Professional Documents
Culture Documents
January 2008
Specifications
400 Industrial Engine
HB (Engine)
HD (Engine)
HH (Engine)
HL (Engine)
HM (Engine)
HN (Engine)
HP (Engine)
HR (Engine)
SENR9971-01
Table of Contents
Specifications Section
Engine Design ..................................................... 4
Fuel Injection Lines .............................................. 7
Fuel Injection Pump ............................................. 8
Fuel Injectors ....................................................... 8
Fuel Priming Pump .............................................. 9
Lifter Group ........................................................... 9
Rocker Shaft ........................................................ 9
Valve Mechanism Cover ...................................... 11
Cylinder Head Valves ........................................... 11
Cylinder Head ...................................................... 13
Turbocharger ....................................................... 15
Exhaust Manifold ................................................. 16
Camshaft ............................................................. 16
Engine Oil Lines ................................................... 18
Engine Oil Relief Valve ........................................ 19
Engine Oil Pump .................................................. 19
Engine Oil Pressure ............................................. 20
Engine Oil Pan ..................................................... 20
Water Temperature Regulator (402C-05 and 403C-07
Engines) .............................................................. 21
Water Temperature Regulator (403C-11, 403C-15,
403C-17, 404C-15, 404C-22 and 404C-22T
Engines) .............................................................. 21
Cylinder Block ...................................................... 23
Crankshaft ........................................................... 23
Connecting Rod Bearing Journal ......................... 25
Main Bearing Journal ............................................ 25
Connecting Rod ................................................... 27
Piston and Rings .................................................. 28
Housing (Front) ..................................................... 31
Gear Group (Front) ............................................... 31
Flywheel ............................................................... 33
Flywheel Housing ................................................ 33
Crankshaft Pulley ................................................. 33
Belt Tension Chart ............................................... 34
Fan Drive ............................................................. 34
Engine Lifting Bracket ........................................... 34
Alternator and Regulator ...................................... 34
Electric Starting Motor ......................................... 35
Coolant Temperature Switch ................................. 36
Engine Oil Pressure Switch .................................. 36
Glow Plugs ........................................................... 37
Fuel Shutoff Solenoid ........................................... 37
Index Section
Index ..................................................................... 38
3
Table of Contents
4
Specifications Section
SENR9971-01
Specifications Section
i02806459
Engine Design
403C-07 Engine
402C-05 Engine
Illustration 2
g00852304
Illustration 1
g01111232
Valve lash
SENR9971-01
5
Specifications Section
403C-11 Engine
Illustration 3
403C-15 Engine
g00852304
Illustration 4
g00852304
Valve lash
Valve lash
6
Specifications Section
SENR9971-01
403C-17 Engine
Illustration 5
404C-15 Engine
g00852304
Illustration 6
g00296424
Valve lash
Valve lash
SENR9971-01
7
Specifications Section
404C-22/404C-22T Engine
i02806464
Illustration 7
g00296424
Illustration 8
g01442026
(1) Torque for the union nuts for the fuel injectors (all
models) ................................ 20 Nm (14.75 lb ft)
