Perkins 402D, 403D & 404D Diesel Engine Manual Set (2001–2003) (P/N SEBU8311-00)

Use the maintenance volume for operating procedures and scheduled service. For engine repairs, the workshop volumes pair fault isolation and adjustment procedures with disassembly instructions and component limits.

The workshop procedures cover the engine and its engine-side electrical circuits. Host-machine transmission, hydraulics, chassis, and in-machine engine removal and installation are covered by the documentation for the machine itself.

Search, Bookmarks, and Wiring Detail

Finding procedures and reading diagrams: Text search works across all four publications, with exceptions including the opening safety notices and labels embedded in drawings. Numbered PDF bookmarks jump to fixed page intervals. Small terminal markings and connector pin numbers on the wiring diagrams are easier to read when zoomed in.

The set is supplied as one printable English PDF with 334 pages, including four front covers, two back covers, three otherwise blank index pages, and a product and dealer information form.

Fuel Injection, Engine Teardown, and Electrical Tests

These selected highlights cover key workshop tasks. The set also includes guidance on engine lifting and storage.

• Fuel system: Fuel injection pump and injector removal and installation, injection timing checks, nozzle testing, air-in-fuel diagnosis, and governor adjustment.
• Cylinder head and valve gear: Cylinder head and rocker shaft procedures, valve lash and valve depth checks, and valve spring removal and installation.
• Timing and lower end: Front housing, camshaft, timing gears, oil pump, pistons, connecting rods, crankshaft, main bearings, and front and rear seals.
• Air intake and cooling: Turbocharger removal and installation, wastegate testing, radiator and cooling-system leak checks, and water pump and thermostat inspection or testing.
• Starting, charging, and shutdown: Battery, alternator, and starter tests, coolant temperature and oil pressure switch checks, and automatic shutdown wiring diagrams.
• Scheduled maintenance: Model-specific refill tables, oil and coolant service, fuel priming, and interval-based checks for belts, filters, air cleaners, hoses, and the radiator.

The workshop volumes are suited to diesel technicians with the required measuring equipment and service tools. Perkins reserves fuel injection nozzle disassembly and repair for personnel with the proper training.

Repair Procedures by Engine Build

Separate procedures distinguish mechanical and electric fuel transfer pumps, naturally aspirated and turbocharged crankcase breathers, water pump and rocker shaft variants, and flywheel housings with or without a back plate. Alternator removal is grouped by output. Governor setup covers front-housing replacement and the boost compensation device where fitted.

The illustrations show front gear timing and a cross-section of the crankshaft wear sleeve. Tool listings identify injector pipe nut tool 27610294, valve spring compressor 21825739, ridge reamer 27610274, piston ring compressor 21825491, and dial indicator group 21825617. Governor setup specifies dial holder 27610331, cylinder-block adapter 27610332, and calibration spring 27610333.

Fault Isolation and Electrical Diagrams

Troubleshooting covers hard starting, rough running, misfire, smoke, power loss, high fuel or oil consumption, abnormal oil pressure, overheating, and starter or charging faults. For an automatic shutdown fault, the connector pin view and wire-color legend help trace the oil pressure switch, coolant temperature switch, or fuel shutoff solenoid circuit. Wiring diagrams cover 14/15-, 40-, and 55-amp alternator configurations and show the glow plug circuit.

Operating and Servicing the Engine

The operating volume covers gauges, prestart checks, glow-plug starting, cold-weather operation, normal and emergency shutdown, and grounding. Its maintenance guidance covers fuel and lubricant selection, extended-life coolant, supplemental coolant additives, and water pump checks.

Compression and Thermostat Test Examples

The compression procedure compares cylinders on the same engine. A difference greater than 350 kPa (51 psi) can indicate cylinder damage. The specifications also give bearing-journal and piston-ring limits, head-gasket selection data, belt tension, and component torques.

For the 403D-15 and 403D-15T, the thermostat starts to open at 80–84 °C (176–183 °F) and is fully open at 95 °C (203 °F).

Repair Cautions

Rotating the crankshaft with the front housing removed can damage the engine. The crankcase breather procedures identify the correct adapter orientation and call out blocked vents. Fuel injection testing, spring-loaded valve work, hot pressurized coolant, rotating assemblies, electrical work, and engine lifting require the precautions specified for each task.