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Perkins 403C-11 Workshop Manual Download Page 8

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

400 Series

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

  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  85

Fuel lift pump 

Operation 11-2 To remove and to fit

  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  87

Fuel injection pump 

Operation 11-3 To remove and to fit

  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  88

Operation 11-4 To eliminate air from the fuel system 

  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  89

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

Summary of Contents for 403C-11

Page 1: ...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...

Page 2: ...case and drive assembly 7 Cylinder block assembly 8 Engine timing 9 Aspiration system 10 Lubrication system 11 Fuel system 12 Cooling system 13 Flywheel and housing 14 Electrical equipment 15 Auxilia...

Page 3: ...RT 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...

Page 4: ...04C 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 re...

Page 5: ...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 39 Piston and piston ring Operation 4 8 To inspect 40 Conne...

Page 6: ...r 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 ins...

Page 7: ...To inspect 67 Cylinder bore Operation 7 4 To inspect 68 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 s...

Page 8: ...nspect 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 85 Fuel l...

Page 9: ...r Operation 13 4 To remove and to fit 100 Backplate and rear oil seal Operation 13 5 To remove and to fit 101 14 Electrical equipment Electrical shut off solenoid Operation 14 1 To remove and to fit 1...

Page 10: ...reen 400 Series 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...

Page 11: ...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 ass...

Page 12: ...cially 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 cont...

Page 13: ...ocal 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 minutes Obtain immediate medi...

Page 14: ...ver 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...

Page 15: ...efore 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 rubbe...

Page 16: ...1 6 Workshop Manual TPD 1458E issue 3 Perkins Confidential Green 400 Series Engine views H1029 H1030...

Page 17: ...The build list increases numerically for both OEMS and distributors Code III country of manufacture Code IV engine serial number Individual serial number commencing with 000001 increasing numerically...

Page 18: ...C 11 Long flywheel housing specification 114 kg Short flywheel housing specification 96 kg Backplate specification 87 kg 403C 15 Long flywheel housing specification 176 kg Short flywheel housing speci...

Page 19: ...m 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 in 1 496 litres 91 in 2 216 litres 135 2 in Firing order 1 2...

Page 20: ...s for setscrews and nuts Thread size Strength Coarse thread Fine thread Pitch mm Torque Torque Torque Pitch mm Torque Torque Torque Nm lbf ft kgf m Nm lbf ft kgf m M 4 8 8 11T 0 7 3 4 2 3 0 3 0 4 M5 8...

Page 21: ...2 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 2...

Page 22: ...uld 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...

Page 23: ...and inlet manifold To remove and to fit Operation 3 1 Notes l An O ring 1 is fitted in the groove in the rocker cover l Inspect the O ring and renew if necessary Engine Torque Nm lbf ft kgf m 403C 11...

Page 24: ...2 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 Engine Torq...

Page 25: ...al Green 15 400 Series To dismantle and to assemble Operation 3 3 Use a suitable puller to extract the rocker shaft Note Remember the position of the recess 1 for assembly Engine Torque Nm lbf ft kgf...

Page 26: ...rocker lever clearance Engine Diameter mm in Standard Service limit 403C 11 403C 15 11 65 11 67 0 4587 0 4595 11 57 0 4555 404C 22 404C 22T 14 95 14 97 0 5886 0 5894 14 87 0 5854 Engine Clearance mm...

Page 27: ...s Confidential Green 17 400 Series Exhaust manifold and gasket To remove and to fit Operation 3 5 Engine Torque Nm lbf ft kgf m 403C 11 Setscrew 9 8 7 2 0 9 Nuts 9 8 7 2 0 9 403C 15 404C 22 404C 22T S...

Page 28: ...E issue 3 Perkins Confidential Green 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...

Page 29: ...19 400 Series 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 T...

Page 30: ...C 11 and 403C 15 Operation 3 8 Notes l All torques should be checked again after tightening l On assembly lubricate cylinder head setscrews with clean oil Engine Torque Nm lbf ft kgf m 403C 11 Cylinde...

