Perkins 402D Operation And Maintenance Manual Download Page 15

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This document is printed from SPI². Not for RESALE

SEBU8311-02

Product Information Section

Model Views

g01304893

Illustration 11

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

ller cap

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

(9) Engine oil

lter

(10) Fuel injection pump
(11) Transfer pump
(12) Fuel

lter

Summary of Contents for 402D

Page 1: ...nted from SPI Not for RESALE SEBU8311 02 January 2010 Operation and Maintenance Manual 402D 403D 404D Industrial Engine GG Engine GH Engine GJ Engine GK Engine GL Engine GM Engine GN Engine GP Engine...

Page 2: ...at appears under the warning explains the hazard and can be either written or pictorially presented Operations that may cause product damage are identified by NOTICE labels on the product and in this...

Page 3: ...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 a...

Page 4: ...Items in the maintenance schedule are referenced to detailed instructions that follow Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Sch...

Page 5: ...oline or harsh chemicals could loosen the adhesive that secures the warning signs The warning signs that are loosened could drop off of the engine Replace any warning sign that is damaged or missing I...

Page 6: ...from SPI Not for RESALE 6 SEBU8311 02 Safety Section Safety Messages g01324126 Illustration 2 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...

Page 7: ...erform maintenance on the engine with the equipment in the servicing position Refer to the OEM information for the procedure for placing the equipment in the servicing position Pressure Air and Water...

Page 8: ...essure in the air system in the hydraulic system in the lubrication system in the fuel system or in the cooling system before any lines fittings or related items are disconnected Coolant When the engi...

Page 9: ...ame Exhaust shields if equipped protect hot exhaust components from oil or fuel spray in case of a line a tube or a seal failure Exhaust shields must be installed correctly Do not weld on lines or tan...

Page 10: ...n cause fires Consult your Perkins dealer or your Perkins distributor for repair or for replacement parts Check lines tubes and hoses carefully Do not use your bare hand to check for leaks Use a board...

Page 11: ...l protective covers must be installed if the engine must be started in order to perform service procedures To help prevent an accident that is caused by parts in rotation work around the parts careful...

Page 12: ...heck the electrical wires daily for wires that are loose or frayed Tighten all loose electrical wires before the engine is started Repair all frayed electrical wires before the engine is started See t...

Page 13: ...ews i02590436 Model View Illustrations The following model views show typical features of the 400 series engines Due to individual applications your engine may appear different from the illustrations...

Page 14: ...This document is printed from SPI Not for RESALE 14 SEBU8311 02 Product Information Section Model Views g01300431 Illustration 10 Typical view of the 403D 15T engine...

Page 15: ...on 11 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 filler cap 5 Throttle lever 6 Cover plate for the accessory dr...

Page 16: ...ontrolled with a mechanically actuated fuel injection pump The engine cylinders are arranged in line The cylinder head assembly has one inlet valve and one exhaust valve for each cylinder Each cylinde...

Page 17: ...that control the engine rpm Some fuel injection pumps have a governor that is electrically controlled A gerotor oil pump is located in the center of the idler gear The engine oil pump sends lubricatin...

Page 18: ...l 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 g00852304 Illustration 14 A Exhaust...

Page 19: ...el 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 15 Engine g00852304 Illustration 16 A Exhaus...

Page 20: ...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 Turbocharged 403D 17 Engine g00852304 Illustration 18 A Exhaust...

Page 21: ...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 404D 22 Engine g00296424 Illustration 20 A Exhaust...

Page 22: ...el Counterclockwise Valve Lash Setting Inlet 0 20 mm 0 008 inch Valve Lash Setting Exhaust 0 20 mm 0 008 inch Injection Indirect 1 Turbocharged 404D 22TA Engine g00296424 Illustration 22 A Exhaust val...

Page 23: ...Number Plate is located above the fuel injection pump on the right side of the cylinder block The following information is stamped on the Serial Number Plate Engine serial number Model and Arrangement...

Page 24: ...ne Refer to illustration 25 The equipment manufacturer must install the label to the equipment This is recommended by Perkins Shibaura Engines Limited The label must be attached to the equipment near...

Page 25: ...s distributor for information regarding fixtures for correct engine lifting i02593735 Engine Storage If the engine will not be started for several weeks the lubricating oil will drain from the cylinde...

