2001–2002 Perkins 400 Series 403C-11, 403C-15, 404C-22, 404C-22T Diesel Engine Workshop Manual (P/N TPD 1458E)

This Perkins 400 Series workshop manual covers the 2001–2002 naturally aspirated 403C-11, 403C-15, and 404C-22 engines, plus the turbocharged 404C-22T. Publication TPD 1458E, Issue 3 (September 2002) assumes the engine has already been removed from its application.

• Cylinder head repair: Head removal, valve-seat correction and lapping, gasket selection, rocker inspection, and valve-clearance adjustment.

• Pistons and crankshaft: Piston-ring inspection, connecting-rod bearing checks, crankshaft regrinding specifications, main-bearing service, and cylinder-bore inspection.

• Timing case and drive: Camshaft and idler-gear removal, gear backlash checks, governor component inspection, and oil-pump end-float adjustment.

• Fuel system: Injector (atomiser) and lift-pump replacement, cassette-type injection-pump removal and installation, spill-pipe timing checks, and fuel-system bleeding.

• Lubrication and cooling: Oil-pump inspection, pressure-relief valve replacement, strainer and suction-pipe service, coolant-pump inspection, and thermostat testing.

• Electrical equipment: Starter motor, alternator, electrical shut-off solenoid, and glow-plug replacement, with charging circuits and automatic-shutdown wiring diagrams.

This manual is written for technicians who service and overhaul these engines.

Cylinder Head and Bottom-End Repair

The cylinder-head procedures link piston-height measurements to gasket thickness, helping a rebuilder select the correct gasket after replacing the block, crankshaft, pistons, or connecting rods. The manual warns that incorrect piston height can damage pistons and valves.

Plastigauge checks cover connecting-rod and main-bearing oil clearances. Crankshaft journal tables distinguish standard and undersize dimensions, while the cylinder-bore section gives inspection limits and specifically warns against flex-honing.

Exploded assembly views, piston-ring gap drawings, and valve-seat width illustrations accompany the repair and inspection sections. Standard and component-specific torque tables provide the related fastener data.

Flywheel procedures cover housing concentricity, face alignment, runout, and starter ring-gear replacement.

Injection Timing and Governor Components

Injection-timing tables distinguish generator-set and industrial applications by engine model and rated speed. The spill-pipe procedure specifies tool 21825680; timing-case work identifies model-specific front oil-seal protectors and illustrates gear-teeth backlash checks.

Injection-pump coverage centers on removal, installation, and timing. Internal injection-pump overhaul is outside this manual’s repair scope. Maximum-fuel settings and final maximum no-load-speed adjustment are reserved for an approved Perkins distributor.

The governor sections address the slider, springs, and related timing-case components. Incorrect slider alignment can cause loss of engine-speed control.

Breather, Lubrication, and Cooling Service

Separate closed-circuit breather procedures cover naturally aspirated and turbocharged engines. Turbocharger coverage is limited to removal and installation on the 404C-22T, which also has the Modine oil cooler.

Lubrication sections provide rotor-tip inspection limits, oil-pressure relief-valve specifications, and identification of the different oil-pressure-switch locations. The oil strainer, suction pipe, sump, and lubricating-oil pipes have their own service instructions.

Cooling coverage includes coolant-pump leakage checks, thermostat opening-temperature and lift testing, fan service, and cylinder-block draining.

Charging Circuits and Automatic Shutdown

Separate wiring diagrams cover the 403C-11 with 15- or 40-amp alternators and the 403C-15, 404C-22, and 404C-22T with 55-amp alternators. Circuit-resistance and voltage-drop tables support electrical checks.

The automatic-shutdown connector view identifies pin numbers, wire colors, and connections. Shutdown schematics explain the response to low oil pressure and high coolant temperature; low coolant level does not trigger automatic shutdown.

Review the opening safety precautions before service work involving high-pressure fuel or rotating machinery, including the specific warning about dangerous acids produced by burned Viton seals.

A Sample of Valve, Compression, and Ring-Gap Data

These figures are a small selection of the inspection and adjustment data in the manual.

Cold intake and exhaust valve-tip clearance is 0.2 mm for all four models. The compression-test table gives a standard pressure above 2,940 kPa at 250 rpm; the manual treats compression testing as a comparison between cylinders, to be considered alongside other symptoms and tests.

For the 403C-11 second compression ring, the standard end gap is 0.12–0.24 mm, with a separate service limit of 1.0 mm.

PDF Navigation and Page Breakdown

Text search and wiring detail: The PDF includes searchable text and embedded bookmarks for chapters and individual operations. Small wiring labels are easier to read when zoomed in.

One printable 128-page PDF in English, organized into 16 chapters. The total includes 10 title and contents pages, 113 chapter-content pages, and five intentionally blank pages.