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.

i

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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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400 Series

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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1

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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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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400 Series

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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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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400 Series

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

H1035

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3

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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3

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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400 Series

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

H1039

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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.

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400 Series

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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1

4

9

3

2

10

13

7

6

12

H1041

400 Series

3

Tightening sequence 404C -22 and 404C-22T Operation 3-9

Engine Torque Nm (lbf ft) kgf m

404C-22
404C-22T

Notes:

l All torques should be checked again after tightening.
l On assembly lubricate cylinder head setscrews with clean oil.

Cylinder head setscrews 101 (74.5) 10,3

12 4

16

15

11

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8

7

3

1

2

513

9

10

6

17

18

14

H1042

3

400 Series

Cylinder head gasket

To remove and to fit Operation 3-10

Align the gasket on the dowels in the cylinder block.

Cautions:

l The gasket must only be fitted with the markings (1) facing up.
l When fitting a new gasket it must be replaced with a gasket of the same thickness as originally fitted. The

gasket thickness can be identified by the part number that is stamped on the gasket.

l The correct piston height must be maintained to prevent damage to the pistons and valves and ensure that

the engine conforms to emission legislation.

Note: Always fit dry.

1

n
a

e

l

c
n

U

d

n

A

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3

To select the correct thickness of cylinder head gasket Operation 3-11

Caution: If the correct piston height above or below the cylinder block is not obtained, damage to the engine
can occur. The difference between the highest and the lowest piston height must not exceed 0.1 mm.

1 Put the piston height tool (A) on the face of the cylinder block and rotate the gauge dial to the zero position.
2 Rotate the crankshaft until the piston crown is approximately at top dead centre (TDC).
3 Carefully put the tool over the top of the piston with the plunger of the gauge in contact with the piston above

the axis of the gudgeon pin.
4 Rotate the crankshaft to ensure that the piston is at the highest position and make a note of the gauge

indication.

Notes:

l If the cylinder block, crankshaft, connecting rods or pistons are changed the piston height will have to be

checked and the correct thickness gasket used.

l If the original piston is used, ensure that it is assembled to the correct connecting rod and is used in the

original cylinder.

Cylinder head gasket selection

Engine Protrusion above cylinder block top face Gasket thickness

403C-11

403C-15

Engine Protrusion below cylinder block top face Gasket thickness

404C-22
404C-22T

0,55 to 0,64 1,2 mm
0,65 to 0,75 1,3 mm
0,60 to 0,69 1,3 mm
0,70 to 0,79 1,4 mm

-0,45 to -0,30 0,4 mm

-0,29 to -0,20 0,5 mm

H1044

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400 Series

Valve and valve spring

To remove and to fit Operation 3-12

Special tools

Description Part number

Valve spring remover 21825663
Valve stem seal replacer 21825623

Notes:

l The oil seal for the inlet valve stem is identified by a silver garter spring.
l The oil seal for the exhaust valve stem is identified by a black garter spring (not shown) with the letters “EX”

on the garter.

Warning! Safety glasses must be worn for this operation.

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3

To inspect - valve spring Operation 3-13

Visually inspect the valve spring for damage.
Use a spring tester to check spring force and free length. Renew the spring if it is outside the service limit.

Engine

Free length (1) mm (in)

Standard Service limit

All models 35,0 (1.378) 33,5 (1.319)

Spring rate when compressed to 30,4 mm (1.197 in)

Engine

N (lbf) kgf

Standard Service limit

All models 79 (17.8) 8,1 68,6 (15.4) 7,0

1

New

Worn

H1046

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400 Series

To inspect - valve stem and thickness of valve head Operation 3-14

Use a micrometer to check the valve stem diameters at positions 1, 2 and 3, if less than the service limit, renew.
Check the valve stem for wear or damage, if outside the service limit, renew.

Inlet valve

Engine

Standard Service limit

Diameter mm (in)

All models 6,955 - 6,970 (0.27382 - 0.27441) 6,89 (0.271)

Exhaust valve

Engine

Standard Service limit

Diameter mm (in)

All models 6,940 - 6,950 (0.27323 - 0.27362) 6,84 (0.269)

Valve head thickness

Engine

Thickness mm (in)

Standard Service limit

All models 0,925 - 1,075 (0.03642 - 0.04232) 0,5 (0.020)

If the valve head thickness (4) is less than the service limit, renew the valve.

1

1

4

2

2

3

3

H1047

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3

Cylinder head to valve stem clearance

To inspect Operation 3-15

Check the clearance (3) between the valve stem and the cylinder head. If the clearance is greater than the
service limit, the valves must be checked for wear, see Operation 3-14, If the valves are within service limits,
renew the cylinder head.

1 Put a new valve in the valve guide.
2 Put a dial test indicator with a magnetic base (1) onto the face of the cylinder head.
3 With the valve lifted 15,0 mm (0.6 in) and the gauge (2) in contact with the edge of the valve head, move the

valve radially away from the gauge. With the head in this position, set the gauge to ‘0’.
4 Move the valve radially across the axis of the cylinder head towards the gauge. Make a note of the reading

on the gauge if the reading is greater than the service limit, renew the cylinder head.

Maximum permissible clearances with a valve lift of 15 mm (0.6 in).
Inlet valve

Engine Clearance mm (in) standard Service limit

403C-11 0,025 - 0,052 (0.0010 - 0.0020) 0,2 (0.008)
403C-15, 404C-22 and 404C-22T 0,030 - 0,060 (0.0012 - 0.0024) 0,2 (0.008)

Exhaust valve

Engine Clearance mm (in) standard Service limit

403C-11 0,045 - 0,072 (0.0020 - 0.0030) 0,25 (0.010)
403C-15, 404C-22 and 404C-22T 0,050 - 0,075 (0.0020 - 0.0030) 0,25 (0.010)

1

2

3

H1048

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400 Series

Cylinder head

To inspect Operation 3-16

Maximum regrind limit mm (in)

Distortion Maximum service limit Maximum regrind

0,05 (0.002) or less 0,12 (0.005) 0,15 (0.006)

Use a straight edge and feeler gauge to check the six positions for distortion.

