Perkins 400 Series Models 403C-11, 403C-15, 404C-22 and 404C-22T WORKSHOP MANUAL 403C-11 Three cylinder naturally aspirated diesel engine 403C-15 Three cylinder naturally aspirated diesel engine 404C-22 Four cylinder naturally aspirated diesel engine 404C-22T Four cylinder turbo charged diesel engine Perkins Confidential: Green Publication TPD 1458E, Issue 3. © Proprietary information of Perkins Engines Company Limited, all rights reserved. The information is correct at the time of print.
7KLV SXEOLFDWLRQ LV ZULWWHQ LQ 3HUNLQV $SSURYHG &OHDU (QJOLVK Chapters 1 General information 2 Specifications 3 Cylinder head assembly 4 Piston and connecting rod assemblies 5 Crankshaft assembly 6 Timing case and drive assembly 7 Cylinder block assembly 8 Engine timing 9 Aspiration system 10 Lubrication system 11 Fuel system 12 Cooling system 13 Flywheel and housing 14 Electrical equipment 15 Auxiliary equipment 16 Special tools The following pages contain a detailed table of contents i
400 Series Contents 1 General information Introduction .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 Safety precautions . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2 POWERPART recommended consumable products ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4 Engine views ... ... ... ... ... ... ... ... ... ...
00 Series Operation 3-3 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15 Operation 3-4 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16 Exhaust manifold and gasket Operation 3-5 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
400 Series 4 Piston and connecting rod assemblies Big end bearing and cap Operation 4-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 33 Piston and connecting rod Operation 4-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 34 Operation 4-3 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..
400 Series Main bearings Operation 5-4 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49 Bearing holder ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50 6 Timing case and drive assembly Timing cover Operation 6-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
400 Series Oil pump end float Operation 6-13 To check and adjust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 63 Governor springs Operation 6-14 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 64 7 Cylinder block assembly Front crankshaft bush Operation 7-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..
400 Series Lubricating oil sump Operation 10-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79 Lubricating oil strainer and suction pipe Operation 10-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 80 Lubricating oil pump Operation 10-5 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...
400 Series Thermostat Operation 12-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 94 Operation 12-5 To drain the cylinder block . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 95 Operation 12-6 To test and to inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 96 13 Flywheel and housing Flywheel Operation 13-1 To remove and to fit ... ... ... ... ...
400 Series Wiring diagram - automatic shutdown 40 amp alternator - 403C-11 ... ... ... ... ... ... ... ..113 Wiring diagram - automatic shutdown 55 amp alternator 403C-15, 404C-22 and 404C-22T .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..114 15 Auxiliary equipment Operation 15-1 None fitted . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..
400 Series 1 General information 1 Introduction This workshop manual has been written to provide assistance for technicians who service and overhaul the Perkins 403C-11, 403C-15, 404C-22 and the 404C-22T engine. The assumption is made that the engine is removed from the application. The engine conforms with USA EPA/CARB and EC emissions legislation for agricultural and industrial applications. Where the information applies only to certain engine types, this is indicated in the text.
1 400 Series Safety precautions These safety precautions are important. You must refer also to the local regulations in the country of use. Some items only refer to specific applications l Only use these engines in the type of application for which they have been designed. l Do not change the specification of the engine. l Do not smoke when you put fuel in the tank. l Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a safe place.
400 Series 1 Viton seals Warnings! l Some seals used in engines and in components fitted to engines are made of Viton. Viton is used by many manufactures and is a safe material under normal conditions of operation. If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this burnt material to come into contact with the skin or with the eyes.
1 400 Series POWERPART recommended consumable products Perkins have made available the products recommended below in order to assist in the correct operation, service and maintenance of your engine and your machine. The instructions for the use of each product are given on the outside of each container. These products are available from your Perkins distributor. POWERPART Antifreeze Protects the cooling system against frost and corrosion. Part number 21825166.
400 Series 1 POWERPART Radiator stop leak For the repair of radiator leaks. Part number 21820127. POWERPART Retainer (high strength) To retain components which have an interference fit. Currently Loctite 638. Part number 21820638. POWERPART Safety cleaner General cleaner in an aerosol container. Part number 21820128. POWERPART Silicone adhesive An RTV silicone adhesive for application where low pressure tests occur before the adhesive sets.
1 400 Series Engine views H1029 H1030 6 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green
1 400 Series Engine identification Engine build lists numbering system The standard engine build list numbering code is defined as follows: Code Example I II III IV V HP TBA U 000001 D Code I Engine build code Code Engine HH HL HP HR 403C-11 403C-15 404C-22 404C-22T Code II engine build list The build list increases numerically for both OEMS and distributors. Code III country of manufacture Code J Country of manufacture Made in Japan U Made in U.K.
1 400 Series Engine lift equipment Recommended torque: lifting eye bolts Engine Nm (lbf ft) kgf m All models 26 (19) 2,6 Maximum engine weights Engine 403C-11 403C-15 404C-22 404C-22T Engine specification Maximum engine weights (dry) (1) Long flywheel housing specification 114 kg Short flywheel housing specification 96 kg Backplate specification 87 kg Long flywheel housing specification 176 kg Short flywheel housing specification 154 kg Backplate specification 150 kg Long flywheel h
400 Series 2 Specifications 2 Basic engine data Engine model Engine build code Number of cylinders 403C-11 403C-15 404C-22 404C-22T HH HL HP HR 3 3 4 4 Cylinder arrangement Vertical in line Cycle Four stroke Direction of rotation Clockwise from the front Induction system Naturally aspirated Combustion system Turbo charged Indirect injection Nominal bore 77 mm (3.03 in) Stroke 81 mm (3.19 in) 90 mm (3.5 in) 100 mm (3.9 in) 23: 1 22.5: 1 23.
