Perkins Series 400 - Manual de Operación y Mantenimiento

8/13/2019 Perkins Series 400 - Manual de Operacin y Mantenimiento

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SEBU8311-01

April 2008

Operation andMaintenance

Manual402D-403D-404D Industrial Engine

GG(Engine)GH (Engine)GJ (Engine)GK (Engine)

GL (Engine)GM (Engine)GN (Engine)GP (Engine)GQ (Engine)GS (Engine)

This document has been printed from SPI. Not for Resale


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Important Safety InformationM ost accidents that involve product operation, maintenance and repair are caused by failure to

observe basic safety rules or precautions. A n 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 andcould result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread 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 S ignal Word such as

D AN G ER, WARN IN G or CA U TIO N . T he Safety Alert WAR NI NG label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written orpictorially presented.

O perations that may cause product damage are identified by N O TIC E labels on the product and in

this publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. Thewarnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,work method or operating technique that is not specifically recommended by Perkins is used,you must satisfy yourself that it is safe for you and for others. You should also ensure that theproduct will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that

was available at the time that the publication was written. The specifications, torques, pressures,

measurements, adjustments, illustrations, and other items can change at any time. These changes can

affect the service that is given to the product. O btain the complete and most current information before

you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for thisproduct Perkins recommends using Perkins

replacement parts.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.



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SEBU8311-01 3Table of Contents

Table of Contents

Foreword ................................................................. 4

Safety Section

Safety Messages .................................................... 5

General Hazard Information ................................... 7

Burn Prevention ...................................................... 8

Fire Prevention and Explosion Prevention .............. 8

Crushing Prevention and Cutting Prevention ........ 10

Before Starting Engine ........................................... 11

Engine Starting ...................................................... 11

Engine Stopping .................................................... 11

Electrical System .................................................. 12

Product Information Section

Model Views ......................................................... 13

Product Identification Information ........................ 23

Operation Section

Lifting and Storage ................................................ 25

Gauges and Indicators .......................................... 28

Features and Controls .......................................... 29

Engine Starting ..................................................... 30

Engine Operation .................................................. 33

Engine Stopping ................................................... 34

Cold Weather Operation ....................................... 35

Maintenance Section

Refill Capacities .................................................... 39

Maintenance Interval Schedule ............................ 58

Warranty Section

Warranty Information ............................................ 89

Index Section

Index ..................................................................... 90



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4 SEBU8311-01Foreword

Foreword

Literature Information

This manual contains safety, operation instructions,

lubrication and maintenance information. Thismanual should be stored in or near the engine areain a literature holder or literature storage area. Read,study and keep it with the literature and engineinformation.

English is the primary language for all Perkinspublications. The English used facilitates translationand consistency.

Some photographs or illustrations in this manualshow detailsor attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuing

improvement and advancement of product designmay have caused changes to your engine which arenot included in this manual. Whenever a questionarises regarding your engine, or this manual, pleaseconsult with your Perkins dealer or your Perkinsdistributor for the latest available information.

Safety

This safety section lists basic safety precautions.In addition, this section identifies hazardous,warning situations. Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, maintenance and

repair onthis product.

Operation

Operating techniques outlined in this manual arebasic. They assist with developing the skills andtechniques required to operate the engine moreefficiently and economically. Skill and techniquesdevelopas the operator gains knowledge of theengine and its capabilities.

The operation section is a reference for operators.Photographs and illustrations guide the operator

through procedures of inspecting, starting, operatingand stopping the engine. This section also includes adiscussion of electronic diagnostic information.

Maintenance

The maintenance section is a guide to engine care.The illustrated, step-by-step instructions are groupedby service hours and/or calendar time maintenanceintervals. Items in the maintenance schedule arereferenced to detailed instructions that follow.

Recommended service should be performed at theappropriate intervals as indicated in the MaintenanceInterval Schedule. The actual operating environmentof the engine also governs the Maintenance IntervalSchedule. Therefore, under extremely severe,dusty, wet or freezing cold operating conditions,

more frequent lubrication and maintenance than isspecified in the Maintenance Interval Schedule maybe necessary.

The maintenance schedule items are organized fora preventive maintenance management program. Ifthe preventive maintenance program is followed, aperiodic tune-up is not required. The implementationof a preventive maintenance management programshould minimize operating costs through costavoidances resulting from reductions in unscheduleddowntime and failures.

Maintenance IntervalsPerform maintenance on items at multiples ofthe original requirement. We recommend that themaintenance schedules be reproduced and displayednear the engine as a convenient reminder. We alsorecommend that a maintenance record be maintainedas part of the engines permanent record.

Your authorized Perkins dealer or your Perkinsdistributor can assist you in adjusting yourmaintenance schedule to meet the needs of youroperating environment.

OverhaulMajor engine overhaul details are not covered inthe Operation and Maintenance Manual exceptfor the interval and the maintenance items in thatinterval. Major repairs should only be carried out byPerkins authorized personnel. Your Perkins dealeror your Perkins distributor offers a variety of optionsregarding overhaul programs. If you experiencea major engine failure, there are also numerousafter failure overhaul options available. Consult withyour Perkins dealer or your Perkins distributor forinformation regarding these options.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birthdefects, and other reproductive harm. Batteryposts, terminals and related accessories contain leadand lead compounds.Wash hands after handling.



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SEBU8311-01 5Safety Section

Safety Messages

Safety Section

i02959960

Safety Messages

There may be several specific warning signs on yourengine. The exact location and a description of thewarning signs are reviewed in this section. Pleasebecome familiar with all warning signs.

Ensure that all of the warning signs are legible. Cleanthe warning signs or replace the warning signs ifthe words cannot be read or if the illustrations arenot visible. Use a cloth, water, and soap to cleanthe warningsigns. Do not use solvents, gasoline, orother harsh chemicals. Solvents, gasoline, or harsh

chemicals could loosen the adhesive that secures thewarning signs. The warning signs that are loosenedcould drop off of the engine.

Replace any warning sign that is damaged ormissing. If a warning sign is attached to a part of theengine that is replaced, install a new warning sign onthe replacement part. Your Perkins dealer or yourdistributor can provide new warning signs.

(A) Universal Warning

Do not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions orheed the warnings could result in serious injuryor death.

g01154807Illustration 1

Typical example

Warning label (A) is installed in different locations.The location will change according to the physicalsize of the engine.



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6 SEBU8311-01Safety SectionSafety Messages


(A) Location of warning label(1) 402D-05(2) 403D-07

(3) 403D-11(4) 403D-15, 403D-15T and 403D-17(5) 404D-15

(6) 404D-22, 404D-22T and 404D-22TA



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General Hazard Information

i02328435

General Hazard Information

g00104545

Illustration 3

Attach a Do Not Operate warning tag or a similarwarning tag to the start switch or to the controlsbefore you service the equipment or before yourepair the equipment.


Wear a hard hat, protective glasses, and otherprotective equipment, as required.

Do not wear loose clothing or jewelry that can snagon controls or on other parts of the engine.

Make sure that all protective guards and all coversare secured in place on the engine.

Keep the engine free from foreign material. Removedebris, oil, tools, and other items from the deck, fromwalkways, and from steps.

Never put maintenancefluids into glass containers.Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care.

Report all necessary repairs.

Do not allow unauthorized personnel on theequipment.

Ensure that the power supply is disconnected before

you work on thebus bar or the glow plugs.

Perform maintenance on the engine with theequipment in the servicing position. Refer to theOEM information for the procedure for placing theequipment in the servicing position.

