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Products
400A and 400D Industrial Engine Operation and Maintenance Manual


Detailed Description:

Operation and Maintenance Manual

400A and 400D industrial engines

GG (engine)

GH (engine)

GJ (Engine)

GK (Engine)

GL (Engine)

GM (Engine)

GN (Engine)

GP (Engine)

GQ (Engine)

GS (Engine)

GT (Engine)

GU (Engine)

GV (engine)

This document is printed from SPI². Not for RESALE


Important safety matters

Most accidents in the operation, maintenance and repair of the product are caused by failure to observe basic safety rules or precautions. If it works

Therefore, before the occurrence of various potential dangers, accidents can often be avoided. Staff must be alerted to potential dangers

Report. Staff must also be trained to acquire the necessary skills and the proper use of tools.

Improper handling, lubrication, maintenance or repair of the product is dangerous and can cause personal injury or death.

You must read and understand the information on the operation, lubrication, maintenance and repair of the product before performing these tasks.

Safety precautions and warnings are provided in this manual and on the product. Failure to heed these warnings will give you or others

Causes personal injury or death.

Identify hazards with "safety warning symbols" and "mark text" such as "danger", "warning", or "beware". The Warning label is shown below.

The meaning of the safety warning symbol is as follows:

note! Be alert! It's about your safety.

Below the warnings are described dangerous situations, some written in words and some graphically.

Operations that can cause product damage are indicated on the product and in this manual by the "Caution" sticker.

Not every situation that could be dangerous can be expected. Therefore, the warnings presented in this manual and the product do not cover all

Happening. If tools, procedures, work methods or techniques are not specifically recommended by Perkins, you must protect yourself and yourself

The safety of others. Also ensure that the method of operation, lubrication, maintenance, or repair procedures you choose will not damage the product or create unsafe conditions.

The materials, technical specifications and diagrams in this manual have been compiled based on information available at the time of writing. Listed technical specifications, torque, pressure

Forces, measured values, adjustments, charts, and other items are subject to change at any time, and these changes will affect product maintenance. So in progress

Before carrying out various operations, you must obtain complete and up-to-date information. The agent has the latest information.

When this product needs to be replaced, it is recommended to use

Perkins original parts or parts of the same technical specification

Pieces. The same technical specifications include, but are not limited to, overall dimensions,

Type, strength and material.

Ignoring this warning can cause premature failure, product damage, or even human

Casualties.

This document is printed from SPI². Not for RESALE


SCBU8311-03

3

table of Contents

table of Contents

Index section

index................................................. .............. 81

Preface ... ...... 4

Security section

Safety Signs................................................ ........... 5

General hazard information ... ..... 7

Preventing burns ... ........... 8

Fire protection and explosion protection ............... ........ 8

Preventing bruises and cuts ... ... 10

Before starting the engine ............... ... 10

Engine start ............ ..... 10

Engine shutdown ... ..... 11

Electrical System................................................ ......... 11

Product information data section

Model view description ............... .... 12

Product Identification Information ................. 22

Operation part

Lifting and storage ... ...... twenty four

Gauges and indicators ... .... 26

Functional parts and controls .............. 27

Engine start ............ ..... 28

Engine operation ... ..... 31

Engine shutdown ... ..... 32

Cold weather operation ... ... 33

Maintenance section

Filling capacity .................. .......... 36

Maintenance recommendations ... ......... 51

Maintenance schedule ... ... 53

Warranty section

Warranty information ............... ... 80

This document is printed from SPI². Not for RESALE


4

Foreword

SCBU8311-03

Foreword

Maintenance cycle

When performing maintenance, you should also do the first few smaller than the specified time interval

Maintenance items. We recommend copying a maintenance schedule and showing

Near the engine as a convenient reminder. We also recommend that

Maintenance records are kept as part of the engine's permanent records.

reference

This manual contains safety information, operating instructions, lubrication and maintenance information

material. This manual should be stored in a folder near the engine or

File storage. Read, analyze and compare this manual with documents and

Engine information is put together.

Perkins authorized agents or Perkins distributors can help you

The operating environment of the machine needs to adjust your maintenance plan.

English is the primary language for all Perkins publications. use English

Easy translation and consistency.

Overhaul

In addition to the overhaul time and maintenance items during this cycle,

Details of engine overhauls are not included in the Operation and Maintenance Manual. only

Perkins authorized personnel should perform overhaul. Perkins agents

And Perkins distributors can provide multiple options for overhaul procedures.

If there is a major engine failure, there are many

Repair options. With Perkins agents or Perkins distributors

Contact for these programs.

Details or options shown on some photos and illustrations in this manual

Parts may differ from those on your engine. For convenience,

Some shields and covers may have been removed. Constant change in product design

Development and development may change the engine, and these changes may

Not included in this manual. When you have any questions about the engine or this manual

When inquiring, consult your Perkins agent or Perkins distributor

The latest information.

Warning in California Proposition 65

Safety

California believes that diesel engine exhaust and some of its components

Branches are carcinogenic, causing birth defects and other reproductive harm.

Lead and lead in battery terminals, terminals, and related accessories

组合。 The compound. Wash hands after contact.

The security section lists basic security considerations. In addition, the headquarters

The points also indicate various dangerous situations and warnings. In operation,

Before skidding, maintaining and repairing this engine, read and understand

Basic notes on the safety section.

operating

The method of operation indicated in this manual is the most basic. They can help

Assist operators to improve technology and skills to be more effective and economical

Run the engine. When the operator gains knowledge and mastery of the engine

After performance, operation skills and methods will be improved.

The operation part is for the operator's reference, and various photos and illustrations guide

The operator inspects, starts, runs, and stops the engine.

This section also contains a discussion of electronic diagnostics.

maintenance

The maintenance section is a guide to engine maintenance. Illustrated step by step

Instructions are organized by working hours and / or calendar time maintenance cycles

of. For the items in the maintenance cycle, please refer to the detailed description later.

The recommended warranty should be performed at the corresponding intervals indicated in the maintenance cycle table.

support. The actual operating environment of the engine will also affect the maintenance cycle.

Therefore, in extremely harsh, dusty, humid or frozen cold conditions

It may require more lubrication and protection than those specified in the maintenance schedule.

Raised many times.

Maintenance items in the maintenance plan are prepared according to the preventive maintenance management program

of. If maintenance is performed in accordance with preventive maintenance management procedures, then

No regular adjustments are required. Implement preventive maintenance management procedures,

By reducing the cost of unplanned downtime and failures,

Minimize operating costs.

This document is printed from SPI². Not for RESALE


SCBU8311-03

5

Security section

Safety Signs

Security section

i03840649

Safety Signs

There may be several special safety signs on the engine. Review of this section

The exact location of these safety signs and their descriptions. Please be familiar with

There are safety signs.

Make sure all safety signs are legible. If safety signs

The description text or figure is not recognized, please wipe or replace. Wipe

Cloth, water and soap wash safety sign. Do not use solvents, gasoline

Or other harsh chemicals. Solvents, gasoline, or harsh chemicals

The article may lose the tackiness of the adhesive to which the safety sign is attached. funeral

Lost viscosity safety signs may come off the engine.

Replace any damaged or missing safety signs. If there are safety signs

The sticker is on the replaced engine part, it should be on the replacement part

Paste new safety signs. Your Perkins agent or distributor can

To provide new safety signs.

(A) General warning

Read and understand the instructions and warnings in the Operation and Maintenance Manual

Do not operate the machine before. Failure to follow these warnings may result in

Casualties.

g01154807

figure 1

Typical example

Warning signs (A) are installed in different positions. Location varies with engine physics

Size varies.

This document is printed from SPI². Not for RESALE


6

Security section

Safety Signs

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g01324126

figure 2

(A) Location of warning signs

(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

This document is printed from SPI². Not for RESALE


SCBU8311-03

7

Security section

General hazard information

i03018725

Before working on the busbar or glow plug, make sure the power is disconnected.

General hazard information

Maintain the engine while the equipment is in the service position. About placing the device

For information on repair locations, see OEM information.

Compressed air and water

Compressed air and / or pressurized water may blow debris and / or hot water out.

This may cause personal injury.

Using compressed air or pressurized water directly on the case may cause

Personal injury.

When using compressed air and / or water for cleaning, wear protective clothing,

Footwear and eye protection. Eye protection includes goggles and protective masks.

The maximum air pressure used for cleaning must be below 205 kPa (30 psi).

