Documente Academic
Documente Profesional
Documente Cultură
July 2016
Specifications
400A and 400D Industrial Engines
GG (Engine)
GH (Engine)
GJ (Engine)
GK (Engine)
GL (Engine)
GM (Engine)
GN (Engine)
GP (Engine)
GR (Engine)
GS (Engine)
GT (Engine)
GU (Engine)
GV (Engine)
This document has been printed from SPI2. NOT FOR RESALE
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
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KENR6223-02 3
Table of Contents
Table of Contents
Specifications Section
Engine Design .....................................................4
Fuel Injection Lines ..............................................9
Fuel Injection Pump ............................................10
Fuel Injector........................................................ 11
Fuel Transfer Pump ............................................12
Lifter Group ........................................................12
Rocker Shaft ......................................................13
Valve Mechanism Cover .....................................14
Cylinder Head Valves ..........................................15
Cylinder Head ....................................................17
Turbocharger ......................................................20
Exhaust Manifold ................................................20
Camshaft............................................................21
Engine Oil Lines .................................................23
Engine Oil Relief Valve .......................................23
Engine Oil Pump ................................................24
Engine Oil Pan ...................................................26
Water Temperature Regulator .............................27
Cylinder Block ....................................................29
Crankshaft .........................................................30
Connecting Rod Bearing Journal .........................31
Main Bearing Journal...........................................32
Connecting Rod .................................................33
Piston and Rings ................................................33
Housing (Front)...................................................37
Gear Group (Front)..............................................37
Flywheel ............................................................39
Flywheel Housing ...............................................39
Crankshaft Pulley ...............................................40
Belt Tension Chart ..............................................40
Fan Drive ...........................................................40
Engine Lifting Bracket..........................................41
Alternator and Regulator .....................................41
Electric Starting Motor ........................................42
Coolant Temperature Switch ................................43
Engine Oil Pressure Switch..................................43
Glow Plugs ........................................................44
Fuel Shutoff Solenoid ..........................................45
Index Section
Index..................................................................46
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4 KENR6223-02
Specifications Section
403D-07 Engine
402D-05 Engine
Illustration 2 g00852304
Cylinder and valve location
(A) Exhaust valve
(B) Inlet valve
Illustration 1 g01111232
Cylinder and valve location Bore . . . . . . . . . . . . . . . . . . . . . . . 67 mm ((2.64 inch))
(A) Exhaust valve
(B) Inlet valve Stroke . . . . . . . . . . . . . . . . . . . . . . 72 mm ((2.83 inch))
When the crankshaft is viewed from the front of the When the camshaft is viewed from the front of the
engine, the crankshaft rotates in the following engine, the camshaft rotates in the following
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
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KENR6223-02 5
Specifications Section
The front of the engine is opposite the flywheel end of 403A-15 and 403D-15 Engine
the engine. The left side and the right side of the
engine are determined from the flywheel end.
Number 1 cylinder is the front cylinder of the engine.
Illustration 4 g00852304
Cylinder and valve location
(A) Exhaust valve
(B) Inlet valve
Inlet valve. . . . . . . . . . . . . 0.2 mm ((0.0078 inch)) When the crankshaft is viewed from the front of the
Exhaust valve . . . . . . . . . 0.2 mm ((0.0078 inch)) engine, the crankshaft rotates in the following
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 2, 3
When the camshaft is viewed from the front of the
When the crankshaft is viewed from the front of the engine, the camshaft rotates in the following
engine, the crankshaft rotates in the following direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
The front of the engine is opposite the flywheel end of
When the camshaft is viewed from the front of the the engine. The left side and the right side of the
engine, the camshaft rotates in the following engine are determined from the flywheel end.
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise Number 1 cylinder is the front cylinder of the engine.
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6 KENR6223-02
Specifications Section
Inlet valve. . . . . . . . . . . . . 0.2 mm ((0.0078 inch)) Inlet valve. . . . . . . . . . . . . 0.2 mm ((0.0078 inch))
Exhaust valve . . . . . . . . . 0.2 mm ((0.0078 inch)) Exhaust valve . . . . . . . . . 0.2 mm ((0.0078 inch))
When the crankshaft is viewed from the front of the The crankshaft is viewed from the front of the engine.
engine, the crankshaft rotates in the following Direction of rotation . . . . . . . . . . . . . . . . . . . Clockwise
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
The camshaft is viewed from the front of the engine.