Caution: Do not grind beyond the maximum limit.

1

3

5

2

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4

H1049

400 Series

3

Valve seat width

#

To inspect and to co rrect Operation 3-17

Special tools

Description Part number

Valve seat cutter 27610030

Inlet valve Exhaust valve

Engine

403C-11 1,70 - 2,10 (0.0670 - 0.0830) 2,5 (0.098) 1,70 - 2,10 (0.0670 - 0.0830) 2,5 (0.098)
403C-15 1,66 - 1,87 (0.0653 - 0.0736) 2,5 (0.098) 1,66 - 1,73 (0.0653 - 0.0681) 2,5 (0.098)
404C-22

404C-22T

1,50 - 2,00 (0.0591 - 0.0790) 2,5 (0.098) 1,94 - 2,16 (0.0764 - 0.0850) 2,5 (0.098)

If the contact face (1) of the valve seat is more than the service limit, check the valve stem for wear, see
Operation 3-14 and the cylinder head to valve stem clearance, see Operation 3-15. If greater than the service
limit, use a seat cutter of 45° to correct the seat.

If the valve stem clearance exceeds the service limit, renew the valve.

Clearance mm (in) Clearance mm (in)

Standard Service limit Standard Service limit

If the bore in the cylinder head for the valves is worn, replace the cylinder head. If the valve seat in the cylinder
head is damaged or worn, cut a new seat if the valve depth will remain within tolerance.

1

45°

Contact
Width

H1050

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400 Series

Valve depth

To check Operation 3-18

If the valve depth (1) is greater than the service limit, use a new valve to check the valve depth.
If the depth still exceeds the service limit, renew the cylinder head. If the depth is within the service limit renew

the valves.

Engine

403C-11 0,65 - 0,95 (0.0256 - 0.0374) 0,85 - 1,15 (0.0335 - 0.0453) 1,8 (0.071)
403C-15 0,85 - 1,15 (0.0335 - 0.0453) 0,85 - 1,15 (0.0335 - 0.0453) 1,8 (0.071)
404C-22

404C-22T

0,65 - 0,95 (0.0256 - 0.0374) 0,65 - 0,95 (0.0256 - 0.0374) 1,8 (0.071)

Inlet standard Exhaust standard Service limit

Depth mm (in)

1

H1051

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3

To lap the contact face of the valve seat Operation 3-19

Use the valve seat cutter to obtain the correct seat contact width and seat recess on a new cylinder head, use
a valve lapping tool and lapping compound to finish.

H1052

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400 Series

Valve tip clearance

To check and to adjust Operation 3-20

The valve adjustment sequence is viewed from the front of the engine.
Rotate the crankshaft clockwise when viewed from the front.

Caution: Only adjust the valve clearances when the engine is cold.

Engine Valve overlap Adjust valves

403C-11
403C-15

404C-22

404C-22T

No. 1 Cylinder 3 and 6
No. 2 Cylinder 2 and 5
No. 3 Cylinder 1 and 4
No. 4 Cylinder 1 and 2
No. 2 Cylinder 5 and 6
No. 1 Cylinder 7 and 8
No. 3 Cylinder 3 and 4

Valve tip clearance (cold)

Inlet 0,2 mm (0.0078 in)

Exhaust 0,2 mm (0.0078 in)

Torque Nm (lbf ft) kgf m

Tappet adjustment nut 14 (10.3) 1,4

H1053

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4

Piston and connecting rod assemblies 4

Big end bearing and cap

To remove and to fit Operation 4-1

Engine Torque Nm (lbf ft) kgf m

403C-11 Nut 32 (23.6) 3,3
403C-15, 404C-22 and 404C-22T Nut 52 (38.3) 5,2

Standard clearance Service limit

0,1 - 0,3 mm (0.004 - 0.012 in) 0,7 mm (0.276 in)

Caution: Ensure that the connecting rod bolts (2) do not damage the crankshaft when the connecting rod is
removed or fitted.

Notes:

l The connecting rods and caps are numbered matched pairs and must be kept together when removed from

the engine. The numbers (1) must be aligned when assembled.

l The piston and connecting rods are matched to a cylinder, record the position of each connecting rod and

piston for correct assembly. After the connecting rods are fitted check for axial movement.

l The fuel adjustment screw must not be altered from the original setting. The maximum no load speed must

be checked after assembly.

2

1

H1054

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400 Series

Piston and connecting rod

To remove and to fit Operation 4-2

The Shibaura name on the inside of the piston must be facing the fuel pump on assembly.
To assemble the connecting rod assembly, see page 35.

1

H1055

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4

To dismantle and to assemble Operation 4-3

The Shibaura (1) name (inside of the piston) must be aligned with the stamped number on the
connecting rod (1).

The numbers stamped on the connecting rods and caps must be the same and aligned.

C

A
M
A

3
2
1

1

H1056

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400 Series

Piston rings

To fit Operation 4-4

Any letters or markings on the surface of the ring will always be positioned on the top face (facing upwards).
Use a suitable piston ring expander to fit the piston rings.

1 Fit the spring of the oil control ring (6) in the bottom groove of the piston with the latch pin (1) inside both
ends of the spring. Fit the oil control ring (4) over the spring (6). Ensure that the ring gap is at 180° to the latch
pin.

2 Fit the second ring (3) with the taper face into the second groove, with the word "TOP" towards the top of
the piston.

New second rings have a green identification mark which must be on the left of the ring gap when the ring is
fitted and the piston is upright.

The second ring has a step (5) at the top inside edge of the tapered face.
3 Fit the top ring (2) with the word 'TOP' towards the top of the piston.

New top rings have a red identification mark which must be on the left of the ring gap when the ring is fitted
and the piston is upright.

4 Ensure that the ring gaps are 90° apart.

1

M

A

6

2

90°

3

4

M

A

90°

5

H1057

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4

To measure the piston ring clearance Operation 4-5

Use a feeler gauge to measure the clearance between the piston ring groove and the piston ring. If the
clearance is greater than the service limit, use a new piston ring and check the clearance again.

