Introduction to Perkins Powered GeneratorsPerkins 400 Series

TEACH + COACH = LEARN

Perkins Shibaura Engines Limited 1996 saw the opening of the Perkins/Shibaura joint venture production facility on the Peterborough site

400 Series Engine Family 404D-22403D-151.5 litres4 cylinder3 cylinderT= Turbocharged, TA= Turbocharged Air to Air Aftercooler, e.g. 404D-22TA C & D emission compliant engines availableStage 3 CompliantEngine Family2.2 litres

400 Series - Engine NomenclatureGN 65432 U 120024 HEngine Family 400 SeriesBuild NumberEngine serial numberCountry of ManufactureEngine TypeYear of Manufacture

Engine NomenclatureConfigurationFamily NameConfigurationFamily Name400C Series400D Series403D-11403D-15404D-15403D-15T404D-22404D-22T403D-07402D-05GGxxxxxGHxxxxxGJxxxxxGKxxxxxGLxxxxxGMxxxxxGNxxxxxGPxxxxx

New Product Offerings

Bore (mm)Stroke (mm)Swept Volume (litres)402D-0567720.507403D-0767720.762403D-1177811.131403D-1584901.496403D-15T84901.496403D-17841001.662404D-1577811.508404D-22841002.216404D-22T841002.216404D-22TA841002.216

Emissions compliance levels 400 Series products cover several power bands which, post- Stage II/Tier 2, will have differences in emissions limits, phasing, and nomenclature

Depending on rated power, 400 Series products will be certified toEU Stage 3AEPA Tier 3EPA Tier 4AEPA Tier 4B

400D Industrial Power RangeExpanded product line-up provides complete certification coverageExisting models have been re-developed to meet the new legislationAdditional models have been introduced to provide greater coverage and flexibility

Introduction and changeover will take place through 2007 to meet the legislation introduction date of 1 January 2008

400D Product Enhancements

CharacteristicChangeAchieved Improvement 400C to 400DBenefit to customerRatingsCurrent 400C ratings maintainedEase of changeover in installationNew Models403D-17, 403D-15T, 404D-22TAIncrease options for customers in mid-range, TA engine increases power range by 10%Installed Package Size Engine envelope as 400C Lower fan position option on 403D-15 upwards Improved cooling allows smaller radiator to be used Ease of changeover in installation/reduce package sizeNoiseFurther Reduction in bare engine dBA + low noise fan optionsEasier to meet machine noise legislation, cost saving in noise attenuation SFCMaintain Tier 2 levelsLevel cost of ownershipGoverningImproved governing recovery and stabilityImproved driveability, lower idle speeds availablePTOSAE A-A and SAE A PTO fixing introduced as standard:significantly increased torque availableSAE standard fitting; more choice of hydraulic pump suppliers;

404D-22TA More power! Builds on the success of the 404C-22T. Turbocharged and Air-to-Air after-cooled engine increases the power of the 400 Series range by 10%!

Same engine package size as the turbo equals class-leading power to envelope and power density

Customer specified after-cooler

Level Cost of Ownership, Easier Servicing Servicing Achievements500 hours service interval as standard1,000 hours tappet (lash) adjustmentNew servicing options available dipstick either sideremote oil filter (under development)timing case oil filler capOil consumption as 400CMeasured SFC as 400C

400C Series

Turbo-Charged 2v Cylinder Heads Improved GoverningTiming controlConstant speed electronic governor option

400D Series

2v Cylinder HeadsImproved governing Significant noise improvement After coolingVariable Speed electronic governor option100 Series

IDINaturally aspirated 2v Cylinder heads

Stage 1Stage 2Stage 3+Minimise Customer Impact by Stage400 Series Technology Progression

400D - Even Quieter! Already leading the market in low noise, 400D provides over 2dB(A) loaded noise improvement!Direct //$ customer value of lower sound attenuation cost on machine

Estimated that sound attenuation on a machine costs 50-75 per dB(A) of reduction Reduced fan speed capability due to improved cooling Cylinder block redesign for noise improvement Timing case stiffening for noise improvement Low noise fan options

General InformationCompression Ignition (Diesel)In-Direct Injection2, 3 or 4 cylinder, four stroke engineLiquid cooledLinerlessThree piece helical gear trainExcellent fuel consumptionEmission Compliant to Tier 2 and Tier 3

Identify the engine components

Cylinder Head Face (403C-11) Pre combustionchambers Additional cooling paths

Pre-combustion Chamber Sectioned cylinder head

Top Cover Design

Streamlining of Inlet Manifold

Closed Circuit Breather (CCB) Environmental benefitProven systemCost effective designGradeability to 35 degrees

Fitted to top cover

Closed Circuit Breather (CCB) Adapter used on Turbo variantsEngine installer must route pipe to turbo inletDiaphragm vent hole

Crankshaft Assembly Bearing holders Rear main oil seal Holder retaining bolts

Crankshaft Assembly

Crankshaft Bearing Holder Positioning Bite mark on outside edge Bite mark on inside edge 1 - Nose (Front) 2 3 4 - Palm (Rear) Plain Thrust Washer groove

Piston Design & Cylinder Overhaul NOTE : Cylinder will not be rebored for overhaulUser must purchase a tested long engine, due to tolerances required with calibration and setting of timing and fuel delivery.