Page 31: ...404C 22 and 404C 22T Operation 3 9 Notes l All torques should be checked again after tightening l On assembly lubricate cylinder head setscrews with clean oil Engine Torque Nm lbf ft kgf m 404C 22 40...

Page 32: ...tted 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 th...

Page 33: ...he 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 indicatio...

Page 34: ...l 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...

Page 35: ...g 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...

Page 36: ...wear or damage if outside the service limit renew Inlet valve Exhaust valve Valve head thickness If the valve head thickness 4 is less than the service limit renew the valve Engine Diameter mm in Stan...

Page 37: ...ge 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...

Page 38: ...d To inspect Operation 3 16 Use a straight edge and feeler gauge to check the six positions for distortion Caution Do not grind beyond the maximum limit Maximum regrind limit mm in Distortion Maximum...

Page 39: ...new the valve 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...

Page 40: ...If the depth still exceeds the service limit renew the cylinder head If the depth is within the service limit renew the valves Engine Depth mm in Inlet standard Exhaust standard Service limit 403C 11...

Page 41: ...ntial Green 31 400 Series 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...

Page 42: ...ewed from the front Caution Only adjust the valve clearances when the engine is cold Engine Valve overlap Adjust valves 403C 11 403C 15 No 1 Cylinder 3 and 6 No 2 Cylinder 2 and 5 No 3 Cylinder 1 and...

Page 43: ...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...

Page 44: ...kins Confidential Green 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 c...

Page 45: ...35 400 Series 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...

Page 46: ...ure 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 identi...

Page 47: ...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 Engin...

Page 48: ...a feeler gauge If the gap is greater than the service limit renew the piston ring Engine Ring number Standard Service limit 403C11 Number 1 ring 0 15 0 27 mm 0 0059 0 0106 in 1 0 mm 0 039 in Number 2...

Page 49: ...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 27 996 28 000 m...

Page 50: ...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 Serv...

Page 51: ...e 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 pi...

Page 52: ...orque 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...

Page 53: ...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...

Page 54: ...This page is intentionally blank...

Page 55: ...5 Crankshaft pulley To remove and to fit Operation 5 1 Note Store the key 1 in a safe place until assembly Engine Torque Nm lbf ft kgf m Special tools Part number 403C 11 Crankshaft nut 123 90 7 12 5...

Page 56: ...lock 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...

Page 57: ...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...

Page 58: ...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 4...

Page 59: ...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 re...

Page 60: ...0 0078 in 403C 15 404C 22 404C 22T 0 044 0 102 mm 0 00150 0 00420 in 0 20 mm 0 0078 in Engine Bearing size mm in Journal Centre crankshaft diameter mm in 403C 11 Standard 1 2 47 965 47 975 1 88830 1...

Page 61: ...ection 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 assemb...

Page 62: ...n 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...

Page 63: ...move and to fit Operation 6 3 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 en...

Page 64: ...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 Ca...

Page 65: ...nder 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 mu...

Page 66: ...e 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...

Page 67: ...vice 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 Engine Height mm in Standard Service limit 403C 11 27 900 28 000 1 0...

Page 68: ...uel 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 Th...

Page 69: ...ns Confidential Green 59 400 Series 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...

Page 70: ...6 60 Workshop Manual TPD 1458E issue 3 Perkins Confidential Green 400 Series Idler gear and oil pump To remove and to fit Operation 6 10 To check the end float see Operation 6 13 H1094 1...

Page 71: ...om 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 un...

Page 72: ...th backlash To check Operation 6 12 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 Engine Timing...

Page 73: ...0 Series 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...

Page 74: ...shop Manual TPD 1458E issue 3 Perkins Confidential Green 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 H...

Page 75: ...on 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...

Page 76: ...haft journal diameter 4 If the oil clearance exceeds the service limit renew the bush or regrind the crankshaft journal and use an undersize bush Engine Standard oil clearance Service limit 403C 11 0...

