Perkins 402D, 403D, 404D Industrial Engine for JCB Set of PDF Manuals

The process of disassembling the most complex motor unit - the engine is quite complicated: special knowledge and skills are required to carry out this process. Such knowledge can be obtained when studying this set of PDF manuals.

This set covers the following PDF manuals:
- Perkins 402D, 403D, 404D Industrial Engine Disassembly and Assembly (KENR6226-01);
- Perkins 402D, 403D, 404D Industrial Engine Specifications (KENR6223-01);
- Perkins 402D, 403D, 404D Industrial Engine Systems Operation Testing and Adjusting (KENR6225-01).

These manuals are is intended for serve, operate, adjusting Perkins Industrial Engines 402D, 403D, 404D (that are installed on JCB machines).

The manuals contain detailed service information, technical specifications, instructions, and illustrations. Also, the manuals provide repair information about technical specifications, torques, pressure, measurements, adjustments, illustrations and other elements.

To view detailed this service manual you should use the links “JCB pdf manual instant preview” and also view the lists of “Contents” that are presented below.

The main thing is to follow the step-by-step recommendations and instructions from these manuals and you will not be confused in the sequence and correctness when disassembling/assembling the engine.

Models covered:
GG (Engine)
GH (Engine)
GJ (Engine)
GK (Engine)
GL (Engine)
GM (Engine)
GN (Engine)
GP (Engine)
GQ (Engine)
GS (Engine)

Contents (KENR6226-01):

• DISASSEMBLY AND ASSEMBLY SECTION
  • Fuel Filter Base - Remove and Install (403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA Engines)
  • Fuel Filter Base - Remove and Install (402D-05 and 403D-07 Engines)
  • Fuel Transfer Pump - Remove and Install (Mechanical Fuel Transfer Pump)
  • Fuel Transfer Pump - Remove and Install (Electrical Fuel Transfer Pump)
  • Fuel Injection Lines - Remove and Install
  • Fuel Shutoff Solenoid - Remove and Install
  • Fuel Injection Pump - Remove and Install
  • Fuel Injector - Remove and Install
  • Turbocharger - Remove and Install
  • Exhaust Manifold - Remove and Install
  • Inlet and Exhaust Valve Springs - Remove and Install
  • Inlet and Exhaust Valves - Remove and Install
  • Engine Oil Line - Remove and Install
  • Engine Oil Cooler - Remove and Install
  • Engine Oil Relief Valve - Remove and Install
  • Engine Oil Pump - Remove
  • Engine Oil Pump - Install
  • Water Pump - Remove and Install (403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA Engines)
  • Water Pump - Remove and Install (402D-05 and 403D-07 Engines)
  • Water Temperature Regulator Housing - Remove and Install
  • Water Temperature Regulator - Remove and Install (402D-05 and 404D-07 Engines)
  • Water Temperature Regulator - Remove and Install (403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA Engines)
  • Flywheel - Remove
  • Flywheel - Install
  • Crankshaft Rear Seal - Remove and Install
  • Crankshaft Wear Sleeve (Rear) - Remove and Install
  • Flywheel Housing - Remove and Install
  • Flywheel Housing - Remove and Install (Engines with Flywheel Housing and Back Plate)
  • Crankshaft Pulley - Remove and Install
  • Crankshaft Front Seal - Remove and Install
  • Housing (Front) - Remove
  • Housing (Front) - Disassemble
  • Housing (Front) - Assemble
  • Housing (Front) - Install
  • Crankcase Breather - Remove and Install (Turbocharged Engines)
  • Crankcase Breather - Remove and Install (Naturally Aspirated Engines)
  • Valve Mechanism Cover - Remove and Install
  • Rocker Shaft and Pushrod - Remove
  • Rocker Shaft - Disassemble (403D-15, 403D-15T, 403D-17, 404D-22, 404D-22T and 404D-22TA Engines)
  • Rocker Shaft - Disassemble (402D-05, 403D-07, 403D-11 and 404D-15 Engines)
  • Rocker Shaft - Assemble (403D-15, 403D-15T,403D-17, 404D-22, 404D-22T and 404D-22TA Engines)
  • Rocker Shaft - Assemble (402D-05, 403D-07, 403D-11 and 404D-15 Engines)
  • Rocker Shaft and Pushrod - Install
  • Cylinder Head - Remove
  • Cylinder Head - Install
  • Lifter Group - Remove and Install
  • Camshaft - Remove
  • Camshaft - Disassemble
  • Camshaft - Assembly
  • Camshaft - Install
  • Engine Oil Pan - Remove and Install
  • Pistons and Connecting Rods - Remove
  • Pistons and Connecting Rods - Disassemble
  • Pistons and Connecting Rods - Assemble
  • Pistons and Connecting Rods - Install
  • Connecting Rod Bearings - Remove (Connecting rods in position)
  • Connecting Rod Bearings - Install (Connecting rods in position)
  • Connecting Rod Bearings - Install
  • Crankshaft Main Bearings - Remove
  • Crankshaft Main Bearings - Install
  • Crankshaft - Remove
  • Crankshaft - Install
  • Bearing Clearance - Check
  • Coolant Temperature Switch - Remove and Install (403D-11, 403D-15, 403D-15T, 403D-17, 404D-15, 404D-22, 404D-22T and 404D-22TA Engines)
  • Coolant Temperature Switch - Remove and Install (402D-05 and 403D-07 Engines)
  • Engine Oil Pressure Switch - Remove and Install
  • Glow Plugs - Remove and Install
  • V-Belts - Remove and Install
  • Fan - Remove and Install
  • Alternator - Remove and Install (65 Amp and 85 Amp Alternators) 
  • Alternator - Remove and Install (55 Amp Alternator)
  • Alternator - Remove and Install (40 Amp Alternator)
  • Alternator - Remove and Install (14 Amp and 15 Amp Alternators)
  • Electric Starting Motor - Remove and Install
• INDEX SECTION
  • Index

Contents (KENR6223-01):

• SPECIFICATION SECTION
  • Engine Design
  • Fuel Injection Lines
  • Fuel Injection Pump
  • Fuel Injector
  • Fuel Transfer Pump
  • Lifter Group
  • Rocker Shaft
  • Valve Mechanism Cover
  • Cylinder Head Valves
  • Cylinder Head
  • Turbocharger
  • Exhaust Manifold
  • Camshaft
  • Engine Oil Lines
  • Engine Oil Relief Valve
  • Engine Oil Pump
  • Engine Oil Pan
  • Water Temperature Regulator
  • Cylinder Block
  • Crankshaft
  • Connecting Rod Bearing Journal
  • Main Bearing Journal
  • Connecting Rod
  • Piston and Rings
  • Housing (Front)
  • Gear Group (Front)
  • Flywheel
  • Flywheel Housing
  • Crankshaft Pulley
  • Belt Tension Bracket
  • Alternator and Regulator
  • Electric Starting Motor
  • Coolant Temperature Switch
  • Engine Oil Pressure Switch
  • Glow Plugs
  • Fuel Shutoff Solenoid
• INDEX SECTION
  • Index

Contents (KENR6225-01):

• SYSTEM OPERATION SECTION
  • General Information
  • Fuel System
  • Air Inlet Exhaust System
  • Cooling System
  • Basic Engine
  • Electrical System
• TESTING AND ADJUSTING SECTION
  • Fuel System
  • Air Inlet and Exhaust System
  • Lubrication System
  • Cooling System
  • Basic Engine
  • Electrical System
• INDEX SECTION
  • Index