If the clearance is within the service limit with a new piston ring, renew the piston rings. If the clearance is
outside the service limit with a new piston ring, renew the piston.

Note: The number 1 piston ring of the 404C-22T is of the ‘keystone’ design, therefore it is difficult to measure
the wear due to it’s position in the piston ring groove. When either number 2 ring or the oil control ring is outside
the service limit renew all rings.

Engine Torque Nm (lbf ft) kgf m Standard Service limit

0,06 - 0,10 mm

(0.0024 - 0.0039 in)

0,05 - 0,09 mm

(0.0020 - 0.0035 in)

0,02 - 0,06 mm

(0.0008 - 0.0024 in)

0,07 - 0,11 mm

(0.0028 - 0.0043 in)

0,04 - 0,08 mm

(0.0016 - 0.0032 in)

0,02 - 0,06 mm

(0.0008 - 0.0024 in)

0,04 - 0,08 mm

(0.0016 - 0.0032 in)

0,02 - 0,06 mm

(0.0008 - 0.0024 in)

0,25 (0.0098 in)

0,25 (0.0098 in)

0,15 (0.0059 in)

0,25 (0.0098 in)

0,25 (0.0098 in)

0,15 (0.0059 in)

0,25 (0.0098 in)

0,15 (0.0059 in)

403C-11

403C-15
404C-22

404C-22T

Number 1 ring

Number 2 ring

Oil control ring

Number 1 ring

Number 2 ring

Oil control ring

Number 2 ring

Oil control ring

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4

To measure the piston ring gap Operation 4-6

If the piston ring is worn or damaged, renew.

Piston ring gap

Clean the carbon from the top of the cylinder bore.
Insert the ring into the cylinder at right angles to the cylinder block and measure the gap with a feeler gauge.

If the gap is greater than the service limit, renew the piston ring.

Engine Ring number Standard Service limit

Number 1 ring 0,15 - 0,27 mm (0.0059 - 0.0106 in) 1,0 mm (0.039 in)

403C11

403C-15
404C-22
404C-22T

Number 2 ring 0,12 - 0,24 mm (0.0047 - 0.0094 in) 1,0 mm (0.039 in)
Oil control ring 0,20 - 0,35 mm (0.0079 - 0.0138 in) 1,0 mm (0.039 in)
Number 1 ring 0,20 - 0,35 mm (0.0079 - 0.0138 in) 1,0 mm (0.039 in)
Number 2 ring 0,20 - 0,40 mm (0.0079 - 0.0158 in) 1,0 mm (0.039 in)
Oil control ring 0,20 - 0,40 mm (0.0079 - 0.0158 in) 1,0 mm (0.039 in)

400 Series

à

38 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

á

H1059

400 Series

4

Piston and connecting rod assemblies

To dismantle and to assemble Operation 4-7

Gudgeon pin

Check the outside diameter of the gudgeon pin. If it is less than the service limit, renew the gudgeon pin.

Engine Outside diameter Service limit

403C-11 20,996 - 21,002 mm (0.82660 - 0.82680 in) 20,98 mm (0.8260 in)
403C-15

404C-22
404C-22T

Engine Standard clearance Service limit

403C-11 -0,004 - +0,004 mm (-0.00016 - +0.00016 in) 0,02 mm (0.0008 in)
403C15

404C-22
404C-22T

27,996 - 28,000 mm (1.10220 - 1.10240 in) 27,98 mm (1.1016 in)

-0,001 - +0,007 mm (-0.00040 - +0.00030 in) 0,02 mm (0.0008 in)

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 39

4

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

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

83,948 - 83,963 mm (3.30503 - 3.30562 in) 83,7 mm (3.295 in)

0,0380 - 0,0720 mm (0.00150 - 0.00283 in) 0,25 mm (0.010 in)

40 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

400 Series

4

Connecting rod

To inspect Operation 4-9

Engine Standard Service limit

All models

The large and small end bores must be parallel with each other within the limits of ± 0,31 mm (0.008 in)
measured 100 mm (3.397 in) each side of the connecting rods axis on a test mandrel.

Check the small end bush for wear or for other damage and renew it if necessary.
Check the fit of the gudgeon pin in the small end bush and check the gudgeon pin for wear.

Distortion for 100 mm (3.937 in) < 0,08 mm (0.0031 in) 0,20 mm (0.0079 in)
Parallel for 100 mm (3.937 in) < 0,05 mm (0.0020 in) 0,15 mm (0.0059 in)

± 0,08 mm
(0,0031 in)

100 mm
(3.937 in)

100 mm
(3.937 in)

± 0,08 mm
(0,0031 in)

H1060

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 41

4

400 Series

Connecting rod bearing clearance

To check Operation 4-10

To check the clearance between the crankshaft bearing journal and the bearing cap.

1 Clean the bearing surfaces and the exposed half of the crankshaft journal.
2 Fit the bearing caps and tighten the bearing cap to torque.
3 Remove the bearing cap of the clearance to be checked.
4 Place a piece of Plastigauge ® across the full width of the bearing surface on the crankshaft journal, fit the

bearing cap and tighten the bearing cap setscrew to the specified torque.

5 Remove the bearing cap but do not move the Plastigauge ®.
6 Use the Plastigauge ® envelope to measure the widest point of the Plastigauge ®. This reading indicates

the bearing clearance in thousandths of an inch.
7 If the bearing clearance is not within the specifications the crankshaft must be reground and undersize

bearings fitted.

Engine Torque Nm (lbf ft) kgf m

403C-11 Bearing carrier setscrew 23 (16.9) 2,3
403C-15, 404C-22 and 404C-22T Bearing carrier setscrew 52 (38.3) 5,2

Engine Journals Standard clearance Service limit

403C-11
403C-15, 404C-22 and 404C-22T All 0,035 - 0,085 mm (0.00138 - 0.00335 in) 0,20 mm (0.0079 in)

1.0

2.0

2.5

3.0

4.0

PLASTIGAUGE

5.0

6.0

7.0

1 and 2 0,039 - 0,092 mm (0.00150 - 0.00360 in) 0,20 mm (0.0079 in)
3 0,029 - 0,082 mm (0.00110 - 0.00320 in) 0,20 mm (0.0079 in)

INCH

H1066

42 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

400 Series

4

Small end bush

To remove and to fit Operation 4-11

Calculate the clearance between the small end bush and the gudgeon pin. if the clearance is greater than the
service limit, renew the bush.