New Piston and Oil Control Ring

404C.22T New Piston and Top Ring

Lubrication Circuit

Oil Filter Design

Lubricating oil Change Every 500 Hours (Or once per year)Drain oil when hot.Always change oil filter at same time. Fit new filters hand tight only. Change Fuel FiltersCheck Drive (V) Belt tensionCheck Batteries, top up if required.Check Air filter

Lube oil Filter

Oil Feed Pipe

Oil Pressure Relief Valves

Oil Pump (Exploded View) Shims

Fitting Idler Hub Special service tool is needed to install the idler hub.3 Sizes of tool available for different engines.

Oil Specification Recommended fluids include API CH-4Maintained drain plug position.Service Period maintained at 500 Hours

Camshaft The Camshaft now has three bob weights on the 400D engine, to assist with governing.

Improved GoverningGoverning AchievementsSignificantly improved response, recovery times and constant speed load acceptance over 400C8% Governing on Variable ratingsVariable Speed Electronic Governor (ECG) OptionHow?Brand new Governor design incorporating optimised lever ratio for improved engine responseImproved tolerance and manufacturing of Governor components

All Speed Governor

Removing the governor link

Governor Rack

Timing case assembly Start Spring

Angleich Governing System Angleich unitGives tailored torque curves and increased torque back up Improved control of low speed ratingsMore robust design gives longer life

Angleich Governing System

Removal of Front Housing New Removal Procedure for front housingSetting engine in position for fitting new housingEnsuring more accurate settingNew Calibration tooling needed. (see notes) Note : For full detailed description see SOTA manual, (brief description below)IF BCD is fitted further instructions can be found

Setting of Fuel screw on new housing Note : For full detailed description see SOTA manual, (brief description below)IF BCD is fitted further instructions can be found

Final Setting of Front housing. Note : For full detailed description see SOTA manual, (brief description below)IF BCD is fitted further instructions can be found

Genset Compensator Spring Compensator Spring Polished slider contact surface

Boost Compensation Device

Installed on Turbo Charger Engines Prevents Overfuelling Aids Smoke Limiting NOTE : For Removing and refitting see SOTA manual.

High Idle Tamper Evident Cap Fitted Additionally to Maximum Fuel and Speed caps Tamper evident cap New style nut

The Fuel SystemFromFuel tankFuel feed pumpFuel filterInjectionpumpInjectors

Cassette type fuel injection pump Cassette fuel pumpRuns on main camshaftRack operated delivery valves

Delivery Valve Fuel inlet Cam follower Rack Pump housing

Fuel injection pump timingCassette type pumpAll fuel pumps no longer spill timed.Pump is fitted with different thickness shims, for different timingsettings.Thicker Shim retards timing. Fit new shims every time pump isreinstalled. Replace shims of same size.

Fuel Injection Pump(103.15)

Introduction of Compact Timing Device Delivery valve plunger

Introduction of Compact Timing Device CTD sub port CTD Cut

Fuel Injectors

Injector spray patternsSpray pattern differencebetween single andmulti-hole injectors

High Pressure Pipes Optimised

Fuel Pump Return Vent pipe

Vent pipe washersOnly 1 special washer per injector

Fuel Filtration Genuine Powerpart filters only!! Earlier type Japanese sourced filter

Fuel Filter Design

Fuel Lift Pumps

Fuel Lift Pump Design

400D Cooling ImprovementsRedesigned cylinder head coolant channelsMore even flow of coolant, less hotspots

Top tank temperature increased from 1100 to 1120

>10% improvement in ambient clearance!!6C improvement

404C-2220.6kWm @ 1500rpmAmbient Clearance53.0C404D-2220.6kWm @ 1500rpmAmbient Clearance59.0C

Liquid Cooled Engine

Daily ChecksCheck Coolant (Water) level.

Cooling System

COOLING SYSTEM A point to remember is that 1/16" (1.58mm) of scale retards as much heat transfer as 4 " (114mm) of cast iron!Loose scale within the cooling system will also cause blockages within the radiator, oil coolers and charge coolersWithout inhibitors in the coolant normal engine vibration causes vacuous pockets on many internal surfaces (especially cylinder liners).The chemicals within the inhibited coolant effectively put a protective layer on all the internal surfaces within the engine. The following diagram should clarify this explanation.