2 400 Series Standard torques Most of the torque tensions on the engine are standard. Special torque tensions are listed in the separate specific torque tables. The standard torque tensions listed in the tables below can be used when a specific torque is not necessary. The torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted. Standard torques for setscrews and nuts Coarse thread 10 Thread size Strength M4 8.
2 400 Series Special torques Torque Nm (lbf ft) kgf m Angleich 5 (3.6) 0,5 Atomiser 64 (47.2) 6,4 Atomiser pipes 23 (16.9) 2,3 Blanking plug rear of cylinder block Crankshaft carrier to block Connecting rod nuts Crankshaft nut 7 (5.1) 0,7 27 (19.9) 2,7 52 (38.3) 5,2 303 (223.5) 30,3 Crankshaft sub assembly 52 (38.3) 5,2 Exhaust manifold 25 (18.4) 2,5 Flywheel 74 (54.5) 7,4 Fuel injection pump 15 (11) 1,5 Fuel injection pump leak off rail 7 (5.1) 0,7 Glow plug Head setscrew 18 (13.
2 400 Series Compression test data Many factors affect compression pressures, the battery, starter motor condition, ambient conditions and the type of gauge used can give a wide variation of results for a given engine. Standard value To be repaired >2940 kPa (426.6 lbf / in²) @ 250 rpm <2450 kPa (355.5 lbf / in²) @ 250 rpm Compression tests should only be used to compare between cylinders of an engine.
400 Series 3 Cylinder head assembly 3 Rocker cover and inlet manifold To remove and to fit Engine 403C-11 403C-15 404C-22 404C-22T Operation 3-1 Torque Nm (lbf ft) kgf m Cap nut 11 (8.1) 1,1 Setscrew 11 (8.1) 1,1 Cap nut 14 (10.3) 1,4 Setscrew 14 (10.3) 1,4 Notes: l An ‘O’ ring (1) is fitted in the groove in the rocker cover. l Inspect the ‘O’ ring and renew if necessary.
3 400 Series Rocker assembly To remove and to fit Engine Operation 3-2 Torque Nm (lbf ft) kgf m 403C-11 Rocker assembly nuts 23 (17.0) 2,3 403C-15 404C-22 404C-22T Rocker assembly nuts 33 (24.3) 3,3 Caution: Ensure that the valve stem caps are on the valve stems and the pushrods are located in the rockers after assembly. Note: An ‘O’ ring (1) is fitted in the groove in the rocker assembly.
3 400 Series To dismantle and to assemble Engine All models Operation 3-3 Torque Nm (lbf ft) kgf m Tappet adjustment nut 14 (10.3) 1,4 Use a suitable puller to extract the rocker shaft. Note: Remember the position of the recess (1) for assembly.
3 400 Series s To inspect Operation 3-4 Rockershaft diameter Engine Diameter mm (in) Standard Service limit 403C-11 403C-15 11,65 - 11,67 (0.4587 - 0.4595) 11,57 (0.4555) 404C-22 404C-22T 14,95 - 14,97 (0.5886 - 0.5894) 14,87 (0.5854) Rocker shaft to rocker lever clearance Engine Clearance mm (in) Standard Service limit 403C-11 403C-15 0,032 - 0,068 (0.00126 - 0.00268) 0,2 (0.008) 404C-22 404C-22T 0,030 - 0,093 (0.00120 - 0.00366) 0,2 (0.
3 400 Series Exhaust manifold and gasket To remove and to fit Engine 403C-11 403C-15 404C-22 404C-22T Operation 3-5 Torque Nm (lbf ft) kgf m Setscrew 9,8 (7.2) 0,9 Nuts 9,8 (7.2) 0,9 Setscrew 25 (18.4) 2,5 Nuts 25 (18.
3 400 Series Fuel injection pipes / fuel return pipes To remove and to fit Engine All models Operation 3-6 Torque Nm (lbf ft) kgf m Fuel injection pipe 23 (16.9) 2,3 Banjo bolt (1) 2,5 (3.
400 Series 3 Cylinder head setscrews To remove and to fit Operation 3-7 Note: If it is necessary to replace the cylinder head the fuel adjustment screw must not be altered from the original setting. The maximum no load speed must be checked after assembly.
3 400 Series Cylinder head Tightening sequence 403C-11 and 403C-15 Engine Operation 3-8 Torque Nm (lbf ft) kgf m 403C-11 Cylinder head setscrews 51 (37.6) 5,2 403C-15 Cylinder head setscrews 101 (74.5) 10,3 Notes: l All torques should be checked again after tightening. l On assembly lubricate cylinder head setscrews with clean oil.
3 400 Series Tightening sequence 404C-22 and 404C-22T Engine 404C-22 404C-22T Operation 3-9 Torque Nm (lbf ft) kgf m Cylinder head setscrews 101 (74.5) 10,3 Notes: l All torques should be checked again after tightening. l On assembly lubricate cylinder head setscrews with clean oil.
3 400 Series Cylinder head gasket To remove and to fit Operation 3-10 Align the gasket on the dowels in the cylinder block. Cautions: l The gasket must only be fitted with the markings (1) facing up. l When fitting a new gasket it must be replaced with a gasket of the same thickness as originally fitted. The gasket thickness can be identified by the part number that is stamped on the gasket.
3 400 Series To select the correct thickness of cylinder head gasket Operation 3-11 Caution: If the correct piston height above or below the cylinder block is not obtained, damage to the engine can occur. The difference between the highest and the lowest piston height must not exceed 0.1 mm. 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).
3 400 Series Valve and valve spring To remove and to fit Operation 3-12 Special tools Description Part number Valve spring remover 21825663 Valve stem seal replacer 21825623 Notes: l The oil seal for the inlet valve stem is identified by a silver garter spring. l The oil seal for the exhaust valve stem is identified by a black garter spring (not shown) with the letters “EX” on the garter. Warning! Safety glasses must be worn for this operation.
