Perkins 400 Series Diesel Engines for JCB Workshop Manual PDF

About This Manual

This workshop manual provides service and repair procedures for the Perkins 400 Series diesel engines listed below, including those used in JCB equipment. It covers the engine and its associated systems rather than the complete JCB machine.

Step-by-step instructions explain component removal, inspection and refitting, with illustrations to help you follow the procedures. Tightening torques and compression test data provide reference values for workshop checks. The electrical section includes alternator wiring diagrams and diagrams for engines equipped with automatic shutdown.

Item Details

Manual type

Workshop manual

Engine manufacturer

Perkins

Engine series

400 Series

Publication number

TPD 1458E, Issue 3

Publication date

September 2002

File format

PDF

Language

English

Pages

128

Open the file with Adobe Acrobat Reader or another PDF viewer. You can save it for offline reference and print individual procedures or the entire manual for use in the workshop.

Models Covered

Check the model shown on your engine identification plate before ordering. Coverage applies to the following diesel engines, not every model in the Perkins 400 Series.

If you are unsure whether this manual matches your engine, contact us before purchasing.

Contents

• 1 General information
  • Introduction
  • Safety precautions
  • POWERPART recommended consumable products
  • Engine views
  • Engine identification
  • Engine lift equipment
• 2 Specifications
  • Basic engine data
  • Standard tightening torques
  • Special tightening torques
  • Compression test data
• 3 Cylinder head assembly
  • Rocker cover and inlet manifold
  • Rocker assembly
  • Exhaust manifold and gasket
  • Fuel injection pipes / fuel return pipes
  • Cylinder head setscrews
  • Cylinder head tightening sequences
  • Cylinder head gasket
  • Valve and valve spring
  • Cylinder head to valve stem clearance
  • Cylinder head inspection
  • Valve seat width
  • Valve depth
  • Valve tip clearance
• 4 Piston and connecting rod assemblies
  • Big end bearing and cap
  • Piston and connecting rod
  • Piston rings
  • Piston and connecting rod assemblies
  • Piston and piston ring
  • Connecting rod
  • Connecting rod bearing clearance
  • Small end bush
• 5 Crankshaft assembly
  • Crankshaft pulley
  • Crankshaft retaining bolts and crankshaft
  • Crankshaft
  • Main bearings
  • Bearing holder
• 6 Timing case and drive assembly
  • Timing cover
  • Angleich
  • Slider
  • Camshaft retaining plate
  • Camshaft and tappets
  • Camshaft assembly
  • Maximum fuel screw and maximum speed screw
  • Front oil seal and PTO cover
  • Idler gear and oil pump
  • Idler hub
  • Gear teeth backlash
  • Oil pump end float
  • Governor springs
• 7 Cylinder block assembly
  • Front crankshaft bush
  • Cylinder block top face
  • Cylinder bore
• 8 Engine timing
• 9 Aspiration system
  • Breather system
  • Turbocharger
• 10 Lubrication system
  • Lubricating oil canister
  • Pressure relief valve
  • Lubricating oil sump
  • Lubricating oil strainer and suction pipe
  • Lubricating oil pump
  • Rotor tip clearance
  • Oil pressure switch
  • Lubricating oil pipes
• 11 Fuel system
  • Atomizers
  • Fuel lift pump
  • Fuel injection pump
• 12 Cooling system
  • Coolant pump
  • Fan and mounting
  • Thermostat
• 13 Flywheel and housing
  • Flywheel
  • Starter ring gear
  • Backplate and rear oil seal
• 14 Electrical equipment
  • Electrical shut-off solenoid
  • Bus-bar / glow plugs
  • Drive belt
  • Alternator
  • Starter motor
  • Wiring diagram: 15 A alternator, 403C-11
  • Wiring diagram: 40 A alternator, 403C-11
  • Wiring diagram: 55 A alternator, 403C-15, 404C-22 and 404C-22T
  • Automatic shutdown connector
  • Automatic shutdown wiring diagram: 15 A alternator, 403C-11
  • Automatic shutdown wiring diagram: 40 A alternator, 403C-11
  • Automatic shutdown wiring diagram: 55 A alternator, 403C-15, 404C-22 and 404C-22T
• 15 Auxiliary equipment
  • Operation 15-1: None fitted
• 16 Special tools
  • Special tools list

Delivery (Instant Download)

This manual is supplied as a digital PDF download. Click “Buy Now” and complete your order. A download link will be provided after payment is confirmed.

No printed manual is included with this delivery option. Contact us if you need help accessing your file.

References

• EPCATALOGS — Perkins 400 Series Diesel Engines for JCB Workshop Manual PDF. Product details and publication preview.
• EPCATALOGS — Delivery Information. Digital download delivery terms.