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
7
68 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green
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. (approximately 10 mm below the cylinder block top face). The lower area is where the oil control
ring is in contact with the cylinder bore when the piston is at B. D. C. (about 100 mm from the top face).
Caution: The 400 Series range of engines must not be flexi honed.
If the bore diameter is larger than the service limit for the engine model listed below, renew the cylinder block
with a long engine.
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 should be tested on an engine test brake and the fuel adjustment
screw set.
If a suitable engine test brake is not available, a long engine is available as a service part.
Engine Bore diameter new cylinder block Service limit
403C-11 77,000 - 77,019 mm (3.03100 - 3.03200 in) 77,200 mm (3.03900 in)
403C-15
404C-22
404C-22T
84,000 - 84,019 mm (3.30710 - 3.30783 in) 84,200 mm (3.31500 in)
H1085
1
2