Perkins Engine 403C-11, 403C-15, 404C-22, 404C-22T Service Manual
Perkins 400 Series
Models 403C-11, 403C-15, 404C-22 and 404C-22T
WORKSHOP MANUAL
403C-11 Three cylinder naturally aspirated diesel
engine
403C-15 Three cylinder naturally aspirated diesel
engine
404C-22 Four cylinder naturally aspirated diesel
engine
404C-22T Four cylinder turbo charged diesel engine
Perkins Confidential: Green
Publication TPD 1458E, Issue 3.
© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in September 2002 by Technical Publications.
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Chapters
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 sy stem
13 Flywheel and housing
14 Electrical equipment
15 Auxiliary equipment
16 Special tools
The following pages contain a detailed table of contents
ii
400 Series
Contents
1 General information
Introduction .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1
Safety precautions . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2
POWERPART recommended consumable products ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4
Engine views ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6
Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7
Engine lift equipment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8
2 Specifications
Basic engine data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9
Standard torques ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 10
Special torques .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 11
Compression test data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 12
3 Cylinder head assembly
Rocker cover and inlet manifold
Operation 3-1 To remove and to fit
Rocker assembly
Operation 3-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 14
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... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..13
400 Series
Operation 3-3 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15
Operation 3-4 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16
Exhaust manifold and gasket
Operation 3-5 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 17
Fuel injection pipes / fuel return pipes
Operation 3-6 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18
Cylinder head setscrews
Operation 3-7 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19
Cylinder head
Operation 3-8 Tightening sequence 403C-11 and 403C-15
. ... ... ... ... ... ... ... ... ... ... ... ... ... 20
Operation 3-9 Tightening sequence 404C-22 and 404C-22T .. ... ... ... ... ... ... ... ... ... ... ... ... 21
Cylinder head gasket
Operation 3-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22
Operation 3-11 To select the correct thickness of cylinder head gasket .. ... ... ... ... ... ... ... 23
Valve and valve spring
Operation 3-12 To remove and to fit
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24
Operation 3-13 To inspect - valve spring ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25
Operation 3-14 To inspect - valve stem and thickness of valve head ... ... ... ... ... ... ... ... ... 26
Cylinder head to valve stem clearance
Operation 3-15 To inspect
. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27
Cylinder head
Operation 3-16 To inspect
. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28
Valve seat width
Operation 3-17 To inspect and to correct ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29
Valve depth
Operation 3-18 To check . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30
Operation 3-19 To lap the contact face of the valve seat . ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31
Valve tip clearance
Operation 3-20 To check and to adjust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 32
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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
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
Small end bush
Operation 4-11 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 43
.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..42
. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 39
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
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Main bearings
Operation 5-4 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49
Bearing holder ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50
6 Timing case and drive assembly
Timing cover
Operation 6-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 51
Operation 6-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 52
Angleich
Operation 6-3 To remove and to fit
.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 53
Slider
Operation 6-4 To remove and to fit
.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 54
Camshaft retaining plate
Operation 6-5 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 55
Camshaft and tappets
Operation 6-6 To remove and to fit
.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 56
Camshaft assembly
Operation 6-7 To inspect
. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 57
Maximum fuel screw and maximum speed screw
Operation 6-8 Location
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 58
Front oil seal and PTO cover
Operation 6-9 To remove and to fit
.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 59
Idler gear and oil pump
Operation 6-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 60
Idler hub
Operation 6-11 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 61
Gear teeth backlash
Operation 6-12 To check ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 62
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Oil pump end float
Operation 6-13 To check and adjust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..63
Governor springs
Operation 6-14 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 64
7 Cylinder block assembly
Front crankshaft bush
Operation 7-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 65
Operation 7-2 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..66
Cylinder block top face
Operation 7-3 To inspect
Cylinder bore
Operation 7-4 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..68
. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 67
8 Engine timing