3 400 Series To inspect - valve spring Operation 3-13 Visually inspect the valve spring for damage. Use a spring tester to check spring force and free length. Renew the spring if it is outside the service limit. Free length (1) mm (in) Engine All models Engine Standard Service limit 35,0 (1.378) 33,5 (1.319) Spring rate when compressed to 30,4 mm (1.197 in) N (lbf) kgf All models Standard Service limit 79 (17.8) 8,1 68,6 (15.
3 400 Series To inspect - valve stem and thickness of valve head Operation 3-14 Use a micrometer to check the valve stem diameters at positions 1, 2 and 3, if less than the service limit, renew. Check the valve stem for wear or damage, if outside the service limit, renew. Inlet valve Diameter mm (in) Engine All models Standard Service limit 6,955 - 6,970 (0.27382 - 0.27441) 6,89 (0.271) Exhaust valve Diameter mm (in) Engine All models Standard Service limit 6,940 - 6,950 (0.27323 - 0.
3 400 Series Cylinder head to valve stem clearance To inspect Operation 3-15 Check the clearance (3) between the valve stem and the cylinder head. If the clearance is greater than the service limit, the valves must be checked for wear, see Operation 3-14, If the valves are within service limits, renew the cylinder head. 1 Put a new valve in the valve guide. 2 Put a dial test indicator with a magnetic base (1) onto the face of the cylinder head. 3 With the valve lifted 15,0 mm (0.
3 400 Series Cylinder head To inspect Operation 3-16 Maximum regrind limit mm (in) Distortion Maximum service limit Maximum regrind 0,05 (0.002) or less 0,12 (0.005) 0,15 (0.006) Use a straight edge and feeler gauge to check the six positions for distortion. Caution: Do not grind beyond the maximum limit.
3 400 Series Valve seat width # To inspect and to correct Operation 3-17 Special tools Description Part number Valve seat cutter Engine 27610030 Inlet valve Exhaust valve Clearance mm (in) Clearance mm (in) Standard Service limit Standard Service limit 403C-11 1,70 - 2,10 (0.0670 - 0.0830) 2,5 (0.098) 1,70 - 2,10 (0.0670 - 0.0830) 2,5 (0.098) 403C-15 1,66 - 1,87 (0.0653 - 0.0736) 2,5 (0.098) 1,66 - 1,73 (0.0653 - 0.0681) 2,5 (0.098) 404C-22 404C-22T 1,50 - 2,00 (0.0591 - 0.
3 400 Series Valve depth To check Operation 3-18 If the valve depth (1) is greater than the service limit, use a new valve to check the valve depth. If the depth still exceeds the service limit, renew the cylinder head. If the depth is within the service limit renew the valves. Engine Depth mm (in) Inlet standard Exhaust standard Service limit 403C-11 0,65 - 0,95 (0.0256 - 0.0374) 0,85 - 1,15 (0.0335 - 0.0453) 1,8 (0.071) 403C-15 0,85 - 1,15 (0.0335 - 0.0453) 0,85 - 1,15 (0.0335 - 0.
400 Series To lap the contact face of the valve seat 3 Operation 3-19 Use the valve seat cutter to obtain the correct seat contact width and seat recess on a new cylinder head, use a valve lapping tool and lapping compound to finish.
3 400 Series Valve tip clearance To check and to adjust Operation 3-20 The valve adjustment sequence is viewed from the front of the engine. Rotate the crankshaft clockwise when viewed from the front. Caution: Only adjust the valve clearances when the engine is cold. Engine 403C-11 403C-15 404C-22 404C-22T Valve overlap Adjust valves No. 1 Cylinder 3 and 6 No. 2 Cylinder 2 and 5 No. 3 Cylinder 1 and 4 No. 4 Cylinder 1 and 2 No. 2 Cylinder 5 and 6 No. 1 Cylinder 7 and 8 No.
400 Series 4 Piston and connecting rod assemblies 4 Big end bearing and cap To remove and to fit Operation 4-1 Engine Torque Nm (lbf ft) kgf m 403C-11 Nut 32 (23.6) 3,3 403C-15, 404C-22 and 404C-22T Nut 52 (38.3) 5,2 Standard clearance Service limit 0,1 - 0,3 mm (0.004 - 0.012 in) 0,7 mm (0.276 in) Caution: Ensure that the connecting rod bolts (2) do not damage the crankshaft when the connecting rod is removed or fitted.
4 400 Series Piston and connecting rod To remove and to fit Operation 4-2 The Shibaura name on the inside of the piston must be facing the fuel pump on assembly. To assemble the connecting rod assembly, see page 35.
4 400 Series To dismantle and to assemble Operation 4-3 The Shibaura (1) name (inside of the piston) must be aligned with the stamped number on the connecting rod (1). 123A MA C The numbers stamped on the connecting rods and caps must be the same and aligned.
4 400 Series Piston rings To fit Operation 4-4 Any letters or markings on the surface of the ring will always be positioned on the top face (facing upwards). Use a suitable piston ring expander to fit the piston rings. 1 Fit the spring of the oil control ring (6) in the bottom groove of the piston with the latch pin (1) inside both ends of the spring. Fit the oil control ring (4) over the spring (6). Ensure that the ring gap is at 180° to the latch pin.
4 400 Series To measure the piston ring clearance Operation 4-5 Use a feeler gauge to measure the clearance between the piston ring groove and the piston ring. If the clearance is greater than the service limit, use a new piston ring and check the clearance again. If the clearance is within the service limit with a new piston ring, renew the piston rings. If the clearance is outside the service limit with a new piston ring, renew the piston.