Page 77: ...w 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 e...

Page 78: ...linder 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 eng...

Page 79: ...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 1...

Page 80: ...essure 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 S...

Page 81: ...e 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...

Page 82: ...tard 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 distrib...

Page 83: ...ged 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...

Page 84: ...ews 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...

Page 85: ...harger 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 Engine Torque Nm lbf ft kgf m 404C 22T...

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Page 87: ...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 to of a turn...

Page 88: ...e To remove and to fit Operation 10 2 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...

Page 89: ...ubricating oil sump To remove and to fit Operation 10 3 Note When the sump is fitted renew the joint 1 Engine Torque Nm lbf ft kgf m 403C 11 Sump setscrews 6 4 4 0 6 Sump drain plug 35 25 8 3 5 403C 1...

Page 90: ...Confidential Green 400 Series Lubricating oil strainer and suction pipe To remove and to fit Operation 10 4 Renew the O ring 1 before the suction pipe is fitted Engine Torque Nm lbf ft kgf m All mode...

Page 91: ...10 Workshop Manual TPD 1458E issue 3 Perkins Confidential Green 81 400 Series Lubricating oil pump To remove and to fit Operation 10 5 To check the end float see Operation 6 13 H1094 1...

Page 92: ...ssue 3 Perkins Confidential Green 400 Series Rotor tip clearance To inspect Operation 10 6 Inner rotor to outer rotor 1 Engine Clearance standard limit Service limit All models 0 01 0 15 mm 0 0004 0 0...

Page 93: ...bricating 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 cm 4 27 lbf in 2 If fitted on the cylinder block the switc...

Page 94: ...bricating oil pipes To remove and to fit Operation 10 8 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 an...

Page 95: ...es 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 origi...

Page 96: ...re 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 t...

Page 97: ...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 outl...

Page 98: ...ed 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 essent...

Page 99: ...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...

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Page 101: ...Workshop Manual TPD 1458E issue 3 Perkins Confidential Green 91 12 400 Series Cooling system 12 Coolant pump To remove and to fit Operation 12 1 Fit new joint 1 on assembly H1102 1...

Page 102: ...12 92 Workshop Manual TPD 1458E issue 3 Perkins Confidential Green 400 Series To inspect Operation 12 2 Start the engine check the coolant pump tell tale hole 1 for coolant leakage 1 H1103...

Page 103: ...400 Series Fan and mounting To remove and to fit Operation 12 3 On assembly check the tension of the belt see Operation 14 3 To remove and to fit the alternator see Operation 14 4 Engine Torque Nm lb...

Page 104: ...3 Perkins Confidential Green 400 Series Thermostat To remove and to fit Operation 12 4 Caution Ensure that the thermostat is correctly seated in the thermostat housing Engine Torque Nm lbf ft kgf m A...

Page 105: ...orkshop Manual TPD 1458E issue 3 Perkins Confidential Green 95 400 Series To drain the cylinder block Operation 12 5 Engine Torque Nm lbf ft kgf m All models Cylinder block drain plug 30 22 0 3 0 1 H1...

Page 106: ...Raise the temperature of the water gradually 3 Record the valve opening temperature and the valve lift Notes l The start to open temperature is stamped on the thermostat l 3 to 5 minutes will be requi...

Page 107: ...ual TPD 1458E issue 3 Perkins Confidential Green 97 13 400 Series Flywheel and housing 13 Flywheel To remove and to fit Operation 13 1 Engine Torque Nm lbf ft kgf m All models Flywheel setscrew 74 54...

Page 108: ...cessary it must be made on the housing and the concentricity checked again Check the housing alignment B The maximum tolerance is given in the table below Any necessary adjustment must be made on the...

Page 109: ...of the flywheel face Operation 13 3 1 Check the flywheel run out with a dial test indicator A This must be less than 0 20 mm 0 008 in total indicator reading 2 Check the alignment of the flywheel fac...