The maximum water pressure used during cleaning must be below 275 kPa (40 psi).

g00104545

Liquid penetration

image 3

Before servicing or repairing the equipment, hang on the start switch or joystick

A "No Operation" or similar warning label.

Even if the engine has been off for a long time, there may still be pressure in the hydraulic circuit

Force exists. If pressure is not released properly, hydraulic pressure can result

Objects such as oil or pipe plugs shoot out at high speed.

Do not disassemble any hydraulic components before releasing pressure, otherwise

May cause personal injury. Do not disassemble anything until pressure is released

Hydraulic components, otherwise it may cause personal injury. About releasing hydraulic pressure

Refer to the OEM information for any steps required for stress.

g00702020

Figure 4

Wear hard hats, goggles, and other protective equipment as required.

Don't wear loose clothes or jewelry as they may catch

Controls or other engine parts.

g00687600

Figure 5

Make sure all guards and covers are properly seated in the engine

Place it on.

Always use planks or cardboard to check for leaks. Under pressure

The sprayed liquid may penetrate human tissues. Liquid penetrates into the body

It can cause severe personal injury and even death. which is

A pinhole-sized loophole can also cause serious people

Bodily injury. If liquid is sprayed onto your skin, it must be treated immediately.

Seek treatment from a doctor familiar with this type of injury.

Keep the engine free of foreign objects. Clear machine floor, aisles and

Debris, oil, tools, and other items on the steps.

Never put maintenance liquids in glass containers. Drain all liquids

Into a suitable container.

Contain spilled liquid

Dispose of liquids in accordance with local regulations.

Use all cleaning solutions with care.

When inspecting, maintaining, testing, adjusting and servicing the engine,

Take care to ensure that spilled liquid is contained in the container.

Before opening any chamber or disassembling any part, be ready to use

Appropriate container to collect effluent.

Report all items that need repair.

Do not allow unauthorized persons to board the machine.

This document is printed from SPI². Not for RESALE


8

Security section

Prevent burns

SCBU8311-03

• Use only tools and equipment suitable for collecting liquids.

• Use only tools and equipment suitable for containing liquids.

Dispose of liquids in accordance with local regulations.

i03018720

Fire and explosion protection

i03018521

Prevent burns

Do not touch any part of the running engine. Launching

Allow the engine to cool down before performing any maintenance on the machine. in

Before opening any pipes, fittings or related parts,

Pneumatic, hydraulic, lubrication, fuel and cooling systems

All the pressure in the system.

Coolant

g00704000

Figure 6

When the engine is at operating temperature, the engine's coolant is hot.

And under pressure. Radiator and lead to heater or engine

There is hot coolant in all of the pipes.

All fuel, most lubricants, and some coolant mixtures

Is flammable.

When flammable liquid leaks or splashes on hot surfaces or electrical components,

Can cause fire. Fire can cause personal injury or property damage.

Contact with hot coolant or steam can cause severe burns. emission

Allow the cooling system components to cool before cooling the system.

Remove engine crankcase cover within fifteen minutes after emergency shutdown

It may cause a flame.

After the engine has stopped and cooled down, check the coolant level.

Before removing the filler cap, make sure that the filler cap is cold. Raise

The cover must be cold enough to touch with bare hands. Remove the filler cap slowly,

Relieve stress.

Determine if the engine is in a ring where flammable gases can be drawn into the intake system

Environment. These gases can cause the engine to overspeed. This may lead

Injury, property damage, or engine damage.

Cooling system additives contain alkali. Alkali can cause personal injury. do not let

Alkali contacts the skin and does not allow it to enter the eyes or mouth.

If the type of application involves the presence of flammable gases, please consult

Your Perkins agent and / or your Perkins distributor to obtain

More information on appropriate protective equipment.

oil

Remove all flammable or conductive materials from the engine, such as fuel, oil, and

Detritus, etc. Do not allow any flammable or conductive materials to accumulate on the engine.

Hot oil and hot lubricating parts can cause personal injury. Don't

Let hot oil contact the skin. Also, don't let hot parts

In contact with skin.

Store all fuel and lubricants in marked containers.

Access to unauthorized persons is prohibited. Mix oily rags with

Any flammable materials are stored in protective containers. Never store flammable materials

Place for smoking.

Accumulator

The electrolyte is acidic. May cause personal injury. Don't let electrolyte

In contact with skin or eyes. Always wear goggles when servicing batteries.

Always wash your hands after touching the battery and its connectors. Use of gloves is recommended.

Do not expose the engine to any open flame.

If piping, piping and seals are damaged,

Equipped) prevents injection of oil or fuel into hot exhaust pipe parts

on. The exhaust bulkhead must be installed correctly.

It is forbidden to perform welding on pipelines or tanks filled with flammable liquids. ban

Never use flames to cut pipes or tanks containing flammable liquids. Welding

Before connecting or flame cutting these pipes or tanks, first use non-flammable solvents

Clean it thoroughly.

Wiring must be kept in good condition. All wires must be properly routed

Place and connect securely. Check all wires daily. please at

Repair loose or worn wires before running the engine. Clean and tight

Fix all circuit connections.

This document is printed from SPI². Not for RESALE


SCBU8311-03

9

Security section

Fire and explosion protection

Remove all unconnected or unnecessary connectors. Do not use than push

It is recommended to use small wires or cables. Do not place any fuses and / or

The breaker is bypassed and shorted.

An arc or spark can cause a fire. Strong connection, as recommended

And properly maintained battery cables help prevent

Arcs and sparks.

Inspect all pipes and hoses for wear or deterioration. Laying of hoses

The route must be appropriate. Pipes and hoses must be properly supported or

Firm tube clamp. Tighten all fittings to the recommended torque. leakage

May cause fire.

The oil filter and fuel filter must be installed correctly. Must filter

The cleaner housing is tightened to the correct torque.

g00704135

Figure 8

The gas emitted from the battery can cause an explosion. The top of the battery

Keep away from open flames or sparks. Do not smoke where the battery is being charged.

Do not use metal objects across the terminals to check

Check the battery charge. A voltmeter or hydrometer must be used.

Improper jumper cable connections can cause explosions that can cause personal injury

harm. For specific instructions, see the operation section of this manual.

Do not charge frozen batteries. Doing so can cause an explosion.

The battery must be kept clean. Each battery grid cell must be covered

Good lid (if equipped). When the engine is running,

Recommended cables, connectors, and battery box covers.

g00704059

Figure 7

Use caution when refueling the engine. Don't start

Smoking while refueling. Also don't go near open flames or sparks

Ground to the engine. Remember to add fuel before adding fuel

The engine stalled.

Fire extinguisher

Make sure you have a fire extinguisher. Familiar with the use of fire extinguishers. Check regularly and

Maintain fire extinguishers. Follow the recommendations on the instruction plate.

Pipes, tubes and hoses

Do not bend high-pressure lines. Do not strike high-pressure lines. Do not install

Any bent or damaged pipe. Don't clamp on high pressure pipe

Anything else.

Repair any loose or damaged pipes. Leaks can cause fire

disaster. Check with your Perkins agent or your Perkins distributor

Ask for repair or replacement of parts.

Carefully inspect the pipes, tubes and hoses. Do not check with bare hands

Check for leaks. Use wooden boards or cardboard to check for leaks. Follow push

Recommended torque to tighten all joints.

Replace the parts if any of the following conditions occur:

• The end fitting is damaged or leaking.

This document is printed from SPI². Not for RESALE


10

Security section

Prevent crushing and cuts

SCBU8311-03

• The outer layer is worn or cut.

• Metal wires are exposed.

• Outer bulge.

• The hose is twisted.

If the engine must be started for maintenance work,

There are protective covers and covers. To prevent accidents caused by rotating parts,

Be careful around the moving parts.

Do not bypass the automatic shutdown circuit. Don't make the automatic shutdown circuit fail

effect. This circuit is provided to prevent personal injury. Simultaneously

It also prevents engine damage.

• The sheath is embedded in the outer layer.

• Displacement of end fittings.

For repair and adjustment information, refer to the Service Manual.

i03018682

Engine start

Make sure that all clamps, guards and insulation panels are installed correctly. This

Helps prevent engine vibration and friction between parts

Rub and excessive heat.

i03018585

Prevent crushing and cuts

Do not use an ether-like spray to aid starting. Otherwise it may lead

Causes explosion and personal injury.

If a warning mark is attached to the engine start switch or control

Do not start the engine or pull the controls. Start at start

Before the flight, consult the person who attached the warning label.