COOLING SYSTEM

Coolant Pump

Thermostat

404C.22T Bypass Blanking Thermostat Bypass blanking thermostat used on turbo as standard

403C-11 Thermostat Separate thermostat assembly Thermoswitch set to 110 degrees Bypass pipe

Alternative oil pressure switch

Engine Protection.The Engine is protected from the following situations:

Low oil pressure (LOP)

High Water [coolant] temperature (HWT)

Overspeed (OS)

An option is available for low coolant level (LCL, or LWL)

Using switches / sensors

Coolant (Water) Temperature sensor

Thermistor sensing devicesResistance (Ohms) varies with temperatureThe Sensor has a Negative Temperature Coefficient (NTC). As temperature increases its resistance decreasesSends signal to EIM / Power Wizard

1000 2,500

Ohms 20 C

Oil Pressure Sensor Engine Oil Pressure Sensor Used for engine protection, Warning/ShutdownProvides signal for pressure gauge, Sends signal to EIM, or Power Wizard

Heavy Duty Electrical Connectors Designed to reduce contamination/corrosion to terminals

Heavy Duty Electrical Connectors Electrical shut off solenoid (ESOS) with fly lead

Heavy Duty Electrical Connectors Fly lead omitted on some later builds

Speed Pick Up Sensor (MPU)Locknut.Pick-up (MPU)1mm air gap.Starter gear toothFlywheel housing

Any Questions before the next section?

Installation Considerations.There are a number of things we need to consider.Ambient Temperatures AccessEnvironmentNoise

UNDERSTANDING NOISE AND ITS EFFECTS13011090806040200DBAUNCOMFORTABLY LOUDVERY LOUDMODERATELY LOUDQUIETVERY QUIETPNEUMATIC DRILL1500KW SET AT 7 METER80 DBA 50KW SET AT 7 METERS85 DBA HEAVY TRAFFIC AT 5 METERSNORMAL CONVERSATIONALLOWABLE HUMAN EXPOSURE IN HOURS90DBA 8 HOURS100DBA 6 HOURS105DBA 1 HOUR110DBA 30 MINUTES115DBA 15 MINUTES

De-rating for Altitude.Naturally aspirated engines will create slightly more exhaust smoke.Always go on the side of caution. Check the specification information before Quoting!

Typical De-rate chart.

?ANY QUESTIONS?

Leroy Somer Alternator FeaturesLow distortionHigh efficienciesAdaptable for bothPMG & AREP systems

Alternators (Exploded view)

Alternator Shunt + PMG Principle

AVR (Automatic Voltage Regulator)

E- VOLTAGEW-WATTSI-CURRENTKVA IS THE APPARENT POWER IS THE SUM OF THE NEGATIVE POWER AND THE POSITIVE POWER (SHADED AREA)KW IS THE REAL POWER WHICH IS THE POSITIVE POWER PF IS THE REAL POWER DIVIDED BY THE APPARENT POWERPOWER FACTOR, KW, KVA

ALTERNATOR AND ACCESSORIESTYPICAL DESIGNARMATURESTATORRECTIFIER ASSYAVREXCITER ASSYEND BEARING

Engine Interface Module.

E.I.MEngine Interface Module (EIM)This unit is a sealed engine mounted module that provides switching relays for the starter and ignition circuits. It also provides over-speed protection. There are automotive type fuses protecting each circuit. LEDs light to show that the circuit is energised. The over-speed is factory set at 55Hz, the indicator light should just be off, although it will occasionally flicker.

PowerWizardLevel 1.0 &Level 2.0Control Systems Training

Systems ComparisonLevel 1Level 4Level 2Level 3Current SystemsNew SystemsSolutionsPowerWizard Level 3.0PowerWizard Level 4.0

OverviewCommon parts from 10 2000kVA;9 32vdc Operating range2 Display Languages;Technician English or Customer languageCommon Engine wiring systemProgrammed using standard EST Service toolSheet steel moduleSpare fault channelsJ1939 communication with Electronic Control Modules

Level 1.0 Control SystemAlarm / Shutdown Protection - Fail to Start, Low Oil Pressure, High Coolant Temperature, Overspeed and;Low / High Battery VoltsStatic Battery Charger FailureUnderspeedLoss of Speed signal detection2 spare fault channels20 Event Fault logJ1939 CAN 1 data link for Service toolNo remote communicationsAC Metering Volts, Amps, FrequencyDC Metering Battery Volts, Hours Run, Engine Jacket Water Temperature, Lube Oil Pressure, Engine Speed

Control Architecture Level 1.0J1939 on electronic enginesHardwired senders on mechanical engines

Level 2.0 Control SystemAuto Start controls, protection and metering as Level 1.0 and;AC Metering kW, kVA, kVar, Power Factor, kW hours, kVar hoursDC Metering Crank Attempt counter, Start counterAlarm / Shutdown Protection - Under / Over Volts, Under / Over Frequency, Overcurrent4 spare fault channelsCAN 2 J1939 Accessory Data LinkDigital I/O modulesRemote AnnunciatorReal time clockService interval counterModbus remote communications using RS485 (2 wire)

Control Architecture Level 2.0CAN J1939 expansion networkCAN J1939ModbusHardwired senders