When the camshaft is viewed from the front of the Direction of rotation . . . . . . . . . . . . . . . . . . . Clockwise
engine, the camshaft rotates in the following
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise The front of the engine is opposite the flywheel end of
the engine. The left side and the right side of the
The front of the engine is opposite the flywheel end of engine are determined from the flywheel end.
the engine. The left side and the right side of the Number 1 cylinder is the front cylinder of the engine.
engine are determined from the flywheel end.
Number 1 cylinder is the front cylinder of the engine.
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KENR6223-02 7
Specifications Section
Inlet valve. . . . . . . . . . . . . 0.2 mm ((0.0078 inch)) Inlet valve. . . . . . . . . . . . . 0.2 mm ((0.0078 inch))
Exhaust valve . . . . . . . . . 0.2 mm ((0.0078 inch)) Exhaust valve . . . . . . . . . 0.2 mm ((0.0078 inch))
When the crankshaft is viewed from the front of the When the crankshaft is viewed from the front of the
engine, the crankshaft rotates in the following engine, the crankshaft rotates in the following
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
When the camshaft is viewed from the front of the When the camshaft is viewed from the front of the
engine, the camshaft rotates in the following engine, the camshaft rotates in the following
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
The front of the engine is opposite the flywheel end of The front of the engine is opposite the flywheel end of
the engine. The left side and the right side of the the engine. The left side and the right side of the
engine are determined from the flywheel end. engine are determined from the flywheel end.
Number 1 cylinder is the front cylinder of the engine. Number 1 cylinder is the front cylinder of the engine.
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8 KENR6223-02
Specifications Section
Inlet valve. . . . . . . . . . . . . 0.2 mm ((0.0078 inch)) Inlet valve. . . . . . . . . . . . . 0.2 mm ((0.0078 inch))
Exhaust valve . . . . . . . . . 0.2 mm ((0.0078 inch)) Exhaust valve . . . . . . . . . 0.2 mm ((0.0078 inch))
When the crankshaft is viewed from the front of the When the crankshaft is viewed from the front of the
engine, the crankshaft rotates in the following engine, the crankshaft rotates in the following
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
When the camshaft is viewed from the front of the When the camshaft is viewed from the front of the
engine, the camshaft rotates in the following engine, the camshaft rotates in the following
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
The front of the engine is opposite the flywheel end of The front of the engine is opposite the flywheel end of
the engine. The left side and the right side of the the engine. The left side and the right side of the
engine are determined from the flywheel end. engine are determined from the flywheel end.
Number 1 cylinder is the front cylinder of the engine. Number 1 cylinder is the front cylinder of the engine.
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KENR6223-02 9
Specifications Section
Illustration 11 g01442026
(1) Torque for the union nuts for the fuel injectors
Illustration 12 g01442096
(3) Torque for the banjo bolt . . . . . 2.5 N·m ((22 lb in))
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10 KENR6223-02
Specifications Section
• Camshaft
• Cylinder block
The following thicknesses of shims are available:
• 0.20 mm (0.008 inch)
Illustration 13 g01329882
Typical example
(3) Shim
The shim adjusts the timing of the fuel injection
pump. A thicker shim retards the timing. A thinner
shim advances the timing. The timing changes 1
degree for each 0.10 mm (0.004 inch) difference in
the thickness of the shim. More than one shim can be
used. If the fuel injection pump is reinstalled, new
shims, which have the same thickness as the original
shims, must be installed.
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KENR6223-02 11
Specifications Section
Fuel Injector
Illustration 14 g01335248
Typical example
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12 KENR6223-02
Specifications Section
i02960092 i06752668
Illustration 16 g00692979
Typical example
Illustration 15 g00819278
Standard maximum clearance
403D-11, 403A-11, 403A-15, 403D-15, 403D-
Typical example
15T, 403D-17, 404A-22, 404D-22, 404D-22T,
(1) Torque for the adjustment screw for the fuel and 404D-22TA . . . . . . 0.058 mm ((0.0023 inch))
priming pump . . . . . . . . . . . . . . . . . 2.5 N·m ((22 lb in)) 402D-05, 403D-07, and 404D-15
. . . . . . . . . . . . . . . . . . . 0.053 mm ((0.0021 inch))
(2) Fuel priming pump Repair limit for all engines
. . . . . . . . . . . . . . . . . . . 0.080 mm ((0.0031 inch))
(3) Flange for the fuel priming pump
Note: The fuel inlet for the fuel priming can be
rotated 360 degrees. The fuel inlet is adjustable in 15
degree increments.