When working under a component, the component should have reliable support.

If no additional maintenance instructions are provided, while the engine is running,

Do not attempt to make adjustments.

If the engine must be started for maintenance work,

There are protective covers and covers. To prevent accidents caused by rotating parts,

Be careful around the moving parts.

Avoid all rotating and moving parts. Until maintenance

Remove the protective cover. Replace the cover after maintenance.

In the operator's operating room or using the engine start switch

Start the engine.

Keep objects away from rotating fan blades. Fan blades will throw or

Cutting objects.

Be sure to follow the "Operation and Maintenance Manual", "Engine Start" (Operation

The procedure described in section) starts the engine. Knowing the right start

The steps help prevent major damage to engine components. Understand positive

Proper startup procedures can help prevent personal injury.

Wear protective goggles when hitting objects to avoid eye injury.

When the object is struck, debris or other debris can fly around. tap

Before objects, make sure that no one is injured by flying debris.

To ensure water jacketed water heater (if equipped) and / or oil

The heater (if equipped) is functioning normally,

Check the water and oil temperature gauges.

i03018734

Before starting the engine

Engine exhaust contains combustion products that are harmful to the human body. Must be in

Start and run the engine in a well-ventilated place. If in a secret

Start the engine in a closed space and exhaust the engine exhaust outdoors.

Before starting a new, serviced, or repaired engine for the first time,

Be prepared to stop in order to stop overspeeding. This can be done with the switch off

Motive fuel supply and / or ignition is done.

Note: The engine is equipped with a cold start automatic setting for normal operating conditions.

Equipment. If the engine will run in severe cold, severe

Cold auxiliary starting device. Generally, engines will be equipped with

Starter in industrial areas.

Engine overspeed should be shut down automatically, it is controlled electronically. in case

Automatic shutdown is not performed automatically. Press the emergency stop button to cut off the supply.

Fuel and / or air to the engine.

Each cylinder of the 400 series engine is equipped with a glow plug to assist lifting

Device to heat the intake air to facilitate starting.

Inspect the engine for potential hazards.

Before starting the engine, make sure that no one is on, under or near the engine.

Make sure no one is around.

If equipped, ensure that the lighting system for the engine is suitable for the conditions

condition. If equipped, make sure all lights are working properly.

This document is printed from SPI². Not for RESALE


SCBU8311-03

11

Security section

Engine shutdown

i03018709

Engine shutdown

To avoid engine overheating and accelerated wear of engine components,

According to the Operation and Maintenance Manual,

The shutdown step in section) stops the engine.

Only use the emergency stop button in emergency situations (if equipped)

Prepare). Do not use the emergency stop button when the engine is stopped normally.

Never start the engine until the problem that caused the emergency stop is resolved.

For a new engine that is started for the first time or a repaired engine,

Ready for shutdown when overspeed occurs. This can be done with shutdown

Engine fuel and / or air supply.

If equipped, to stop the electronically controlled engine,

Power of motivation.

i02616968

Electrical System

Never disconnect the charging device from the battery while the charging device is working

Circuit or battery circuit cable. Flammable gas produced by batteries

May be ignited by sparks.

To prevent sparks from igniting flammable gases from some batteries,

The negative “−” jump start cable should be connected to

The negative “−” terminal of the moving motor. If the starter motor is not equipped with a negative “−”

Terminal, please connect jumper start cable to the cylinder.

Check the wires every day for looseness. Before the engine starts, tighten

All loose wires. Repair everything before starting the engine

Scratched wires. For specific startup instructions, refer to the Operating

Operation and Maintenance Manual.

Grounding method

In order to obtain the best performance and reliability of the engine, it is necessary to make the engine

The electrical system is properly grounded. Improper grounding can cause uncontrolled

And unreliable circuit paths.

Uncontrolled circuits can cause damage to main bearings, crankshaft journal surfaces, and aluminum

Damage to quality parts.

Engines without an engine-to-frame ground strap may be electrically

Damage due to discharge.

To ensure that the engine and engine electrical system work properly,

Use the ground strap of the engine to the rack, this ground strap is directly connected to the power storage

Pool. This path can be grounded directly to the frame through the engine.

All ground points must be tight and free of corrosion. Engine AC

The motor must pass a current sufficient to support its full charge current.

The wire is grounded to the negative "-" terminal of the battery.

This document is printed from SPI². Not for RESALE


12

Product information data section

Model view description

SCBU8311-03

Product information data section

Model view description

i03840669

Model view

The following model views show typical features of the 400 series engines.

Depending on the application, your engine may look similar to the picture

Shown different.

Note: Detailed individual components are only available for 404D-22T turbocharged

Engine.

g01299985

Figure 9

402D-05 engine typical view

This document is printed from SPI². Not for RESALE


SCBU8311-03

13

Product information data section

Model view description

g01300431

Figure 10

403D-15T engine typical view

This document is printed from SPI². Not for RESALE


14

Product information data section

Model view description

SCBU8311-03

g01304893

Figure 11

404D-22T engine front right side view

(1) Fuel shut-off solenoid valve

(2) No. 1 injector

(5) Throttle stick

(9) Engine oil filter

(10) Fuel injection pump

(6) Accessory drive cover

(7) Engine oil level gauge

(8) Engine oil cooler

(3) Water pump

(11) Oil transfer pump

(4) Bottom engine oil filler cap

(12) Fuel filter

This document is printed from SPI². Not for RESALE


SCBU8311-03

15

Product information data section

Model view description

g01305224

Figure 12

404D-22T engine left front side view

(13) Top engine oil filler port

(14) Crankcase ventilator

(15) Rear lifting ears

(19) Water temperature regulator housing

(20) Starter motor solenoid valve

(21) Electric starter 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

(16) Intake elbow

(17) Valve cover

(18) Turbocharger

The crankshaft of a two-cylinder engine has two main bearing journals. Three-cylinder launch

The crankshaft of the machine has four main bearing journals. Crankshaft of a four-cylinder engine

There are five main bearing journals. Axial clearance is set by the stop on the rear main bearing

Push washer control.

i03840670

Engine description

In order to ensure the correct assembly of the gears, the timing gears are labeled

Remember. When No. 1 cylinder is at the top dead center of its compression stroke, the crankshaft teeth

The marked teeth on the wheels and camshaft gears should align with the idler wheels.

The 400 series engines are all inter-injection engines. Engine by machinery

Driven fuel injection pump control. The engine cylinders are arranged inline.

Each cylinder on the cylinder head assembly has an intake valve and an exhaust valve.

The valve for each cylinder has a valve spring.

The crank gear rotates the idler gear, which in turn causes the camshaft gear and

Engine oil pump gear rotates.

The piston has two compression rings and an oil control ring. Guarantee normal life

The height of the plug is important so that the piston does not touch the cylinder head. correct

High piston height also ensures efficient fuel combustion (this is also necessary

) To meet emissions requirements.

The fuel injection pump is installed in the cylinder block. The operation of the fuel injection pump

Wheel control. The oil pump is located on the right side of the cylinder block. The operation of the oil pump is also

Cam controlled by camshaft.

This document is printed from SPI². Not for RESALE


16

Product information data section

Model view description

SCBU8311-03

Engine technical parameters

Fuel injection pumps meet the requirements of emissions regulations. If you need to

For any adjustments of time and high idle speed, please contact your Perkins distributor

Or your Perkins agent. Some fuel injection pumps are mechanical

Governor to control engine speed. Some fuel injection pumps use electronics

Control the governor.

Note: The front end of the engine is the end opposite the flywheel end of the engine.

The left and right sides of the engine are judged from the flywheel end of the engine. 1

The No. cylinder is the foremost cylinder.

The cycloidal oil pump is located in the middle of the idler gear. Engine oil pump

The full valve and engine oil filter send oil to the main oil gallery. Rocker

The high-pressure engine oil is received through an external oil pipe erected between the main oil passage and the cylinder block.

Coolant flowing from the bottom of the radiator flows through the belt-driven centrifugal water

Pump. The coolant is cooled by the radiator and its temperature is passed by a water temperature

Adjuster.

Engine efficiency, emission control efficiency and engine performance depend on

To follow recommended procedures for proper operation and maintenance. Engine sex

Energy and efficiency also depend on the use of recommended fuels, lubricants and cooling

liquid. For additional information on maintenance issues, please refer to the

Maintenance Manual, "Maintenance Schedule".