Control System Components with 400 Series engines

Dc System Components on Perkins 400 Series engines

Panel LayoutAlarm LampShutdown LampLamp Test KeyAlarm Mute/ Acknowledge KeyRun KeyStop KeyAuto KeyEscape KeyEnter KeyCursor KeysAc Overview KeyEngine Overview Key

Navigation KeysAC Overview The AC Overview key will navigate the display to first screen of AC information.Engine Overview The Engine Overview key will navigate the display to the first screen of engine information.Alarm Acknowledge / Mute Pressing the Mute / Acknowledge key will cause the horn relay output to turn off and silence the horn. Pressing the key will also cause any yellow or red flashing lights to turn off or to become solid depending on the active status of the alarms. The Acknowledge key may also be configured to send out a Global Alarm Silence on J1939 Data Link which will silence horns on annunciators.Lamp Test Pressing and holding the Lamp Test key will cause all of the LEDs and the display screen pixels to turn on until the key is released.RUN Pressing the RUN key will cause the engine to enter the RUN mode.AUTO Pressing the AUTO key will cause the engine to enter the AUTO mode.STOP Pressing the STOP key will cause the engine to enter the STOP mode.Escape The ESCAPE key is used during menu navigation in order to navigate up through the menu structure. Each key press causes the user to move backwards/upwards through the navigation menus. The Escape key is also used to cancel out of data entry screens during setpoint programming. If the Escape key is pressed during setpoint programming, none of the changes made on screen will be saved to memory.Enter The Enter key is used during menu navigation to select menu items in order to navigate forward/downward in the menu/sub-menu structure. The Enter key is also used during setpoint programming in order to save setpoints changes. Pressing the Enter key during setpoint programming causes setpoint changes to be saved to memory.

Alarm IndicatorsYellow Warning Light A flashing yellow light indicates that there are unacknowledged active warnings. A solid yellow light indicates that there are acknowledged warnings active. If there are any active warnings the yellow light will change from flashing yellow to solid yellow after the Alarm Acknowledge key is pressed. If there are no longer any active warnings, the yellow light will turn off after the Acknowledge key is pressed.

Red Shutdown Light A flashing red light indicates that there are unacknowledged active shutdown events. A solid red light indicates that there are acknowledged shutdown events active. If there are any active shutdown events the red light will change from flashing red to solid red after the Alarm Acknowledge key is pressed. Any condition that has caused a shutdown event must be manually reset. If there are no longer any active shutdown events, the red light will turn off.

Panel ConfigurationThe control module is software configuredSet points can be adjusted by the operator or service engineer from the front of the module or by using the service tool depending on the password level requiredSet points are password protectedDisplay language is controlled by the base flash file. Each file contains a customer language and technician EnglishThe service tool can be used to download new base flash files to the moduleThe base flash files are referenced by the panel serial number and can be e-mailed from FG Wilson for that serial numberControl modules cannot be reprogrammed to different levels

Menu Tree

Password ProtectionThere are 3 levels of password protection on the PowerPort control panel. The level of password protection that is required for each setpoint is identified on the parameter setpoint entry screen. A security level identification number 1, 2, or 3 next to a padlock symbol is displayed on the parameter setpoint entry screen. If the password level is currently at the required level of protection when viewing a parameter, the padlock will not appear.Drop to Minimum Security LevelThe first option on the security screen is DROP TO MIN LEVEL. This would be used when leaving the control. If it is not initiated manually, the controller will automatically revert to minimum level after 10 minutes.From the MAIN MENU, select the CONFIGURE menu.a. Press the ENTER key in order to select CONFIGURE. SECURITY will be highlighted.b. Press the ENTER key in order to select SECURITY. DROP TO MIN LEVEL will be displayed.c. Press the ENTER key to select DROP TO MIN LEVELd. The system will now be at the minimum level of securityNote: The current level of security is displayed at the top of he display any time the system is in the SECURITY screen.

Password ProtectionEnter Level 1 or 2 PasswordFrom the MAIN MENU, select the CONFIGURE menu.a. Press the ENTER key in order to select CONFIGURE. SECURITY will be highlighted.b. Press the ENTER key in order to select SECURITY. DROP TO MIN LEVEL will be highlighted.c. Press the DOWN key in order to highlight ENTER LEVEL 1 OR 2d. Press the ENTER key in order to select ENTER LEVEL 1 or 2. ENTER PASSWORD FOR DESIRED LEVEL is displayed. Also shown is a 16 digit display with 0 highlighted at the far right. e. Press the UP or DOWN key in order to select the desired number.f. Press the RIGHT key in order to highlight the next character to be entered. Press the UP or DOWN key in order to select the desired number.g. Continue until the correct password has been entered for the corresponding level. When all digits of the password are correctly entered press the ENTER key. The current level of password protection is displayed and parameters can be set.Note: The panel will go to the highest level of security authorized by the password.Note: Passwords can have to 16 digits but can use as few as 1 digit.