Note: The flange of the fuel priming pump has two
sets of locating holes. This allows the fuel priming
pump to be mounted in four positions for the outlet
connection.
(4) O-ring
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KENR6223-02 13
Specifications Section
i06752670
Rocker Shaft
Illustration 18 g01440976
Typical example
All models . . . . . . . . . . . . . . . . 10 N·m ((89 lb in)) Service limit . . . . . . . . . .11.57 mm ((0.4555 inch))
(2) Torque for the nuts Diameter of the rocker shaft for the 403A-15,
403D-15, 403D-15T, 403D-17, 404A-22, 404D-
402D-05 and 403D-07 . . . . . . 10 N·m ((89 lb in)) 22, 404D-22T, and 404D-22TA engines
. . . . 14.95 to 14.97 mm ((0.5886 to 0.5894 inch))
403A-11, 403D-11, and 404D-15
. . . . . . . . . . . . . . . . . . . . . . . . . . 23 N·m ((17 lb ft)) Service limit . . . . . . . . . 14.87 mm ((0.5854 inch))
403A-15, 403D-15, 403D-15T, 403D-17, 404A- (4) Torque for the studs
22, 404D-22, 404D-22T, and 404D-22TA
. . . . . . . . . . . . . . . . . . . . . . . . . . 33 N·m ((24 lb ft)) 402D-05 and 403D-07 engines
. . . . . . . . . . . . . . . . . . . . . . . . . 10 N·m ((89 lb in))
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14 KENR6223-02
Specifications Section
i06752673
Illustration 19 g01440948
Minimum permissible clearance for the 403A-15, All models . . . . . . . . . . . . . . . . 10 N·m ((89 lb in))
403D-15, 403D-15T, 403D-17, 404A-22, 404D-
22, 404D-22T, and 404D-22TA engines (2) Torque for the setscrews for the connector on the
. .0.030 to 0.093 mm ((0.00120 to 0.00366 inch)) inlet manifold
Maximum permissible clearance (All models) All models . . . . . . . . . . . . . . . . . 14 N·m ((10 lb ft))
. . . . . . . . . . . . . . . . . . . . . . .0.2 mm ((0.008 inch)) (3) Torque for the cap nuts for the valve mechanism
cover
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KENR6223-02 15
Specifications Section
i06753489 Service limit for the standard test force for 403A-
11, 403D-11, 403A-15, 403D-15, 403D-15T,
Cylinder Head Valves 403D-17, 404D-15, 404A-22, 404D-22, 404D-
22T, and 404D-22TA . . . . . . . . . 68.6 N ((15.4 lb))
Illustration 21 g00903737
Typical example
Standard test force for 403A-11, 403D-11, 403A- (5) Exhaust valve guide
15, 403D-15, 403D-15T, 403D-17, 404D-15,
(A) Clearance between the exhaust valve and the
404A-22, 404D-22, 404D-22T, and 404D-22TA
valve guide
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 N ((17.8 lb))
402D-05, 403D-07, 403A-11, 403D-11, and
Standard test force for 402D-05 and 403D-07
404D-15
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 N ((15.3 lb))
. . . . 0.045 to 0.072 mm ((0.0020 to 0.0030 inch))
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16 KENR6223-02
Specifications Section
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KENR6223-02 17
Specifications Section
i06753534
Cylinder Head
Illustration 25 g00903760
Illustration 26 g00819698
(D) Valve seat angle. . . . . . . . . . . . . . . . . . 45 degrees Typical example
(E) Contact face (1) Dowel pins
Exhaust valve The dowel pins in the cylinder block hold the cylinder
402D-05, 403D-07, 403A-11, 403D-11, and head gasket in the correct position when the cylinder
404D-15 head is installed.