Illustration 9
g01442096
8
Specifications Section
SENR9971-01
i02806478
Fuel Injectors
Illustration 10
g00899711
Illustration 11
g01335248
Camshaft
Cylinder block
The following thicknesses of shims are available:
SENR9971-01
9
Specifications Section
i02202509
i02806499
Lifter Group
Illustration 13
g00692979
g00819278
i02806502
Rocker Shaft
Illustration 14
g01440959
10
Specifications Section
SENR9971-01
Illustration 16
g01440948
g01440976
SENR9971-01
11
Specifications Section
i02806551
Illustration 17
i02806610
g01441024
Illustration 18
g00903737
12
Specifications Section
SENR9971-01
Illustration 19
g00903744
Illustration 20
g00845823
SENR9971-01
13
Specifications Section
g00903773
Cylinder Head
Illustration 23
g00819698
Illustration 22
g00903760
14
Specifications Section
SENR9971-01
Table 1
Gasket
Thickness
0.55 to 0.64 mm
(0.0217 to 0.0252 inch)
1.2 mm
(0.047 inch)
0.65 to 0.75 mm
(0.0256 to 0.0295 inch)
1.3 mm
(0.051 inch)
Table 2
Gasket
Thickness
1.3 mm
(0.051 inch)
1.4 mm
(0.055 inch)
Illustration 24
g01317344
Table 3
Gasket
Thickness
0.45 to 0.55 mm
(0.0177 to 0.0217 inch)
1.3 mm
(0.051 inch)
0.56 to 0.70 mm
(0.0220 to 0.0276 inch)
1.4 mm
(0.055 inch)
Table 4
Gasket
Thickness
0.45 to 0.30 mm
(0.0177 to 0.0118 inch)
0.4 mm
(0.016 inch)
0.29 to 0.20 mm
(0.0114 to 0.0079 inch)
0.5 mm
(0.020 inch)
Table 5
Gasket
Thickness
0.29 to 0.20 mm
(0.0114 to 0.0079 inch)
0.5 mm
(0.020 inch)
Illustration 25
g01317351
SENR9971-01
15
Specifications Section
Turbocharger
Illustration 26
g00900074
Illustration 28
g00921767
(1) Tighten the banjo bolt for the oil supply line to the
following torque. .................... 18 Nm (13.3 lb ft)
(2) Tighten the nuts that secure the turbocharger
to the exhaust manifold to the following
torque. ...................................... 25 Nm (18 lb ft)
Illustration 27
Typical example
g00900977
(3) Tighten the setscrews for the oil drain tube to the
following torque. ......................... 10 Nm (7 lb ft)
16
Specifications Section
SENR9971-01
i02807732
Exhaust Manifold
Illustration 29
g01441994
(1) Torque for the nuts and the setscrews for the
exhaust manifold
Service limit
i02807784
Camshaft
Illustration 30
g00819857
SENR9971-01
17
Specifications Section
Illustration 31
g00295323
Illustration 32
g01442485
18
Specifications Section
SENR9971-01
i02139045
Illustration 33
g01093847
SENR9971-01
19
Specifications Section
i02807898
Illustration 35
g00458938
g00820218
(1) Circlip
(2) Collar
(1) Use a new O-ring seal when the engine oil relief
valve is installed.
(4) Shim
(3) Spring
(7) Spring
Illustration 36
g00459701
20
Specifications Section
SENR9971-01
i02145682
(9) Bushing
Oil Pressure(1)
(1)
i02141054
Illustration 37
g01088627
Illustration 38
(1) Gasket
g00820013
(4) Tighten the bolts for the engine oil pan to the
following torque. .......................... 11 Nm (8 lb ft)
0.10 mm
0.15 mm
0.20 mm
0.50 mm
SENR9971-01
21
Specifications Section
Illustration 39
g00820021
(1) O-ring
(2) Oil suction tube
(3) Tighten the bolts for the oil strainer to the
following torque. .......................... 11 Nm (8 lb ft)
Illustration 41
(4) Strainer
Note: Install a new O-ring (1) in the hole of the
cylinder block when the oil suction tube is removed
or replaced.
i02894912
g01441030
Illustration 40
g00877006
g00877006
22
Specifications Section
SENR9971-01
g01441067
Illustration 43
g01441066
Illustration 45
g01441069
SENR9971-01
23
Specifications Section
Cylinder Block
Crankshaft
Illustration 46
g00904878
Illustration 47
g00901145
Illustration 48
Typical crankshaft for a 3 cylinder engine
g01113243
24
Specifications Section
SENR9971-01
Illustration 50
Illustration 49
g00904902
g00904925
Standard thickness for 403C-15, 403C-17, 404C22 and 404C-22T engines ........ 2.95 to 3.00 mm
(0.1161 to 0.1181 inch)
Service limit for 403C-15, 403C-17, 404C-22 and
404C-22T engines ........... 2.80 mm (0.1102 inch)
Note: The thrust washer for the 402C-05, 403C-07,
403C-11 and 404C-15 engines is machined into the
holder for the main bearing.