Password ProtectionEnter level 3 passwordFrom the MAIN MENU, select the CONFIGURE menu.a. Press the ENTER key to select CONFIGURE. SECURITY will be highlighted.b. Press the ENTER key in order to select SECURITY. DROP TO MIN LEVEL will be displayed.c. Press the DOWN key in order to highlight ENTER LEVEL 3. Press ENTER to select ENTER LEVEL 3 .d. A 16 digit number is shown and ENTER RESPONSE is highlighted. Copy this number and call the factory to obtain the password, do not exit from this screen.e. When the factory response is received, press ENTER to select ENTER RESPONSE. ENTER RESPONSE is displayed. Also shown is a 16 digit entry field where the password will be entered.f. Press the UP or DOWN key in order to increase or decrease the highlighted digit to the correct password.g. Press the RIGHT key in order to highlight the next character to be entered. Press the UP or DOWN key in order to increase or decrease the highlighted digit to the correct password.h. Continue to set all 16 digits until the factory provided password is displayed.i. When all digits of the factory password are correctly entered, press the ENTER key. The current level (LEVEL 3) of security is displayed and parameters can be set.

Password ProtectionChange level 1 or level 2 passwordFrom the MAIN MENU, select the CONFIGURE menu.a. Press the ENTER key in order to select CONFIGURE. SECURITY will be highlighted.b. Press the ENTER key in order to select SECURITY. DROP TO MIN LEVEL will be highlightedc. Make sure that the current level of security is at least as high as the level of the password tobe changed.d. Press the DOWN key to highlight CHANGE LEVEL 1 PSWD. Press the ENTER key toselect CHANGE LEVEL 1 PSWDe. CHANGE LEVEL 1 PSWD is displayed. Use the cursor keys to set the new password.f. Press the RIGHT key in order to highlight the next character to be entered. Press the UP or DOWN key in order to increase or decrease the highlighted digit to the desired number.g. Continue until the desired password is displayed.h. Press the ENTER key. The password is now set.Note: To change level 2 password, substitute CHANGE LEVEL 2 PSWD for CHANGE LEVEL 1PSWD in step 1.d above.Note: To disable a security level, set the password to a single zero.

Digital InputsThere are 6 digital inputs on Level 1.0 and 8 digital inputs on Level 2.0;4 of these inputs will always be used;Digital Input #1 Is used for the emergency stop.Digital Input #2 Is used for remotely starting and stopping the generator set. If the input is active and the engine mode switch is in AUTO, the engine will attempt to start and run. Once the input becomes inactive the engine will enter into cooldown (if programmed) and then stop.Digital Input #3 Is used for High Engine Temperature shutdownDigital Input #4 Is used for Low Oil Pressure shutdownThe remainder of the inputs can be configured. The main purpose for the other Digital Inputs is to add additional monitoring capabilities. The inputs can be configured by going to the Event I/P Functions parameter under the Setpoints menu. The Digital Input parameter can only be set to Active High or Active Low in order to initiate a High Warning, Low Warning, High Shutdown, Low Shutdown, or Status.

Data LinksThe digital module has up to three different data links depending on level:Two CANBUS (J1939) Data LinksUsed for local communication among modules associated with a single Genset e.g. ECM, Annunciators etc.Operates at speeds up to 250kbpsCAN 1 is used to connect from the digital module to an ECMThe service tool should be connected to the Can 1 connection to enable programming of the digital moduleCAN 2 is used by the Remote AnnunciatorThe service tool should be connected to the CAN 2 connection to enable programming of the Annunciator if the Annunciator is connectedOne RS485 SCADA (Systems Control And Data Acquisition) Data LinkUses MODBUS protocol at speeds up to 2.4kbpsCan be used to connect remotely through a modem using a RS485 to RS232 converterHalf Duplex connection (2 wires)Password levels are to restrict access

Additional I/O ModulesAnnunciator Module16 channel display unit for remote information about the current system status. Can be used to announce faults and/or status signals, it also allows the operator to silence the horn or acknowledge faults to the system.Connects to the CAN2 J1939 data link on the PowerWizard Level 2.0 moduleThere are 17 pair of LEDs on the annunciators front panel;16 pairs of LEDs are used to announce events, diagnostics, and ready signals17th pair of LEDs is used as combined network/module status LED to inform operator of a problem with the data link connection.Each pair of LEDs consists of two of the following 3 colors: green, yellow, and red. E.g. A pair of red and yellow LEDs may be configured for Engine Oil Pressure. If a low engine oil pressure Warning is read over the data link, the Annunciator will flash the Yellow LED and the siren will sound. If the low engine oil pressure Shutdown is read over the data link, the Annunciator will flash the Red LED and the siren will sound.Maximum distance 240metres from generating setProgrammed using Electronic Service ToolIn the the Configuration screen. Each LED pair has four settings: Suspect Parameter Number (SPN), Trigger Type, Trigger Severity Level, and Failure Mode Identifier (FMI).