. . . . . . 1.70 to 2.10 mm ((0.0670 to 0.0830 inch))
(2) Cylinder head gasket
403A-15, 403D-15, 403D-15T, and 403D-17 Table 2
. . . . . . 1.66 to 1.73 mm ((0.0653 to 0.0681 inch)) Selection of Head Gasket for the 402D-05, 403D-07, 403A-11,
403D-11, and 404D-15 Engines
404A-22, 404D-22, 404D-22T, and 404D-22TA
Piston Height above Top Face of Cylin- Gasket Thickness
. . . . . . 1.94 to 2.16 mm ((0.0764 to 0.0850 inch))
der Block
Service limit (All models) . .2.5 mm ((0.098 inch)) 0.55 to 0.64 mm (0.0217 to 0.0252 inch) 1.2 mm
(0.047 inch)
Inlet valve
0.65 to 0.75 mm (0.0256 to 0.0295 inch) 1.3 mm
402D-05, 403D-07, 403A-11, 403D-11, and
(0.051 inch)
404D-15
. . . . . . 1.70 to 2.10 mm ((0.0670 to 0.0830 inch))
Table 3
403A-15, 403D-15, 403D-15T, and 403D-17 Selection of Head Gasket for the 403A-15, 403D-15, and
. . . . . . 1.66 to 1.87 mm ((0.0653 to 0.0736 inch)) 403D-15T Engines
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18 KENR6223-02
Specifications Section
Table 4
Selection of Head Gasket for the 403D-17 Engine 403D-07, 403A-11, 403D-11, 403A-15,
Piston Height Above Top Face of Cylin- Gasket Thickness 403D-15, 403D-15T, and 403D-17 Engines
der Block
0.45 to 0.55 mm (0.0177 to 0.0217 inch) 1.3 mm
(0.051 inch)
Table 5
Selection of Head Gasket for the 404A-22, 404D-22, 404D-22T,
and 404D-22TA Engines
Illustration 27 g01317344
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KENR6223-02 19
Specifications Section
404D-15, 404A-22, 404D-22, 404D-22T, Maximum limit for regrinding the cylinder head
and 404D-22TA Engines . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm ((0.006 inch))
Note: Use a straight edge and a feeler gauge to
check the six positions for distortion.
Illustration 29 g01309552
Illustration 30 g00900977
Typical example
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20 KENR6223-02
Specifications Section
i02961020 i06752663
Illustration 32 g00899933
Typical example
(1) Gasket
(2) Torque for the nuts and the setscrews for the
Illustration 31 g00921767
exhaust manifold
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KENR6223-02 21
Specifications Section
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22 KENR6223-02
Specifications Section
Illustration 35 g01297670
Typical example
(4) Tighten the setscrews for the retainer plate for the
camshaft to the following torque. . 11 N·m ((8.0 lb ft))
(5) Retainer plate for the camshaft
(6) Camshaft gear
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KENR6223-02 23
Specifications Section
i02961066
Illustration 36 g01093847
Typical example
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24 KENR6223-02
Specifications Section
Note: When the engine oil relief valve is installed, Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gerotor pump
ensure that all components are clean. Lightly
lubricate all components with clean engine oil. (1) Circlip
(1) A new O-ring should be used when the engine oil (2) Collar
relief valve is installed.
(3) Spring
(2) Tighten the engine oil relief valve to the following
torque.. . . . . . . . . . . . . . . . . . . . . . . . 64 N·m ((47 lb ft)) (4) Shim
The engine oil pressure at the engine oil relief valve (5) Oil pump cover
is the following value. (6) Inner rotor
403A-11, 403D-11, and 404D-15 Number of lobes . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . . . . . 304 to 500 kPa ((44 to 73 psi))
(7) Spring
403A-15, 403D-15, 403D-15T, and 403D-17
. . . . . . . . . . . . . . . 262 to 359 kPa ((38 to 52 psi)) (8) Outer rotor
i05164987
NOTICE
If the front housing is not installed, do not turn the
crankshaft. Damage to the engine may occur.
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KENR6223-02 25
Specifications Section
between C-clip (1) and collar (2) must not exceed the
following distance.
. . . . . . . . . . . 0.10 to 0.15 mm ((0.004 to 0.006 inch))
• 0.15 mm
• 0.20 mm
• 0.50 mm
Illustration 39 g00459701
Illustration 40 g01088627
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26 KENR6223-02
Specifications Section
i02586871 (3) Tighten the bolts for the oil strainer to the
following torque. . . . . . . . . . . . . . . . . 11 N·m ((8 lb ft))
Engine Oil Pan
(4) Strainer
Illustration 41 g00820013
(1) Gasket
(2) Engine oil pan
(3) Washer
(4) Tighten the bolts for the engine oil pan to the
following torque. . . . . . . . . . . . . . . . . 11 N·m ((8 lb ft))
(5) Tighten the drain plugs of the engine oil pan to the
following torque. . . . . . . . . . . . . . . . 35 N·m ((26 lb ft))
Illustration 42 g00820021
(1) O-ring
(2) Oil suction tube
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KENR6223-02 27
Specifications Section
Illustration 44 g01112497
Typical example
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28 KENR6223-02
Specifications Section
Illustration 47 g01114381
Water temperature regulator for turbocharged
engines
(2) Cover
(3) Water temperature regulator
(4) Gasket
Illustration 46 g01114379
Water temperature regulator for naturally aspirated
engines
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KENR6223-02 29
Specifications Section
i06753455
Cylinder Block
Illustration 49 g00901145
Typical example
(1) Diameter of the bore in the cylinder block Note: The front bush for the crankshaft must be
installed with the chamfer toward the cylinder block.