Pressure Air and Water

Pressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.

The direct application of pressurized air orpressurized water to the body could result in personalinjury.

When pressurized air and/or water is used forcleaning, wear protective clothing, protective shoes,and eye protection. Eye protection includes gogglesor a protective face shield.

The maximum air pressure for cleaning purposesmust be below 205 kPa (30 psi). The maximumwater pressure for cleaning purposes must be below275 kPa (40 psi).

Fluid PenetrationPressure can be trapped in the hydraulic circuit longafter the engine has been stopped. The pressure cancause hydraulic fluid or items such as pipe plugs toescape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has been relievedor personal injury may occur. Refer to the OEMinformation for any procedures that are required torelievethe hydraulic pressure.



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8 SEBU8311-01Safety SectionBurn Prevention


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can cause

serious injury and possible death. A pin hole leak cancause severe injury. Iffluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid Spillage

Care must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting and repair of theengine. Make provision to collect the fluid with asuitable container before any compartment is openedor before any component is disassembled.

Only use the tools that are suitable for collectingfluids and equipment that is suitable for collectingfluids.

Only use the tools that are suitable for containingfluids and equipment that is suitable for containingfluids.

Obey all local regulations for the disposal of liquids.

i02143195

Burn Prevention

Do not touch any part of an operating engine.

Allow the engine to cool before any maintenanceis performed on the engine. Relieve all pressurein the air system, in the hydraulic system, in thelubrication system, in the fuel system, or in thecooling system before any lines, fittings or relateditems are disconnected.

Coolant

When the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

Check the coolant level after the engine has stoppedand the engine has been allowed to cool.

Ensure that the fi ller cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.

Cooling system conditioner contains alkali. Alkali can

cause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

Oils

Hot oil and hot lubricating components can causepersonal injury. Do not allow hot oil to contact theskin. Also, do not allow hot components to contactthe skin.

Batteries

Electrolyte is an acid. Electrolyte can cause personal

injury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.

i02813488

Fire Prevention and ExplosionPrevention




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Fire Prevention and Explosion Prevention

All fuels, mostlubricants, and some coolant mixturesare flammable.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and property

damage.

A flash fire may result if the covers for the enginecrankcase are removed within fifteen minutes afteran emergency shutdown.

Determine whether the engine will be operated in anenvironment that allows combustible gases to bedrawn into the air inlet system. These gases couldcause the engine to overspeed. Personal injury,property damage, or engine damage could result.

If the application involves the presence of combustiblegases, consult your Perkins dealer and/or your

Perkins distributor for additional information aboutsuitable protection devices.

Remove all flammable combustible materials orconductive materials such as fuel, oil, and debris fromthe engine. Do not allow any flammable combustiblematerials or conductive materials to accumulate onthe engine.

Store fuels and lubricants in correctly markedcontainers away from unauthorized persons. Storeoily rags and any flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil or fuel spray in case of a line,a tube, ora seal failure. Exhaust shields must beinstalled correctly.

Do not weld on lines or tanks that contain flammablefluids. Do not flame cut lines or tanks that containflammable fluid. Clean any such lines or tanksthoroughly with a nonflammable solvent prior towelding orflame cutting.

Wiring must be kept in good condition. All electricalwires must be correctly routed and securely attached.Check all electrical wires daily. Repair any wiresthat are loose or frayed before you operate theengine. Clean all electrical connections and tightenall electrical connections.

Eliminate all wiring that is unattached or unnecessary.Do not use any wires or cables that are smaller thanthe recommended gauge. Do not bypass any fusesand/or circuit breakers.

Arcing or sparking could cause a fire. Secureconnections, recommended wiring, and correctlymaintained battery cables will help to prevent arcingor sparking.

Inspect all lines and hoses for wear or for

deterioration. The hoses must be correctly routed.The lines and hoses must have adequate supportand secure clamps. Tighten all connections to therecommendedtorque. Leaks can cause fires.

Oil fi lters and fuel fi lters must be correctly installed.The filter housings must be tightened to the correcttorque.


Use caution when you are refueling an engine. Donot smoke while you are refueling an engine. Do notrefuel an engine near open flames or sparks. Alwaysstop the engine before refueling.



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10 SEBU8311-01Safety SectionCrushing Prevention and Cutting Prevention


Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.

Incorrect jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

Do not charge a frozen battery. This may cause anexplosion.

The batteries must be kept clean. The covers(if equipped) must be kept on the cells. Use therecommended cables, connections, and battery boxcovers when the engine is operated.

Fire Extinguisher

Make sure that a fire extinguisher is available. Be

familiar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged. Do not clip any other items to the highpressure lines.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Perkins dealer or yourPerkins distributor for repair or for replacement parts.

Check lines, tubes and hoses carefully. Do not useyour bare hand to check for leaks. Use a board or

cardboard tocheck for leaks. Tighten all connectionsto the recommended torque.

Replace the parts if any of the following conditionsare present:

End fittings are damaged or leaking.

Outer coverings are chafed or cut.

Wires are exposed.

Outer coverings are ballooning.

Flexible part of the hoses are kinked.

Outer covers have embedded armoring.

End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During engine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.

i02143194

Crushing Prevention andCutting Prevention

Support the component correctly when work beneaththe component is performed.

Unless other maintenance instructions are provided,never attempt adjustments while the engine isrunning.

Stay clear of all rotating parts and of all movingparts. Leave the guards in place until maintenance

is performed. After the maintenance is performed,reinstall the guards.

Keep objects away from moving fan blades. The fanblades will throw objects or cut objects.

When objects are struck, wear protective glasses inorder to avoid injury to the eyes.

Chips or other debris may fly off objects when objectsare struck. Before objects are struck, ensure that noone will be injured by flying debris.



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Before Starting Engine

i02813489


Before the initial start-up of an engine that is new,serviced or repaired, make provision to shut theengine off, in order to stop an overspeed. This maybe accomplished by shutting off the air and/or fuelsupply to the engine.

Overspeed shutdown should occur automatically forengines that are controlled electronically. If automaticshutdown does not occur, press the emergency stopbutton in order to cut the fuel and/or air to the engine.

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on,

underneath, or close to the engine. Ensure that thearea is free of personnel.

If equipped, ensure that the lighting system for theengine is suitable for the conditions. Ensure that alllights work correctly, if equipped.

All protective guards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident that is caused by parts in rotation, workaround the parts carefully.

Do not bypass the automatic shutoff circuits. Do not

disable the automatic shutoff circuits. The circuits areprovided in order to help prevent personal injury. Thecircuitsare also provided in order to help preventengine damage.

See the Service Manual for repairs and foradjustments.

i02157354

Engine Starting

Do not use aerosol types of starting aids such asether. Such use could result in an explosion andpersonal injury.

If a warning tag is attached to the engine start switchor to the controls, DO NOT start the engine or movethe controls. Consult with the person that attachedthe warning tag before the engine is started.

All protectiveguards and all protective covers mustbe installed if the engine must be started in orderto perform service procedures. To help prevent anaccident thatis caused by parts in rotation, workaround the parts carefully.

Start the engine from the operators compartment orfrom the engine start switch.

Always startthe engine according to the procedurethat is described in the Operation and MaintenanceManual, Engine Starting topic in the OperationSection. Knowing the correct procedure will help toprevent major damage to the engine components.Knowing the procedure will also help to preventpersonal injury.