Page 26: ...e the drain plug 1 from the side of the cylinder block in order to drain the engine Ensure that the drain hole is not restricted 4 Open the tap or remove the drain plug at the bottom of the radiator i...

Page 27: ...811 POWERPART Lay Up 2 around the rocker shaft assembly Replace the filler cap or the valve mechanism cover Seal the vent of the fuel tank or the fuel filler cap with waterproof tape Remove the altern...

Page 28: ...t Temperature Typical temperature range is 71 to 96 C 160 to 205 F The maximum allowable temperature with the pressurized cooling system at 90 kPa 13 psi is 110 C 230 F Higher temperatures may occur u...

Page 29: ...hutoff The fuel shutoff solenoid is located on the fuel injection pump When the fuel shutoff solenoid is activated the solenoid moves the fuel rack to the OFF position g01305771 Illustration 28 1 Fuel...

Page 30: ...ins products of combustion which may be harmful to your health Always start and operate the engine in a well ventilated area and if in an enclosed area vent the exhaust to the outside Do not start the...

Page 31: ...rting motor to cool Then repeat steps 2 through step 5 7 Turn the engine start switch to the OFF position in order to stop the engine i02177935 Starting with Jump Start Cables Improper jump start cabl...

Page 32: ...rechargeable Refer to Operation and Maintenance Manual Battery Replace and Testing and Adjusting Manual Battery Test i01903609 After Starting Engine Note In temperatures from 0 to 60 C 32 to 140 F th...

Page 33: ...e fuel economy Perkins design and technology in manufacturing provides maximum fuel efficiency in all applications Follow the recommended procedures in order to attain optimum performance for the life...

Page 34: ...cy stop button refer to the OEM information Ensure that any components for the external system that support the engine operation are secured after the engine is stopped i03756631 After Stopping Engine...

Page 35: ...ose heat immediately upon shutdown This means that an engine can be shut down for a period of time and the engine can still have the ability to start readily Install the correct specification of engin...

Page 36: ...ted in order to warm up completely the carbon deposits become thicker This can cause the following problems Free operation of the valves is prevented Valves become stuck Pushrods may become bent Other...

Page 37: ...the engine s maximum power and the engine s fuel efficiency When Group 2 diesel fuels are used the following components provide a means of minimizing problems in cold weather Glow plugs if equipped E...

Page 38: ...storage tank and into the engine fuel tank Fuel Filters It is possible that a primary fuel filter is installed between the fuel tank and the engine fuel inlet After you change the fuel filter always p...

Page 39: ...filters will require additional oil Refer to the OEM specifications for the capacity of the auxiliary oil filter 2 The Total Lubrication System includes the capacity for the Crankcase Oil Sump plus th...

Page 40: ...mpartment or System Minimum Maximum Crankcase Oil Sump 1 8 9 L 9 4 qt 10 6 L 11 2 qt Total Lubrication System 2 1 More than one style of sump may be used on these engines Use these values to estimate...

Page 41: ...System in this row 2 The Total Cooling System capacity includes the capacity of the Engine plus the External System Enter the value for the capacity of the Total Cooling System in this row 404D 15 Eng...

Page 42: ...that operate at various conditions Only use commercial oils that meet the following classifications EMA DHD 1 multigrade oil preferred oil API CH 4 multigrade oil preferred oil ACEAE5 In order to mak...

Page 43: ...on deposit for engines that use aluminum pistons single piece Oil performance is also established for engines that operate in areas with high sulfur diesel fuel All of these improvements allow the API...

Page 44: ...f the oil change intervals for any type of oil Re refined Base Stock Oils Re refined base stock oils are acceptable for use in Perkins engines if these oils meet the performance requirements that are...

Page 45: ...e engines may be equipped with an oil sampling valve If oil analysis is required the oil sampling valve is used to obtain samples of the engine oil The oil analysis will complement the preventive main...

Page 46: ...erty Maximum Limit Chloride Cl 40 mg L Sulfate SO4 100 mg L Total Hardness 170 mg L Total Solids 340 mg L Acidity pH of 5 5 to 9 0 For a water analysis consult one of the following sources Local water...