4 400 Series To measure the piston ring gap Operation 4-6 If the piston ring is worn or damaged, renew. Piston ring gap Clean the carbon from the top of the cylinder bore. Insert the ring into the cylinder at right angles to the cylinder block and measure the gap with a feeler gauge. If the gap is greater than the service limit, renew the piston ring. Engine 403C11 403C-15 404C-22 404C-22T Ring number Standard Service limit Number 1 ring 0,15 - 0,27 mm (0.0059 - 0.0106 in) 1,0 mm (0.
4 400 Series Piston and connecting rod assemblies To dismantle and to assemble Operation 4-7 Gudgeon pin Check the outside diameter of the gudgeon pin. If it is less than the service limit, renew the gudgeon pin. Engine Outside diameter Service limit 403C-11 20,996 - 21,002 mm (0.82660 - 0.82680 in) 20,98 mm (0.8260 in) 403C-15 404C-22 404C-22T 27,996 - 28,000 mm (1.10220 - 1.10240 in) 27,98 mm (1.1016 in) Standard clearance Service limit 403C-11 -0,004 - +0,004 mm (-0.00016 - +0.
4 400 Series Piston and piston ring To inspect Operation 4-8 Piston If the outer surface of the piston is damaged (cracked, scored, burning etc) renew. Piston skirt Check the larger diameter of the piston skirt (10 mm from bottom). Check the inside diameter (thrust direction) of the cylinder. Calculate the clearance between the cylinder and the piston.
4 400 Series Connecting rod To inspect Operation 4-9 Engine All models Standard Service limit Distortion for 100 mm (3.937 in) < 0,08 mm (0.0031 in) 0,20 mm (0.0079 in) Parallel for 100 mm (3.937 in) < 0,05 mm (0.0020 in) 0,15 mm (0.0059 in) The large and small end bores must be parallel with each other within the limits of ± 0,31 mm (0.008 in) measured 100 mm (3.397 in) each side of the connecting rods axis on a test mandrel.
4 400 Series Connecting rod bearing clearance To check Operation 4-10 To check the clearance between the crankshaft bearing journal and the bearing cap. 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.
4 400 Series Small end bush To remove and to fit Operation 4-11 Calculate the clearance between the small end bush and the gudgeon pin. if the clearance is greater than the service limit, renew the bush. Engine Clearance mm (in) Service limit mm (in) 403C-11 0,010 - 0,025 (0.00040 - 0.00099) 0.08 (0.0031) 403C-15 404C-22 404C-22T 0,010 - 0,025 (0.00040 - 0.00099) 0,10 (0.
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400 Series 5 Crankshaft assembly 5 Crankshaft pulley To remove and to fit Engine Operation 5-1 Torque Nm (lbf ft) kgf m 403C-11 Crankshaft nut 123 (90.7) 12,5 403C-15 404C-22 404C-22T Crankshaft nut 304 (224.2) 30,9 Special tools Part number Crankshaft pulley remover 21825619 Note: Store the key (1) in a safe place until assembly.
5 400 Series Crankshaft retaining bolts and crankshaft To remove and to fit Engine 403C-11 403C-15 404C-22 404C-22T Operation 5-2 Torque Nm (lbf ft) kgf m Crankshaft bearing holder setscrew 27 (19.9) 2,7 Crankshaft bearing holder to block (allen screws) 27 (19.9) 2,7 Crankshaft bearing holder setscrew 52 (38.3) 5,2 Crankshaft bearing holder to block (allen screws) 27 (19.
5 400 Series Crankshaft To inspect for deflection Operation 5-3 1 Support the crankshaft on V-blocks. 2 Position a dial gauge on the crankshaft centre journal, and turn the crankshaft gradually by one full turn. 3 If the gauge reading is more than the service limit, renew or regrind the crankshaft. Engine Deflection mm (in) All models Standard Service limit 0,03 or less (0.011) 0,06 (0.
5 400 Series Crankshaft journal diameter Engine Size Standard 403C-11 Standard diameter Service limit 47,964 - 47,975 mm (1.88830 - 1.88880 in) 47,90 mm (1.8860 in) Undersize 0,25 mm (0.01 in) 47,714 - 47,725 mm (1.87850 - 1.87890 in) 47,65 mm (1.8750 in) Undersize 0,50 mm (0.02 in) 47,464 - 47,475 mm (1.86870 - 1.86910 in) 47,40 mm (1.8660 in) 403C-15 404C-22 404C-22T Standard 67,957 - 67,970 mm (2.67550 - 2.67597 in) 67,90 mm (2.6732 in) Undersize 0,25 mm (0.01 in) 67,707 - 67,720 mm (2.
5 400 Series Main bearings To dismantle and to assemble Operation 5-4 Engine 403C-11 Torque Nm (lbf ft) kgf m Bearing holder setscrew 23 (16.9) 2,3 403C-15, 404C-22 and 404C-22T Bearing holder setscrew 52 (38.3) 5,2 End float If the end float is greater than the service limit check the thrust washers for wear. Note: Item (1) only used on 404C-22 and 404C-22T. Engine Standard clearance Service limit 0,10 - 0,30 mm (0.0040 - 0.0120 in) 0,50 mm (0.
5 400 Series Bearing holder Centre bearing 1 Remove the bearing holder and inspect for peeling, melting, stepped wear and damage. if it is damaged renew. 2 Use Plastigauge ® to measure the oil clearance (see Operation 4-10) between the crankshaft centre journal and the bearing. If the oil clearance is greater than the service limit, renew the bearings or regrind the centre journal and use undersize bearings. Engine Standard oil clearance Service limit 403C-11 0,039 - 0,106 mm (0.00153 - 0.
400 Series 6 Timing case and drive assembly 6 Timing cover To remove Operation 6-1 Engine Special tools Description 403C-11 Part number Front oil seal protector 21825620 403C-15, 404C-22 and 404C-22T Front oil seal protector 21825621 Cautions: l If the timing case assembly or internal governor components are replaced the fuel adjustment screw should not be adjusted. The maximum no load speed should be checked after assembly.