To ensure that the jacket water heater (if equipped)and/or the lube oil heater (if equipped) is workingcorrectly, check the water temperature gauge and the

oil temperature gauge during the heater operation.

Engine exhaust contains products of combustionwhich can be harmful to your health. Always start theengine andoperate the engine in a well ventilatedarea. If the engine is started in an enclosed area,vent the engine exhaust to the outside.

Note: The engine is equipped with an automaticdevice for cold starting for normal conditions ofoperation. If the engine will be operated in very coldconditions, then an extra cold starting aid may berequired. Normally, the engine will be equipped withthe correct type of starting aid for your region of

operation.

The 400 Series engines are equipped with a glowplug starting aid in each individual cylinder that heatsthe intake air in order to improve starting.

i02590389

Engine Stopping

To avoid overheating of the engine and accelerated

wear of the engine components, stop the engineaccording to this Operation and Maintenance Manual,Engine Stopping topic (Operation Section).

Use the Emergency Stop Button (if equipped)ONLY in an emergency situation. DO NOT use theEmergency Stop Button for normal engine stopping.

After an emergency stop, DO NOT start the engineuntil the problem that caused the emergency stophas been corrected.



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12 SEBU8311-01Safety SectionElectrical System

On the initial start-up of a new engine or an enginethat has been serviced, make provisions to stop theengine if an overspeed condition occurs. This may beaccomplishedby shutting off the fuel supply and/orthe air supply to the engine.

If equipped, in order to stop an electronicallycontrolled engine, cut the power to the engine.

i02176668

Electrical System

Never disconnect any charging unit circuit or batterycircuit cable from the battery when the charging unitis operating. A spark can cause the combustiblegases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustiblegases that are produced by some batteries, thenegative jump start cable should be connectedlast from the external power source to the negative terminal of the starting motor. If the starting motoris not equipped with a negative terminal, connectthe jump start cable to the engine block.

Check the electrical wires daily for wires that areloose or frayed. Tighten all loose electrical wiresbefore the engine is started. Repair all frayedelectrical wires before the engine is started. Seethe Operation and Maintenance Manual for specific

starting instructions.

Grounding Practices

Correct grounding for the engine electrical systemis necessary for optimum engine performanceand reliability. Incorrect grounding will result inuncontrolled electrical circuit paths and in unreliableelectrical circuit paths.

Uncontrolled electrical circuit paths can result indamage to main bearings, to crankshaft bearing

journal surfaces, and to aluminum components.

Engines that are installed without engine-to-frameground straps can be damaged by electricaldischarge.

To ensure that the engine and the engine electricalsystems function correctly, an engine-to-frameground strap with a direct path to the battery must beused. This path may be provided by way of a directengine ground to the frame.

All grounds should be tight and free of corrosion. Theengine alternator must be grounded to the negative- battery terminal with a wire that is adequate tohandle the full charging current of the alternator.



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SEBU8311-01 13Product Information Section

Model Views

Product InformationSection

Model Viewsi02590436

Model View Illustrations

The following model views show typical featuresof the 400 series engines. Due to individualapplications, your engine may appear different fromthe illustrations.

Note: Individual components are detailed on the404D-22T turbocharged engine only.


Typical view of the 402D-05 engine



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14 SEBU8311-01Product Information SectionModel Views


Typical view of the 403D-15T engine



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Model Views


Front and right side view of the 404D-22T Engine

(1) Fuel shutoff solenoid(2) Number one fuel injector(3) Water pump(4) Lower engine oil fi ller cap

(5) Throttle lever(6) Cover plate for the accessory drive(7) Engine oil level gauge(8) Engine oil cooler

(9) Engine oil fi lter(10) Fuel injection pump(11) Transfer pump(12) Fuel filter



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Front and left side view of the 404D-22T Engine

(13) Top engine oil fi ller cap(14) Crankcase breather(15) Rear Lifting eye(16) Air inlet elbow(17) Valve mechanism cover(18) Turbocharger

(19) Water temperature regulator housing(20) Starting motor solenoid(21) Electric starting motor(22) Alternator(23) Engine oil pan(24) Engine oil drain plug

(25) Fan drive belt(26) Crankshaft pulley(27) Coolant temperature switch(28) Cooling fan

i02959055

Engine Description

The 400 series engines are indirect injection engines.The engines are controlled with a mechanicallyactuated fuel injection pump. The engine cylindersare arranged in-line.

The cylinder head assembly has one inlet valve andone exhaust valve for each cylinder. Each cylindervalve has a single valve spring.

The pistons have two compression rings and anoil control ring. It is important to ensure the correctpiston height so that the piston does not contact thecylinder head. The correct piston height also ensures

efficient combustion of fuel that is necessary in orderto conform to requirements for emissions.

The crankshaft for a two cylinder engine has twomain bearing journals. The crankshaft for a threecylinder engine has four main bearing journals. Thecrankshaft for a four cylinder engine has five mainbearing journals. End play is controlled by the thrustwashers that are located on the rear main bearing.



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Model Views

The timing gears are stamped with timing marks inorder to ensure the correct assembly of the gears.When the No. 1 piston is at top center compressionstroke, the teeth that are stamped on the crankshaftgear and the camshaft gear will be in alignment withthe idler gear.

The crankshaft gear turns the idler gear which thenturns the camshaft gear and the gear for the engineoil pump.

The fuel injection pump is mounted in the cylinderblock. The fuel injection pump is operated by lobeson the camshaft. The fuel transfer pump is locatedon the right hand side of the cylinder block. Thefuel transfer pump is also operated by lobes on thecamshaft.

The fuel injection pump conforms to requirementsfor emissions. If any adjustments to the fuel injection

pump timing and high idle are required you mustrefer to your Perkins distributoror your Perkinsdealer. Some fuel injection pumps have mechanicalgovernors that control the engine rpm. Some fuelinjectionpumps have a governor that is electricallycontrolled.

A gerotoroil pump is located in the center of the idlergear. The engine oil pump sends lubricating oil to themain oil gallery through a pressure relief valve and anengine oil fi lter. The rocker arms receive pressurizedoil through an externally located oil line that runs fromthe main oil gallery to the cylinder head.

Coolant from the bottom of the radiator passesthrough the belt driven centrifugal water pump. Thecoolantis cooled by the radiator and the temperatureis regulated by a water temperature regulator.

Engine efficiency, efficiency of emission controls, andengine performance depend on adherence to correctoperation and maintenance recommendations.Engineperformance and efficiency also depend onthe use of recommended fuels, lubrication oils, andcoolants. Refer to the Operation and MaintenanceManual, Maintenance Interval Schedule for moreinformation on maintenance items.

Engine Specifications

Note: The front end of the engine is opposite theflywheel end of the engine. The left and the right sideof the engine are determined from the flywheel end.The No. 1 cylinder is the front cylinder.