Operation 8-1 Injection timing . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 69
Operation 8-2 To check the timing of the fuel injection pump ... ... ... ... ... ... ... ... ... ... ... ... .. 70
9 Aspiration system
Breather system
Operation 9-1 Closed circuit, naturally aspirated - to clean and to renew .. ... ... ... ... ... ... ..73
Operation 9-2 Closed circuit turbo charged - to clean and to renew ... ... ... ... ... ... ... ... ... .. 74
Turbocharger
Operation 9-3 To remove and to fit
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..75
10 Lubrication system
Lubricating oil canister
Operation 10-1 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..77
Pressure relief valve
Operation 10-2 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 78
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Lubricating oil sump
Operation 10-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79
Lubricating oil strainer and suction pipe
Operation 10-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 80
Lubricating oil pump
Operation 10-5 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 81
Rotor tip clearance
Operation 10-6 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 82
Oil pressure switch
Operation 10-7 To remove and to fit
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 83
Lubricating oil pipes
Operation 10-8 To remove and to fit
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 84
11 Fuel system
Atomisers
Operation 11-1 To remove and to fit
Fuel lift pump
Operation 11-2 To remove and to fit
Fuel injection pump
Operation 11-3 To remove and to fit
Operation 11-4 To eliminate air from the fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 89
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 85
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 87
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 88
12 Cooling system
Coolant pump
Operation 12-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 91
Operation 12-2 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 92
Fan and mounting
Operation 12-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 93
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Thermostat
Operation 12-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 94
Operation 12-5 To drain the cylinder block . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 95
Operation 12-6 To test and to inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..96
13 Flywheel and housing
Flywheel
Operation 13-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 97
Operation 13-2 To check for concentricity and alignment of the flywheel housing . ... ... ..98
Operation 13-3 To check for run-out of the flywheel and alignment of the flywheel face .99
Starter ring gear
Operation 13-4 To remove and to fit
Backplate and rear oil sea l
Operation 13-5 To remove and to fit
. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 100
... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 101
14 Electrical equipment
Electrical shut off solenoid
Operation 14-1 To remove and to fit
Bus-bar / glowplugs
Operation 14-2 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 104
Drive belt
Operation 14-3 To inspect an d to adjust .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 105
Alternator
Operation 14-4 To remove and to fit
. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 103
. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 106
Starter motor
Operation 14-5 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 107
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
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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
Operation 15-1 None fitted . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..115
16 Special tools
Special tools list .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..117
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1
General information 1
Introduction
This workshop manual has been written to provide assistance for technicians who service and overhaul the
Perkins 403C-11, 403C-15, 404C-22 and the 404C-22T engine. The assumption is made that the engine is
removed from the application.
The engine conforms with USA EPA/CARB and EC emissions legislation for agricultural and industrial
applications.
Where the information applies only to certain engine types, this is indicated in the text.
Special tools are available and listed in chapter 16. POWERPART recommended consumable products are
listed in this chapter. There is a reference to the relevant special tools and consumable products at the
beginning of each operation.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: This indicates that there is a possible danger to the engine.
Note: Is used where the information is important, but there is not a danger.
Warning! Read and remember the "Safety precautions". They are given for your protection and must be used
at all times.
Generally, if new joints are to be fitted, it is accepted that the faces for the joint will be cleaned, as this is normal
workshop practice. Also, it is understood that during assembly and inspection, all parts are to be thoroughly
cleaned and lubricated, and where present, burrs and scale are to be removed.
All open ports of high-precision components e.g. fuel injection equipment must be covered until assembly, to
prevent the entry of foreign matter.
When either the "left" or the "right" side of the engine is referred to, it is when viewed from the flywheel end.
When fitting setscrews or studs into holes that enter oil, coolant or air passages, a suitable sealant should be
used to prevent leakage.
Micro encapsulated anaerobic sealant (M.E.A.S.) has been applied to the threads instead of jointing
compounds or other sealants when the fasteners are fitted in through holes into oil or coolant passages. The
identification of these fasteners, as supplied, is by the colour of the sealant.
With M.E.A.S. sealed studs, the sealed end must be fitted into the component. The threaded holes must have
a 1,59 mm (0.0625 in) 45° chamfer to ensure that the M.E.A.S. sealant is not removed when the new fasteners
are fitted. If the fasteners have to be removed and fitted again, the threads must be cleaned and a suitable
sealant used.