6 400 Series To fit Operation 6-2 Engine Special tools Description Part number 403C-11 Front oil seal protector 21825620 403C-15 404C-22 404C-22T Front oil seal protector 21825621 To fit 1 The fuel injection pump, see Operation 11-3 and the keyway in the crankshaft must be removed before the timing case is fitted. Fit the front oil seal protector. 2 To fit the PTO cover, see Operation 6-9.
6 400 Series Angleich To remove and to fit Engine 403C-15, 404C-22 404C-22T Operation 6-3 Torque Nm (lbf ft) kgf m Angleich (1) 5 (3.6) 0,5 Notes: l The internal setting for the Angleich must not be altered. l Apply a little Loctite 275 to threads (2) before assembly. l The Angleich is not fitted to the 403C-11 engine.
6 400 Series Slider To remove and to fit Operation 6-4 The slider (2) must be fitted with the slot (4) held captive by the pin (3). When fitting the timing case care must be taken to ensure correct alignment of the slider contact (1) with the governor lever. Caution: Incorrect alignment of the slider (2) on the pin (3) may result in the loss of engine speed control.
6 400 Series Camshaft retaining plate To remove and to fit Engine All models Operation 6-5 Torque Nm (lbf ft) kgf m Camshaft retainer plate setscrews 11 (8) 1,1 The camshaft retainer plate is fitted between the cylinder block and the camshaft gear. The camshaft retainer plate is fastened by either two setscrews or a setscrew and an allen screw. Note: If the camshaft assembly is replaced the fuel adjustment screw must not be altered from the original setting.
6 400 Series Camshaft and tappets To remove and to fit Operation 6-6 Caution: Remove the lift pump see Operation 11-2 and the fuel injection pump see Operation 11-3 before removing the camshaft. Note: If the camshaft assembly is replaced the fuel adjustment screw must not be altered from the original setting. The maximum no load speed must be checked after assembly. Lubricate the tappets with clean lubricating oil before assembly.
6 400 Series Camshaft assembly To inspect Operation 6-7 Height of cam for inlet and exhaust valves (1). Engine Height mm (in) Standard Service limit 26,955 - 27,010 (1.06120 - 1.06340) 26,5 (1.0276) 403C-15, 404C-22 and 404C-22T 34,065 - 34,120 (1.34114 - 1.34330) 33,7 (1.3270) 403C-11 Height of cam for fuel feed pump (2). Engine Height mm (in) Standard Service limit 27.900 - 28,000 (1.09842 - 1.10240) 27,0 (1.0630) 403C-15, 404C-22 and 404C-22T 31,900 - 32,000 (1.25590 - 1.25984) 30,0 (1.
6 400 Series Maximum fuel screw and maximum speed screw Location Operation 6-8 Engine All models Torque Nm (lbf ft) kgf m Maximum fuel screw lock nut 14 (10.3) 1,4 Maximum speed screw lock nut 14 (10.3) 1,4 Caution: The fuel adjustment setscrew must be set correctly for the engine to comply with emissions legislation. This must only be carried out by an approved Perkins distributor. Notes: l The maximum fuel setscrew (1) and the maximum speed setscrew (2) must not be adjusted by the operator.
6 400 Series Front oil seal and PTO cover To remove and to fit Operation 6-9 An ‘O’ ring (1) is fitted in the groove (2) on the front of the timing case. A joint (3) is used on the rear of the timing case PTO cover.
6 400 Series Idler gear and oil pump To remove and to fit Operation 6-10 To check the end float, see Operation 6-13.
6 400 Series Idler hub To remove and to fit Operation 6-11 To remove the lubricating oil pump idler hub the crankshaft must be removed. The oil pump idler hub can then be removed with a suitable drift and hammer from the inside of the engine block. 1 Fit the location pin (1) into the block. 2 Place the idler hub (4) into the idler hub tool (3) and fit on the location pin (1). 3 Using the hammer (2) hit the idler hub tool until the hub is fitted.
6 400 Series Gear teeth backlash To check Engine All models Operation 6-12 Timing gear tolerances mm (in) Standard Service limit 0,08 (0.0032) 0,25 (0.0098) Measure the clearances one at a time with a feeler gauge at each of the locations shown. If the measurement is outside the service limit fit new gears.
6 400 Series Oil pump end float To check and adjust Operation 6-13 Use a feeler gauge to check the oil pump end float (2). Adjust with 0,1 - 0,15 - 0,2 and 0,5 mm shims (1). Engine Standard clearance mm (in) Service limit mm (in) All models 0,10 - 0,15 (0.0040 - 0.0060) 0,20 (0.
6 400 Series Governor springs To inspect Operation 6-14 The diagram shows the correct position for the start spring (1) and the governor spring (2).
400 Series 7 Cylinder block assembly 7 Front crankshaft bush To remove and to fit Operation 7-1 Caution: Ensure that the lubrication oil hole in the bush, aligns with the oil gallery in the block. To remove the bush use a suitable drift and hammer from the inside of the block. Use a suitable press to fit the crankshaft bush. Note: The bush must be fitted with the chamfered side (2) towards the cylinder block, with the join (1) at the top.
7 400 Series To inspect Operation 7-2 1 Check the bush for damage, wear and contact. If damaged, worn or poor contact renew the bush. 2 Using a cylinder gauge and a micrometer, measure the bush (A) and the crankshaft journal (B) to calculate the clearance. 3 Measure the inside diameters at positions (A1) and (A2) at each position measure in both directions (A3) and (A4) as shown. The oil clearance is the difference between the larger value and the maximum crankshaft journal diameter.