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402D-05 Engine


(A) Exhaust valves(B) Inlet valves

Table 1

402D-05 Engine Specifications

Maximum OperatingSpeed (rpm)

3600 rpm

Cylinders andArrangement

In-Line two cylinder

Bore 67 mm (2.64 inch)

Stroke 72 mm (2.83 inch)

Displacement 0.507 L (30.939 in3)

Aspiration NA(1)

Compression Ratio 23.5:1Firing Order 1-2

Rotation that is viewedfrom the flywheel

Counterclockwise

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting(Exhaust)

0.20 mm (0.008 inch)

Injection Indirect

(1) Naturally Aspirated

403D-07 Engine



Table 2



3600 rpm


In-Line three cylinder




Aspiration NA(1)

Compression Ratio 23.5:1Firing Order 1-2-3


Counterclockwise



0.20 mm (0.008 inch)

Injection Indirect




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Model Views

403D-11 Engine



Table 3



3600 rpm






Aspiration NA(1)

Compression Ratio 23:1Firing Order 1-2-3


Counterclockwise



0.20 mm (0.008 inch)

Injection Indirect


403D-15 Engine



Table 4



3000 rpm






Aspiration NA(1)



Counterclockwise



0.20 mm (0.008 inch)

Injection Indirect




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403D-15T Engine



Table 5

403D-15T Engine Specifications


3000 rpm






Aspiration T(1)



Counterclockwise



0.20 mm (0.008 inch)

Injection Indirect

(1) Turbocharged

403D-17 Engine



Table 6



2600 rpm






Aspiration NA(1)



Counterclockwise



0.20 mm (0.008 inch)

Injection Indirect




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Model Views

404D-15 Engine



Table 7



3000 rpm


In-Line four cylinder




Aspiration NA(1)

Compression Ratio 23.5:1Firing Order 1-3-4-2


Counterclockwise



0.20 mm (0.008 inch)

Injection Indirect


404D-22 Engine



Table 8



3000 rpm



Bore 84.0 mm (3.31 inch)

Stroke 100.0 mm (3.94 inch)


Aspiration NA(1)



Counterclockwise



0.20 mm (0.008 inch)

Injection Indirect




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404D-22T Engine



Table 9

404D-22T Engine Specifications


3000 rpm






Aspiration T(1)



Counterclockwise



0.20 mm (0.008 inch)

Injection Indirect

(1) Turbocharged

404D-22TA Engine



Table 10

404D-22TA Engine Specifications


2800 rpm






Aspiration TA(1)



Counterclockwise



0.20 mm (0.008 inch)

Injection Indirect

(1) Turbocharged aftercooled



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Product Identification Information

Product IdentificationInformation

i02643641

Engine IdentificationPerkins engines are identified by a serial number.This number is shown on a serial number plate thatis mounted above the fuel injection pump on the righthand side of the engine block.

An example of an engine number isGP*****U000001M.

GP ___ ___ ___________________________________Type of engine

U ___ ___ ______________________Built in the United Kingdom

*****_______ _______________The list number of the engine

000001 __ ___ ______________________Engine Serial Number

M ___ ___ ______________________________Year of Manufacture

Perkins dealers or Perkins distributors need all ofthese numbers in order to determine the componentsthat were included with the engine. This permitsaccurate identification of replacement part numbers.

i02157258

Serial Number Plate


Typical serial number plate

The Serial Number Plate is located above the fuelinjection pump on the right side of the cylinder block.

The following information is stamped on the SerialNumber Plate: Engine serial number, Model, and

Arrangement number.

i02164876

Reference NumbersInformation for the following items may be needed toorder parts. Locate the information for your engine.Record the information in the appropriate space.Make a copy of this list for a record. Keep theinformation for future reference.

Record for Reference

Engine Model _____ __________________________________________

Engine Serial number___ ___ _______________________________

Engine Low Idle rpm _____ _________________________________

Engine Full Load rpm ______ _______________________________

Primary Fuel Filter______ ___________________________________

Water Separator Element ____ ____________________________

Secondary Fuel Filter Element ___ ___ ____________________

Lubrication Oil Filter Element ____ _______________________

Auxiliary Oil Filter Element _____ __________________________

Total Lubrication System Capacity __ ____ _______________

Total Cooling System Capacity _______ __________________

Air Cleaner Element ____ ____ _______________________________

Fan Drive Belt _____ ___ ______________________________________

Alternator Belt _____ ___ ______________________________________



24/94

24 SEBU8311-01Product Information SectionProduct Identification Information

i02959144

Emissions Certification Film


Typical example


Typical example

Perkins Shibaura Engines Limited will supply the

fuel label with every engine. Refer to illustration25. The equipment manufacturer must install thelabel to the equipment. This is recommended byPerkins Shibaura Engines Limited. The label must beattached to the equipment near the fuel inlet. Thiswill comply with the EPA regulations. The equipmentmanufacturer may install another fuel label. If anotherfuel label is used, the equipment manufacturer mustsend a drawing or a photo of the label to PerkinsShibaura Engines Limited through the PerkinsDistributor. This will ensure compliance of the label.



25/94

SEBU8311-01 25Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

i02164186

Engine Lifting


NOTICENever bend the eyebolts and the brackets. Only loadthe eyebolts and the brackets under tension. Remem-ber that the capacity of an eyebolt is less as the anglebetween the supporting members and the object be-comes less than 90 degrees.

When it is necessary to remove a component at anangle, only use a link bracket that is properly rated forthe weight.

Use a hoist to remove heavy components. Usean adjustable lifting beam to lift the engine. Allsupporting members (chains and cables) should beparallel to each other. The chains and cables shouldbe perpendicular to the top of the object that is beinglifted.

Some removals require lifting the fixtures in order toobtain correct balance and safety.

To remove the engine ONLY, use the lifting eyes thatare on the engine.

Lifting eyes are designed and installed for specificengine arrangements. Alterations to the lifting eyesand/or the engine make the lifting eyes and the liftingfixtures obsolete. If alterations are made, ensurethat correct lifting devices are provided. Consultyour Perkins dealer or your Perkins distributor forinformation regarding fixtures for correct enginelifting.

i02593735

Engine Storage

If the engine will not be started for several weeks, thelubricating oil will drain from the cylinder walls andfrom the piston rings. Rust can form on the cylinderwalls. Rust on the cylinder walls will cause increasedengine wear and a reduction in engine service life.

Lubrication System

To help prevent excessive engine wear, use thefollowing guidelines:

Complete all of the lubrication recommendations that

are listed in this Operation and Maintenance Manual,Maintenance Interval Schedule (MaintenanceSection).

If an engine is out of operation and if use of the engineis not planned, special precautions should be made.If the engine will be stored for more than one month,a complete protection procedure is recommended.

Use the following guidelines :

Completely clean the outside of the engine.

Drain the fuel system completely and refillthe system with preservative fuel. 1772204POWERPART Lay-Up 1 can be mixed withthe normal fuel in order to change the fuel intopreservative fuel.

If preservative fuel is not available, the fuel systemcan be fi lled with normal fuel. This fuel must bediscarded at the end of the storage period togetherwith the fuel filter elements.

Operate the engine until the engine reaches normaloperating temperature. Stop any leaks from fuel,lubricating oil or air systems. Stop the engine anddrain the lubricating oil from the oil pan.



26/94

26 SEBU8311-01Operation SectionLifting and Storage

Renew the canister(s) of the lubricating oil filter.

Fill the oil pan to the Full Mark on the engine oillevel gauge with new, clean lubricating oil. Add1762811 POWERPART Lay-Up 2 to the oil inorder to protect the engine against corrosion. If

1762811 POWERPART Lay-Up 2 is not available,use a preservative of the correct specificationinstead of the lubricating oil. If a preservative isused, this must be drained completely at the end ofthe storage period and the oil pan must be refilledto the correct level with normal lubricating oil.

Cooling System

To help prevent excessive engine wear, use thefollowing guidelines:

NOTICE

Do not drain the coolant whilethe engine is still hot andthe system is under pressure because dangerous hotcoolant canbe discharged.