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400 Series
Safety precautions
These safety precautions are important. You must refer also to the local regulations in the country of use.
Some items only refer to specific applications
l Only use these engines in the type of application for which they have been designed.
l Do not change the specification of the engine.
l Do not smoke when you put fuel in the tank.
l Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
l Do not put diesel fuel in the tank during engine operation (unless it is absolutely necessary).
l Do not add lubricating oil, or adjust the engine while it runs (unless you have had the correct training; even
then extreme care must be used to prevent injury).
l Do not make adjustments that you do not understand.
l Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
l Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation.
l Do not permit loose clothing or long hair near moving parts.
l Keep away from moving parts during engine operation. Warning! Some moving parts cannot be seen
clearly while the engine runs.
l Do not operate the engine if a safety guard has been removed.
l Do not remove the filler cap or any component of the cooling system while the engine is hot and while the
coolant is under pressure, because dangerous hot coolant can be discharged.
l Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the
gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially
to the eyes.
l Disconnect the battery terminals before a repair is made to the electrical system.
l Only one person must control the engine.
l Ensure that the engine is operated only from the control panel or from the operators position.
l If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
l Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons.
Protect your hands with gloves or a special solution to protect the skin.
l Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets of clothing.
l Discard used lubricating oil in accordance with local regulations to prevent contamination.
l Ensure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is
started.
l Use extreme care if emergency repairs must be made in adverse conditions.
l The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes.
l Always use a safety cage to protect the operator when a component is to be pressure tested in a container
of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to
be pressure tested.
l Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
l Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and debris away from
the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.
l Do not clean an engine while it runs or while it is hot. If cold cleaning fluids are applied to a hot engine,
certain components on the engine could be damaged.
l Fit only genuine Perkins parts.
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Viton seals
Warnings!
l Some seals used in engines and in components fitted to engines are made of Viton. Viton is used by many
manufactures and is a safe material under normal conditions of operation. If Viton is burned, a product of
this burnt material is an acid which is extremely dangerous. Never allow this burnt material to come into
contact with the skin or with the eyes. If it is necessary to come into contact with components which have
been burnt, ensure that the precautions which follow are used:
l Ensure that the components have cooled.
l Use Neoprene gloves and discard the gloves safely after use.
l Wash the area with calcium hydroxide solution and then with clean water.
l Disposal of components and gloves which are contaminated must be in accordance with local regulations.
If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or
with calcium hydroxide solution for 15 - 60 mi nutes. Obtain immediate medical attention.
Safety cautions when an engine is cleaned
Care should be taken, when an engine is cleaned with a high pressure cleaning system.
Cautions:
l Do not wash an engine while it runs or while it is hot. If cold cleaning fluids are applied to a hot engine,
certain components on the engine could be damaged.
l Leave the engine to cool for at least one hour and disconnect the battery connections before cleaning.
l Do not wash any part of the fuel injection pump (FIP), cold start device, electrical shut off solenoid (ESOS)
or electrical connectors.
l Ensure that the alternator, starter motor and any other electrical components are shielded and not directly
cleaned by the high pressure cleaning system.
If these cautions are ignored, the engine or certain components could be damaged, fail to operate and also
make the manufacturer’s warranty invalid.
1
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400 Series
POWERPART recommended consumable products
Perkins have made available the products recommended below in order to assist in the correct operation,
service and maintenance of your engine and your machine. The instructions for the use of each product are
given on the outside of each container. These products are available from your Perkins distributor.
POWERPART Antifreeze
Protects the cooling system against frost and corrosion.
Part number 21825166.
POWERPART Easy Flush
Cleans the cooling system.
Part number 21825001.
POWERPART Gasket and flange sealant
To seal flat faces of components where no joint is used. Especially suitable for aluminium components.
Part number 21820518.
POWERPART Gasket remover
An aerosol for the removal of sealants and adhesives.
Part number 21820116.
POWERPART Griptite
To improve the grip of worn tools and fasteners.
Part number 21820129.