Engine Clearance mm (in) Service limit mm (in)

403C-11 0,010 - 0,025 (0.00040 - 0.00099) 0.08 (0.0031)
403C-15

404C-22
404C-22T

0,010 - 0,025 (0.00040 - 0.00099) 0,10 (0.0040)

H1061

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 43

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400 Series

5

Crankshaft assembly 5

Crankshaft pulley

To remove and to fit Operation 5-1

Engine Torque Nm (lbf ft) kgf m Special tools Part number

403C-11 Crankshaft nut 123 (90.7) 12,5
403C-15

404C-22
404C-22T

Note: Store the key (1) in a safe place until assembly.

Crankshaft nut 304 (224.2) 30,9

Crankshaft pulley remover 21825619

1

H1062

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 45

5

400 Series

Crankshaft retaining bolts and crankshaft

To remove and to fit Operation 5-2

Engine Torque Nm (lbf ft) kgf m

403C-11
403C-15

404C-22
404C-22T

Cautions:

l Ensure that the lubricating oil pressure relief valve has been removed before the crankshaft is removed or

fitted.

l Ensure that the oil ways in the bearings align with the oil ways in the cylinder block.

Remove the bearing holder setscrews (1) and lift the crankshaft assembly out vertically.
Note: If the crankshaft or crankshaft bearings are replaced the fuel adjustment screw must not be altered from

the original setting. The maximum no load speed must be checked after assembly.

Crankshaft bearing holder setscrew 27 (19.9) 2,7
Crankshaft bearing holder to block (allen screws) 27 (19.9) 2,7
Crankshaft bearing holder setscrew 52 (38.3) 5,2

Crankshaft bearing holder to block (allen screws) 27 (19.9) 2,7

1

H1063

46 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

400 Series

556

5

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.

Engine Deflection mm (in)

Standard Service limit

All models 0,03 or less (0.011) 0,06 (0.0023)

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:

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

Note: Use No. 400 emery cloth for final polishing.

2

2

1

3

1

6

4

A

1

2 3

B

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 47

H1064

5

400 Series

Crankshaft journal diameter

Engine Size Standard diameter Service limit

Standard 47,964 - 47,975 mm (1.88830 - 1.88880 in) 47,90 mm (1.8860 in)

403C-11

403C-15
404C-22
404C-22T

Undersize 0,25 mm (0.01 in) 47,714 - 47,725 mm (1.87850 - 1.87890 in) 47,65 mm (1.8750 in)
Undersize 0,50 mm (0.02 in) 47,464 - 47,475 mm (1.86870 - 1.86910 in) 47,40 mm (1.8660 in)
Standard 67,957 - 67,970 mm (2.67550 - 2.67597 in) 67,90 mm (2.6732 in)
Undersize 0,25 mm (0.01 in) 67,707 - 67,720 mm (2.66563 - 2.66614 in) 67,65 mm (2.6634 in)
Undersize 0,50 mm (0.02 in) 67,457 - 67,470 mm (2.65579 - 2.65630 in) 67,40 mm (2.6535 in) *

Crankshaft pin diameter

Engine Size Standard diameter Service limit

Standard 40,964 - 40,975 mm (1.61280 - 1.61320 in) 40,90 mm (1.6102 in)

403C-11

403C-15
404C-22
404C-22T

Undersize 0,25 mm (0.01 in) 40,714 - 40,725 mm (1.60290 - 1.60330 in) 40,65 mm (1.6003 in)
Undersize 0,50 mm (0.02 in) 40,464 - 40,475 mm (1.59310 - 1.59350 in) 40,40 mm (1.5905 in)
Standard 51,964 - 51,975 mm (2.04582 - 2.04626 in) 51,90 mm (2.0433 in)
Undersize 0,25 mm (0.01 in) 51,714 - 51,725 mm (2.03598 - 2.03641 in) 51,65 mm (2.0335 in)
Undersize 0,50 mm (0.02 in) 51,464 - 51,475 mm (2.02614 - 2.02660 in) 51,40 mm (2.0236 in) *

Note: If the diameter is less than the maximum undersize service limit (*), the crankshaft must be renewed.

48 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

400 Series

5

Main bearings

To dismantle and to assemble Operation 5-4

Engine Torque Nm (lbf ft) kgf m

403C-11 Bearing holder setscrew 23 (16.9) 2,3
403C-15, 404C-22 and 404C-22T Bearing holder setscrew 52 (38.3) 5,2

End float

If the end float is greater than the service limit check the thrust washers for wear.

Note: Item (1) only used on 404C-22 and 404C-22T.

Engine Standard clearance Service limit

403C-11 0,10 - 0,30 mm (0.0040 - 0.0120 in) 0,50 mm (0.0197 in)
403C-15, 404C-22 and 404C-22T 0,10 - 0,40 mm (0.0040 - 0.0160 in) 0,50 mm (0.0197 in)

Engine Thrust washer thickness Service limit

403C-11
403C-15, 404C-22 and 404C-22T 2,95 - 3,00 mm (0.1161 - 0.1181 in) 2,80 mm (0.1102 in)

21,85 - 21,95 mm (0.8602 - 0.8641 in)

21,6 mm (0.8503 in)

1 Identify the location of bearing carriers on the crankshaft and mark before removal.
2 Install bearing carriers on the crankshaft, ensure that the lubricating oil holes align with the feed holes in the

cylinder block.

3 Check end float clearance.
Note: Ensure that the thrust washers are aligned correctly, fitted with their oil grooves towards the crankshaft.

4 Check the thrust washers for wear, poor contact or damage, if damaged renew.

1

H1067

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 49

5

400 Series

Bearing holder

Centre bearing

1 Remove the bearing holder and inspect for peeling, melting, stepped wear and damage. if it is damaged

renew.

