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
5
Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 47
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.
4 When the measured diameter is less than the service limit, regrind and use undersized bearings and bushes.
Crankshaft inspection
1 Check the oil seal contact face for damage or wear.
2 Check oil holes for clogging.
3 Check crankshaft journal (A4) and crank pin (A3) for stepped wear. Take measurements of diameters (A5-
A5) and (A6-A6) at positions (A1) and (A2). If the maximum difference between the measurements (stepped
wear) is more than the service limit of 0,05 mm (0.0019 in) then correction is required.
Grinding specification
When grinding the crankshaft, work with the following specifications:
Note: Use No. 400 emery cloth for final polishing.
Engine Deflection mm (in)
Standard Service limit
All models 0,03 or less (0.011) 0,06 (0.0023)
Radius at pin / journal (B1) 3 mm (0.118 in) ± 0,2 mm (± 0.0078 in)
Finish precision (B2) 1.6Z (∇ ∇ ▼)
Radius around oil hole (B3) 2 mm (0.787 in) maximum / 5 mm (0.196 in) minimum
B
1
2 3
A
3
4
1
2
1
2
5
5
6
6
H1064