage should be 14.0 ± 0.5 volts.
6. After ten minutes charging current should decrease to approximately 10 amperes.

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

1. Check wiring insulation and connections.
2. Refer to the OEM-supplied manual for correct battery test procedures.

⚠ Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.

Tools: Plastigauge (Green), Plastigauge (Red), Plastigauge (Blue), Plastigauge (Yellow)

1. Put a piece of Plastigauge on the crown of the bearing that is in the cap.
2. Do not allow Plastigauge to extend over the edge of the bearing.
3. Install the bearing cap using correct torque-turn specifications; do not use an impact wrench.
4. Do not turn the crankshaft when Plastigauge is installed.
5. Carefully remove the cap without removing the Plastigauge.
6. Measure the width of the Plastigauge.
7. Remove all Plastigauge before installing the bearing cap.

1. Record condition of charge in battery at each regular inspection.
2. Test charging unit and voltage regulator on the engine whenever possible.
3. Replace regulator if rate of charge is not correct.

⚠ Measure compression on all cylinders to avoid improper diagnosis.

Tools: compression gauge

1. Remove fuel injector from cylinder to be measured.
2. Connect suitable compression gauge to cylinder.
3. Disconnect fuel shutoff solenoid.
4. Operate starter motor and record pressure on gauge.
5. Repeat for each cylinder.

Tools: digital multimeter

1. Use digital multimeter to measure resistance of the sensor.
2. When coolant is 30°C or less, disconnect wire connector and measure resistance; should be approximately 1660 Ohms.
3. Repeat at approximately 70°C; resistance should be approximately 428 Ohms.
4. Replace sensor if resistance is not within given values.

1. Check coolant level in cooling system.
2. Check coolant contamination and correct specification.
3. Check for air in the cooling system.
4. Check sending unit and radiator for restrictions or debris.
5. Check filler cap, fan, fan shroud and drive belt tension.
6. Check cooling system hoses and clamps.
7. Check for restriction in air inlet and exhaust systems.
8. Check water temperature regulator and water pump.
9. Consider high outside temperatures and applied load.
10. Check engine timing.