Description
Perkins 402D-404D Engine Disassembly Manual is the factory disassembly and assembly publication for the Perkins 402D, 403D and 404D industrial engine range. It provides illustrated, sequential procedures for removing, dismantling, assembling and installing major engine components.
This manual is intended for professional engine rebuilders, plant engineers and workshop technicians carrying out mechanical repair or overhaul work. Procedures include safety notices, cleanliness requirements, tightening torques, component identification, installation notes and references to required service tools where applicable.
Coverage spans naturally aspirated and turbocharged variants. Instructions are divided by engine model where component arrangements or procedures differ.
FUEL SYSTEM
The fuel-system section provides removal and installation procedures for mechanical and electrical components, with particular attention to preventing contamination and correctly identifying disconnected pipes and hoses.
- Fuel filter base removal and installation
- Mechanical fuel transfer pump
- Electrical fuel transfer pump
- Fuel injection lines and return lines
- Fuel shut-off solenoid
- Fuel injection pump
- Fuel injector removal and installation
- Fuel-system priming references
CYLINDER HEAD AND VALVE GEAR
Detailed procedures cover dismantling and reassembly of the cylinder head and associated valve-operating components. Separate rocker-shaft instructions are provided for the relevant engine groups.
- Inlet and exhaust valve springs
- Inlet and exhaust valves
- Valve mechanism cover
- Rocker shaft and pushrods
- Rocker-shaft disassembly and assembly
- Cylinder-head removal and installation
- Lifter group removal and installation
- Camshaft removal, dismantling and assembly
ENGINE LUBRICATION AND COOLING
The manual covers the principal components of the engine lubrication and cooling systems, including model-specific water-pump and thermostat arrangements.
- Engine oil lines
- Engine oil cooler
- Oil pressure relief valve
- Engine oil pump removal and installation
- Engine oil pan
- Water pump removal and installation
- Water-temperature regulator housing
- Water-temperature regulator
- Coolant-temperature switch
- Engine oil-pressure switch
CRANKSHAFT, PISTONS AND TIMING COMPONENTS
Workshop procedures are included for major bottom-end components and the front and rear engine assemblies. The instructions cover component handling, bearing work and checks required during assembly.
- Pistons and connecting rods
- Connecting-rod bearings
- Crankshaft main bearings
- Crankshaft removal and installation
- Bearing-clearance checking
- Front housing dismantling and assembly
- Crankshaft front and rear seals
- Rear crankshaft wear sleeve
- Crankshaft pulley
- Flywheel and flywheel housing
AIR, EXHAUST AND ENGINE AUXILIARIES
Additional procedures address the air and exhaust equipment fitted to applicable naturally aspirated and turbocharged engines, together with common electrical and belt-driven auxiliaries.
- Turbocharger removal and installation
- Exhaust manifold
- Turbocharged-engine crankcase breather
- Naturally aspirated-engine crankcase breather
- Glow plugs
- V-belts and cooling fan
- 40, 55, 65 and 85 amp alternators
- 14 and 15 amp alternators
- Electric starting motor
DISASSEMBLY AND ASSEMBLY INFORMATION
Procedures use numbered steps and technical illustrations to establish the correct sequence of work. Where stated in the publication, the manual supplies tightening torques, orientation notes, contamination precautions and special-tool details.
- Removal and installation sequences
- Component dismantling and reassembly
- Fastener tightening torques
- Seal and O-ring replacement instructions
- Component alignment and orientation notes
- Fluid containment precautions
- Cleanliness and open-port protection
- Model-specific procedural differences
PERKINS 402D-404D ENGINE DISASSEMBLY MANUAL MODELS COVERED
- 402D-05
- 403D-07
- 403D-11
- 403D-15
- 403D-15T
- 403D-17
- 404D-15
- 404D-22
- 404D-22T
- 404D-22TA
ENGINE PREFIXES
GG, GH, GJ, GK, GL, GM, GN, GP, GQ and GS.
MANUAL DETAILS
- Publication: KENR6226-01
- Edition date: April 2008
- Manual type: Disassembly and Assembly
- Page count: 108
- Language: English
The Perkins 402D-404D Engine Disassembly Manual is specifically concerned with mechanical disassembly and assembly. It should be used alongside the appropriate operation, maintenance, systems operation, testing and adjusting information where those separate publications are required.
This is a useful workshop reference for planned engine overhaul, component replacement and correct reassembly of the listed Perkins industrial engines.
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