Page 47: ...tment with an SCA at the initial fill Read the label or the instructions that are provided by the OEM of the product In stationary engine applications and marine engine applications that do not requir...

Page 48: ...illed operate the engine until the coolant level reaches the normal operating temperature and until the coolant level stabilizes As needed add the coolant mixture in order to fill the system to the sp...

Page 49: ...ifreeze glycol concentration in order to ensure adequate protection against boiling or freezing Perkins recommends the use of a refractometer for checking the glycol concentration Perkins engine cooli...

Page 50: ...nt is contaminated or whenever the coolant is foaming i02959101 Fluid Recommendations Fuel Specification Glossary ISO International Standards Organization ASTM American Society for Testing and Materia...

Page 51: ...5 Distillation C 10 at 282 C 539 6 F maximum 90 at 360 C 680 F maximum D86 ISO 3405 Flash Point C legal limit D93 ISO 2719 Thermal Stability Minimum of 80 reflectance after aging for 180 minutes at 15...

Page 52: ...FRR test If the lubricity of a fuel does not meet the minimum requirements consult your fuel supplier Do not treat the fuel without consulting the fuel supplier Some additives are not compatible These...

Page 53: ...of less than 4000 ppm Table 38 Territory Fuel Requirements from 2010 EPA Ultra Low Sulfur 15 ppm maximum Sulfur Power Ultra Low sulphur 10 ppm maximum for less than or equal to 37 kW Low sulphur 300...

Page 54: ...mbustion Classification of the Fuels Diesel engines have the ability to burn a wide variety of fuels These fuels are divided into four general groups Ref to table 39 Table 39 Fuel Groups Classificatio...

Page 55: ...oil Soybean oil or rapeseed oil are the primary feedstocks These fuels are together known as Fatty Acid Methyl Esters FAME Raw pressed vegetable oils are NOT acceptable for use as a fuel in any conce...

Page 56: ...the user is prepared to accept some risk then limit biodiesel to a maximum of B5 Examples of applications that should limit the use of biodiesel are the following Standby Generator sets and certain em...

Page 57: ...commended This is due to potential damage to the fuel system or the engine Your fuel supplier or the fuel manufacturer will add the appropriate supplemental diesel fuel additives Perkins recognizes th...

Page 58: ...asks 1 Stop the engine 2 Wait for ten minutes Do not loosen the high pressure fuel lines in order to remove air pressure from the fuel system Engine Oil To relieve pressure from the lubricating system...

Page 59: ...any of the ECM pins g01143634 Illustration 31 4 Connect the welding ground cable directly to the part that will be welded Place the ground cable as close as possible to the weld in order to reduce th...

Page 60: ...Every 500 Service Hours Fuel System Filter Replace 83 Every 500 Service Hours or 1 Year Battery Electrolyte Level Check 64 Cooling System Supplemental Coolant Additive SCA Test Add 69 Engine Air Clea...

Page 61: ...re thoroughly with clean water 8 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 9 Inspect the core in order to ensure cleanliness Pressure test the core If...

Page 62: ...an Belts Inspect Adjust Inspection To maximize the engine performance inspect the belts for wear and for cracking Replace belts that are worn or damaged For applications that require multiple drive be...

Page 63: ...or death Ensure proper ventilation for batteries that are in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteri...

Page 64: ...1 L 1 qt of clean water Use a solution of ammonium hydroxide Thoroughly rinse the battery case with clean water i02323088 Battery or Battery Cable Disconnect The battery cables or the batteries should...

Page 65: ...the water pump the water temperature regulator and the hoses if necessary Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait...

Page 66: ...system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a...

Page 67: ...5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 3 Fill the cooling system with clean water Install the cooling system filler cap 4 Start and run the e...

Page 68: ...his will allow you to accurately check the coolant level This will also help in avoiding the risk of introducing an air lock into the coolant system 1 Observe the coolant level in the coolant recovery...

Page 69: ...Necessary NOTICE Do not exceed the recommended amount of sup plemental coolant additive concentration Excessive supplemental coolant additive concentration can form deposits on the higher temperature...

Page 70: ...er NOTICE Failure to replace your water temperature regulator on a regularly scheduled basis could cause severe engine damage Perkins engines incorporate a shunt design cooling system and require oper...

