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
4
40 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green
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. If the clearance is more than the service limit, or piston diameter is less than service limit, renew
the piston
Engine Cylinder diameter Service limit
403C-11 76,932 - 76,947 mm (3.02880 - 3.02940 in) 76,7 mm (3.020 in)
403C-15
404C-22
404C-22T
83,948 - 83,963 mm (3.30503 - 3.30562 in) 83,7 mm (3.295 in)
Engine Clearance between piston and cylinder Service limit
403C-11 0,0525 - 0,0865 mm (0.00210 - 0.00340 in) 0,25 mm (0.010 in)
403C-15
404C-22
404C-22T
0,0380 - 0,0720 mm (0.00150 - 0.00283 in) 0,25 mm (0.010 in)