Additional I/O ModulesThermocouple ModuleThe Thermocouple Module (TC) is capable of reading twenty inputs from thermocouples and is also capable of generating diagnostics. The diagnostics that are generated by this Module are maintained in non-volatile memoryThe Thermocouple Module will read the inputs and then calculate the temperature in Celsius. The Thermocouple Module will then broadcast the information onto the J1939 data link. The PowerPort Module will read the information from the Thermocouple Module and display the information on the display screen.The Thermocouple Module is capable of storing twenty diagnostics log entries. The log can be viewed from the PowerPort Module. All of the diagnostic messages are broadcast on the J1939 data link. The PowerPort Module reads these messages and reacts depending on its settings. Any of the inputs can be disabled to prevent unnecessary diagnostic faults.The Thermocouple Module is configured by using EST on the primary data link.

Additional I/O ModulesDiscrete Input/Output ModuleThis Module is capable of reading twelve discrete inputs, operating eight relay outputs and can be mounted on the Genset or remotely. It is configured using EST.The Module has twelve inputs with four return channels. These inputs can be activated by either switching to a return or to battery negative.Inputs that generate a warning message will auto-reset whenever the input is removed. Inputs that generate a shutdown message will continue until the input returns to a non-active state and a reset message is received on the J1939 Data Link.The Discrete I/O Module has eight " Form C" relay outputs. Each output can be configured for either general or specific events. For general events, each output activates whenever any Alarm Condition, Shutdown Condition, or Alarm and/or Shutdown Condition exists.For specific events, each output activates when the diagnostic message contains the SPN and FMI combination that matches the SPN and FMI combination that is programmed for that particular output.

Additional I/O ModulesResistive Temperature Device ModuleThis Module is a temperature scanner capable of reading eight Platinum RTD inputs. The eight Platinum RTD inputs can have two, three, or four-wire configurations.The Module is also capable of generating diagnostics. The diagnostics that are generated by the RTD Module are maintained in non-volatile memory. The RTD Module is capable of storing the twenty diagnostic log entries.The Resistive Temperature Device (RTD) Module will read the inputs and then calculate the temperature in Celsius. The RTD Module will then broadcast the information onto the J1939 data link.Each of the 8 inputs have sensor diagnostics in order to detect open or short circuits that go to the RTD sensors. Over temperature warnings and Shutdowns as well as Under temperature warnings are detected by comparing the measured temperature to the Low Warning, the High Warning, the High Shutdown temperatures stored in the module.

Service ToolThe new control modules will be supported by Perkins EST Tools

CANBus J1939 CodesFailure mode identifier (FMI)Type of failure that has been experienced by the componentSuspect Parameter Number (SPN)The SPN is a number that identifies the specific component of the electronic control system that has experienced a diagnostic code.Parameter Group Numbers (PGN)Parameter Groups are organized according to Generator, Utility, and Bus related parameter quantities.

SummaryDifferentiated, integrated solution Competitively priced, 21st century productIncreased feature bundling Consistent directionIncreased quality and reliabilityIndustry leading family of control systemsQuality, Increased Functionality and Growth

The 400C series complies with EPA (Environmental Protection Agency) and CARB (Californian Air Regulation Board) Tier 2 and EPA Stage II emissions, 400D complies with 2008 EU Stage IIIA and EPA/CARB "Tier 3 plus". Essentially they meet the relevant legislation for 2008, but the EPA has skipped a tier in nomenclature because there is less future legislation to come below 37 kW.

External features of the engines are very similar, this will ensure a smooth transition from one engine series to the other.

Standard Perkins Engine number systemAlways quote engine number when ordering spares.1-2-3-4-5-6-7-8-9-10-11-12-13-Note the additional cooling paths. This improves cylinder head cooling thus reducing the radiator package size.The combustion chambers have been rationalised across the engine range.

The throat angle is still 45 degrees.

The 3 cylinder pepper pot combustion chambers are no longer used.

Valve lash adjustment still required at 1000 hours

Similar top cover design to that of 400C series.Allows easier valve clearance adjustment (Valve lash)

Options for the air inlet can be either in the end, side or top of the cover.

All top covers are manufactured from the same casting.

The radiator support boss, situated at the front of the top cover

It is recommended that the dipstick is removed when refilling the engine with oil, this will allow the oil to flow freely. If a back pressure builds up, on refilling, a small amount of oil may carry over into the inlet manifold via the CCB.Closed circuit breather (CCB) is used on all 400 range.

Crankcase gases are re-directed via a diaphragm control valve and the inlet manifold back into the combustion chamber.

This eliminates any external crankcase/engine breathing thus improving the environment, particularly when engines are used in confined spaces.Take care that the breather hole does not get blocked.

An adapter is used, For 404C22T, 404D22T, and 404D22TA to allow a pipe to be fitted and routed to the turbo inlet. (Less than 6 from the turbo inlet).