2 Use Plastigauge ® to measure the oil clearance (see Operation 4-10) between the crankshaft centre

journal and the bearing. If the oil clearance is greater than the service limit, renew the bearings or regrind
the centre journal and use undersize bearings.

Engine Standard oil clearance Service limit

403C-11 0,039 - 0,106 mm (0.00153 - 0.00401 in) 0,20 mm (0.0078 in)
403C-15

404C-22

404C-22T

Engine / Bearing size mm (in) Journal Centre crankshaft diameter mm (in)
403C-11

Standard

Undersize 0,25 (0.01)

Undersize 0,50 (0.02)

403C-15

Standard 1, 2, 3 67,957 - 67,970 (2.67550 - 2.67597)
Undersize 0,25 (0.01) 1, 2, 3 67,707 - 67,720 (2.66563 - 2.66614)
Undersize 0,50 (0.02) 1, 2, 3 67,457 - 67,470 (2.65579 - 2.65630)

404C-22 and 404C-22T

Standard 1, 2, 3, 4 67,957 - 67,970 (2.67550 - 2.67597)
Undersize 0,25 (0.01) 1, 2, 3, 4 67,707 - 67,720 (2.66563 - 2.66614)
Undersize 0,50 (0.02) 1, 2, 3, 4 67,457 - 67,470 (2.65579 - 2.65630)

0,044 - 0,102 mm (0.00150 - 0.00420 in) 0,20 mm (0.0078 in)

1, 2 47,965 - 47,975 (1.88830 - 1.88880)

3 47,954 - 47,965 (1.88800 - 1.88840)

1, 2 47,714 - 47,725 (1.87850 - 1.87890)

3 47,704 - 47,715 (1.87810 - 1.87850)

1, 2 47,464 - 47,475 (1.86870 - 1.86910)

3 47,454 - 47,465 (1.86250 - 1.86870)

50 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

400 Series

6

Timing case and drive assembly 6

Timing cover

To remove Operation 6-1

Engine Special tools

Description Part number

403C-11 Front oil seal protector 21825620
403C-15, 404C-22 and 404C-22T Front oil seal protector 21825621

Cautions:

l If the timing case assembly or internal governor components are replaced the fuel adjustment screw should

not be adjusted. The maximum no load speed should be checked after assembly.

l The fuel injection pump, see Operation 11-3 and the keyway in the crankshaft must be removed before the

timing case is removed.

l Ensure that the stop lever arm (1) is held clockwise in tension for removal and assembly.

Note: If the timing case is renewed, a new emission label must be fitted as shown (2).
1 To remove the PTO cover, see Operation 6-9.

2 To remove and to fit the crankshaft pulley, see Operation 5-1.

1

2

3

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 51

H1068

6

400 Series

To fit Operation 6-2

Engine Special tools

Description Part number

403C-11 Front oil seal protector 21825620
403C-15

404C-22
404C-22T

To fit
1 The fuel injection pump, see Operation 11-3 and the keyway in the crankshaft must be removed before the

timing case is fitted. Fit the front oil seal protector.

2 To fit the PTO cover, see Operation 6-9.
3 Ensure the oil pin (3) locates in the hole in the idler gear and that the stop lever arm (1) is held clockwise in

tension for removal and assembly.
4 Remove the oil seal protector (4) after fitting the timing cover. Fit the key into the key way in the crankshaft

nose.

5 To fit the crankshaft pulley, see Operation 5-1.
Note: If the timing case is renewed, a new emission label must be fitted as shown (2).

Front oil seal protector 21825621

Caution: If the timing case assembly or internal governor components are replaced the fuel adjustment screw
should not be adjusted. The maximum no load speed should be checked after assembly.

1

2

3

4

52 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

H1069

400 Series

6

Angleich

To remove and to fit Operation 6-3

Engine Torque Nm (lbf ft) kgf m

403C-15,
404C-22
404C-22T

Notes:

l The internal setting for the Angleich must not be altered.
l Apply a little Loctite 275 to threads (2) before assembly.
l The Angleich is not fitted to the 403C-11 engine.

Angleich (1) 5 (3.6) 0,5

1

2

H1070

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 53

6

400 Series

Slider

To remove and to fit Operation 6-4

The slider (2) must be fitted with the slot (4) held captive by the pin (3).
When fitting the timing case care must be taken to ensure correct alignment of the slider contact (1) with the

governor lever.

Caution: Incorrect alignment of the slider (2) on the pin (3) may result in the loss of engine speed control.

1

2

4

3

H1071

54 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

400 Series

6

Camshaft retaining plate

To remove and to fit Operation 6-5

Engine Torque Nm (lbf ft) kgf m

All models Camshaft retainer plate setscrews 11 (8) 1,1

The camshaft retainer plate is fitted between the cylinder block and the camshaft gear. The camshaft retainer
plate is fastened by either two setscrews or a setscrew and an allen screw.

Note: If the camshaft assembly is replaced the fuel adjustment screw must not be altered from the original
setting. The maximum no load speed must be checked after assembly.

H1072

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 55

6

400 Series

Camshaft and tappets

To remove and to fit Operation 6-6

Caution: Remove the lift pump see Operation 11-2 and the fuel injection pump see Operation 11-3 before
removing the camshaft.

Note: If the camshaft assembly is replaced the fuel adjustment screw must not be altered from the original
setting. The maximum no load speed must be checked after assembly.

Lubricate the tappets with clean lubricating oil before assembly.

1

H1073

56 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

400 Series

6

Camshaft assembly

To inspect Operation 6-7

Height of cam for inlet and exhaust valves (1).

Engine Height mm (in)

Standard Service limit

403C-11 26,955 - 27,010 (1.06120 - 1.06340) 26,5 (1.0276)
403C-15, 404C-22 and 404C-22T 34,065 - 34,120 (1.34114 - 1.34330) 33,7 (1.3270)

Height of cam for fuel feed pump (2).

Engine Height mm (in)

Standard Service limit

403C-11 27.900 - 28,000 (1.09842 - 1.10240) 27,0 (1.0630)
403C-15, 404C-22 and 404C-22T 31,900 - 32,000 (1.25590 - 1.25984) 30,0 (1.1810)

Height of cam for fuel injection pump (3).