Page 110: ...ring gear To remove and to fit Operation 13 4 If the ring gear is excessively worn renew When the wear is not excessive remove the ring gear and fit 90 from the original position To fit the ring gear...

Page 111: ...models have the backplate and the housing fitted together Note On assembly ensure that Powerpart silicone sealant is used between the cylinder block and the rear end oil seal Engine Torque Nm lbf ft k...

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Page 113: ...eries Electrical equipment 14 Electrical shut off solenoid To remove and to fit Operation 14 1 Special requirements Notes l The washer is fitted with an integral O ring l Always use a new washer on as...

Page 114: ...ins Confidential Green 400 Series Bus bar glowplugs To remove and to fit Operation 14 2 Engine Torque Nm lbf ft kgf m 403C 11 Glow plug 12 8 9 1 2 Busbar nut 1 2 0 9 0 12 403C 15 404C 22 404C 22T Glow...

Page 115: ...t and to adjust Operation 14 3 Press down the centre of the belt on the longest free length with a finger force of 49 Newtons 11 lbf 5 kgf approximately Check the belt for cracks or contamination by o...

Page 116: ...14 106 Workshop Manual TPD 1458E issue 3 Perkins Confidential Green 400 Series Alternator To remove and to fit Operation 14 4 On assembly check the tension of the drive belt see Operation 14 3 H1114...

Page 117: ...kshop Manual TPD 1458E issue 3 Perkins Confidential Green 107 400 Series Starter motor To remove and to fit Operation 14 5 Warning The battery must be disconnected before the starter motor is removed...

Page 118: ...Alternator charging 14 amp 2 cyl 15 amp 3 cyl 0 036 2 cyl 0 033 3 cyl 0 5 Volt See Glow Plugs Circuit Starter motor solenoid 15 75 amp 0 04 0 63 Volt See Glow Plugs Circuit STD glow plugs via glow si...

Page 119: ...or charging 40 amp 0 0125 s 0 5 Volt See Glow Plugs Circuit Starter motor solenoid 15 75 amp 0 04 s 0 63 Volt See Glow Plug Circuit STD glow plugs via glow signal Peak max 39 amp 0 0128 s 0 5 Volt 1 A...

Page 120: ...tery The light is extinguished when the engine is operated and the alternator is generating The use of a lower wattage bulb than the rating above will increase the speed at which the alternator will o...

Page 121: ...y and it extinguishes when the alternator operates The use of a lower wattage bulb than the above will increase speed at which self excitation occurs upon initial run up e g a charge lamp with a lower...

Page 122: ...witch If the water temperature exceeds 105 C 4 C Oil Pressure Switch If the oil pressure falls below 0 3 kgf cm 4 27 lbf in 1 Max current draw for standard oil pressure switch is 0 42 amps 5 Watt lamp...

Page 123: ...ure switch If the water temperature exceeds 105 C 4 C Oil Pressure Switch If the oil pressure falls below 0 3 kgf cm 4 27 lbf in 1 Max current draw for standard oil pressure switch is 0 42 amps 5 Watt...

Page 124: ...s below 0 3 kgf cm 4 27 lbf in top cover option or 1 0 kgf cm 14 22 lbf in oil rail option Cautions l There is no automatic shutdown for low water levels l Diode capacity current 3 amps reverse voltag...

Page 125: ...Workshop Manual TPD 1458E issue 3 Perkins Confidential Green 115 15 400 Series Auxiliary equipment 15 None fitted Operation 15 1...

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Page 127: ...he correct tool locally contact The Perkins Service Department Peterborough PE1 5NA England UK Tel 44 1733583000 Fax 441733582240 Telex 32501 PERKEN G Description Illustration Valve spring remover Par...

Page 128: ...3 Perkins Confidential Green 400 Series Fuel pump spill pipe Part number 21825680 Front oil seal protector 403C 11 part number 21825620 403C 15 404C 22 part number 21825621 Valve seat cutter Part num...

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