(3) Top thrust washer
SENR9971-01
25
Specifications Section
i02808966
Diameter
Service limit
Standard
34.964 to 34.975 mm
(1.3765 to 1.3770
inch)
34.9 mm
(1.3740 inch)
Undersize
0.25 mm
(0.010 inch)
34.714 to 34.725 mm
(1.3667 to 1.3671
inch)
34.65 mm
(1.3642 inch)
Undersize
0.50 mm
(0.020 inch)
34.464 to 34.475 mm
(1.3568 to 1.3573
inch)
34.4 mm
(1.3543 inch)(1)
Standard clearance
402C-05 and 403C-07 .......... 0.031 to 0.079 mm
(0.00122 to 0.00311 inch)
403C-11 and 404C-15 .......... 0.035 to 0.083 mm
(0.0014 to 0.0033 inch)
403C-15, 403C-17, 404C-22 and
404C-22T .............................. 0.035 to 0.085 mm
(0.00138 to 0.00335 inch)
Service limit
All models ....................... 0.20 mm (0.0079 inch)
i02808967
Table 8
Size
Journal
Diameter
Service
limit
42.964 to
42.975 mm
(1.69150 to
1.69193 inch)
42.90
mm
(1.6890
inch)
45.948 to
45.959 mm
(1.80897 to
1.80941 inch)
45.90
mm
(1.8071
inch)
42.714 to
42.725 mm
(1.68165 to
1.68210 inch)
42.65
mm
(1.6791
inch)
45.698 to
45.709 mm
(1.79913 to
1.79960 inch)
45.65
mm
(1.7972
inch)
42.464 to
42.475 mm
(1.67181 to
1.67224 inch)
42.40
mm
(1.6693
inch)(1)
45.448 to
45.459 mm
(1.78930 to
1.78972 inch)
45.40
mm
(1.7874
inch)(1)
Diameter
Service limit
Standard
40.964 to 40.975 mm
(1.61280 to 1.61320
inch)
40.90 mm
(1.6102 inch)
Undersize
0.25 mm
(0.010 inch)
40.714 to 40.725 mm
(1.60290 to 1.60330
inch)
40.65 mm
(1.6003 inch)
Undersize
0.50 mm
(0.020 inch)
40.464 to 40.475 mm
(1.59310 to 1.59350
inch)
40.40 mm
(1.5905 inch)(1)
Standard
Undersize
0.25 mm
(0.010 inch)
Table 9
(1)
Journals
Diameter
Service limit
Standard
51.964 to 51.975 mm
(2.04582 to 2.04626
inch)
51.90 mm
(2.0433 inch)
Undersize
0.25 mm
(0.010 inch)
51.714 to 51.725 mm
(2.03598 to 2.03641
inch)
51.65 mm
(2.0335 inch)
Undersize
0.50 mm
(0.020 inch)
51.464 to 51.475 mm
(2.02614 to 2.02660
inch)
51.40 mm
(2.0236 inch)(1)
Undersize
0.50 mm
(0.020 inch)
26
Specifications Section
SENR9971-01
Table 11
Table 12
Journal
Diameter
Service
limit
1 and 2
42.964 to
42.975 mm
(1.69150 to
1.69193 inch)
42.90
mm
(1.6890
inch)
45.948 to
45.959 mm
(1.80897 to
1.80941 inch)
45.90
mm
(1.8071
inch)
1 and 2
42.714 to
42.725 mm
(1.68165 to
1.68210 inch)
42.65
mm
(1.6791
inch)
45.698 to
45.709 mm
(1.79913 to
1.79960 inch)
45.65
mm
(1.7972
inch)
1 and 2
42.464 to
42.475 mm
(1.67181 to
1.67224 inch)
42.40
mm
(1.6693
inch)(1)
45.448 to
45.459 mm
(1.78930 to
1.78972 inch)
45.40
mm
(1.7874
inch)(1)
Standard
Undersize
0.25 mm
(0.010 inch)
Undersize
0.50 mm
(0.020 inch)
3
Journal
Diameter
Service
limit
1 and 2
47.965 to
47.975 mm
(1.88830 to
1.88880 inch)
47.90
mm
(1.8858
inch)
47.954 to
47.965 mm
(1.88800 to
1.88830 inch)
47.90
mm
(1.8858
inch)
1 and 2
47.714 to
47.725 mm
(1.87850 to
1.87890 inch)
47.65
mm
(1.8750
inch)
47.704 to
47.715 mm
(1.87810 to
1.87850 inch)
47.65
mm
(1.8750
inch)
1 and 2
47.464 to
47.475 mm
(1.86870 to
1.86910 inch)
47.40
mm
(1.8660
inch)(1)
47.454 to
47.465 mm
(1.86250 to
1.86870 inch)
47.40
mm
(1.8660
inch)(1)
Standard
Undersize
0.25 mm
(0.010 inch)
Undersize
0.50 mm
(0.020 inch)
SENR9971-01
27
Specifications Section
Table 13
Journal
Diameter
Service
limit
1, 2 and 3
47.965 to
47.975 mm
(1.88830 to
1.88880 inch)
47.90
mm
(1.8858
inch)
47.954 to
47.965 mm
(1.88800 to
1.88830 inch)
47.90
mm
(1.8858
inch)
1, 2 and 3
47.714 to
47.725 mm
(1.87850 to
1.87890 inch)
47.65
mm
(1.8750
inch)
47.704 to
47.715 mm
(1.87810 to
1.87850 inch)
47.65
mm
(1.8750
inch)
1, 2 and 3
47.464 to
47.475 mm
(1.86870 to
1.86910 inch)
47.40
mm
(1.8660
inch)(1)
47.454 to
47.465 mm
(1.86250 to
1.86870 inch)
47.40
mm
(1.8660
inch)(1)
Standard
Undersize
0.25 mm
(0.010 inch)
Undersize
0.50 mm
(0.020 inch)
Connecting Rod
Table 14
(1)
Journals
Diameter
Service
limit
Standard
67.957 to 67.970 mm
(2.67550 to 2.67597
inch)
67.90 mm
(2.6732
inch)
Undersize
0.25 mm
(0.010 inch)