If freezing temperatures are expected, check thecooling system for adequate protection againstfreezing. Refer to this Operation and MaintenanceManual, Fluid Recommendations (MaintenanceSection).

NOTICETo prevent frost damage, ensure that all the coolant isremoved from the engine. This is important if the sys-

tem is drained after it has beenflushed with water, or ifan antifreeze solution too weak to protect the systemfrom frosthas been used.


Typical example

1. Ensure that thevehicle is on level ground.

2. Remove the fi ller cap of the cooling system.

3. Remove the drain plug (1) from the side of thecylinder block in order to drain the engine. Ensure

that the drainhole is not restricted.

4. Open the tap or remove the drain plug at thebottom of the radiator in order to drain the radiator.If the radiator does not have a tap or a drain plug,disconnect the hose at the bottom of the radiator.

5. Flush the cooling system with clean water.

6. Fit the drainplugs and the filler cap. Close the tapor connect the radiator hose.

7. Fill the cooling system with an approved antifreezemixture because this gives protection against

corrosion.

Note: Certain corrosion inhibitors could causedamage to some engine components. Contact theService Department of Perkins for advice.

8. Operate the engine for a short period in order tocirculate the lubricating oil and the coolant in theengine.

9. Disconnectthe battery. Put the battery into safestorage in a fully charged condition. Before thebattery is put into storage, protect the terminalsagainst corrosion. 1734115 POWERPART

Lay-Up 3 can be used on the terminals.

10. Clean the crankcase breather if one is installed.Seal the end of the pipe.

11. Remove thefuel injectors and spray 1762811POWERPART Lay-Up 2 for one or two secondsinto each cylinder bore with the piston at BDC.

12. Slowly rotate the crankshaft for one completerevolution and then replace the fuel injectors.

Induction System

Remove the air filter assembly. If necessary,remove the pipes that are installed betweenthe air filter assembly and the turbocharger.Spray 1762811POWERPART Lay-Up 2 into theturbocharger. The duration of the spray is printedon the container. Seal the turbocharger withwaterproof tape.



27/94


Lifting and Storage

Exhaust System

Remove the exhaust pipe. Spray 1762811POWERPART Lay-Up 2 into the turbocharger. Theduration of the spray is printed on the container.Seal the turbocharger with waterproof tape.

General Items

If the lubricating oil filler is installed on the valvemechanism cover, remove the filler cap. If thelubricating oil fi ller cap is not installed on the valvemechanism cover, remove the valve mechanismcover. Spray 1762811 POWERPART Lay-Up 2around the rocker shaft assembly. Replace thefiller cap or the valve mechanism cover.

Seal the vent of the fuel tank or the fuelfi ller capwith waterproof tape.

Remove the alternator drive belts and put the drivebelts into storage.

In order to prevent corrosion, spray the engine with1734115 POWERPART Lay-Up 3. Do not spraythe area inside the alternator.

When the engine protection has been completed inaccordance with these instructions, this ensures thatno corrosion will occur. Perkins are not responsiblefor damage which may occur when an engine is instorage after a period in service.

Your Perkins dealer or your Perkins distributor canassist in preparing the engine for extended storageperiods.



28/94

28 SEBU8311-01Operation SectionGauges and Indicators

Gauges and Indicators

i02216960

Gauges and Indicators

Your engine may not have the same gauges or all ofthe gauges that are described. For more informationabout the gauge package, see the OEM information.

Gauges provide indications of engine performance.Ensure that the gauges are in good working order.Determine the normal operating range by observingthe gauges over a period of time.

Noticeable changes in gauge readings indicatepotential gauge or engine problems. Problems may

also be indicated by gauge readings that changeeven if the readings are within specifications.Determine and correct the cause of any significantchange in the readings. Consult your Perkins dealeror your Perkins distributor for assistance.

NOTICEIf no oil pressure is indicated, STOP the engine. Ifmaximum coolant temperature is exceeded, STOPthe engine. Engine damage can result.

Engine OilPressure The oil pressureshould be greatest after a cold engine is

started. The typical engine oil pressure withSAE10W30is 207 to 413 kPa (30 to 60 psi) at ratedrpm.

A lower oil pressure is normal at low idle. If the loadis stableand the gauge reading changes, performthe following procedure:

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

Jacket Water Coolant Temperature Typical temperature range is 71 to 96C(160 to 205F). The maximum allowable

temperature with the pressurized cooling systemat 90 kPa (13 psi) is 110C (230F). Highertemperatures may occur under certain conditions.The water temperature reading may vary accordingto load. The reading should never exceed the boilingpoint for the pressurized system that is being used.

If the engine is operating above the normal rangeand steam becomes apparent, perform the followingprocedure:

1. Reduce the loadand the engine rpm.

2. Inspect the cooling system for leaks.

3. Determine if the engine must be shut downimmediately or if the engine can be cooled by

reducing the load.

Tachometer This gauge indicates enginespeed (rpm). When the throttle control leveris moved to the full throttle position without

load, the engine is running at high idle. The engine isrunning at the full load rpm when the throttle controllever is at the full throttle position with maximumrated load.

NOTICETo help prevent engine damage, never exceed thehigh idle rpm. Overspeeding can result in serious

damage to the engine. The engine can be operatedat high idle without damage, but should never beallowed to exceed high idle rpm.

Ammeter This gauge indicates theamount of charge or discharge in thebattery charging circuit. Operation of the

indicator should be to the right side of 0 (zero).

Fuel Level This gauge indicates the fuellevel in the fuel tank. The fuel level gaugeoperates when the START/STOP switch

is in the ON position.

Service Hour Meter The gauge indicatesoperating time of the engine.



29/94


Features and Controls

Features and Controls

i02593769

Fuel Shutoff

The fuel shutoff solenoid is located on the fuelinjection pump. When the fuel shutoff solenoid isactivated, the solenoid moves the fuel rack to theOFF position.


(1) Fuel shutoff solenoid

If an electronically controlled governor has beeninstalled the governor operates the fuel rack in orderto stop the engine.



30/94

30 SEBU8311-01Operation SectionEngine Starting

Engine Starting

i02194223


Before the engine is started, perform the requireddaily maintenance and any other periodicmaintenance that is due. Refer to the Operationand Maintenance Manual, Maintenance IntervalSchedule for more information.

For the maximum service life of the engine, make athorough inspection within the engine compartmentbefore the engine is started. Look for the followingitems: oil leaks, coolant leaks, loose bolts, andexcessive dirt and/or grease. Remove any excess

dirt and/or grease buildup. Repair any faults thatwere identified during the inspection.

Inspect the cooling system hoses for cracks andfor loose clamps.

Inspect the alternator and accessory drive belts forcracks, breaks, and other damage.

Inspect the wiring for loose connections and forworn wiresor frayed wires.

Check the fuel supply. Drain water from the waterseparator(if equipped). Open the fuel supply valve

(if equipped).

NOTICEAll valves in the fuel return line must be open beforeand during engine operation to help prevent high fuelpressure. High fuel pressure may cause fi lter housingfailure or other damage.

If the engine has not been started for several weeks,fuel may have drained from the fuel system. Airmay have entered the fi lter housing. Also, when fuelfilters have been changed, some air pockets will betrappedin the engine. In these instances, prime the

fuel system. Refer to the Operation and MaintenanceManual, Fuel System - Prime for more informationon priming the fuel system.

Engine exhaust contains products of combustionwhich may be harmful to your health. Always startand operate the engine in a well ventilated areaand, if in an enclosed area, vent the exhaust to theoutside.