This document is printed from SPI². Not for RESALE


SCBU8311-03

17

Product information data section

Model view description

402D-05 engine

403D-07 engine

g01108476

g00852304

Figure 13

Figure 14

(A) Exhaust valve

(B) Intake valve

(A) Exhaust valve

(B) Intake valve

Table 1

Table 2

402D-05 engine technical parameters

403D-07 engine technical parameters

Operating speed (rpm)

Cylinder and configuration assembly

Cylinder bore

3600 rpm

In-line two-cylinder

Operating speed (rpm)

Cylinder and configuration assembly

Cylinder bore

3600 rpm

Inline three cylinder

67 mm (2.64 inch)

72 mm (2.83 inch)

67 mm (2.64 inch)

72 mm (2.83 inch)

stroke

stroke

Displacement

0.507 L (30.939 in

3

)

Displacement

0.762 L (46.500 in)

3

Intake method

NA

(1)

Intake method

NA

(1)

Compression ratio

23.5: 1

1-2

Compression ratio

23.5: 1

1-2-3

Ignition sequence

Ignition sequence

Direction of rotation viewed from the flywheel end

Valve clearance setting (intake)

Valve clearance setting (exhaust)

Counterclockwise

The direction of rotation viewed from the flywheel end

Valve clearance setting (intake)

Valve clearance setting (exhaust)

Counterclockwise

0.20 mm (0.008 inch)

0.20 mm (0.008 inch)

Spurt

0.20 mm (0.008 inch)

0.20 mm (0.008 inch)

Spurt

Fuel injection method

Fuel injection

(1) Naturally aspirated

(1) Naturally aspirated

This document is printed from SPI². Not for RESALE


18

Product information data section

Model view description

SCBU8311-03

403D-11 engine

403D-15 engine

g00852304

g00852304

Figure 15

Figure 16

(A) Exhaust valve

(B) Intake valve

(A) Exhaust valve

(B) Intake valve

table 3

Table 4

403D-11 engine technical parameters

403D-15 engine technical parameters

Operating speed (rpm)

Cylinder and configuration assembly

Cylinder bore

3600 rpm

Inline three cylinder

Operating speed (rpm)

Cylinder and configuration assembly

Cylinder bore

3000 rpm

Inline three cylinder

77 mm (3.03 inch)

81 mm (3.19 inch)

84 mm (3.31 inch)

90 mm (3.54 inch)

stroke

stroke

Displacement

1.131 L (69.018 in

3

)

Displacement

1.496 L (91.291 in)

3

Intake method

NA

(1)

Intake method

NA

(1)

Compression ratio

23: 1

1-2-3

Compression ratio

22.5: 1

1-2-3

Ignition sequence

Ignition sequence

The direction of rotation viewed from the flywheel end

Valve clearance setting (intake)

Valve clearance setting (exhaust)

Counterclockwise

The direction of rotation viewed from the flywheel end

Valve clearance setting (intake)

Valve clearance setting (exhaust)

Counterclockwise

0.20 mm (0.008 inch)

0.20 mm (0.008 inch)

Spurt

0.20 mm (0.008 inch)

0.20 mm (0.008 inch)

Spurt

Fuel injection

Fuel injection

(1) Naturally aspirated

(1) Naturally aspirated

This document is printed from SPI². Not for RESALE


SCBU8311-03

19

Product information data section

Model view description

403D-15T engine

403D-17 engine

g00852304

g00852304

Figure 17

Figure 18

(A) Exhaust valve

(B) Intake valve

(A) Exhaust valve

(B) Intake valve

table 5

Table 6

403D-15T engine technical parameters

403D-17 engine technical parameters

Operating speed (rpm)

Cylinder and configuration assembly

Cylinder bore

3000 rpm

Inline three cylinder

Operating speed (rpm)

Cylinder and configuration assembly

Cylinder bore

2600 rpm

Inline three cylinder

84 mm (3.31 inch)

90 mm (3.54 inch)

84 mm (3.31 inch)

100 mm (3.94 inch)

stroke

stroke

Displacement

1.496 L (91.291 in

3

)

Displacement

1.66 L (101.3 in)

3

Intake method

T

(1)

Intake method

NA

(1)

Compression ratio

22.5: 1

1-2-3

Compression ratio

23.1: 1

1-2-3

Ignition sequence

Ignition sequence

The direction of rotation viewed from the flywheel end

Valve clearance setting (intake)

Valve clearance setting (exhaust)

Counterclockwise

The direction of rotation viewed from the flywheel end

Valve clearance setting (intake)

Valve clearance setting (exhaust)

Counterclockwise

0.20 mm (0.008 inch)

0.20 mm (0.008 inch)

Spurt

0.20 mm (0.008 inch)

0.20 mm (0.008 inch)

Spurt

Fuel injection

Fuel injection

(1) Turbocharged

(1) Naturally aspirated

This document is printed from SPI². Not for RESALE


20

Product information data section

Model view description

SCBU8311-03

404D-15 engine

404D-22 engine

g00296424

g00296424

Figure 19

Figure 20

(A) Exhaust valve

(B) Intake valve

(A) Exhaust valve

(B) Intake valve

Table 7

Table 8

404D-15 engine technical parameters

404D-22 engine technical parameters

Operating speed (rpm)

Cylinder and configuration assembly

Cylinder bore

3000 rpm

In-line four-cylinder

Operating speed (rpm)

Cylinder and configuration assembly

Cylinder bore

3000 rpm

In-line four-cylinder

77 mm (3.03 inch)

81 mm (3.19 inch)

84.0 mm (3.31 inch)

100.0 mm (3.94 inch)

stroke

stroke

Displacement

1.508 L (92.024 in

3

)

Displacement

2.216 L (135.229 in)

3

Intake method

NA

(1)

Intake method

NA

(1)

Compression ratio

23.5: 1

1-3-4-2

Counterclockwise

Compression ratio

23.3: 1

1-3-4-2

Counterclockwise

Ignition sequence

Ignition sequence

The direction of rotation viewed from the flywheel end

Valve clearance setting (intake)

Valve clearance setting (exhaust)

The direction of rotation viewed from the flywheel end

Valve clearance setting (intake)

Valve clearance setting (exhaust)

0.20 mm (0.008 inch)

0.20 mm (0.008 inch)

Spurt

0.20 mm (0.008 inch)

0.20 mm (0.008 inch)

Spurt

Fuel injection

Fuel injection

(1) Naturally aspirated

(1) Naturally aspirated

This document is printed from SPI². Not for RESALE


SCBU8311-03

twenty one

Product information data section

Model view description

404D-22T engine

404D-22TA engine

g00296424

g00296424

Figure 21

Figure 22

(A) Exhaust valve

(B) Intake valve

(A) Exhaust valve

(B) Intake valve

Table 9

Table 10

404D-22T engine technical parameters

404D-22TA engine technical parameters

Operating speed (rpm)

Cylinder and configuration assembly

Cylinder bore

3000 rpm

In-line four-cylinder

Operating speed (rpm)

Cylinder and configuration assembly

Cylinder bore

2800 rpm

In-line four-cylinder

84.0 mm (3.31 inch)

100.0 mm (3.94 inch)

84.0 mm (3.31 inch)

100.0 mm (3.94 inch)

stroke

stroke

Displacement

2.216 L (135.229 in

3

)

Displacement

2.216 L (135.229 in)

3

Intake method

T

(1)

Intake method

TA

(1)

Compression ratio

23.5: 1

1-3-4-2

Counterclockwise

Compression ratio

23.5: 1

1-3-4-2

Counterclockwise

Ignition sequence

Ignition sequence

The direction of rotation viewed from the flywheel end

Valve clearance setting (intake)

Valve clearance setting (exhaust)

The direction of rotation viewed from the flywheel end

Valve clearance setting (intake)

Valve clearance setting (exhaust)

0.20 mm (0.008 inch)

0.20 mm (0.008 inch)

Spurt

0.20 mm (0.008 inch)

0.20 mm (0.008 inch)

Spurt

Fuel injection

Fuel injection

(1) Turbocharged

(1) Turbocharged aftercooling

This document is printed from SPI². Not for RESALE


twenty two

Product information data section

Product identification information

SCBU8311-03

Product identification information

i02890279

Reference No

i03826058

Engine identification

When ordering parts, information on the following items may be required.

Find out your engine information. Fill in these information in the appropriate places

material. Make a copy of this list for your records. Save this information to

For future reference.