67.707 to 67.720 mm
(2.66563 to 2.66614
inch)
67.65 mm
(2.6634
inch)
Undersize
0.50 mm
(0.020 inch)
67.457 to 67.470 mm
(2.65579 to 2.65630
inch)
67.40 mm
(2.6535
inch)(1)
Illustration 51
g01442588
28
Specifications Section
SENR9971-01
i02808972
Illustration 52
g01442499
Typical example
Illustration 53
g00845975
Refer to Testing and Adjusting, Connecting Rod Inspect for the procedure to measure distortion and
parallelism of the connecting rod.
Illustration 54
g00845969
SENR9971-01
29
Specifications Section
30
Specifications Section
SENR9971-01
(4) Piston
SENR9971-01
31
Specifications Section
i02808993
Table 15
Injection timing
Engine
Maximum rated
engine speed
Injection timing
(BTDC) in
degrees(1)
402C-05 Genset
1800
12 1
402C-05 Genset
3000
20 1
402C-05 Genset
3600
21 1
402C-05
Industrial engine
2800
18 1
402C-05
Industrial engine
3000
20 1
402C-05
Industrial engine
3200
20 1
402C-05
Industrial engine
3600
21 1
403C-07 Genset
1800
12 1
403C-07 Genset
3000
20 1
403C-07 Genset
3600
21 1
403C-07
Industrial engine
2800
18 1
403C-07
Industrial engine
3000
20 1
403C-07
Industrial engine
3200
20 1
403C-07
Industrial engine
3400
21 1
403C-07
Industrial engine
3600
21 1
403C-11 Genset
1500
18 1
403C-11 Genset
1800
18 1
403C-11 Genset
3000
23 1
403C-11 Genset
3600
22 1
403C-11
Industrial engine
2200
23 1
403C-11
Industrial engine
2400
23 1
403C-11
Industrial engine
2600
23 1
403C-11
Industrial engine
2800
23 1
403C-11
Industrial engine
3000
23 1
403C-15 Genset
1500
14 1
Housing (Front)
Illustration 55
g00827564
(continued)
32
Specifications Section
SENR9971-01
Injection timing
Injection timing
Engine
Maximum rated
engine speed
Injection timing
(BTDC) in
degrees(1)
Engine
Maximum rated
engine speed
Injection timing
(BTDC) in
degrees(1)
403C-15 Genset
1800
14 1
3000
20 1
403C-15 Genset
3000
20 1
404C-22
Industrial engine
403C-15
Industrial engine
2200
22 1
404C-22T
Industrial engine
2800
18 1
403C-15
Industrial engine
2400
22 1
404C-22T
Industrial engine
3000
18 1
403C-15
Industrial engine
2600
22 1
403C-15
Industrial engine
2800
20 1
403C-15
Industrial engine
3000
20 1
403C-17
Industrial engine
2400
20 1
403C-17
Industrial engine
2600
20 1
404C-15 Genset
1500
18 1
404C-15 Genset
1800
18 1
404C-15 Genset
3000
23 1
Illustration 56
404C-15 Genset
3600
22 1
404C-15
Industrial engine
2200
23 1
(1)
(2)
(3)
(4)
404C-15
Industrial engine
2400
23 1
404C-15
Industrial engine
2600
23 1
404C-15
Industrial engine
2800
23 1
404C-15
Industrial engine
3000
23 1
404C-22 Genset
1500
15 1
404C-22 Genset
1800
12 1
404C-22 Genset
3000
18 1
404C-22
Industrial engine
2200
18 1
404C-22
Industrial engine
2400
18 1
404C-22
Industrial engine
2600
20 1
404C-22
Industrial engine
2800
20 1
(1)
(continued)
g00821197
Feeler gauge
Timing mark on the crankshaft gear
Timing mark on the camshaft gear
Timing mark on the idler gear
SENR9971-01
33
Specifications Section
i02142620
Flywheel
Illustration 57
g00820355
Crankshaft Pulley
Flywheel Housing
Illustration 59
g00904688
Illustration 58
g01442020
34
Specifications Section
SENR9971-01
i02142647
(1)
(2)
i02142675
Fan Drive
Illustration 60
i02809027
g00904732
Illustration 61
g00909016
Typical example
i02142717
SENR9971-01
35
Specifications Section
Start Relays
Starting Motor
Illustration 62
g00379835
Illustration 63
g00381753
36
Specifications Section
SENR9971-01
i02142810
Illustration 64
g01094334
Illustration 65
g00904803
SENR9971-01
37
Specifications Section
i02809106
Glow Plugs
Illustration 66
g00904843
Illustration 67
g00820306
38
Index Section
SENR9971-01
Index
Fuel Priming Pump ................................................ 9
Fuel Shutoff Solenoid ............................................ 37
A
Alternator and Regulator ....................................... 34
G
B
Belt Tension Chart ................................................. 34
