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
Workshop Manual TPD 1458E, issue 3 - Perkins Confidential: Green v
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 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 35
Piston rings
Operation 4-4 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 36
Operation 4-5 To measure the piston ring clearance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 37
Operation 4-6 To measure the piston ring gap .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 38
Piston and connecting rod assemblies
Operation 4-7 To dismantle and to assemble
. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 39
Piston and piston ring
Operation 4-8 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 40
Connecting rod
Operation 4-9 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 41
Connecting rod bearing clearance
Operation 4-10 To check
.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 42
Small end bush
Operation 4-11 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 43
5 Crankshaft assembly
Crankshaft pulley
Operation 5-1 To remove and to fit
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 45
Crankshaft retaining bolts and crankshaft
Operation 5-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 46
Crankshaft
Operation 5-3 To inspect for deflection ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 47