POWERPART Hydraulic threadseal
To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and pneumatic systems.
Part number 21820121.
POWERPART Industrial grade super glue
Instant adhesive designed for metals, plastics and rubbers.
Part number 21820125.
POWERPART Lay-Up 1
A diesel fuel additive for protection against corrosion.
Part number 1772204.
POWERPART Lay-Up 2
Protects the inside of the engine and of other closed systems.
Part number 1762811.
POWERPART Lay-Up 3
Protects outside metal parts.
Part number 1734115.
POWERPART Metal repair putty
Designed for external repair of metal and plastic.
Part number 21820126.
POWERPART Pipe sealant and sealant primer
To retain and seal pipe connections with coarse threads. Pressure systems can be used immediately.
Part number 21820122.
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400 Series
POWERPART Radiator stop leak
For the repair of radiator leaks.
Part number 21820127.
POWERPART Retainer (high strength)
To retain components which have an interference fit. Currently Loctite 638.
Part number 21820638.
POWERPART Safety cleaner
General cleaner in an aerosol container.
Part number 21820128.
POWERPART Silicone adhesive
An RTV silicone adhesive for application where low pressure tests occur before the adhesive sets. Used for
sealing flange where oil resistance is needed and movement of the joint occurs.
Part number 21826038.
POWERPART Silicone RTV sealing and jointing compound
Silicone rubber sealant which prevents leakage through gaps. Currently Hylosil.
Part number 1861108.
1
POWERPART Stud and bearing lock
To provide a heavy duty seal to components that have a light interference fit.
Part number 21820119 or 21820120.
POWERPART Threadlock and nutlock
To retain small fasteners where easy removal is necessary.
Part number 21820117 or 21820118.
POWERPART Universal jointing compound
Universal jointing compound which seals joints. Currently Hylomar.
Part number 1861117.
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Engine views
400 Series
H1029
H1030
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400 Series
Engine identification
Engine build lists numbering system
The standard engine build list numbering code is defined as follows:
Code I II III IV V
Example HP TBA U 000001 D
Code I Engine build code
Code HH HL HP HR
Engine 403C-11 403C-15 404C-22 404C-22T
Code II engine build list
The build list increases numerically for both OEMS and distributors.
Code III country of manufacture
Code J U
Country of manufacture Made in Japan Made in U.K.
Code IV engine serial number
Individual serial number commencing with 000001 increasing numerically.
1
Code V year of manufacture
Code H J
Year 2001 2002
Perkins
LIST NO SERIAL NO TYPE
TYPE
H1031
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1
Engine lift equipment
Recomm en d ed torque : l if ting eye bolt s
Engine Nm (lbf ft) kgf m
All models 26 (19) 2,6
Maximum engine weights
400 Series
Engine Engine specification Maximum engine
weights (dry)
Long flywheel housing speci fic at ion 114 kg
403C-11
403C-15
404C-22
404C-22T
(1) Engine may alter with final specification.
Short flywheel housing specification 96 kg
Backplate specification 87 kg
Long flywheel housing speci fic at ion 176 kg
Short flywheel housing specification 154 kg
Backplate specification 150 kg
Long flywheel housing speci fic at ion 220 kg
Short flywheel housing specification 196 kg
Backplate specification 184 kg
Long flywheel housing speci fic at ion 230 kg
Short flywheel housing specification 206 kg
Backplate specification 194 kg
(1)
H1032
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400 Series
2
Specifications 2
Basic engine data
Engine model 403C-11 403C-15 404C-22 404C-22T
Engine build code HH HL HP HR
Number of cy linde rs 3 3 4 4
Cylinder
arrangement
Cycle Four stroke
Direction of rotation Clockwise from the front
Induction system Naturally aspirated Turbo charged
Combustion system Indirect injection
Nominal bore 77 mm (3.03 in) 84 mm (3.3 in)
Stroke 81 mm (3.19 in) 90 mm (3.5 in) 100 mm (3.9 in)
Compression ratio 23: 1 22.5: 1 23.3: 1
Cubic capacity 1,131 litres (69 in³) 1,496 litres (91 in³) 2,216 litres (135.2 in³)
Firing order 1, 2, 3 1, 2, 3 1, 3, 4, 2
Valve tip clearance (cold)
Inlet 0,2 mm (0.0078 in)
Exhaust 0,2 mm (0.0078 in)
Governor Mechanical all speed
Fuel injection Cassette type fuel injection pump
Electrical system 12 Volt
Lubricating oil
pressure relief valve
Lubricating oil
pressure switch
located on to p cover
Lubricating oil
pressure switch
located on cylinder
block oil rail
304 - 500 kPa 262 - 359 kPa 352 - 448 kPa
49,0 kPa 29,4 kPa
49,0 kPa 98,0 kPa
Vertical in line
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Standard torques
Most of the torque tensions on the engine are standard. Special torque tensions are listed in the separate
specific torque tables. The standard torque tensions listed in the tables below can be used when a specific
torque is not necessary.
The torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted.
Standard torques for setscrews and nuts
Coarse thread Fine thread
Thread size Strength
M 4
M5
M6
M8
M10
M12
M14
M16
8.8
11T
8.8
11T
8.8
11T
8.8
11T
8.8
11T
8.8
11T
8.8
11T
8.8
11T
Pitch
mm
0,7
0,8
1,0
1,25
1,5
1,75
2,0
2,0
Torque Torque Torque
Nm lbf ft kgf m Nm lbf ft kgf m
3
4
6
8
10
14
26
32
50
62
75
104
118
157
167
230
2
3
4
6
7
10
19
24
37
46
55
77
87
116
123
170
0,3
0,4
0,6
0,8
1,0
1,4
2,7
3,3
5,1
6,3
7,6
10,6
12,0
16,0
17,0
23,4
Pitch
mm
1,0
1,25
1,25
1,5
1,5
Torque Torque Torque
----
----
---30
35
56
66
84
113
132
167
175
245
22
26
41
49
62
83
97
123
129
181
3,0
3,6
5,7
6,7
8,6
11,5
13,5
17,0
17,8
25,0
Bolt strength Examples of applicable material
8.8
11T
S45C
SCM435
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Special torques
Torque Nm (lbf ft) kgf m
Angleich 5 (3.6) 0,5
Atomiser 64 (47.2) 6,4
Atomiser pipes 23 (16.9) 2,3
Blanking plug rear of cylinder block 7 (5.1) 0,7
Crankshaft carrier to block 27 (19.9) 2,7
Connecting rod nuts 52 (38.3) 5,2
Crankshaft nut 303 (223.5) 30,3
Crankshaft sub assembly 52 (38.3) 5,2
Exhaust manifold 25 (18.4) 2,5
Flywheel 74 (54.5) 7,4
Fuel injection pump 15 (11) 1,5
Fuel injection pump leak off rail 7 (5.1) 0,7
Glow plug 18 (13.2) 1,8
Head setscrew 101 (74.5) 10,3
Leak off rail 27 (19.9) 2,7
Lift pump banjo 12 (8.8) 1,2
Lift pump mounting setscrew 6 (4.4) 0,6
Oil pipe 12 (8.8) 1,2
Oil strainer 10 (7.3) 1,0
Relief valve 64 (47.2) 6,4
Timing case 10 ( 7.3) 1,0
Rocker assembly nuts 33 (24.3) 3,3
Rocker cover 14 (10.3) 1,4
Electrical shut off solenoid 18 (13.2) 1,8
Sump drain plug 35 (25.8) 3,5
Temperature switch 27 (19.9) 2,7
Thermostat setscrew 14 (10.3) 1,4
2
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Compression test data
Many factors affect compression pressures, the battery, starter motor condition, ambient conditions and the
type of gauge used can give a wide variation of results for a given engine.
Standard value To be repaired
>2940 kPa (426.6 lbf / in²) @ 250 rpm <2450 kPa (355.5 lbf / in²) @ 250 rpm
Compression tests should only be used to compare between cylinders of an engine. If one or more cylinders
vary by more than 350 kPa (50 lbf / in²) then those cylinders may be faulty.