7 400 Series Cylinder block top face To inspect Operation 7-3 Inspect the cylinder block top face for cracks, damage and warping in the same way as for the cylinder head, see Operation 3-16. If outside service limit, renew the cylinder block. Caution: The fuel adjustment screw must be set by an approved Perkins dealer to ensure that the engine will comply with emissions legislation. If the cylinder block is renewed, the engine must be tested on an engine test brake and the fuel adjustment screw set.
7 400 Series Cylinder bore To inspect Operation 7-4 1 Visually inspect cylinder bore. There should be no scoring or corrosion. 2 Measure the cylinder bore using a cylinder gauge at the upper, middle and lower areas (piston ring contact area) in the direction of the crankshaft (1) and at the right angle to the crankshaft (2). 3 The upper area in the cylinder block is where the top ring is in contact with the cylinder bore when the piston is at T.D.C.
400 Series 8 Engine timing 8 Injection timing Operation 8-1 Engine Maximum rated engine speed rev/min Injection timing (BTDC) 403C-11 Gen-set 1500 18° ± 1° 403C-11 Gen-set 1800 18° ± 1° 403C-11 Gen-set 3000 23° ± 1° 403C-11 Gen-set 3600 22° ± 1° 403C-11 Industrial 2200 23° ± 1° 403C-11 Industrial 2400 23° ± 1° 403C-11 Industrial 2600 23° ± 1° 403C-11 Industrial 2800 23° ± 1° 403C-11 Industrial 3000 23° ± 1° 403C-15 Gen-set 1500 14° ± 1° 403C-15 Gen-set 1800 14° ± 1°
8 400 Series To check the timing of the fuel injection pump Engine All models Special tools Spill pipe Operation 8-2 Part number 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.
8 400 Series 6 Connect a suitable clean fuel reservoir (1), which has a tap and contains approximately 0,2 litres (¼ pint) of clean fuel, to the fuel injection pump inlet. 7 Put a suitable waste fuel (3) container below the pipe neck and open the tap, if set correctly the fuel should flow. Note: The fuel reservoir should be approximately 152 mm (6 in) above the fuel injection pump. 8 Turn the crankshaft slowly until the fuel flow reduces to a drop which falls every 7 - 10 seconds.
8 400 Series 10 If the engine timing is incorrect adjust the thickness of the fuel injection pump shim. Note: Changing the fuel injection pump shim by 0,1 mm will change the timing by approximately one degree. Thicker shims will retard the timing and thinner shims will advance the timing. 11 Fit the delivery valve (1) and tighten the delivery valve holder. Caution: The maximum no load speed must be set by an approved Perkins distributor.
400 Series 9 Aspiration system 9 Breather system Closed circuit, naturally aspirated - to clean and to renew Operation 9-1 To clean the engine breather assembly The breather assembly should be renewed every 2000 hours. Caution: Ensure that the components of the breather assembly are fitted in their correct position (1 - 6). If they are incorrectly fitted, the engine may be damaged. 1 Release the four setscrews (2) and remove the breather cover (1), the spring (6) and the diaphragm assembly (4).
9 400 Series Closed circuit turbo charged - to clean and to renew Operation 9-2 To clean the engine breather assembly The breather assembly should be renewed every 2000 hours. Caution: Ensure that the components of the breather assembly are fitted in their correct position (1 - 7). If they are incorrectly fitted, the engine may be damaged. 1 Release the four setscrews (2) and remove the breather cover (1), the spring (7), the diaphragm assembly (4) and the adaptor (6).
9 400 Series Turbocharger To remove and to fit Engine Operation 9-3 Torque Nm (lbf ft) kgf m Turbocharger to manifold nuts 404C-22T 25 (18.4) 2.5 Elbow securing set screws 32,4 (23.9) 3,3 Oil feed pipe banjo bolt to turbocharger 20 (14.8) 2,0 Oil drain pipe set screws 10 (7.3) 1,0 Oil feed pipe set screws to cylinder block The turbocharger is fitted only to the 404C-22T engine. Caution: The bearing housing of the turbocharger must be lubricated with clean engine oil on assembly.
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400 Series 10 Lubrication system 10 Lubricating oil canister To fit Operation 10-1 1 Lubricate the seal with clean engine oil before assembly. 2 Tighten by hand until the seal contacts the mounting face of the block. 3 Tighten the canister by a further ½ to ¾ of a turn by hand only. Note: Do not overtighten oil filter. 4 The modine cooler (1) and fastener (2) are fitted only to the 404C-22T.
10 400 Series Pressure relief valve To remove and to fit Engine All models Operation 10-2 Torque Nm (lbf ft) kgf m Pressure relief valve 64 (47) 6,5 Renew the ‘O’ ring (1) when the pressure relief valve is fitted to the cylinder block. Caution: When the crankshaft is removed or fitted the pressure relief valve must be removed first.
10 400 Series Lubricating oil sump To remove and to fit Engine 403C-11 403C-15 404C-22 404C-22T Operation 10-3 Torque Nm (lbf ft) kgf m Sump setscrews 6 (4.4) 0,6 Sump drain plug 35 (25.8) 3,5 Sump setscrews 11 (8) 1,1 Sump drain plug 35 (25.8) 3,5 Note: When the sump is fitted renew the joint (1).
10 400 Series Lubricating oil strainer and suction pipe To remove and to fit Engine Operation 10-4 Torque Nm (lbf ft) kgf m All models Suction strainer setscrews 11 (8) 1,1 Renew the “O” ring (1) before the suction pipe is fitted.
400 Series 10 Lubricating oil pump To remove and to fit Operation 10-5 To check the end float, see Operation 6-13.
10 400 Series Rotor tip clearance To inspect Engine All models Operation 10-6 Clearance standard limit Service limit 0,01 - 0,15 mm (0.0004 - 0.0060 in) 0,25 mm (0.0098 in) Inner rotor to outer rotor (1).