Perkins engines are identified by a serial number. This number is marked on

The serial number plate on the injection pump on the right side of the engine block

Archival records for reference

For example, the engine number is GP ***** U000001T.

engine model _________________________________________________________

Engine production serial number __________________________________________________

Engine low idle ______________________________________________________

Engine full load speed ________________________________________________

Primary fuel filter _________________________________________________________

Water separator element ______________________________________________________

Fuel secondary filter element __________________________________________________

Lube filter element part number _______________________________________________

Auxiliary oil filter element part number ___________________________________________

Total lubrication system capacity __________________________________________________

Total cooling system capacity __________________________________________________

Air filter element __________________________________________________

Fan drive belt ______________________________________________________

Alternator belt __________________________________________________

G_______________________________________________________ Engine Series

P _______________________________________________________ Engine type

***** _____________________________________________ Engine list number

U ______________________________________________________ Country of production

0 ___________________________________ The first digit is the production code.

00001 ____________________________________________ Engine serial number

T ___________________________________________________________ Year of production

Perkins agents or Perkins distributors need these numbers in order to

Identify the parts included on the engine. So that it can be accurately identified

Part number of the part that needs to be replaced.

i03018730

Serial number plate

g01094203

Figure 23

Typical serial number plate

The serial number plate is located above the injection pump on the right side of the cylinder block.

The following information is embossed on the serial number plate: Engine serial number, type

Number and configuration assembly number.

This document is printed from SPI². Not for RESALE


SCBU8311-03

twenty three

Product information data section

Product identification information

i03840671

Emission certification film

g01478138

Figure 24

Typical example

g01476654

Figure 25

Typical example

Perkins Shibaura Engine Co., Ltd. will provide fuel for each engine

Oil label. Please refer to Figure 25. The device manufacturer must install the device

Install this sign. This is a recommendation from Perkins Shibaura Engine Co., Ltd.

practice. This tag must be affixed to the fuel inlet of the equipment. This way

Meets EPA regulations. Equipment manufacturers can install additional fuel

Oil label. If other fuel labels are used, the equipment manufacturer must

Send a pattern or photo of this sign to Perkins through a Perkins distributor

Shibaura Engine Co., Ltd. This will ensure compliance with the signage requirements.

This document is printed from SPI². Not for RESALE


twenty four

Operation part

Lifting and storage

SCBU8311-03

Operation part

Lifting ears are designed and installed for specific engine configuration assemblies. change

Moving the lifting eyes and / or the engine will invalidate the lifting eyes and lifting gear. If you hang

Ears and / or engines have been modified to ensure proper lifting

Device. Ask your Perkins dealer or your Perkins distributor

To obtain information on proper engine lifting fixtures.

Lifting and storage

i03840673

i03018702

Engine storage

Engine lifting

If the engine has not been started for several weeks, the oil will be removed from the cylinder wall and piston

Flowing out of the ring. There may be rust on the tank wall. Corrosion on the cylinder walls will lead

This results in increased engine wear and reduced engine life.

Lubrication system

To prevent excessive engine wear, follow these guidelines:

Completed in this Operation and Maintenance Manual, “Maintenance Schedule” (Maintenance

Section) for all lubrication recommendations listed.

If the engine is not running or if the engine has not been planned for use,

Special precautions should be taken. If the engine is stored more than one

It is recommended to develop a complete protection procedure.

Follow these guidelines:

• Thoroughly clean the outside of the engine.

• Drain the fuel system and fill it with anti-corrosion

oil. 1772204 POWERPART Lay-Up 1

Common fuels are used to convert fuel into antiseptic oil.

• If anticorrosive fuel is not available, ordinary fuel can be injected into the fuel system

oil. This fuel must be filtered with the fuel filter at the end of the storage period

The core is discarded together.

g01097527

• Run the engine until the engine has reached normal operating temperature. Hinder

Stop any leaks from fuel, oil, or air systems. Close hair

Motive, draining the oil in the oil pan.

Figure 26

note

Never bend eyebolts and brackets. Eyebolts and brackets only

Can withstand tension load. Remember when the angle between the support member and the object

When the degree is less than 90 °, the bearing capacity of the eyebolts becomes small.

• Replace the canister of the lubricant filter.

• Fill new oil pan with engine oil until engine oil

Full scale position of the ruler. Add 1762811 POWERPART

Lay-Up 2 into the oil to protect the engine from corrosion. in case

1762811 POWERPART Lay-Up 2 is not available, please use

Replace the oil with a preservative with the correct technical parameters. If you make

With a preservative, it must be completely discharged after the storage period

Clean and refill the oil pan with the correct grade of normal lubricant.

When parts must be moved at an angle, use

Constant load link bracket.

Use a crane to remove heavy components. Use an adjustable crane

Beam lifting engine. All load-bearing components (chains and ropes)

They should be parallel to each other. The top surface of the chain and wire rope as much as possible

Can stay vertical.

cooling system

Some removals require lifting with lifting tools to ensure correct

Balance and safety.

To prevent excessive engine wear, follow these guidelines:

Use the lifting ears on the engine only when disassembling the engine.

This document is printed from SPI². Not for RESALE


SCBU8311-03

25

Operation part

Lifting and storage

8. Run the engine for a short time, so that the lubricant and coolant are in the engine.

Medium circulation flow.

note

Do not discharge while the engine is still hot and the system is under pressure

Coolant, because there is a danger that hot coolant will be discharged.

9. Disconnect the battery. When the battery is fully charged,

Store safely. Corrosion-proof the terminals before storing the battery

protection. 1734115 POWERPART Lay-Up 3 can

Used on terminals.

If the engine is expected to run below zero, check the cooling system

Is it adequately protected against frost? Refer to this Operation and Maintenance

Manual, "Fluid Recommendations" (Maintenance Section).

10. Clean the crankcase breather (if installed). Seal the tube ends.

11. Remove the injector and place 1762811 POWERPART Lay-Up

2Inject into each cylinder for one or two seconds while the piston remains in BDC position

彩乐乐网.

note

To prevent frost damage, ensure that all coolant is drained from the engine.

If the system has been drained after being flushed with water, or antifreeze is used

Performance is too poor to protect the system from frost, then this will not be

Often important.

12. Slowly rotate the crankshaft one full turn, then replace the injector.

Air intake system

• Remove the air cleaner assembly. Remove air filter if necessary

The line between the cleaner assembly and the turbocharger. Add to the turbine

The sprayer was sprayed with 1762811 POWERPART Lay-Up 2.

The spray duration is printed on the container. Seal with waterproof tape

Turbocharger.

Exhaust system

• Remove the exhaust pipe. Injecting into a turbocharger

1762811

POWERPART Lay-Up 2. Spray duration printed on container

on. Seal the turbocharger with waterproof tape.

General Project

• If the oil filler port is installed on the valve mechanism cover, remove the filler

Mouth cover. If the oil filler cap is not installed on the valve mechanism cover

To remove the valve mechanism cover. Spray around rocker shaft assembly

1762811 POWERPART Lay-Up 2. Replace filler port

Cover or valve mechanism cover.

g01298045

Figure 27

Typical example

• Seal the fuel tank vent or fuel filler cap with waterproof tape.

• Remove the drive belt of the alternator and store it.

1. Make sure the vehicle is on level ground.

2. Remove the filler cap of the cooling system.

• To prevent corrosion, use

1734115

POWERPART Lay-Up

3. Remove the drain plug (1) from the cylinder block side to drain the engine.

Make sure the drain hole is not blocked.

3 Spray the engine. Do not spray inside the alternator.

After completing all engine protection according to the instructions above, there will be no

Corrosion occurs. Perkins is wrong with the engine during a period of maintenance

Responsible for damages that occur during later storage.

4. Open the cover and remove the drain plug on the bottom of the radiator so that the drain

Put the radiator. If the radiator has no cover or drain plug, then

Disconnect the hose from the bottom of the radiator.

Your Perkins agent or your Perkins distributor can help you

Prepare the engine for long-term storage.

5. Rinse the cooling system with clean water.

6. Install the drain plug and filler cap. Cover or connect

Heater hose.

7. Fill the cooling system with an approved antifreeze mixture as it

Can prevent corrosion.

Note: Some corrosion inhibitors may damage engine components. Contact Perth

The service department of Kings gets advice on how to use it.

This document is printed from SPI². Not for RESALE


26

Operation part

Gauges and indicators

SCBU8311-03

Gauges and indicators

Tachometer-This meter indicates the engine speed. Without negative

When loading, move the throttle lever to the full throttle position.