Camshaft ...............................................................
Connecting Rod.....................................................
Markings on the Connecting Rod.......................
Connecting Rod Bearing Journal...........................
Coolant Temperature Switch .................................
Crankshaft ............................................................
Crankshaft Pulley ..................................................
Cylinder Block........................................................
Cylinder Head........................................................
Measuring the Distortion of the Cylinder Head ..
Tightening Procedure for the Cylinder Head......
Cylinder Head Valves ............................................
16
27
28
25
36
23
33
23
13
15
14
11
Housing (Front)...................................................... 31
I
Important Safety Information ................................. 2
L
Lifter Group............................................................ 9
M
E
Electric Starting Motor ...........................................
Start Relays .......................................................
Starting Motor ....................................................
Engine Design .......................................................
402C-05 Engine .................................................
403C-07 Engine .................................................
403C-11 Engine .................................................
403C-15 Engine .................................................
403C-17 Engine .................................................
404C-15 Engine .................................................
404C-22/404C-22T Engine ................................
Engine Lifting Bracket............................................
Engine Oil Lines ....................................................
Engine Oil Pan.......................................................
Oil Suction Tube and Oil Strainer ......................
Engine Oil Pressure...............................................
Engine Oil Pressure Switch ...................................
Engine Oil Pump....................................................
Engine Oil Relief Valve ..........................................
Exhaust Manifold ...................................................
35
35
35
4
4
4
5
5
6
6
7
34
18
20
21
20
36
19
19
16
P
Piston and Rings ................................................... 28
Markings on the Piston ...................................... 28
Piston and Piston Rings..................................... 28
R
Rocker Shaft.......................................................... 9
S
Specifications Section ........................................... 4
T
Table of Contents................................................... 3
Turbocharger ......................................................... 15
F
Fan Drive ...............................................................
Flywheel ................................................................
Flywheel Housing ..................................................
Fuel Injection Lines................................................
Fuel Injection Pump...............................................
Fuel Injectors .........................................................
34
33
33
7
8
8
V
Valve Mechanism Cover........................................ 11
SENR9971-01
W
Water Temperature Regulator (402C-05 and 403C-07
Engines)............................................................... 21
Water Temperature Regulator Housing ............. 21
Water Temperature Regulator (403C-11, 403C-15,
403C-17, 404C-15, 404C-22 and 404C-22T
Engines)............................................................... 21
Water Temperature Regulator Housing ............. 22
39
Index Section
Printed in U. K.