Engine Height mm (in)

Standard Service limit

403C-11 39,900 - 40,100 (1.57090 - 1.57870) 39,8 (1.5669)
403C-15, 404C-22 and 404C-22T 41,940 - 42,060 (1.65120 - 1.65590) 41,8 (1.6450)

1

3

2

H1074

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 57

6

400 Series

Maximum fuel screw and maximum speed screw

Location Operation 6-8

Engine Torque Nm (lbf ft) kgf m

All models

Caution: The fuel adjustment setscrew must be set correctly for the engine to comply with emissions
legislation. This must only be carried out by an approved Perkins distributor.

Notes:

l The maximum fuel setscrew (1) and the maximum speed setscrew (2) must not be adjusted by the

operator.

l Under certain circumstances it may be necessary to remove the anti tamper device for the maximum fuel

setscrew. This must only be carried out by an approved Perkins distributor.

l Any adjustment to the maximum fuel screw will require an engine test brake, and also a check of maximum

no load speed to confirm the settings.

Maximum fuel screw lock nut 14 (10.3) 1,4
Maximum speed screw lock nut 14 (10.3) 1,4

1

3

2

H1075

58 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

400 Series

6

Front oil seal and PTO cover

To remove and to fit Operation 6-9

An ‘O’ ring (1) is fitted in the groove (2) on the front of the timing case.
A joint (3) is used on the rear of the timing case PTO cover.

3

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 59

2

1

H1076

6

Idler gear and oil pump

To remove and to fit Operation 6-10

To check the end float, see Operation 6-13.

400 Series

H1094/1

60 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

400 Series

6

Idler hub

To remove and to fit Operation 6-11

To remove the lubricating oil pump idler hub the crankshaft must be removed. The oil pump idler hub can then
be removed with a suitable drift and hammer from the inside of the engine block.

1 Fit the location pin (1) into the block.
2 Place the idler hub (4) into the idler hub tool (3) and fit on the location pin (1).
3 Using the hammer (2) hit the idler hub tool until the hub is fitted.

Engine Special tools

Description Part number

403C-11 Idler hub fitting tool 21825625
403C-15

404C-22
404C-22T

Caution: Always fit a new idler gear hub, do not fit the old hub, as it may be damaged when removed.

Idler hub fitting tool 21825626

1

2

3

1

4

H1078

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 61

6

400 Series

Gear teeth backlash

To check Operation 6-12

Engine Timing gear tolerances mm (in)

Standard Service limit

All models 0,08 (0.0032) 0,25 (0.0098)

Measure the clearances one at a time with a feeler gauge at each of the locations shown. If the measurement
is outside the service limit fit new gears.

H1079

62 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

400 Series

6

Oil pump end float

To check and adjust Operation 6-13

Use a feeler gauge to check the oil pump end float (2).
Adjust with 0,1 - 0,15 - 0,2 and 0,5 mm shims (1).

Engine Standard clearance mm (in) Service limit

mm (in)

All models 0,10 - 0,15 (0.0040 - 0.0060) 0,20 (0.0079)

1

2

H1080

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 63

6

400 Series

Governor springs

To inspect Operation 6-14

The diagram shows the correct position for the start spring (1) and the governor spring (2).

1

2

H1081

64 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

400 Series

7

Cylinder block assembly 7

Front crankshaft bush

To remove and to fit Operation 7-1

Caution: Ensure that the lubrication oil hole in the bush, aligns with the oil gallery in the block.

To remove the bush use a suitable drift and hammer from the inside of the block.
Use a suitable press to fit the crankshaft bush.
Note: The bush must be fitted with the chamfered side (2) towards the cylinder block, with the join (1) at the

top.

1

2

H1082/1

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 65

7

400 Series

To inspect Operation 7-2

1 Check the bush for damage, wear and contact. If damaged, worn or poor contact renew the bush.
2 Using a cylinder gauge and a micrometer, measure the bush (A) and the crankshaft journal (B) to calculate

the clearance.
3 Measure the inside diameters at positions (A1) and (A2) at each position measure in both directions (A3)

and (A4) as shown. The oil clearance is the difference between the larger value and the maximum crankshaft
journal diameter.

Engine Standard oil clearance Service limit

403C-11 0,039 - 0,106 mm (0.00150 - 0.00420 in) 0,20 mm (0.0078 in)
403C-15

404C-22
404C-22T

4 If the oil clearance exceeds the service limit, renew the bush, or regrind the crankshaft journal and use an
undersize bush.

403C-11

403C-15
404C-22
404C-22T

0,044 - 0,116 mm (0.00173 - 0.00456 in) 0,20 mm (0.0078 in)

Bush size Crankshaft journal O.D finished size

Standard 47,964 - 47,975 mm (1.88830 - 1.88880 in)
0,25 mm (0.01 in) 47,714 - 47,725 mm (1.87850 - 1.87890 in)
0,50 mm (0.02 in) 47,464 - 47,475 mm (1.86870 - 1.86910 in)
Standard 67,957 - 67,970 mm (2.67550 - 2.67597 in)
0,25 mm (0.01 in) 67,707 - 67,720 mm (2.66563 - 2.66614 in)
0,50 mm (0.02 in) 67,457 - 67,470 mm (2.65579 - 2.65630 in)

H1083

66 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

400 Series

7

Cylinder block top face

To inspect Operation 7-3

Inspect the cylinder block top face for cracks, damage and warping in the same way as for the cylinder head,
see Operation 3-16.

If outside service limit, renew the cylinder block.