The fitting of this pipe will be the responsibility of the engine installer, not Perkins.

The diaphragm vent hole, fitted to all CCBs, must be kept clear

The CCB has a 2000 hour service interval

The crankshafts is machined from heat-treated chromium molybdenum forged steel.

The main and big end journals and the oil seal contact areas are induction hardened.

Thrust washers positioned in the rear main bearing housing control the lateral movement and thrust.

For the 403.11 engine and smaller, these washers are cast as part of the Aluminium rear bearing housing.

Two thrust washers are used in the lower part of the holder for the 403-15, and three (as shown) for the 404-22 Both front and rear end oil seals are made from synthetic rubber. The front is fitted into the timing case and the rear seal is fitted into the rear crankcase face recess.

The outside diameter of the crankshaft bearing holders reduce as they get nearer the front of the engine.

To assist in identification, bite marks are machined in holders 1 and 3 as shown.

The leading edge of the holders are chamfered to assist in initial location into the tunnel cylinder block

Alloy rear bearing holder, incorporating thrust washers used on 403-11 and below

Always ensure the oil feed hole in the bearing holder is on the correct side to align with the hole in the cylinder block.

This Conformable oil control ring has the ability to alter its shape slightly to conform to the varying dimensions of the bore.

The Pistons and connecting rods are matched

The Shibaura name on the inside of the piston must be on fuel pump side of engine on assembly

The finish of the cylinder bore doesnt allow it to be Flexi-Honed

There are NO oversize pistons available.Keystone top ring on Turbocharged engines.

Give better gas sealing at higher cylinder pressures.Note external oil feed to cylinder head

Oil Circuit remains the same 100 and 400C Series

Compact timing gear/oil pump assembly

Take Care the fuel filter will fit here, always use the correct filter!The rocker shaft assembly is lubricated via an external oil pipe.

The Longer valve (upper) Fitted to all engines in family except 404.22 Pressure: 262 359 Kpa [38 52 PSI]

The Shorter valve (lower) 404.22 ONLY. Pressure 352 448 Kpa [50 65 PSI] The lubricating oil pump is incorporated into the idler gear, optimising space. Backlash (Gear clearance) is checked between C clip and spring seat.

Tool 1 21825624 402D-05 and 403D-07Tool 2 21825625 403D-11 and 404D-15Tool 3 27610324 - 403D-15, 15T, 404D-22T, and 404D-22TA Idler hub replacement is impossible without the tool!CF-4, CG4 can be used but at reduced life specificationAlways use correct grade of oilThe camshaft is fitted to the left hand side of the cylinder block viewed from the front.

The camshaft is made from an induction hardened forged steel.

In addition to operating the inlet/exhaust valves and fuel lift pump there are lobes to operate the fuel injection pump.

The camshaft is supported on splash fed needle roller bearings.The above picture shows a governing device from a 400C engine. (Note the four bob weights)

1. Control rod (linked to the pump element)2. Centrifugal weights3. Sliding sleeve4. Lever5. Lever6. Throttle lever7. Stop lever8. Main Governor spring9. Start spring10. Adjusting screw for max fuel delivery11. Adjusting screw for max RPM (high idling)

Remove solenoid before trying to remove pump.

Remove pump securing nuts.

Lift pump out until spring clip is visible

Carefully extract the clip, do NOT drop in to engine!

Lift link off.After removing solenoid, fuel pump rack can be seen.

This should always move freelyWhen re-fitting the timing case, care should be taken to ensure the new procedure is followed correctly.The above picture shows the old 400C timing case.Used on the 403c.15 and above.

The Angleich unit works by trimming down the fuel delivery as the governor weights and spring come into equilibrium. (Achieving Setpoint RPM)

A change in Setpoint RPM caused by the slowing of the engine as a load is applied (Step Change) allows the unit to quickly increase the fuel giving a rapid increase in torque.

This torque back-up gives increased power as engine load is increased at any governed speed.

The units are set up in Japan, by ISM, for compressive resistance and for movement. They are then checked by PSEL on a 10,000 checking machine.

Each unit is set for a particular engine type which means that a unit set up for a 404C.22 will not suite a 403C.15 or vice versa.

Only used on variable speed engines.1. Record Engine Low Idle, and High idle speeds.2. Give four turns of high idle trimmer screw and record new high idle.3. Remove cover, and fuel pump and fit alien screw tooling4. Remove start spring and fit Calibration Spring (part #27610333)5. Reinstall housing WITHOUT GASKET6. Fit Adaptor and Dial Gauge into Fuel rack7. Wind plunger to touch fuel rack and, push plunger another 2mm to begin to move fuel rack. And now lock it into position, zeroing the dial gauge.8. Push Plunger and pull plunger several times, checking that the dial gauge returns to zero.

If the fuel rack has heavy resistance to movement, remove the pump and wash it. Return it into the engine and try the test again.

