Workshop Manual
Table Of Contents
- Perkins 400 Series
- 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
- Wiring diagram 15 amp alternator - 403C-11 108
- Wiring diagram 40 amp alternator - 403C-11 109
- Wiring diagram 55 amp alternator 403C-15, 404C-22 and 404C-22T 110
- Automatic shutdown connector 111
- Wiring diagram - automatic shutdown 15 amp alternator - 403C-11 112
- 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
- 16 Special tools
- General information
- Introduction
- Safety precautions
- POWERPART recommended consumable products
- POWERPART Antifreeze
- POWERPART Easy Flush
- POWERPART Gasket and flange sealant
- POWERPART Gasket remover
- POWERPART Griptite
- POWERPART Hydraulic threadseal
- POWERPART Industrial grade super glue
- POWERPART Lay-Up 1
- POWERPART Lay-Up 2
- POWERPART Lay-Up 3
- POWERPART Metal repair putty
- POWERPART Pipe sealant and sealant primer
- POWERPART Radiator stop leak
- POWERPART Retainer (high strength)
- POWERPART Safety cleaner
- POWERPART Silicone adhesive
- POWERPART Silicone RTV sealing and jointing compound
- POWERPART Stud and bearing lock
- POWERPART Threadlock and nutlock
- POWERPART Universal jointing compound
- Engine views
- Engine identification
- Engine lift equipment
- Specifications
- Cylinder head assembly
- Piston and connecting rod assemblies
- Crankshaft assembly
- Timing case and drive assembly
- Cylinder block assembly
- Engine timing
- Aspiration system
- Lubrication system
- Fuel system
- Cooling system
- Flywheel and housing
- Electrical equipment
- Electrical shut off solenoid
- Bus-bar / glowplugs
- Drive belt
- Alternator
- Starter motor
- To remove and to fit Operation 14-5
- Wiring diagram 15 amp alternator - 403C-11
- Wiring diagram 40 amp alternator - 403C-11
- Wiring diagram 55 amp alternator 403C-15, 404C-22 and 404C-22T
- Automatic shutdown connector
- Wiring diagram - automatic shutdown 15 amp alternator - 403C-11
- Wiring diagram - automatic shutdown 40 amp alternator - 403C-11
- Wiring diagram - automatic shutdown 55 amp alternator 403C-15, 404C-22 and 404C-22T
- Auxiliary equipment
- Special tools
3
Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 23
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 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.
Notes:
l If the cylinder block, crankshaft, connecting rods or pistons are changed the piston height will have to be
checked and the correct thickness gasket used.
l If the original piston is used, ensure that it is assembled to the correct connecting rod and is used in the
original cylinder.
Cylinder head gasket selection
Engine Protrusion above cylinder block top face Gasket thickness
403C-11
0,55 to 0,64 1,2 mm
0,65 to 0,75 1,3 mm
403C-15
0,60 to 0,69 1,3 mm
0,70 to 0,79 1,4 mm
Engine Protrusion below cylinder block top face Gasket thickness
404C-22
404C-22T
-0,45 to -0,30 0,4 mm
-0,29 to -0,20 0,5 mm
H1044