Do not start theengine or move any of the controlsif there is a DO NOT OPERATE warning tag orsimilar warning tag attached to the start switch orto the controls.

Ensure that the areas around the rotating parts are

clear.

All of the guards must be put in place. Check fordamaged guards or for missing guards. Repairany damaged guards. Replace damaged guardsand/or missing guards.

Disconnect any battery chargers that are notprotected against the high current drain thatis created when the electric starting motor isengaged. Check electrical cables and check thebattery for poor connections and for corrosion.

Reset all of the shutoffs or alarm components (if

equipped).

Check the engine lubrication oil level. Maintain theoil level between the ADD mark and the FULLmark on theengine oil level gauge.

Check the coolant level. Observe the coolant levelin the header tank (if equipped). Maintain thecoolant level to the FULL mark on the headertank.

If the engine is not equipped with a header tankmaintain the coolant level within 13 mm (0.5 inch)of the bottom of the filler pipe. If the engine is

equipped with a sight glass, maintain the coolantlevel in the sight glass.

Observe the air cleaner service indicator (ifequipped). Service the air cleaner when the yellowdiaphragm enters the red zone, or when the redpiston locks in the visible position.

Ensure that any equipment that is driven by theengine has been disengaged from the engine.Minimize electrical loads or remove any electricalloads.

i02665533

Starting the Engine




31/94


Engine Starting

Refer to the OEMmanual for your type of controls.Use the following procedure to start the engine.

1. Move the throttle lever to the low idle positionbefore you start the engine.

NOTICEDo not operatethe glow plugs for more than 60 sec-onds at one time. Damage to the glow plugs could oc-cur.

2. Turn the engine start switch to the HEAT position.Hold the engine start switch in the HEAT positionfor 6 seconds until the glow plug indicator lightilluminates. This will activate the glow plugs andaid in the starting of the engine.

NOTICEDo not crank the engine for more than 30 seconds.

Allow the electric starting motor to cool for two minutesbefore cranking the engine again.

3. While the glow plug indicator light is illuminated,turn the engine start switch to the START positionand crank the engine.

4. When the engine starts, release the engine startswitch.

5. Slowly move the throttle lever to the low idleposition and allow the engine to idle. Refer tothe Operation and Maintenance Manual, After

Starting Engine topic.

Note: If the glow plug indicator light illuminatesrapidly for 2 to 3 seconds, or if the glow plug indicatorlight fails to illuminate, a malfunction exists in the coldstart system. Do not use ether or other starting fluidsto start the engine.

6. If the engine does not start, release the enginestart switch and allow the electric starting motor tocool. Then, repeat steps 2 through step 5.

7. Turn the engine start switch to the OFF position inorder to stop the engine.

i02177935

Starting with Jump StartCables

Improper jump start cable connections can causean explosion resulting in personal injury.

Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jump startcable ends to contact each other or the engine.

Note: If it is possible, first diagnose the reasonfor the starting failure. Make any necessaryrepairs. If the engine will not start only due tothe condition of the battery, either charge thebattery, or start the engine with jump start cables.The condition of the battery can be recheckedafter the engine has been switched OFF.

NOTICEUsing a battery source with the same voltage as theelectric starting motor. Use ONLY equal voltage for

jump starting. The use of higher voltage will damagethe electrical system.

Do not reverse the battery cables. The alternator can

be damaged. Attach ground cable last and removefirst.

When using an external electrical source to start theengine, turn the generator set control switch to theOFF position. Turn all electrical accessories OFF be-fore attaching the jump start cables.

Ensure that the main power switch is in the OFF posi-tion before attaching the jump start cables to the en-gine being started.

1. Turn the start switch to the OFF position. Turn offall the engines accessories.

2. Connect one positive end of the jump start cableto the positive cable terminal of the dischargedbattery. Connect the other positive end of the jumpstart cable to the positive cable terminal of theelectrical source.



32/94

32 SEBU8311-01Operation SectionEngine Starting

3. Connect one negative end of the jump start cableto the negative cable terminal of the electricalsource. Connect the other negative end of the

jump start cable to the engine block or to thechassis ground. This procedure helps to preventpotential sparks from igniting the combustible

gases that are produced by some batteries.

4. Start the engine.

5. Immediately after the stalled engine is started,disconnect the jump start cables in reverse order.

After jump starting, the alternator may not be able tofully recharge batteries that are severely discharged.The batteries must be replaced or charged to thecorrect voltage with a battery charger after the engineis stopped. Many batteries which are consideredunusable are still rechargeable. Refer to Operationand Maintenance Manual, Battery - Replace and

Testing and Adjusting Manual, Battery - Test.

i01903609

After Starting Engine

Note: In temperatures from 0 to 60C (32 to 140F),the warm-up time is approximately three minutes. Intemperatures below 0C (32F), additional warm-uptime may be required.

When the engine idles during warm-up, observe thefollowing conditions:

Check for any fluid or for any air leaks at idle rpmand at one-half full rpm (no load on the engine)before operating the engine under load. This is notpossible in some applications.

Operate the engine at low idle until all systemsachieve operating temperatures. Check all gaugesduring the warm-up period.

Note: Gauge readings should be observed andthe data should be recorded frequently while the

engine is operating. Comparing the data over timewill help to determine normal readings for eachgauge. Comparing data over time will also helpdetect abnormal operating developments. Significantchanges in the readings should be investigated.



33/94

SEBU8311-01 33Operation SectionEngine Operation

Engine Operation

i02176671

Engine Operation

Correct operation and maintenance are key factorsin obtaining the maximum life and economy ofthe engine. If the directions in the Operation andMaintenanceManual are followed, costs can beminimized and engine service life can be maximized.

The engine can be operated at the rated rpm after theengine reaches operating temperature. The enginewill reach normal operating temperature soonerduring a lowengine speed (rpm) and during a lowpower demand. This procedure is more effective than

idling the engine at no load. The engine should reachoperatingtemperature in a few minutes.

Gauge readings should be observed and the datashould be recorded frequently while the engineis operating. Comparing the data over time willhelp to determine normal readings for each gauge.Comparing data over time will also help detectabnormal operating developments. Significantchanges in the readings should be investigated.

i02330149

Fuel Conservation Practices

The ef

ficiency of the engine can affect the fueleconomy. Perkins design and technology in

manufacturing provides maximum fuel efficiency inall applications. Follow the recommended proceduresin order to attain optimum performance for the lifeof the engine.

Avoid spilling fuel.

Fuel expandswhen the fuel is warmed up. The fuelmay overflow from the fuel tank. Inspect fuel lines forleaks. Repair the fuel lines, as needed.

Be aware of the properties of the different fuels.

Use only the recommended fuels.

Avoid unnecessary idling.

Shut off theengine rather than idle for long periods oftime.

Observe theair cleaner service indicator frequently.Keep the air cleaner elements clean.

Maintain the electrical systems.

One damaged battery cell will overwork the alternator.This will consume excess power and excess fuel.

Ensure that the drive belts are correctly adjusted.The drive belts should be in good condition.

Ensure that all of the connections of the hoses aretight. Theconnections should not leak.

Ensure that the driven equipment is in goodworking order.

Cold engines consume excess fuel. Utilize heatfrom the jacket water system and the exhaustsystem, when possible. Keep cooling systemcomponents clean and keep cooling system

components in good repair. Never operate theengine without water temperature regulators.