Do not move position of Dial gauge, and pull the plunger out to a position off of the fuel rack and retain in position using a suitable clip. To prevent plunger bending.Remove the Pump. Remove old front housing again.Remove the Allen bolt fitted before, and calibration spring and install it into new housing.Install the front housing and the fuel pump.Remove the clip from the plunger, and allow the plunger to touch fuel rack again.Adjust fuel screw shown above and look at the reading on the dial gauge, wind the reading past zero then return the reading to zero again.Use a wrench as shown to tighten the locknut

Remove the Dial Gauge and adaptorsRemove the fuel injection pumpRemove the front housing, remove the calibration spring, and refit the original start spring.Remove the Allen head bolt fitted to the lever assembly.Replace the gasketInstall the new housing.Set protrusion of Low idle screw (12) and high idle (11) to the same settings as the old housing.Set the high idle trimmer screw (3) to the fully out position and then screw in two turns.Reinstall the fuel pump and start the engine allowing it to reach normal operating tempRun the engine at low idle and adjust the low idle screw to the speed previously recordedRun the engine and adjust the high idle screw to the speed previously recordedRun the engine at high idle and adjust the high idle trimmer screw to previously recorded speed.Install the tamper proof caps.

To improve constant speed stability on Genset engines, a compensator spring is used on the governor linkage.

This reduces overshoot as the unit reacts to the load applied. Therefore the Setpoint RPM is quickly achieved without surging above and below this desired rating

The contact area on the slider contact plate is coated and polished to reduce friction.When the Engine is accelerated from a low RPM, the governor lever on the fuel rack comes into contact with the BCD fuel stopper.This prevents excessive movement of the governor lever and thus controls the fuel delivered.As the engine RPM increases the increased intake manifold pressure is felt on the diaphragm in the BCD.As the BCD fuel stopper is moved by the diaphragm piston, the governor lever is allowed to operate over the full range.

Adjustment ScrewDiaphragm PistonStopperIntake Manifold Pressure InletGovernor Lever

The tamper evident cap, shown, is fitted to the maximum speed screw. This is used in conjunction with the tamper evident cap fitted to the max. speed adjustment screw, fitted in the block.

Note: The both the fuel and oil filters have the same thread size. It is possible to fit the incorrect filter. Make sure that you (and you customers) always use the correct filters!Cassette type fuel injection pump. Fitted on the cylinder block and operated by the engine camshaft.

The engine timing is adjusted by changing the FIP shim.

The engine can be stopped by either a mechanical fuel shut off lever or an electrical fuel shut off solenoid.

No spill timing possible, use the same thickness shims.

Do not use sealant on the shims.

Rack must be free to move.Shims available:-0.20mm (0.008inch)0.30mm (0.012inch)0.40mm (0.016inch)0.50mm (0.020inch)

NOTE : If shims are lost Technical Help Desk can provide information from Engine History log.What is CTD? (Compact Timing Device).

This device allows the cassette type fuel injection pump to alter its timing depending on the throttle position.

By reducing the initial injection volume it improves timing control.

Benefits - Reduction in noise/diesel knock. (this is probably the greatest contributory factor in noise reduction for the 400).Reduction in NOx (Nitric Oxide) emissions.Reduction in smoke at low speed.Although different in appearance and specification, all 400 Series injectors are of the Pintle type. (Single hole nozzle)

It is recommended that Powerpart universal jointing compound is applied to the threads when refitting/replacing injectors.The high pressure pipe internal diameter has been optimised, tuning them to work more effectively with the injectors and FIP.

This gives a more accurate fuel delivery, and has a positive impact on fuel consumption, smoke and emissions.Fuel pump return /self venting pipe is now standard on all 400 Series engines.

This pipe allows any air, that may have become entrapped in the fuel, to escape back to the fuel tankRemember special washer with vent hole.The fuel filter allows for a commonality of parts across the Peterborough engine range.

This gives a better availability and a possibility of cost reduction for service parts through the distributor network.

Fuel filter servicing maintained at 500 hours

Top left - FCM latest type, fitted to most engines.

Top right - electric pumpFill cooling system slowly. Always use anti-freeze.Dont remove thermostat if faulty, this may cause the engine to overheat, coolant will take least line of resistance and may not circulate around cylinder headThe 403C-11 thermostat housing has been rationalised in-line with the product range.

Previous 3 cylinder engines, 103C-10 and below, had the thermostat positioned within the water impeller housing.Coolant temperature switch (Green)

Oil pressure switch (Red - 0.3kgf), fitted to rocker assembly / cylinder head

Oil pressure switch (Blue - 1.0kgf), fitted to cylinder block main oil gallery.

Compliant to electrical standard IP67.Always remove this unit before removing the fuel injection pump. Screw in by hand, do not use tools. Important Note: When re-fitting the Sensor ensure that a tooth is in line with the hole. Screw in by hand until it just touches the magnet then unscrew (turn Anti-clockwise) by ONE TURN and then tighten the lock nut.This will give the correct clearance of one millimetre. These units create a 3 5v AC signal.