402D-05 and 403D-07 Ensure that the oil hole in the front bush for the
. .67.000 to 67.019 mm ((2.6378 to 2.6385 inch)) crankshaft is aligned with the oil hole in the cylinder
block.
403A-11, 403D-11, and 404D-15
. .77.000 to 77.019 mm ((3.0310 to 3.0320 inch))
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30 KENR6223-02
Specifications Section
(1) Tighten the bolts of the holder for the main (4) Tighten the retaining bolts for the crankshaft to
bearing to the following torque. the following torque.
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KENR6223-02 31
Specifications Section
(continued)
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32 KENR6223-02
Specifications Section
i06752939
Service
Size Journal Diameter
limit
Main Bearing Journal 47.964 to 47.975
47.90 mm
mm
1, 2 and 3 (1.8858
(1.8883 to 1.8888
inch)
inch)
Standard
47.954 to 47.965
47.90 mm
Table 9 mm
4 (1.8858
(1.88800 to
Diameter of 402D-05 Main Bearing Journals inch)
1.88830 inch)
Service
Size Journal Diameter
limit Table 13
42.964 to 42.975 Diameter of 403D-15, 403D-15, 403D-15T, 403D-17, 404D-22,
42.90 mm
mm 404D-22, 404D-22T, and 404D-22TA Main Bearing Journals
1 (1.6890
(1.69150 to
inch) Journals Diameter Service limit
1.69193 inch)
Standard 67.957 to 67.970 mm 67.90 mm
45.948 to 45.959 Standard
45.90 mm (2.67550 to 2.67597 inch) (2.6732 inch)
mm
2 (1.8071
(1.80897 to
inch)
1.80941 inch)
Clearance between the main bearing and the main
bearing journal
Table 10
Diameter of 403D-07 Main Bearing Journals Standard clearance
402D-05 and 403D-07
Service . . . . 0.035 to 0.088 mm ((0.0014 to 0.0035 inch))
Size Journal Diameter
limit
42.964 to 42.975 403A-11, 403D-11, and 404D-15
42.90 mm
1 and 2
mm
(1.6890 . . . . 0.039 to 0.092 mm ((0.0015 to 0.0036 inch))
(1.69150 to
inch)
1.69193 inch) 403A-15, 403D-15, 403D-15T, and 403D-17
Standard
45.948 to 45.959 . . . . . . . . . . . . . . . . . . . . . 0.044 mm to 0.102 mm
45.90 mm
mm ((0.0017 inch to 0.0040 inch))
3 (1.8071
(1.80897 to
inch)
1.80941 inch) 404D-22, 404D-22, 404D-22T, and 404D-22TA
. . . . 0.044 to 0.102 mm ((0.0017 to 0.0040 inch))
Table 11
Service limit (All models) . . . 0.20 mm ((0.0079 inch))
Diameter of 403A-11 and 403D-11 Main Bearing Journals
Service
Size Journal Diameter
limit
47.964 to 47.975
47.90 mm
mm
1 and 2 (1.8858
(1.8883 to 1.8888
inch)
inch)
Standard
47.954 to 47.965
47.90 mm
mm
3 (1.8858
(1.88800 to
inch)
1.88830 inch)
This document has been printed from SPI2. NOT FOR RESALE
KENR6223-02 33
Specifications Section
Illustration 53 g00693257
Typical example Illustration 54 g00555416
Typical example
(1) Connecting rod
The pistons and connecting rods are matched to
(2) Piston pin bearing each cylinder. Note the position of each connecting
rod and piston for correct assembly.
Clearance between the piston pin and the piston
pin bearing (All models) Identification marks (1) on the connecting rod and on
. .0.010 to 0.025 mm ((0.00040 to 0.00099 inch)) the connecting rod cap must be matched and
aligned. When the connecting rod is installed
Service limit correctly, the marks should face the right side of the
402D-05 and 403D-07 . . 0.10 mm ((0.004 inch)) engine.
403A-11, 403D-11, and 404D-15 engines Refer to Systems Operation, Testing and Adjusting,
. . . . . . . . . . . . . . . . . . . . 0.08 mm ((0.0031 inch)) “Connecting Rod - Inspect” for the procedure to
measure distortion and parallelism of the connecting
rod.