The engine is running at high idle speed. At maximum rated load

Down, the throttle lever is at full throttle, and the engine turns at full load.

Run at low speed.

i03018687

Gauges and indicators

note

To help prevent engine damage, never exceed high idle speeds.

Overspeed can cause severe damage to the engine. The engine can be at high

Run at idle without damage, but never exceed high idle speeds.

The gauges on your engine may be different or not available

All the following instruments. For more information on the instrument cluster, please refer to the original

Information provided by the original equipment manufacturer.

The gauge is used to indicate engine performance. Ensure that the meter is in good working order

Operation status. After observing the meter for a while, you can be sure that it is normal

Operating range.

Ammeter-This meter indicates the

The amount of charge or discharge. Gauge pointer should be at "0" (zero)

Bit right action.

A significant change in the gauge reading indicates a potential gauge or engine problem.

question. Even if the meter reading is within the specification range, its reading can be changed.

Can indicate a problem. Identify and correct any significant change in readings

Cause. Ask your Perkins agent or your Perkins

Distributors ask for help.

Fuel Level-This meter indicates the level of fuel in the fuel tank.

Fuel level gauge at "START / STOP"

The switch works when it is in the "ON" position.

Hour Meter-This gauge indicates the running time of the engine.

note

If inorganic oil pressure is displayed, stop the engine. If launched

Engine coolant exceeds maximum coolant temperature, stop engine. meeting

Causes engine damage.

Engine oil pressure-after a cold engine starts,

The oil pressure should be at its maximum. At rated speed,

Typical SAE10W30 engine oil pressure is

207 to 413 kPa (30 to 60 psi).

Low oil pressure at low idle is normal. If the load is stable but the

If the meter reading changes, perform the following steps:

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check and maintain oil level.

Water jacket water coolant temperature gauge-typical temperature range

It is 71 to 96 ° C (160 to 205 ° F). The pressure is

Maximum capacity of 90 kPa (13 psi) pressurized cooling system

Allowable temperature is 110 ° C (230 ° F). May produce in some cases

Higher temperatures. As the load varies, the engine coolant temperature reads

The number is different. For pressurized systems in use, the reading should always be

Far from exceeding the boiling point.

If the engine is operating within the normal range and steam is generated,

Do the following:

1. Reduce load and engine speed.

2. Check the cooling system for leaks.

3. Decide if the engine must be shut down immediately or if it can

Reduce the load to cool the engine.

This document is printed from SPI². Not for RESALE


SCBU8311-03

27

Operation part

Functional components and controls

Functional components and controls

i03840674

Fuel shutdown

The fuel shut-off solenoid valve is located on the fuel injection pump. When fuel cut off solenoid

When the valve is on, the solenoid pushes the fuel rack to the "OFF" position.

g01305771

Figure 28

(1) Fuel shut-off solenoid valve

If an electronically controlled regulator is installed, the regulator will run the fuel rack

The engine is stopped.

This document is printed from SPI². Not for RESALE


28

Operation part

Engine start

SCBU8311-03

Engine start

• Disconnect all high power consumption when not starting electric motors

Battery charger with current protection. Check cables and power storage

The pool is not well connected and corroded.

i03018700

• Reset all shutdown devices or alarm components (if equipped).

Before starting the engine

• Check engine oil level. Keep the oil level in the engine

Between the "ADD" mark and the "FULL" mark on the dipstick.

Before starting the engine, perform the required daily maintenance and other regular

maintenance. For details, refer to the Operation and Maintenance Manual,

Maintenance periodic table ".

Check the coolant level. Observe in the collection tank (if equipped)

Coolant level. Keep the coolant level on the collection tank

"FULL" mark.

• In order to achieve the maximum service life of the engine,

Before doing so, thoroughly inspect the engine compartment. See the following

Head: Oil leaks, coolant leaks, loose bolts and excessive dirt

And / or sludge. Remove excess dirt and sludge. Check

Check for faults found during the repair.

• If the engine is not equipped with a water collection tank,

Keep oil level 13 mm (0.5 inch) from bottom of filler tube

Inside. If the engine is equipped with a sight gauge, maintain the coolant level

In the visual inspection table.

• Check the air filter maintenance indicator (if equipped). When yellow

When the diaphragm enters the red zone or the red piston is locked in the visible position,

Take care of the air filter.

• Inspect the cooling system hoses for cracks and loose clamps.

• Check the alternator and auxiliary drive belts for cracks and breaks

Cracks and other damage.

Ensure that all engine-powered equipment is disconnected from the engine.

Minimize electrical loads and remove any electrical loads.

• Inspect wiring and wiring harnesses for loose connections, and for worn wires or

Abrasions.

• Check fuel supply. Drain the oil-water separator (if equipped)

Standing water. Open the fuel supply valve (if equipped).

note

All fuel lines must be opened before and during engine operation

There are valves to prevent excessive fuel pressure. High fuel pressure possible

Causes failure or other damage to the filter housing.

If the engine has not been started for several weeks, fuel may be removed from the fuel system

Vented. Air may enter the filter housing. And replace the fuel filter

When cleaning, some air bubbles will be trapped in the engine fuel system. in

In these cases, fill the oil with a hand oil pump. More about pumping fuel

For system information, refer to the Operation and Maintenance Manual, "Fuel

System-Pumping ".

Engine exhaust contains combustion products that are harmful to the human body. Must be good

Start and run the engine in a well-ventilated area.

Exhaust air to the outside.

• If the engine start switch or the

Operation "warning label or similar warning label, do not start

Machine or move any control device.

• Make sure there are no foreign objects around moving parts.

• All shields must be in place. Check for damage or loss

Shroud. Repair any damaged guards. Replace damaged and / or lost

Lost shield.

This document is printed from SPI². Not for RESALE


SCBU8311-03

29

Operation part

Engine start

i03334315

i03840672

Engine start

Start with jump start cable

Do not use a spray starting aid like ether. Otherwise

Can cause explosion and personal injury.

Improper jump-start cable connection can cause an explosion and cause personal injury

harm.

Prevent sparks around the battery. Sparks can cause gas explosions.

Do not let the jumper start cable ends contact each other or the engine.

See the original equipment manufacturer (OEM) for your specific type of manipulation

manual. Use the following steps to start the engine.

1. Before starting the engine, move the throttle lever to the low idle position.

NOTE: If possible, first diagnose the cause of the inability to start. Make any

Necessary repairs. If the engine fails to start only due to the battery

Condition, charge the battery, or use a jump-start cable.

Start the engine.

note

Do not use the glow plug for more than 60 seconds at a time. Glow plug may be damaged

damage.

After the engine is turned off, the condition of the battery can be checked again.

2. Turn the engine start switch to the HEAT position. Will send

The motor start switch remains in the HEAT position for 6 seconds,

Until the glow plug indicator lights up. This will enable the glow plug to help

The engine starts.

note

Use a battery power source with the same voltage as the electric starter motor. Cross

Only the same voltage can be used for starting. Use of higher voltage will damage

Electrical System.

note

Do not crank the engine for more than 30 seconds. Before cranking again, let

The starter motor is cooled for 2 minutes.

Do not reversely connect the battery cables. Otherwise the alternator may be damaged

Bad. The ground cable should be connected last and disconnected first.

When starting the engine with external power, turn the engine control switch

Go to the "OFF" position. Before connecting the jumper start cable,

All electrical accessories are closed.

3. While the glow plug indicator is on, turn the engine start switch

Go to the START position and drag the engine.

Before connecting the jump start cable to the engine being started, make sure that the main

The power switch is in the OFF position.

4. When the engine starts, release the engine start switch.

5. Slowly move the throttle lever to the low idle position to allow the engine

Idle operation. See Operation and Maintenance Manual, "Startup

Behind the Engine "theme.

1. Turn the start switch to the OFF position. Close all posts

Motivation attachment.

NOTE: If the glow plug light is on briefly for 2 to 3 seconds or the glow plug

The light is off, indicating a fault in the cold start system. Do not use

Ether or other starting fluid to start the engine.

2. Connect one positive terminal of the jump start cable to the discharged storage battery

Positive terminal of the cell. Connect the other positive terminal of the starting cable

The terminal is connected to the positive cable terminal of the power supply.

6. If the engine does not start, release the engine start switch to

Cool the starter motor. Then, repeat steps 2 through 5.

3. Connect one negative terminal of the jump start cable to the negative terminal of the power supply

Cable terminal. Connect the other end of the jump start cable

To the engine cylinder block or chassis ground point. This step helps

Prevent potential sparks from igniting flammable gases from some batteries.