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 must 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 Standard value Service limit

All models Less than 0,05 mm (0.002 in) 0,12 mm (0.005 in)

1

3

5

6

4

2

H1084

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 67

7

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)

1

2

H1085

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8

Engine timing 8

Injection timing Operation 8-1

Engine Maximum rated engine speed rev/min Injection timing (BTDC)

403C-11 Gen-set 1500 18° ± 1°
403C-11 Gen-set 1800 18° ± 1°
403C-11 Gen-set 3000 23° ± 1°

403C-11 Gen-set 3600 22° ± 1°
403C-11 Industrial 2200 23° ± 1°
403C-11 Industrial 2400 23° ± 1°
403C-11 Industrial 2600 23° ± 1°
403C-11 Industrial 2800 23° ± 1°
403C-11 Industrial 3000 23° ± 1°

403C-15 Gen-set 1500 14° ± 1°

403C-15 Gen-set 1800 14° ± 1°

403C-15 Gen-set 3000 20° ± 1°

403C-15 Gen-set 3600 20° ± 1°
403C-15 Industrial 2200 22° ± 1°
403C-15 Industrial 2400 22° ± 1°
403C-15 Industrial 2600 22° ± 1°
403C-15 Industrial 2800 20° ± 1°
403C-15 Industrial 3000 20° ± 1°

404C-22 Gen-set 1500 12° ± 1°

404C-22 Gen-set 1800 12° ± 1°

404C-22 Gen-set 3000 18° ± 1°
404C-22 Industrial 2200 18° ± 1°
404C-22 Industrial 2400 18° ± 1°
404C-22 Industrial 2600 20° ± 1°
404C-22 Industrial 2800 20° ± 1°
404C-22 Industrial 3000 20° ± 1°

404C-22T Industrial 2800 18° ± 1°

If the fuel injection pump is replaced or renewed, the same shim thickness as originally fitted should be used.
The fuel adjustment screw must not be adjusted from the original setting. The maximum no load speed must
be checked after assembly.

No service parts are available for the 400 Series fuel injection pump.

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8

400 Series

To check the timing of the fuel injection pump Operation 8-2

Engine Special tools Part number

All models Spill pipe 21825680

1 Set the piston for number one cylinder to TDC on the compression stroke. Turn the crankshaft counter
clockwise a quarter of a revolution.

2 Remove the ESOS, high pressure fuel pipes and low pressure fuel pipes from the fuel injection pump.
3 Ensure that the fuel pump rack is in the maximum fuel position.
4 Remove the delivery valve holder for number 1 cylinder and remove the delivery valve. Store the delivery

valve in clean fuel until assembly.

Note: The fuel pump may have to be removed to an upright position to remove and to fit the delivery valves.
5 Connect the fuel pump spill pipe (1) to the delivery valve holder for number 1 cylinder.

Continued

1

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8

6 Connect a suitable clean fuel reservoir (1), which has a tap and contains approximately 0,2 litres (¼ pint) of

clean fuel, to the fuel injection pump inlet.
7 Put a suitable waste fuel (3) container below the pipe neck and open the tap, if set correctly the fuel should

flow.

Note: The fuel reservoir should be approximately 152 mm (6 in) above the fuel injection pump.
8 Turn the crankshaft slowly until the fuel flow reduces to a drop which falls every 7 - 10 seconds. This is then

the timing point.
9 Use the value shown by the timing mark (2) with the injection timing tables on page 69.

Continued

1

P
O
T

0

1

0

2

0

3

3

2

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8

10 If the engine timing is incorrect adjust the thickness of the fuel injection pump shim.
Note: Changing the fuel injection pump shim by 0,1 mm will change the timing by approximately one degree.

Thicker shims will retard the timing and thinner shims will advance the timing.
11 Fit the delivery valve (1) and tighten the delivery valve holder.

Caution: The maximum no load speed must be set by an approved Perkins distributor.

12 The engine must be tested on an engine test brake to check the maximum no load speed and engine
settings after assembly.

Note: There are no service parts available for the 400 Series fuel injection pump.

Engine Torque Nm (lbf ft) kgf m

All models Delivery valve holder 42 (31.0) 4,2

400 Series

1

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9

Aspiration system 9

Breather system

Closed circuit, naturally aspirated - to clean and to renew Operation 9-1

To clean the engine breather assembly

The breather assembly should be renewed every 2000 hours.

Caution: Ensure that the components of the breather assembly are fitted in their correct position (1 - 6). If
they are incorrectly fitted, the engine may be damaged.

1 Release the four setscrews (2) and remove the breather cover (1), the spring (6) and the diaphragm
assembly (4).

Caution: It is important that the area around the vent hole (3) is clean.

2 Clean the breather cavity (5) in the rocker cover.
3 Clean the breather in clean diesel fuel
4 Fit the breather assembly into the cavity in the rocker cover, ensuring that the breather cover, diaphragm

and spring are assembled correctly and that the vent hole (3) faces towards the flywheel.
Tighten the four setscrews.

Clean the breather only with a clean diesel fuel. If the breather is damaged or the diaphragm perforated, renew
the breather.

1

6

5

2

3

4

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9

400 Series

Closed circuit turbo charged - to clean and to renew Operation 9-2

To clean the engine breather assembly

The breather assembly should be renewed every 2000 hours.

Caution: Ensure that the components of the breather assembly are fitted in their correct position (1 - 7). If
they are incorrectly fitted, the engine may be damaged.

1 Release the four setscrews (2) and remove the breather cover (1), the spring (7), the diaphragm assembly
(4) and the adaptor (6).

Caution: It is important that the area around the vent hole (3) is clean.

2 Clean the breather cavity (5) in the rocker cover.
3 Clean the breather in clean diesel fuel.
4 Fit the breather assembly into the cavity in the rocker cover, ensuring that the breather cover, diaphragm

and spring are assembled correctly and that the vent hole (3) faces towards the flywheel.
Tighten the four setscrews.

Clean the breather only with a clean diesel fuel. If the breather is damaged or the diaphragm perforated, renew
the breather.

1

7

6

5

2

3

4

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400 Series

9

Turbocharger

To remove and to fit Operation 9-3

Engine Torque Nm (lbf ft) kgf m

Turbocharger to manifold nuts 25 (18.4) 2.5
Elbow securing set screws 32,4 (23.9) 3,3
Oil feed pipe banjo bolt to

404C-22T

The turbocharger is fitted only to the 404C-22T engine.

Caution: The bearing housing of the turbocharger must be lubricated with clean engine oil on assembly.