Page 71: ...orrect air cleaner element Check the precleaner if equipped daily for accumulation of dirt and debris Remove any dirt and debris as needed Operating conditions dust dirt and debris may require more fr...

Page 72: ...the element is properly cleaned and inspected When the primary air cleaner element is cleaned check for rips or tears in the filter material The primary air cleaner element should be replaced at least...

Page 73: ...er element with damaged pleats gaskets or seals Discard damaged primary air cleaner elements Storing Primary Air Cleaner Elements If a primary air cleaner element that passes inspection will not be us...

Page 74: ...The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur The yellow diaphragm enters the red zone The red piston locks in the...

Page 75: ...damage may occur if the breather assembly is not working correctly 5 For turbocharged engines install a new joint 6 and the spacer 5 6 Install a new diaphragm and plate 4 for the breather assembly int...

Page 76: ...Drain the crankcase with the oil warm This draining method allows the waste particles that are suspended in the oil to be drained correctly Failure to follow this recommended procedure will cause the...

Page 77: ...ap Refer to the Operation and Maintenance Manual for more information on lubricant specifications Fill the crankcase with the correct amount of oil Refer to the Operation and Maintenance Manual for mo...

Page 78: ...he test fluid can pierce the skin and cause serious injury to the operator Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension NOT...

Page 79: ...com ponent containing fluids Dispose of all fluids according to local regulations and mandates Use the following procedure in order to prime the fuel system If air enters the fuel system the air must...

Page 80: ...Priming the system Ensure that the air is removed from the primary filter Loosen vent screws 1 Refer to illustration 49 Operate the priming pump When fuel free from air flows from the vent screw tight...

Page 81: ...ectrical priming pump 9 Fuel transfer pump g01304597 Illustration 54 10 Connector bolt 11 Fuel return line 12 Connector bolt Hand Priming Pump 6 In order to identify the hand priming pump refer to ill...

Page 82: ...ctrical priming pump refer to illustration 53 1 Ensure that fuel valve 2 for the fuel filter that has an element is in the ON position Refer to illustration 50 2 Loosen vent screw 3 4 or 5 on the fuel...

Page 83: ...suitable cover over discon nected fuel system component NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the...

Page 84: ...is drained into a suitable container g01334895 Illustration 58 Typical example Note Do not fill the fuel filter with fuel The fuel will not be filtered and the fuel could be contaminated Contaminated...

Page 85: ...Prime i02627223 Fuel System Primary Filter Water Separator Drain Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start swi...

Page 86: ...fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow So...

Page 87: ...system and the hoses for the coolant system Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components a...

Page 88: ...idle This will help in the removal of debris and the drying of the core Slowly reduce the engine speed to low idle and then stop the engine Use a light bulb behind the core in order to inspect the cor...

Page 89: ...and clean the electrical connections Refer to the Systems Operation Testing and Adjusting Manual Electric Starting System Test for more information on the checking procedure and for specifications or...

Page 90: ...oil leaks or coolant leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed The guards must be in the correct place Repair damaged guards or replace missing guards Wip...

Page 91: ...st the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery Check the condition of the gauge...

Page 92: ...y be certified to comply with exhaust emission standards and gaseous emission standards that are prescribed by the law at the time of manufacture and this engine may be covered by an Emissions Warrant...

Page 93: ...Equipment Check 70 E Electrical System 12 Grounding Practices 12 Emergency Stopping 34 Emissions Certification Film 24 Emissions Warranty Information 92 Engine Clean 70 Engine Air Cleaner Element Dual...

Page 94: ...tration 7 Pressure Air and Water 7 H Hoses and Clamps Inspect Replace 86 Replace the Hoses and the Clamps 87 I Important Safety Information 2 L Lifting and Storage 25 M Maintenance Interval Schedule 6...

Page 95: ...This document is printed from SPI Not for RESALE SEBU8311 02 95 Index Section Warranty Section 92 Water Pump Inspect 91 Welding on Engines with Electronic Controls 58...

Page 96: ...This document is printed from SPI Not for RESALE 96 SEBU8311 02 Index Section...

Page 97: ...on in the Operation and Maintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Seri...

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Summary of Contents for 402D

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Summary of Contents for 402D

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