Compression tests should not be the only method used to show the condition of an engine, but they should be
used together with other symptoms and tests.
How to do a compression test
Note: Before the compression test, ensure that the battery is in good condition and fully charged. Also ensure
the starter motor is in good condition.
1 Ensure that the valve tip clearances are set correctly.
2 Remove the atomisers, see Operation 11-1.
3 Fit a suitable gauge into the atomiser hole of the cylinder to be tested.
4 Disconnect the stop solenoid or put the stop solenoid in the no fuel position. Operate the starter motor and
record the pressure indicated on the gauge.
Caution: Do not remove the stop solenoid as this will allow the engine to start.
5 Repeat for each cylinder.
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3
Cylinder head assembly 3
Rocker cover and inlet manifold
To remove and to fit Operation 3-1
Engine Torque Nm (lbf ft) kgf m
403C-11
403C-15
404C-22
404C-22T
Notes:
l An ‘O’ ring (1) is fitted in the groove in the rocker cover.
l Inspect the ‘O’ ring and renew if necessary.
Cap nut 11 (8.1) 1,1
Setscrew 11 (8.1) 1,1
Cap nut 14 (10.3) 1,4
Setscrew 14 (10.3) 1,4
1
H1034
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Rocker ass embly
To remove and to fit Operation 3-2
Engine Torque Nm (lbf ft) kgf m
403C-11 Rocker assembly nuts 23 (17.0) 2,3
403C-15
404C-22
404C-22T
Caution: Ensure that the valve stem caps are on the valve stems and the pushrods are located in the rockers
after assembly.
Note: An ‘O’ ring (1) is fitted in the groove in the rocker assembly.
Rocker assembly nuts 33 (24.3) 3,3
1
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To dismantle and to assemble Operation 3-3
Engine Torque Nm (lbf ft) kgf m
All models Tappet adjustment nut 14 (10.3) 1,4
Use a suitable puller to extract the rocker shaft.
Note: Remember the position of the recess (1) for assembly.
1
H1036
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s
400 Series
To inspect Operation 3-4
Rockershaft diameter
Engine
403C-11
403C-15
404C-22
404C-22T
Rocker shaft to rocker lever clearance
Engine
403C-11
403C-15
404C-22
404C-22T
11,65 - 11,67 (0.4587 - 0.4595) 11,57 (0.4555)
14,95 - 14,97 (0.5886 - 0.5894) 14,87 (0.5854)
0,032 - 0,068 (0.00126 - 0.00268) 0,2 (0.008)
0,030 - 0,093 (0.00120 - 0.00366) 0,2 (0.008)
Standard Service limit
Standard Service limit
Diameter mm (in)
Clearance mm (in)
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Exhaust manifold and gasket
To remove and to fit Operation 3-5
Engine Torque Nm (lbf ft) kgf m
403C-11
403C-15
404C-22
404C-22T
Setscrew 9,8 (7.2) 0,9
Nuts 9,8 (7.2) 0,9
Setscrew 25 (18.4) 2,5
Nuts 25 (18.4) 2,5
H1038
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Fuel injection pipes / fuel return pipes
To remove and to fit Operation 3-6
Engine Torque Nm (lbf ft) kgf m
All models
Fuel injection pipe 23 (16.9) 2,3
Banjo bolt (1) 2,5 (3.2) 0,25
1
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3
Cylinder head setscrews
To remove and to fit Operation 3-7
Note: If it is necessary to replace the cylinder head the fuel adjustment screw must not be altered from the
original setting. The maximum no load speed must be checked after assembly.
H1040
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Cylinder head
Tightening sequence 403C-11 and 403C-15 Operation 3-8
Engine Torque Nm (lbf ft) kgf m
403C-11 Cylinder head setscrews 51 (37.6) 5,2
403C-15 Cylinder head setscrews 101 (74.5) 10,3
Notes:
l All torques should be checked again after tightening.
l On assembly lubricate cylinder head setscrews with clean oil.
11
5
8
14
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4
9
3
2
10
13
7
6
12
H1041
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