403A-15, 403D-15, 403D-15T, and 403D-17
engines . . . . . . . . . . . . . . 0.10 mm ((0.004 inch))
i06753450
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34 KENR6223-02
Specifications Section
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KENR6223-02 35
Specifications Section
Note: New top piston rings for the 404D-22T, and Note: Install the word “Top” toward the top of the
404D-22TA have a yellow identification mark which piston. New intermediate rings have a green
must be on the left of the ring gap when the top identification mark which must be on the left of the
piston ring is installed on an upright piston. ring gap when the intermediate ring is installed on an
upright piston.
Note: The top surface of the piston ring should be
equally distant from the top face of the cylinder block Note: The top surface of the piston ring should be
at all points before the piston ring end gap is equally distant from the top face of the cylinder block
measured with a feeler gauge. at all points before the piston ring end gap is
measured with a feeler gauge.
(2) Intermediate ring
(3) Oil control ring
Shape of intermediate ring (B) . . . . . . . . . . . Taper
402D-05 and 403D-07
402D-05 and 403D-07 Clearance between piston ring groove and oil
Clearance between piston ring groove and control ring
intermediate ring . . . . . . 0.02 to 0.06 mm ((0.0008 to 0.0024 inch))
. . . . . . 0.05 to 0.09 mm ((0.0020 to 0.0035 inch))
Service limit for clearance of oil control ring
Service limit for clearance of intermediate ring . . . . . . . . . . . . . . . . . . . . 0.15 mm ((0.0059 inch))
. . . . . . . . . . . . . . . . . . . . 0.25 mm ((0.0098 inch))
Gap of oil control ring
Gap of intermediate ring . . . . . . 0.10 to 0.30 mm ((0.0039 to 0.0118 inch))
. . . . . . 0.10 to 0.25 mm ((0.0039 to 0.0098 inch))
Service limit for gap of oil control ring
Service limit for gap of intermediate ring . . . . . . . . . . . . . . . . . . . . . . .1.0 mm ((0.039 inch))
. . . . . . . . . . . . . . . . . . . . . . .1.0 mm ((0.039 inch))
403A-11, 403D-11, and 404D-15
403A-11, 403D-11, and 404D-15 Clearance between piston ring groove and oil
Clearance between piston ring groove and control ring
intermediate ring . . . . . . 0.02 to 0.06 mm ((0.0008 to 0.0024 inch))
. . . . . . 0.05 to 0.09 mm ((0.0020 to 0.0035 inch))
Service limit for clearance of oil control ring
Service limit for clearance of intermediate ring . . . . . . . . . . . . . . . . . . . . 0.15 mm ((0.0059 inch))
. . . . . . . . . . . . . . . . . . . . 0.25 mm ((0.0098 inch))
Gap of oil control ring
Gap of intermediate ring . . . . . . 0.15 to 0.35 mm ((0.0059 to 0.0138 inch))
. . . . . . 0.20 to 0.35 mm ((0.0079 to 0.0138 inch))
Service limit for gap of oil control ring
Service limit for gap of intermediate ring . . . . . . . . . . . . . . . . . . . . . . .1.0 mm ((0.039 inch))
. . . . . . . . . . . . . . . . . . . . . . .1.0 mm ((0.039 inch))
403A-15, 403D-15, 403D-15T, 403D-17, 404A-
403A-15, 403D-15, 403D-15T, 403D-17, 404A- 22, 404D-22, 404D-22T, and 404D-22TA
22, 404D-22, 404D-22T, and 404D-22TA Clearance between piston ring groove and oil
Clearance between piston ring groove and control ring
intermediate ring . . . . . . 0.02 to 0.06 mm ((0.0008 to 0.0024 inch))
. . . . . . 0.04 to 0.08 mm ((0.0016 to 0.0032 inch))
Service limit for clearance of oil control ring
Service limit for clearance of intermediate ring . . . . . . . . . . . . . . . . . . . . 0.15 mm ((0.0059 inch))
. . . . . . . . . . . . . . . . . . . . 0.25 mm ((0.0098 inch))
Gap of oil control ring
403A-15, 403D-15, 403D-15T, 403D-17, 404A- . . . . . . 0.25 to 0.50 mm ((0.0098 to 0.0197 inch))
22, and 404D-22 gap of the intermediate ring
. . . . . . . . 0.2 to 0.4 mm ((0.0079 to 0.0157 inch)) Service limit for gap of oil control ring
. . . . . . . . . . . . . . . . . . . . . . .1.0 mm ((0.039 inch))
404D-22T and 404D-22TA gap of the
intermediate ring The oil control ring has two components. The two
. . . . . . . . . . 0.5 to 0.7 mm ((0.020 to 0.023 inch)) components of the oil control ring are installed in the
following order.