Note: There is an ‘O’ ring fitted between the oil feed pipe for the turbocharger and the cylinder block.

turbocharger
Oil drain pipe set screws 10 (7.3) 1,0
Oil feed pipe set screws to cylinder

block

20 (14.8) 2,0

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400 Series

10

Lubrication system 10

Lubricating oil canister

To fit Operation 10-1

1 Lubricate the seal with clean engine oil before assembly.
2 Tighten by hand until the seal contacts the mounting face of the block.
3 Tighten the canister by a further ½ to ¾ of a turn by hand only.
Note: Do not overtighten oil filter.

4 The modine cooler (1) and fastener (2) are fitted only to the 404C-22T.

1

2

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10

400 Series

Pressure relief valve

To remove and to fit Operation 10-2

Engine Torque Nm (lbf ft) kgf m

All models Pressure relief valve 64 (47) 6,5

Renew the ‘O’ ring (1) when the pressure relief valve is fitted to the cylinder block.

Caution: When the crankshaft is removed or fitted the pressure relief valve must be removed first.

1

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400 Series

10

Lubricating oil sump

To remove and to fit Operation 10-3

Engine Torque Nm (lbf ft) kgf m

403C-11
403C-15

404C-22
404C-22T

Note: When the sump is fitted renew the joint (1).

Sump setscrews 6 (4.4) 0,6
Sump drain plug 35 (25.8) 3,5
Sump setscrews 11 (8) 1,1

Sump drain plug 35 (25.8) 3,5

1

H1092

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10

400 Series

Lubricating oil strainer and suction pipe

To remove and to fit Operation 10-4

Engine Torque Nm (lbf ft) kgf m

All models Suction strainer setscrews 11 (8) 1,1

Renew the “O” ring (1) before the suction pipe is fitted.

1

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400 Series

10

Lubricating oil pump

To remove and to fit Operation 10-5

To check the end float, see Operation 6-13.

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10

400 Series

Rotor tip clearance

To inspect Operation 10-6

Engine Clearance standard limit Service limit

All models 0,01 - 0,15 mm (0.0004 - 0.0060 in) 0,25 mm (0.0098 in)

Inner rotor to outer rotor (1).

1

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10

Oil pressure switch

To remove and to fit Operation 10-7

Engine Torque Nm (lbf ft) kgf m

All models Oil pressure switch 10 (7.3) 1,0

The lubricating oil pressure switch can be found in two positions.

1 If fitted on the top cover, the switch (1) is brown in colour and rated to 0,3 kgf/cm² (4.27 lbf/in²).
2 If fitted on the cylinder block, the switch (2) is blue in colour and rated to 1,0 kgf/cm² (14.22 lbf/in²).

1

2

H1096

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10

400 Series

Lubricating oil pipes

To remove and to fit Operation 10-8

Engine Torque Nm (lbf ft) kgf m

All models Banjo bolt 12 (8.8) 1,2

Note: The lubricating oil flow through the banjo bolt (2 and 4) is restricted.
Check the pipe for leaks and damage.
When fitting use new washers (1) and (3).

1

2

3

4

84 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

H1097

400 Series

11

Fuel system 11

Atomisers

To remove and to fit Operation 11-1

Engine Torque Nm (lbf ft) kgf m Test pressure kgf/cm² (lbf/in²) ats

Atomiser 64 (47) 6,5 150 (2133) 145

All models

Cautions:

l Use only deep sockets for this operation.
l Connections should be blanked off until assembly.
l Washer (1) has two small holes 180° apart.
l Discard old washer (2), on assembly fit new nozzle washer.

Note: If the atomisers or injection pipes are replaced it is essential that the fuel adjustment screw is not altered
from the original settings. The maximum no load speed must be checked after assembly.

Atomiser high-pressure pipes 23 (16.9) 2,3
Nut - leak off-rail 27 (19.9) 2,7

Continued

1

3

2

H1098/1

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11

Before fitting the atomiser, clean and dry the male and female threads of the atomiser and the cylinder head.
Apply a 2 mm (0.08 in) bead of sealant POWERPART universal jointing compound, part number 1861117, to

extend 6 mm (0.24 in) along the first two threads of the atomiser (3).

400 Series

1

3

2

H1098/1

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400 Series

11

Fuel lift pump

To remove and to fit Operation 11-2

Engine Torque Nm (lbf ft) kgf m

All models

The fuel inlet for the fuel lift pump can rotate 360° and is adjustable in 15° increments.
The fuel lift pump flange has two sets of locating holes this allows the pump to be fitted in four positions for the

outlet connection.

Lift pump setscrew 6 (4.4) 0,6
Lift pump inlet adjusting bolt (1) 2,5 (1.8) 0,25

1

H1099

Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green 87

11

400 Series

Fuel injection pump

To remove and to fit Operation 11-3

Engine Torque Nm (lbf ft) kgf m

403C-11 Fuel injection pump fasteners 6 (4.4) 0,6
403C-15

404C-22
404C-22T

Caution: Connections should be blanked off until assembly.

Notes:

l If the fuel injection pump is renewed, shims of the same thickness as originally fitted should be used.
l If a new fuel injection pump is fitted, it should be replaced with a fuel pump with the same part number as

originally fitted.

l When the fuel injection pump is replaced it is essential that the fuel adjustment screw is not altered from

the original setting. The maximum no load speed should be checked after assembly.

Fuel injection pump fasteners 15 (11) 1,5

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88 Workshop Manual, TPD 1458E, issue 3 - Perkins Confidential: Green

400 Series

11

To eliminate air from the fuel system Operation 11-4

1 Loosen the vent screw on the fuel filter (1).
2 Operate the hand primer until fuel, free of air, flows from the vent screw. Tighten the vent screw (1).
3 loosen the vent screw on the fuel injection pump (2). Operate the hand primer until fuel, free of air, flows.

Tighten the vent screw (2).
4 Attempt to start the engine using the starter motor for a maximum of 15 seconds, wait for 30 seconds before

trying again.

Cautions:

l When using the starter motor, do not exceed continuous rotation of more than 15 seconds periods. If the

engine does not run, on initial rotation, wait for 30 seconds and try again.

l Connections should be blanked off until assembly.

1

2

H1101

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