Description
Perkins 400 Series Workshop Manual for the 403C-11, 403C-15, 404C-22 and 404C-22T diesel engines. This factory workshop publication provides specifications, dismantling and assembly instructions, inspection procedures, adjustments and component repair information for the specified three- and four-cylinder engines.
It is intended for professional engine technicians, machinery workshops and experienced repairers undertaking routine workshop repairs or major engine work. Procedures are arranged as numbered operations, supported by engine data, torque information, inspection criteria and model-specific instructions where applicable.
The manual distinguishes between the naturally aspirated 403C-11, 403C-15 and 404C-22 engines and the turbocharged 404C-22T. It also includes engine identification information, safety precautions, recommended consumable products and lifting guidance.
CYLINDER HEAD AND VALVE GEAR
The cylinder-head section covers removal, assembly, inspection and adjustment of the principal valve-gear components. Separate cylinder-head tightening sequences are given for the three- and four-cylinder engine groups.
- Rocker cover, inlet manifold and rocker assembly
- Exhaust manifold and gasket
- Fuel injection and return pipes
- Cylinder-head removal and tightening sequences
- Selection of the correct head-gasket thickness
- Valve and valve-spring inspection
- Valve-stem clearance, valve-seat width and valve depth
- Valve-seat correction, lapping and valve-tip clearance
PISTONS, CONNECTING RODS AND CRANKSHAFT
Detailed operations address dismantling, measurement and reassembly of the main internal engine components.
- Big-end bearings and caps
- Piston and connecting-rod removal and assembly
- Piston-ring fitting, clearance and ring-gap measurement
- Piston, ring and connecting-rod inspection
- Connecting-rod bearing-clearance checks
- Small-end bush replacement
- Crankshaft removal and deflection inspection
- Main bearings and bearing holder
TIMING DRIVE AND CYLINDER BLOCK
The timing and block chapters provide workshop procedures for the gear train, camshaft, governor components and cylinder-block inspection.
- Timing-cover removal and installation
- Camshaft, tappets and retaining plate
- Camshaft inspection
- Idler gear, idler hub and oil pump
- Gear-tooth backlash checks
- Oil-pump end-float adjustment
- Governor-spring inspection
- Cylinder-block top face and cylinder-bore inspection
ENGINE TIMING, ASPIRATION AND FUEL SYSTEM
Fuel-system and timing coverage includes component replacement, injection timing checks and fuel-system bleeding. Aspiration procedures account for both naturally aspirated and turbocharged variants.
- Fuel-injection timing
- Fuel-injection pump timing checks
- Closed-circuit breather servicing
- Turbocharger removal and installation
- Atomiser removal and installation
- Fuel lift-pump replacement
- Fuel-injection pump removal and installation
- Elimination of air from the fuel system
LUBRICATION AND COOLING SYSTEMS
These chapters cover service and inspection of the components responsible for oil circulation and engine cooling.
- Lubricating-oil canister and pressure-relief valve
- Oil sump, strainer and suction pipe
- Lubricating-oil pump removal and installation
- Oil-pump rotor-tip clearance inspection
- Oil-pressure switch and lubricating-oil pipes
- Coolant-pump removal and inspection
- Fan and mounting
- Thermostat removal, testing and inspection
FLYWHEEL AND ELECTRICAL EQUIPMENT
Flywheel procedures include alignment measurements, while the electrical chapter provides component operations and model-specific wiring diagrams.
- Flywheel removal and installation
- Flywheel-housing concentricity and alignment
- Flywheel run-out and face alignment
- Starter ring gear, backplate and rear oil seal
- Electrical shut-off solenoid
- Bus-bar and glowplugs
- Drive-belt inspection and adjustment
- Alternator and starter-motor removal
- 15, 40 and 55 amp alternator wiring diagrams
- Automatic-shutdown wiring diagrams
TESTING AND ADJUSTMENT
The Perkins 400 Series Workshop Manual contains specifications and measurement procedures required when assessing component condition and completing accurate engine assembly.
- Basic engine data and compression-test data
- Standard and special tightening torques
- Bearing, piston-ring and valve clearances
- Crankshaft-deflection inspection
- Timing-gear backlash
- Injection-pump timing
- Flywheel and housing alignment
- Thermostat testing
PERKINS 400 SERIES WORKSHOP MANUAL MODEL COVERAGE
- 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 turbocharged diesel engine
MANUAL DETAILS
- Manufacturer: Perkins Engines Company Limited
- Manual type: Workshop Manual
- Publication number: TPD 1458E
- Issue: Issue 3
- Publication date: September 2002
- Length: 128 PDF pages
- Language: English
This Perkins 400 Series Workshop Manual is an engine-specific technical reference rather than a complete machine service manual. Its coverage is confined to the listed Perkins engines and their associated fuel, cooling, lubrication, aspiration and electrical equipment.
The publication is particularly useful where accurate workshop sequences, inspection methods, tightening information and wiring diagrams are required for repair or overhaul work.
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