Service limit for gap of intermediate ring 1. Spring (D)
. . . . . . . . . . . . . . . . . . . . . . .1.2 mm ((0.047 inch))
2. Oil control ring (C)
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36 KENR6223-02
Specifications Section
Note: A latch pin is used in order to hold both ends of Service limit . . . . . . . . . . . 83.7 mm ((3.295 inch))
the spring of the oil control ring in position. The ends
of the spring of the oil control ring must be 180 Clearance of the piston skirt to the cylinder wall
degrees opposite the end gap of the oil control ring. . . . . . . . . . . . . . . . . . . . . . . . 0.0380 to 0.0720 mm
((0.00150 to 0.00283 inch))
Note: The top surface of the piston ring should be
equally distant from the top face of the cylinder block Service limit . . . . . . . . . . . 0.25 mm ((0.010 inch))
at all points before the piston ring end gap is
measured with a feeler gauge. Diameter of the piston pin
. . 27.994 to 28.000 mm ((1.1021 to 1.1024 inch))
(4) Piston
Service limit . . . . . . . . . 27.98 mm ((1.1016 inch))
402D-05 and 403D-07
Diameter of the piston skirt Clearance between the hole for the piston pin
. . . . . . . . . . . . . . . . . . . . .66.9375 to 66.9525 mm and the piston pin
((2.6353 to 2.6359 inch)) . . . . . . . . . . . . . . . . . . . . . . . −0.001 to +0.011 mm
((−0.0004 to +0.0004 inch))
Service limit . . . . . . . . . . 66.7 mm ((2.6260 inch))
Service limit . . . . . . . . . . 0.02 mm ((0.0008 inch))
Clearance of the piston skirt to the cylinder wall
. . . . 0.048 to 0.082 mm ((0.0019 to 0.0032 inch)) Refer to Specifications, “Cylinder Head” for the piston
height for a given gasket thickness.
Service limit . . . . . . . . . . . 0.25 mm ((0.010 inch))
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KENR6223-02 37
Specifications Section
Table 14
Injection timing
(continued)
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38 KENR6223-02
Specifications Section
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KENR6223-02 39
Specifications Section
i02590383 i06753426
Illustration 59 g00820355
(2) Tighten the setscrews on the flywheel to the (1) Torque for the setscrews for the back plate
following torque. . . . . . . . . . . . . . . . 74 N·m ((55 lb ft))
402D-05 and 403D-07 . . . . . . . 15 N·m ((11 lb ft))
Maximum flywheel runout . . . 0.20 mm ((0.008 inch))
403A-11, 403D-11, and 404D-15
. . . . . . . . . . . . . . . . . . . . . . . . 50 N·m ((36.9 lb ft))
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40 KENR6223-02
Specifications Section
Illustration 61 g00904688
Typical example
i02585985
Table 15
i02590411
Fan Drive
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KENR6223-02 41
Specifications Section
i06753431
Illustration 62 g00904732
i02590622
Illustration 63 g00909016
Typical Example
All engines are equipped with two engine lifting
brackets. The rotation of the alternator is clockwise when the
alternator is viewed from the pulley.
Tighten the setscrew on each engine lifting
bracket to the following torque. The regulator of the alternator is sealed. The
regulator is a nonserviceable part.
. . . . . . . . . . . . . . . . . . . . . . . . . . 26 N·m ((20 lb ft))
Polarity . . . . . . . . . . . . . . Negative ground to the case
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42 KENR6223-02
Specifications Section
404D-15 . . . . . . . . . . . . . . . . . . . . . . . .40 amperes (1) Tighten the battery terminal nut to the following
torque.. . . . . . . . . . . . . . . . . . . . . . . . 15 N·m ((11 lb ft))
i06753446
(2) Tighten the two mounting bolts to the following
Electric Starting Motor torque.. . . . . . . . . . . . . . . . . .50 ± 6 N·m ((37 ± 4 lb ft))
Start Relays
Illustration 64 g00379835
Starting motor and starting motor solenoid
Power rating . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.0 kW (4) When the ignition switch is in the OFF position or
the RUN position, the relay switch is closed across
Power rating the contact “30” and the contact “87a” .