All of these items will help maintain operatingtemperatures.



34/94

34 SEBU8311-01Operation SectionEngine Stopping

Engine Stopping

i02334873

Stopping the Engine

NOTICE

Stopping the engine immediately after it has beenworking under load, can result in overheating and ac-celerated wear of the engine components.

Avoid accelerating the engine prior to shutting it down.

Avoiding hot engine shutdowns will maximize tur-bocharger shaft and bearing life.

Note: Individual applications will have differentcontrol systems. Ensure that the shutoff proceduresare understood. Use the following general guidelinesin order to stop the engine.

1. Remove the load from the engine. Reduce theengine speed (rpm) to low idle. Allow the engineto idle forfive minutes in order to cool the engine.

2. Stop the engine after the cool down periodaccording to the shutoff system on the engine andturn the ignition key switch to the OFF position.If necessary, refer to the instructions that areprovided by the OEM.

i01903586

EmergencyStopping

NOTICE

Emergency shutoff controls are for EMERGENCY useONLY. DO NOT use emergency shutoff devices orcontrols for normal stopping procedure.

The OEM may have equipped the application withan emergency stop button. For more informationabout the emergency stop button, refer to the OEMinformation.

Ensure that any components for the external systemthat support the engine operation are secured afterthe engine is stopped.

i02176672

After Stopping Engine

Note:Before you check the engine oil, do not operatethe engine for at least 10 minutes in order to allowthe engine oil to return to the oil pan.

Check the crankcase oil level. Maintain the oil levelbetween the MIN mark and the MAX mark onthe engine oil level gauge.

If necessary, perform minor adjustments. Repairany leaks andtighten any loose bolts.

If the engine is equipped with a service hour meter,note the reading. Perform the maintenance thatis in the Operation and Maintenance Manual,

Maintenance Interval Schedule.

Fill the fuel tank in order to help preventaccumulation of moisture in the fuel. Do not overfillthe fuel tank.

NOTICEOnly use antifreeze/coolant mixtures recommended inthe Coolant Specifications that are in the Operationand Maintenance Manual. Failure to do so can causeengine damage.

Allow the engine to cool. Check the coolant level.

If freezing temperatures are expected, checkthe coolant for correct antifreeze protection. Thecooling system must be protected against freezingto the lowest expected outside temperature. Addthe correct coolant/water mixture, if necessary.

Perform all required periodic maintenance on alldriven equipment. This maintenance is outlined inthe instructions from the OEM.



35/94


Cold Weather Operation


i02717265


Perkins Diesel Engines can operate effectively incold weather. During cold weather, the starting andthe operation of the diesel engine is dependent onthe following items:

The type of fuel that is used

The viscosity of the engine oil

The operation of the glow plugs

Optional Cold starting aid

Battery condition

This section will cover the following information:

Potential problems that are caused by cold weatheroperation

Suggest steps which can be taken in order tominimize starting problems and operating problemswhen the ambient air temperature is between0 to40 C (32 to 40 F).

The operation and maintenance of an engine infreezing temperatures is complex . This is becauseof the following conditions:

Weather conditions

Engine applications

Recommendations from your Perkins dealer oryour Perkins distributor are based on past provenpractices. The information that is contained inthis section provides guidelines for cold weatheroperation.

Hints for Cold Weather Operation

If the engine will start, operate the engine until aminimum operating temperature of 81 C (177.8 F)is achieved. Achieving operating temperature willhelp prevent the intake valves and exhaust valvesfrom sticking.

The cooling system and the lubrication systemfor the engine do not lose heat immediately uponshutdown. This means that an engine can be shutdown for a period of time and the engine can stillhave the ability to start readily.

Install the correct specification of engine lubricantbefore the beginning of cold weather.

Check all rubber parts (hoses, fan drive belts, etc)weekly.

Check all electrical wiring and connections for anyfraying or damaged insulation.

Keep all batteries fully charged and warm.

Fill the fuel tank at the end of each shift.

Check the air cleaners and the air intake daily.Check the air intake more often when you operatein snow.

Ensure that the glow plugs are in working order.Refer to Testing and Adjusting Manual, Glow Plug- Test.

Personal injury or property damage can resultfrom alcohol or starting fluids.

Alcohol or startingfluids are highlyflammable andtoxic and if improperly stored could result in injuryor propertydamage.


For jump starting with cables in cold weather,refer to the Operation and Maintenance Manual,Starting with Jump Start Cables. for instructions.

Viscosity of the Engine LubricationOil

Correct engine oil viscosity is essential. Oil viscosityaffects the amount of torque that is needed to

crank the engine. Refer to this Operation andMaintenance Manual, Fluid Recommendations forthe recommended viscosity of oil.

Recommendations for the Coolant

Provide cooling system protection for the lowestexpected outside temperature. Refer to this Operationand Maintenance Manual, Fluid Recommendationsfor the recommended coolant mixture.



36/94

36 SEBU8311-01Operation SectionCold Weather Operation

In cold weather, check the coolant often for thecorrect glycol concentration in order to ensureadequate freeze protection.

Engine Block Heaters

Engine block heaters (if equipped) heat theengine jacket water that surrounds the combustionchambers. This provides the following functions:

Startability is improved.

Warm up time is reduced.

An electric block heater can be activated oncethe engine isstopped. An effective block heateris typically a 1250/1500 W unit. Consult yourPerkins dealer or your Perkins distributor for moreinformation.

Idling the Engine

When idling after the engine is started in coldweather, increase the engine rpm from 1000 to 1200rpm. This will warm up the engine more quickly.Maintaining an elevated low idle speed for extendedperiods will be easier with the installation of a handthrottle. The engine should not be raced in order tospeed up the warm up process.

While the engine is idling, the application of a lightload (parasitic load) will assist in achieving theminimum operating temperature. The minimum

operating temperature is 82 C (179.6 F).

Recommendations for CoolantWarm Up

Warm up an engine that has cooled below normaloperating temperatures due to inactivity. This shouldbe performed before the engine is returned to fulloperation. During operation in very cold temperatureconditions, damage to engine valve mechanisms canresult from engine operation for short intervals. Thiscan happen if the engine is started and the engine isstoppedmany times without being operated in order

to warm up completely.

When theengine is operated below normal operatingtemperatures, fuel and oil are not completely burnedin the combustion chamber. This fuel and oil causessoft carbon deposits to form on the valve stems.Generally, the deposits do not cause problems andthe deposits are burned off during operation atnormal engine operating temperatures.

When the engine is started and the engine is stoppedmany times without being operated in order to warmup completely, the carbon deposits become thicker.This can cause the following problems:

Free operationof the valves is prevented.

Valves become stuck.

Pushrods may become bent.

Other damage to valve train components canresult.

For this reason, when the engine is started,the engine must be operated until the coolanttemperature is 71 C (160 F) minimum. Carbondeposits on the valve stems will be kept at a minimumand the free operation of the valves and the valvecomponents will be maintained.

In addition, the engine must be thoroughly warmed inorder to keep other engine parts in better conditionand the service life of the engine will be generallyextended. Lubrication will be improved. There will be

less acid and less sludge in the oil. This will providelonger service life for the engine bearings, the pistonrings, and other parts. However, limit unnecessaryidle time to ten minutes in order to reduce wear andunnecessary fuel consumption.