7. Turn the engine start switch key to OFF (OFF)

Position to stop the engine.

4. Start the engine.

5. Immediately after starting a stalled engine, turn it off in the reverse order

Open the jumper start cable.

After jump start, the alternator may not discharge severely discharged electricity

The battery is fully recharged. After the engine is stopped, the battery must be replaced or

Charge the battery to the correct voltage. Many batteries are considered not

It can be used again, but it can still be recharged. See Operation

Operation and Maintenance Manual, "Battery-Replace" and "Testing and Adjusting Hands"

Booklet, "Battery-Testing".

This document is printed from SPI². Not for RESALE


30

Operation part

Engine start

SCBU8311-03

i03018716

After starting the engine

Note: Warm-up time at temperatures from 0 to 60 ° C (32 to 140 ° F)

It takes about 3 minutes. At temperatures below 0 ° C (32 ° F), possible

Need extra warm up time.

When the engine is warming up and idling, observe the following conditions:

• Before applying load to the engine,

When the machine is under no load), check for liquid or gas.

leakage. This is not possible in some applications.

• Run the engine at low idle speed until all systems reach operating temperature.

During warm-up, check all gauges.

Note: When the engine is running, the instrument reading should be observed, and the number is often recorded.

according to. Comparing long-term data will help determine the normality of each meter

reading. Comparing long-term data will also help identify abnormal operations

Developments. The cause of the significant change in reading should be identified.

This document is printed from SPI². Not for RESALE


SCBU8311-03

31

Operation part

Engine running

Engine running

i03018699

Fuel economy guidelines

i02856952

Engine running

Engine efficiency affects fuel economy. Perkins design and

The manufacturing process brings the highest fuel efficiency to all types of applications. follow

Recommended procedure for best performance over the life of the engine.

Proper operation and maintenance is to obtain the maximum service life and

Economic key factors. If you follow the Operation and Maintenance Manual

In the instructions to do, the cost of use can be minimized and the service life

Can be maximized.

• Avoid fuel spills.

The fuel expands when heated. Fuel may overflow from the fuel tank. an examination

Check for leaks in the fuel lines. Perform required repairs to the fuel lines.

When the operating temperature is reached, the engine can run at rated speed.

The engine reaches normal operation at low engine speeds and low power requirements

The operating temperature will be faster. This program is more effective than engine idling

effective. The engine should reach operating temperature within minutes.

• Know the characteristics of different fuels. Use only recommended fuel.

• Avoid unnecessary idling.

When the engine is running, the instrument readings should be observed and data often recorded.

Comparing long-term data will help determine normal readings for each meter.

Comparing long-term data will also help identify abnormal operating conditions.

Exhibition change. The cause of the significant change in reading should be identified.

Stop the engine instead of prolonged idle.

• Observe the air filter maintenance indicator frequently. Keep air filtration

Filter element is clean.

• Maintenance of electrical systems

A bad accumulator can overwork the alternator. This

Will consume extra power and fuel.

• Make sure the drive belt is adjusted correctly. The drive belt should be in good condition.

• Make sure all hoses are tightly connected. The connection should not leak.

• Make sure that the driven equipment is in good condition.

• Cold engines consume extra fuel. Use as much water as possible from the water jacket

System and exhaust system heat. Keep cooling system components clean and

Well maintained. Never operate without a water temperature regulator

engine. All of these items will help maintain operating temperatures.

This document is printed from SPI². Not for RESALE


32

Operation part

Engine shutdown

SCBU8311-03

Engine shutdown

i03826057

After the engine is stopped

i03018704

Engine shutdown

Note: Before checking the engine oil, stop the engine for at least 10

Minutes to allow sufficient time for the engine oil to return to the sump.

• Check engine crankcase oil level. Keep the oil level in the engine

"MIN" mark and "MAX" of oil dipstick

Between tags.

note

Stopping the engine immediately while the engine is running with load will lead to

Overheating and accelerated wear of engine components.

• Make minor adjustments if necessary. Repair every leak and

Tighten any loose bolts.

Avoid accelerating operations before shutting down the engine.

To avoid hot engine shutdown, increase the turbocharger shaft and bearing

life.

• If the engine is equipped with an hour meter, record its reading. Press this

Perform maintenance as described in the Operation and Maintenance Manual, “Maintenance Interval Schedule”.

Note: The control system will be different depending on the application. Ensure understanding shutdown

program. Use the following general guidelines to stop the engine.

• Fill the fuel tank to prevent moisture from accumulating in the tank. Fuel tank is not

Go overfilled.

1. Remove the load from the engine. Reduce engine speed to low idle

speed. Allow the engine to idle for 5 minutes to cool the engine.

note

Under the heading Capacities and recommendations in this Operation and Maintenance Manual

Use only recommended antifreeze / coolant mixtures. Don't do it

Causes engine damage.

2. After the cooling cycle specified by the shutdown system on the engine,

Shut down the engine and turn the ignition key switch to the OFF position

彩乐乐网. If necessary, refer to the original equipment manufacturer (OEM)

Instructions provided.

• Allow the engine to cool down. Check the coolant level.

• If freezing temperatures are expected, check the antifreeze protection of the coolant

is it right or not. The cooling system must be protected from the expected

Freezes at the lowest external temperature. If necessary, add normal

Coolant / water mixture.

i03018541

Emergency stop

• Perform all necessary periodic maintenance on all driven equipment. This guarantee

The support is described in the OEM's instruction manual.

note

The emergency stop control is for emergency use only. Never put an emergency stop

The mechanical or control device is used for the normal shutdown process.

The OEM may have assembled an emergency stop button. More about emergency stop

See the OEM information for the machine button.

Ensure that all external systems that support engine operation after engine shutdown

Some parts are safe and reliable.

This document is printed from SPI². Not for RESALE


SCBU8311-03

33

Operation part

Cold weather operation

Cold weather operation

• Fill the fuel tank at the end of each shift.

• Check air filters and air inlets daily. When running on snowy days

Check the air inlets more frequently.

i03018686

Cold weather operation

• Make sure the glow plug is working properly. See Testing and Adjusting Hands

Booklet, "Glow Plug-Test".

Perkins diesel engines can operate effectively in cold weather. In the cold

Starting and running a diesel engine in weather depends on the following:

Alcohol or starting fluid can cause personal injury or property damage.

• Type of fuel used

• Viscosity of engine oil

• Glow plug work

Alcohol or starter fluid is highly flammable and toxic if stored without

It may cause personal injury or property damage.

• Optional cold start aid

• Battery status

Do not use a spray starting aid like ether. Otherwise

Can cause explosion and personal injury.

• Information on jump start using cables in cold weather,

See Operation and Maintenance Manual, "Using Jump Start Cables

Startup ".

This section will introduce the following information:

• Potential problems caused by operation in cold weather

• To minimize ambient air temperature between 0 and −40 ° C

(32 to −40 ° F)

Recommended steps.

Engine oil viscosity

It is necessary to use engine oil with the correct viscosity.

The viscosity of the oil affects the value of the turning torque. See this Maintenance and

Maintenance Manual, "Oil Recommendations" for recommended oil viscosity.

The operation and maintenance of the engine at freezing temperatures is very complicated. this is

Caused by:

Recommended coolant

• Weather conditions

The coolant should provide the cooling system with the lowest expected outside temperature

protection of. Refer to this Service and Maintenance Manual, "Fluid Recommendations"

Learn about recommended coolant mixtures.

• Engine application type

The suggestion from your Perkins agent or Perkins distributor is

Based on past proven practices. The information contained in this section is cold

Provide guidance on weather operations.

In cold weather, check the glycol concentration of the coolant frequently.

No, to ensure adequate anti-freeze protection.

Cold weather operation recommendations

Engine block heater

• If the engine can start, run the engine until it reaches

81 ° C (177.8 ° F) minimum operating temperature. Reach working temperature

It will help prevent the intake and exhaust valves from sticking.

The engine block heater (if equipped) heats the

Engine cylinder liner water. The heater provides the following functions:

• Improve starting performance.

• Reduce warm-up time.

• The engine's cooling system and lubrication system will not immediately follow the shutdown

Dissipates all heat. This means the engine is down for a while

After that, it still has the ability to start easily.

Once the engine is stopped, the electric block heater can be energized to work. Have

Typical block heaters have a typical electrical power of 1250/1500 W units.

Consult your Perkins agent or your Perkins distributor for

For more information.