402D-05 and 403D-07 Standard . . . . . . . .0.8 kW (5) When the ignition switch is in the START position,
Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 kW the relay switch is closed across the contact “30” and
the contact “87” . Then, the starting motor is
403A-11 and 403D-11 Standard. . . . . . . . .1.4 kW engaged.
Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 kW Maximum voltage drop in closed position. . . . 0.150 to
404D-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4 kW 0.250 V
(6) Connector pins on the start relay
403A-15, 403D-15, 403D-15T, 403D-17, 404A-
22, 404D-22, 404D-22T, and 404D-22TA . . . . 2.0 Resistance between contact “85” and contact “86”
kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 ± 0.7 ohms
Minimum average cranking rpm . . . . . . . . . . . . . . 130
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KENR6223-02 43
Specifications Section
i02590668 i06753447
Illustration 66 g01094334
Typical coolant temperature switch
Illustration 67 g01335504
Typical example
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44 KENR6223-02
Specifications Section
403A-15, 403D-15, 403D-15T, 403D-17, 404A- (1) Torque for the nut on the bus bar (All models)
22, 404D-22, 404D-22T, and 404D-22TA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 N·m ((11 lb in))
. . . . . . . . . . . . . . . . . . . . . . . 68.9 kPa ((10.0 psi)) (2) Torque for the glow plug
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KENR6223-02 45
Specifications Section
i02591042
Illustration 69 g00820306
(2) Washer
Ensure that the washer is replaced with a new
washer during the installation of the fuel shutoff
solenoid (1).
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46 KENR6223-02
Index Section
Index
A Glow Plugs .........................................................44
Alternator and Regulator......................................41
H
B Housing (Front)...................................................37
Belt Tension Chart...............................................40
I
C Important Safety Information ..................................2
Camshaft............................................................21
Connecting Rod ..................................................33 L
Markings on the Connecting Rod ......................33
Connecting Rod Bearing Journal ..........................31 Lifter Group ........................................................12
Coolant Temperature Switch ................................43
Crankshaft..........................................................30
Crankshaft Pulley................................................40 M
Cylinder Block.....................................................29 Main Bearing Journal...........................................32
Cylinder Head .....................................................17
Measuring the Distortion of the Cylinder Head....19
Tightening Procedure for the Cylinder Head.......18 P
Cylinder Head Valves ..........................................15
Piston and Rings .................................................33
Markings on the Piston .....................................34
E Piston and Piston Rings ...................................34
Electric Starting Motor .........................................42
Start Relays ....................................................42 R
Starting Motor..................................................42
Engine Design ......................................................4 Rocker Shaft.......................................................13
402D-05 Engine.................................................4
403A-11 and 403D-11 Engines............................5 S
403A-15 and 403D-15 Engine.............................5
403D-07 Engine.................................................4 Specifications Section ...........................................4
403D-15T Engine ..............................................6
403D-17 Engine.................................................6
404A-22 and 404D-22 Engines ...........................7 T
404D-15 Engine.................................................7 Table of Contents ..................................................3
404D-22T Engine ..............................................8 Turbocharger ......................................................20
404D-22TA Engine.............................................8
Engine Lifting Bracket..........................................41
Engine Oil Lines..................................................23 V
Engine Oil Pan....................................................26
Oil Suction Tube and Oil Strainer ......................26 Valve Mechanism Cover ......................................14
Engine Oil Pressure Switch..................................43
Engine Oil Pump .................................................24
Engine Oil Relief Valve ........................................23 W
Exhaust Manifold ................................................20 Water Temperature Regulator ..............................27
Water Temperature Regulator Housing for 402D-
05, and 402D-07 Engines ...............................27
F Water Temperature Regulator Housing for 403A-
Fan Drive............................................................40 11, 403D-11, 403A-15, 403D-15, 403D-15T,
Flywheel.............................................................39 403D-17, 404D-15, 404A-22, 404D-22, 404D-
Flywheel Housing................................................39 22T, and 404D-22TA Engines..........................28
Fuel Injection Lines ...............................................9
Fuel Injection Pump.............................................10
Fuel Injector........................................................ 11
Fuel Shutoff Solenoid ..........................................45
Fuel Transfer Pump.............................................12
G
Gear Group (Front)..............................................37
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This document has been printed from SPI2. NOT FOR RESALE
KENR6223
©2016 Perkins Engines Company Limited
All Rights Reserved
48 July 2016
This document has been printed from SPI2. NOT FOR RESALE