10 400 Series Oil pressure switch To remove and to fit Engine All models Operation 10-7 Torque Nm (lbf ft) kgf m Oil pressure switch 10 (7.3) 1,0 The lubricating oil pressure switch can be found in two positions. 1 If fitted on the top cover, the switch (1) is brown in colour and rated to 0,3 kgf/cm² (4.27 lbf/in²). 2 If fitted on the cylinder block, the switch (2) is blue in colour and rated to 1,0 kgf/cm² (14.22 lbf/in²).
10 400 Series Lubricating oil pipes To remove and to fit Engine All models Operation 10-8 Torque Nm (lbf ft) kgf m Banjo bolt 12 (8.8) 1,2 Note: The lubricating oil flow through the banjo bolt (2 and 4) is restricted. Check the pipe for leaks and damage. When fitting use new washers (1) and (3).
400 Series 11 Fuel system 11 Atomisers To remove and to fit Engine Operation 11-1 Torque Nm (lbf ft) kgf m Atomiser All models Test pressure kgf/cm² (lbf/in²) ats 64 (47) 6,5 Atomiser high-pressure pipes 23 (16.9) 2,3 Nut - leak off-rail 27 (19.9) 2,7 150 (2133) 145 Cautions: l Use only deep sockets for this operation. l Connections should be blanked off until assembly. l Washer (1) has two small holes 180° apart. l Discard old washer (2), on assembly fit new nozzle washer.
11 400 Series Before fitting the atomiser, clean and dry the male and female threads of the atomiser and the cylinder head. Apply a 2 mm (0.08 in) bead of sealant POWERPART universal jointing compound, part number 1861117, to extend 6 mm (0.24 in) along the first two threads of the atomiser (3).
11 400 Series Fuel lift pump To remove and to fit Engine Operation 11-2 Torque Nm (lbf ft) kgf m All models Lift pump setscrew 6 (4.4) 0,6 Lift pump inlet adjusting bolt (1) 2,5 (1.8) 0,25 The fuel inlet for the fuel lift pump can rotate 360° and is adjustable in 15° increments. The fuel lift pump flange has two sets of locating holes this allows the pump to be fitted in four positions for the outlet connection.
11 400 Series Fuel injection pump To remove and to fit Engine Operation 11-3 Torque Nm (lbf ft) kgf m 403C-11 Fuel injection pump fasteners 6 (4.4) 0,6 403C-15 404C-22 404C-22T Fuel injection pump fasteners 15 (11) 1,5 Caution: Connections should be blanked off until assembly. Notes: l If the fuel injection pump is renewed, shims of the same thickness as originally fitted should be used.
11 400 Series To eliminate air from the fuel system Operation 11-4 1 Loosen the vent screw on the fuel filter (1). 2 Operate the hand primer until fuel, free of air, flows from the vent screw. Tighten the vent screw (1). 3 loosen the vent screw on the fuel injection pump (2). Operate the hand primer until fuel, free of air, flows. Tighten the vent screw (2). 4 Attempt to start the engine using the starter motor for a maximum of 15 seconds, wait for 30 seconds before trying again.
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400 Series 12 Cooling system 12 Coolant pump To remove and to fit Operation 12-1 Fit new joint (1) on assembly.
12 400 Series To inspect Operation 12-2 Start the engine check the coolant pump tell-tale hole (1) for coolant leakage.
12 400 Series Fan and mounting To remove and to fit Operation 12-3 On assembly check the tension of the belt, see Operation 14-3.
12 400 Series Thermostat To remove and to fit Engine All models Operation 12-4 Torque Nm (lbf ft) kgf m Setscrew 14 (10.3) 1,4 Caution: Ensure that the thermostat is correctly seated in the thermostat housing.
12 400 Series To drain the cylinder block Engine All models Operation 12-5 Torque Nm (lbf ft) kgf m Cylinder block drain plug 30 (22,0) 3,0 1 H1106 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 95
12 400 Series To test and to inspect Operation 12-6 Visually inspect for damage, renew the thermostat if the valve is open at ambient temperature. 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. Engine Temperature when thermostat valve starts to open °C (°F) Temperature when thermostat valve fully open °C (°F) 403C-11 75 (167) 87 (189) 403C-15 404C-22 80 to 84 (176 to 183.
400 Series 13 Flywheel and housing 13 Flywheel To remove and to fit Engine All models Operation 13-1 Torque Nm (lbf ft) kgf m Flywheel setscrew 74 (54.
13 400 Series To check for concentricity and alignment of the flywheel housing Operation 13-2 Check the housing concentricity with a dial test indicator (A). The run-out limit is given in the table below. If any adjustment is necessary, it must be made on the housing and the concentricity checked again. Flywheel housing bore run-out SAE 5 Flywheel housing SAE 4 Flywheel housing All models 0,20 mm (0.008 in) 0,23 mm (0.009 in) Check the housing alignment (B).
13 400 Series To check for run-out of the flywheel and alignment of the flywheel face Operation 13-3 1 Check the flywheel run-out with a dial test indicator (A). This must be less than 0,20 mm (0.008 in) total indicator reading. 2 Check the alignment of the flywheel face (B). During this check, keep the crankshaft pressed toward the front to remove the effect of crankshaft end-float.
13 400 Series Starter ring gear To remove and to fit Operation 13-4 If the ring gear is excessively worn, renew. When the wear is not excessive remove the ring gear and fit 90° from the original position. To fit the ring gear heat to 120 °C to 150 °C (248 °F to 301°F). Caution: Heat evenly, do not locally overheat.
13 400 Series Backplate and rear oil seal To remove and to fit Operation 13-5 Only the 404C-22 engines / models have the backplate and the housing fitted together. Engine 403C-11 403C-15 404C-22 404C-22T Torque Nm (lbf ft) kgf m Setscrew - backplate 50 (36.9) 5,1 Setscrew - housing 50 (36.9) 5,1 Setscrew - backplate 25 (18.8) 2,6 Setscrew - housing 25 (18.8) 2,6 Note: On assembly ensure that Powerpart silicone sealant is used between the cylinder block and the rear end oil seal.