The Water Temperature Regulator andInsulatedHeater Lines

The engine is equipped with a water temperatureregulator. When the engine coolant is below thecorrect operating temperature jacket water circulatesthrough the engine cylinder block and into the

engine cylinder head. The coolant then returns to thecylinder block via an internal passage that bypassesthe valve of the coolant temperature regulator. Thisensures that coolant flows around the engine undercold operating conditions. The water temperatureregulator begins to open when the engine jacketwater has reached the correct minimum operatingtemperature. As the jacket water coolant temperaturerises above the minimum operating temperature thewater temperature regulator opens further allowingmore coolant through the radiator to dissipate excessheat.

The progressive opening of the water temperature

regulator operates the progressive closing of thebypasspassage between the cylinder block andhead. This ensures maximum coolant flow tothe radiator in order to achieve maximum heatdissipation.

Note: Perkins discourages the use of all airflowrestriction devices such as radiator shutters.Restriction of the airflow can result in the following:high exhaust temperatures, power loss, excessivefan usage, and reduction in fuel economy.



37/94



A cab heater is beneficial in very cold weather. Thefeed from the engine and the return lines from thecab should be insulated in order to reduce heat lossto the outsideair.

Insulating the Air Inlet and Engine

Compartment

When temperatures below 18 C (0 F) will befrequently encountered, an air cleaner inlet thatis located in the engine compartment may bespecified. An air cleaner that is located in the enginecompartmentmay also minimize the entry of snowinto the air cleaner. Also, heat that is rejected by theengine helps to warm the intake air.

Additional heat can be retained around the engine byinsulating the engine compartment.

i02322217

Fuel and the Effect from ColdWeather

Note: Only use grades of fuel that are recommendedby Perkins. Refer to this Operation and MaintenanceManual, Fluid Recommendations.

The following fuels can be used in this series ofengine.

Group 1

Group 2

Group 3

Special Fuels

Perkins prefer only Group 1 and Group 2 fuels foruse in this series of engines.

Group 1 fuels are the preferred Group of Fuels forgeneral use by Perkins. Group 1 fuels maximize

engine life and engine performance. Group 1 fuelsare usually less available than Group 2 fuels.Frequently, Group 1 fuels are not available in colderclimates during the winter.

Note: Group 2 fuels must have a maximum wearscar of 650 micrometers (HFRR to ISO 12156-1).

Group 2 fuels are considered acceptable for issuesof warranty. This group of fuels may reduce the lifeof the engine, the engines maximum power, and theengines fuel efficiency.

When Group 2 diesel fuels are used the followingcomponents provide a means of minimizing problemsin cold weather:

Glow plugs (if equipped)

Engine coolant heaters, which may be an OEMoption

Fuel heaters,which may be an OEM option

Fuel line insulation, which may be an OEM option

There are three major differences between Group1 fuels and Group 2 fuels. Group 1 fuels have thefollowing different characteristics to Group 2 fuels.

A lower cloud point

A lower pour point

A higher energy per unit volume of fuel

Note:Group 3 fuels reduce the life of the engine. Theuse of Group 3fuels is not covered by the Perkinswarranty.

Group 3 fuels include Low Temperature Fuels andAviation Kerosene Fuels.

Special fuels include Biofuel.

The cloud point is a temperature that allows waxcrystals toform in the fuel. These crystals can cause

the fuel fi lters to plug.

The pour point is the temperature when diesel fuelwill thicken. The diesel fuel becomes more resistantto flow through fuel lines, fuel fi lters,and fuel pumps.

Be aware of these facts when diesel fuel ispurchased. Consider the average ambient airtemperature for the engines application. Enginesthat are fueled in one climate may not operate well ifthe engines are moved to another climate. Problemscan resultdue to changes in temperature.

Before troubleshooting for low power or for poor

performance in the winter, check the fuel for waxing.

Low temperature fuels may be available for engineoperation at temperatures below 0 C (32 F). Thesefuels limit the formation of wax in the fuel at lowtemperatures.

For more information on cold weather operation, referto the Operation and Maintenance Manual, ColdWeather Operation and Fuel Related Components inCold Weather.



38/94

38 SEBU8311-01Operation SectionCold Weather Operation

i01903588

Fuel Related Components inCold Weather

Fuel Tanks

Condensation can form in partially fi lled fuel tanks.Top off the fuel tanks after you operate the engine.

Fuel tanks should contain some provision for drainingwater and sediment from the bottom of the tanks.Some fuel tanks use supply pipes that allow waterand sediment to settle below the end of the fuelsupply pipe.

Some fuel tanks use supply lines that take fuel

directly from the bottom of the tank. If the engine isequipped with this system, regular maintenance ofthe fuel system fi lter is important.

Drain the water and sediment from any fuel storagetank at the following intervals: weekly, oil changes,and refueling of the fuel tank. This will help preventwater and/or sediment from being pumped from thefuel storage tank and into the engine fuel tank.

Fuel Filters

It is possible that a primary fuel filter is installedbetween the fuel tank and the engine fuel inlet. Afteryou change the fuel filter, always prime the fuelsystem in order to remove air bubbles from the fuelsystem. Refer to the Operation and MaintenanceManual in the Maintenance Section for moreinformation on priming the fuel system.

The micron rating and the location of a primary fuelfilter is important in cold weather operation. Theprimary fuel filter and the fuel supply line are the mostcommon components that are affected by cold fuel.

Fuel Heaters

Note: The OEM may equip the application with fuelheaters. If this is the case, disconnect an electric typeof fuel heater in warm weather in order to preventoverheating of the fuel. If the type of fuel heater is aheat exchanger, the OEM should have included abypass for warm weather. Ensure that the bypass isoperational during warm weather in order to preventoverheating of the fuel.

For more information about fuel heaters (if equipped),refer to the OEM information.



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SEBU8311-01 39Maintenance Section

Refill Capacities

Maintenance Section

Refill Capacities

i02959059

Refill Capacities

Lubrication System

The refill capacities for the engine crankcasereflect the approximate capacity of the crankcaseor sump plus standard oil filters. Auxiliary oil filtersystems will require additional oil. Refer to the OEMspecifications for the capacity of the auxiliary oil fi lter.

Refer to the Operation and Maintenance Manual,Maintenance Section for more information onLubricant Specifications.

402D-05 Engine

Table 11

402D-05 EngineRefill Capacities

Compartment or System Minimum Maximum

Crankcase Oil Sump(1) 1.61 L

(1.7 qt)2.01 L(2.1 qt)

Total Lubrication System(2)

(1) These values are the approximate capacities for the crankcaseoil sump which includes the standard factory installed oil fi lters.Engines with auxiliary oil fi lters will require additional oil. Referto the OEM specifications for the capacity of the auxiliary oilfilter.

(2) The Total Lubrication System includes the capacity for theCrankcase Oil Sump plus the capacity of factory installed oilfilters and other filters added to the lubrication system. Enterthe value for the capacity of the Total Lubrication System inthis row.

403D-07 Engine

Table 12

403C-07 EngineRefill Capacities

Compartment or System Minimum Maximum

Crankcase Oil Sump(1) 2.35 L

(2.5 qt)3.05 L(3.2 qt)

Total Lubrication System(2)

(1) These values are the approximate capacities for the crankcaseoil sump which includes the standard factory installed oil fi lters.Engines with auxiliary oil fi lters will require additional oil. Referto the OEM specifications for the capacity of the auxiliary oilfilter.

(2) The Total Lubrication System includes

Perkins Series 400 - Manual de Operación y Mantenimiento

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Transcript of Perkins Series 400 - Manual de Operación y Mantenimiento