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400 Series 14 Electrical equipment 14 Electrical shut off solenoid To remove and to fit Operation 14-1 Special requirements Engine All models Torque Nm (lbf ft) kgf m Solenoid 17 (12) 1,7 Notes: l The washer is fitted with an integral “O” ring. l Always use a new washer on assembly.
14 400 Series Bus-bar / glowplugs To remove and to fit Engine 403C-11 403C-15 404C-22 404C-22T Operation 14-2 Torque Nm (lbf ft) kgf m Glow plug 12 (8.9) 1,2 Busbar nut 1,2 (0.9) 0,12 Glow plug 18 (13) 1,8 Busbar nut 1,2 (0.
14 400 Series Drive belt To inspect and to adjust Operation 14-3 Press down the centre of the belt on the longest free length with a finger force of 49 Newtons, 11 lbf, 5 kgf approximately. Engine Deflection in mm (in) 403C-11 5 (0.19) 403C-15 6 (0.23) 404C-22 404C-22T 7 (0.27) Check the belt for cracks or contamination by oil or grease.
14 400 Series Alternator To remove and to fit Operation 14-4 On assembly check the tension of the drive belt, see Operation 14-3.
400 Series 14 Starter motor To remove and to fit Operation 14-5 Warning! The battery must be disconnected before the starter motor is removed.
14 400 Series Wiring diagram 15 amp alternator - 403C-11 Cable number Circuit Alternator charging Starter motor solenoid STD glow plugs (via glow signal) Circuit current Maximum circuit resistance Maximum circuit volt drop Remarks 14 amp (2 cyl) 15 amp (3 cyl) 0.036 ³ (2 cyl) 0.033 ³ (3 cyl) 0.5 Volt See Glow Plugs Circuit 15.75 amp 0.04 ³ 0.63 Volt See Glow Plugs Circuit (Peak max) 26 amp (2 cyl) 39 amp (3 cyl) 0.0192 ³ (2 cyl) 0.0128 ³ (3 cyl) 0.
14 400 Series Wiring diagram 40 amp alternator - 403C-11 Circuit current Maximum circuit resistance Maximum circuit volt drop Remarks 40 amp 0.0125 ³s 0.5 Volt See Glow Plugs Circuit Starter motor solenoid 15.75 amp 0.04 ³s 0.63 Volt See Glow Plug Circuit STD glow plugs (via glow signal) (Peak max) 39 amp 0.0128 ³s 0.5 Volt Cable number Circuit Alternator charging Wiring diagram maximum circuit resistance The resistance of battery cables 1,2 and 3 must not exceed 0.0018 ³.
14 400 Series Wiring diagram 55 amp alternator 403C-15, 404C-22 and 404C-22T Charging circuit Cable number Circuit Circuit current Maximum circuit resistance Maximum circuit volt drop Remarks Alternator charging 4, 7, 11 55 Amps 0.0143 ohm 0.50 Volt See glow plugs circuit Starter motor solenoid 4, 5, 6 15.75 Amps 0.0400 ohm 0.63 Volt See glow plugs circuit 4, 5, 8, 9, 10 (Peak max) 52 Amps 0.0139 ohm 0.
14 400 Series Automatic shutdown connector 55 Amp alternator charge lamp Note: Alternator charge lamp rating: 12V - 2.2W at 850 rev/min. When the engine is at rest the alternator charge lamp is illuminated via the battery and it extinguishes when the alternator operates. The use of a lower wattage bulb than the above will increase speed at which self excitation occurs upon initial run up, e.g. a charge lamp with a lower wattage bulb will have a rating of 12V - 1.2W at 1300 rev/min.
14 400 Series Wiring diagram - automatic shutdown 15 amp alternator - 403C-11 Automatic shutdown operation conditions If the conditions below last for more than 10 seconds during the start operation, the engine will shut down. If the conditions below last for more than 2 seconds while the engine is operated, the engine will shut down. Warning! There is no protection against low water levels. Conditions Water temperature switch: If the water temperature exceeds 105 °C ± 4 °C.
14 400 Series Wiring diagram - automatic shutdown 40 amp alternator - 403C-11 Automatic shutdown operation symptoms If the conditions below last for more than 10 seconds during the start operation, the engine will shut down. If the conditions below last for more than 2 seconds while the engine is operated, the engine will shut down. Warning! There is no protection against low water levels. Conditions Water temperature switch: If the water temperature exceeds 105 °C ± 4 °C.
14 400 Series Wiring diagram - automatic shutdown 55 amp alternator 403C-15, 404C-22 and 404C-22T Automatic shutdown operating conditions If the conditions listed below continues for more than ten seconds while starting, or two seconds while the engine is being operated, the engine will shutdown. If the water temperature exceeds 110 °C (230 °F) ± 3°C (5 °F) If the oil pressure falls below 0,3 kgf / cm² (4.27 lbf / in² top cover option) or 1,0 kgf / cm² (14.22 lbf / in² oil rail option).
400 Series 15 Auxiliary equipment None fitted Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 15 Operation 15-1 115
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400 Series 16 Special tools 16 Special tools list These tools are available locally through your Perkins distributor. If you cannot obtain the correct tool locally contact: The Perkins Service Department, Peterborough, PE1 5NA, England, UK. Tel. +44 1733583000 Fax +441733582240 Description Telex 32501 PERKEN G.
16 400 Series Description Illustration Fuel pump spill pipe Part number 21825680 Front oil seal protector 403C-11 part number 21825620 403C-15, 404C-22 part number 21825621 Valve seat cutter Part number 27610030 118 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green