• Before the cold weather arrives, raise the fuel to achieve the correct technical parameters.

Motive lubricant.

• Check all rubber parts (hose, fan drive belt, etc.).

• Check all electrical wiring and connections for any wear and insulation

Damage phenomenon.

• Keep all batteries fully charged and warm.

This document is printed from SPI². Not for RESALE


34

Operation part

Cold weather operation

SCBU8311-03

Engine idling

Water temperature regulator and insulated heater pipe

The engine is equipped with a water temperature regulator. When engine coolant is low

At the correct operating temperature, the liner water is circulated through the engine block

Into the engine cylinder head. The coolant then passes through the coolant temperature

The internal channel of the regulator returns to the cylinder. It ensures that the coolant

Flows through the engine in cold operating conditions. Water in the engine cylinder liner has reached

When the correct minimum operating temperature is reached, the water temperature regulator is turned on. when

When the temperature of the cylinder liner water coolant exceeds the minimum working temperature, the water temperature is adjusted

The radiator will open even more so that more coolant flows through the radiator to dissipate

Excessive heat.

When the engine is idling after starting in cold weather, turn the engine

The speed is increased to 1000 to 1200 rpm. This will make the launch faster

Warm up. If a manual throttle is installed, use this control

Keeps engine speed at elevated low idle speed for extended periods

Operation is easier. The engine should not be increased by "high speed operation"

Quick warm-up process.

Apply light load (additional load) during engine idling

It will help to keep the minimum operating temperature. Minimum working temperature is

82 ° C (179.6 ° F).

The progressive opening of the water temperature regulator can gradually close the cylinder block and the cylinder head.

Between sideways. This ensures maximum coolant flow to the radiator

For best heat dissipation.

Coolant temperature rise recommendations

Allows the engine to cool below normal operating temperature due to non-operation

temperature. This operation should be performed before the engine returns to full operation

get on. During operation in very cold weather conditions, the engine

Short-term operation will cause damage to the engine valve mechanism. If launched

The machine was shut down many times after it was started, but it was not run to completely

Warm up, the above will happen.

Note: Perkins discourages the use of all airflow limiting devices, such as cooling

Device curtain. Restriction of airflow can have the following consequences: High exhaust temperature,

Power loss, fan overuse and reduced fuel economy.

Cab heaters are useful in extremely cold weather conditions. From

The supply pipe of the motive and the return pipe from the cab should be insulated to reduce

Low external heat loss.

When the engine is operating below normal operating temperature,

Oil and engine oil cannot burn completely. These fuels and oils cause the valves

Soft carbon deposits formed on the rod. Generally speaking, these carbon deposits will not cause problems.

Problems, they can be burned when the engine is at normal operating temperature.

Insulation of air intake and engine room

When frequently encountered weather conditions where the outside temperature is below −18 ° C (−0 ° F)

In the case of an engine, the air filter inlet may be provided in the engine room.

Air filters located in the engine compartment can also be minimized

Snow gets into the air cleaner. At the same time, the heat isolated from the engine helps

For heating the intake air.

Stopped many times after the engine was started without running

In order to completely warm up, these carbon deposits will accumulate. This will cause

The following questions:

• Valves do not work freely

By insulating the engine compartment,

The heat is retained.

• Valve issue.

• The putter may bend.

i03018726

Fuel and cold weather effects

• Other damage to valve train components is possible.

For this reason, after starting, the engine must be run until

Coolant temperature reaches at least 71 ° C (160 ° F). So that

Carbon deposits on the valve stems are kept to a minimum and enable valve and valve components to

Enough to work.

Note: Use only fuel grades recommended by Perkins. See this Operation

And Maintenance Manual, "Fluid Recommendations".

In addition, the engine must be warmed up completely so that other

The components are in better condition, and the service life of the engine will usually be

Will be extended. Lubrication will be improved. Acids and sludge in motor oil will

Will decrease. This will cause engine bearings, piston rings and other parts

Has a longer life. However, unnecessary idle time will be

Limited to ten minutes to reduce wear and unnecessary fuel consumption.

This series of engines can use the following fuels.

• Group 1

• Group 2

• Group 3

• Special fuel

In this series of engines, Perkins only prefers to use Group 1 and

2 sets of fuel.

Group 1 fuel is the fuel of choice for Perkins. 1st

Fuel can maximize engine life and performance. With the first

Compared to Group 2 fuel, Group 1 fuel has less availability. Usually, in

Group 1 fuel cannot be used in cold winter conditions.

This document is printed from SPI². Not for RESALE


SCBU8311-03

35

Operation part

Cold weather operation

NOTE: Group 2 fuel must have a maximum wear mark of 650 microns

(HFRR to ISO 12156-1).

i03018697

Fuel related components in cold weather

In the terms of the warranty, Group 2 fuel is considered acceptable. This group

Fuel may reduce engine life, engine maximum

Power and fuel efficiency.

Fuel tank

When using Group 2 diesel, the following components provide a maximum

Ways to reduce problems in cold weather:

Condensation may form on an underfilled fuel tank. Before you run launch

Fill the fuel tank after the aircraft.

• Glow plug (if equipped)

The fuel tank should include facilities for discharging water and sediment from the bottom.

Some fuel tanks use a high-end pipe end in the fuel tank

Deposits of water and sediment.

• Engine coolant heater, may be an OEM option.

• Fuel heater, may be an OEM option.

• Fuel pipe insulation, may be an OEM option.

Some fuel tanks use a fuel supply pipe that takes fuel directly from the bottom of the fuel tank.

If the engine is equipped with such a system, regularly maintain the fuel system filter

Cleaners are important.

There are three main differences between Group 1 fuels and Group 2 fuels. versus

Compared to Group 2 fuel, Group 1 fuel has the following different characteristics.

Drain water and sediment from the fuel storage tank under the following conditions: Weekly,

When changing the oil and when filling the fuel tank. This will help prevent water

And sediment is pumped from the storage tank into the engine fuel tank.

• Low cloud point

• Low pour point

Fuel Filter

• Higher energy per unit capacity fuel

There may be a primary fuel filter installed in the fuel tank and engine fuel

Between imports. After replacing the fuel filter, pump the fuel system to

This removes air bubbles from the fuel system. More about Pumped Fuel System

For information, please refer to the maintenance section of the Operation and Maintenance Manual.

Note: Group 3 fuel will reduce engine life. Use number 3

Group fuel is not covered by Perkins' warranty.

Group 3 fuel includes low temperature fuel and aviation kerosene.

Special fuels include biofuels.

The micron level and position of the primary fuel filter during cold weather operation

When the main. Primary fuel filters and fuel lines are the most common cold states

Fuel affected components.

The cloud point is the temperature at which paraffin crystals begin to form in the fuel. These crystals

Body can cause the fuel filter to become clogged.

Fuel heater

The pour point is the temperature at which the diesel will thicken. Diesel is flowing through the fuel pipe,

Resistance increases at the fuel filter and fuel pump.

NOTE: OEMs may be equipped with fuel heaters. If this is the case

If so, the fuel heater should be disconnected in warm weather to prevent fuel

heat. If the type of fuel heater uses a heat exchanger, the OEM should

Install a bypass device for use in warm weather. Ensure warm days

The under-gas bypass facility works normally to prevent overheating of the fuel.

Keep these values in mind when buying diesel. Considering engine applications

Ambient temperature. Refueling works well under certain climatic conditions

Motivation if moved to different climatic conditions

otherwise. Temperature changes can cause problems.

For more information on fuel heaters (if equipped), see

Read the OEM information.

Before troubleshooting and troubleshooting of low power or poor performance in winter,

First check whether the fuel has waxed out.

At temperatures below 0 ° C (32 ° F), the engine may require

Use low temperature fuel. These fuels limit fuel in low temperature conditions

Generation of wax.

For more information on operation in cold weather conditions,

Operation and Maintenance Manual, "Operating in cold climates and fuel related

component".

This document is printed from SPI². Not for RESALE


36

Maintenance section

Filling capacity

SCBU8311-03

Maintenance section

Filling capacity

403D-11 engine

Table 13

403D-11 engine

Filling capacity

Cabin or system

lowest

highest

i03334302

4.4 L

(4.6494

qt)

3.4 L

(3.6 qt)

Filling capacity

Crankcase oil sump

(1)

Total lubrication system capacity

(2)

(1) These values are approximate capacities of the crankcase sump, including factory-installed

Lubrication system

Capacity of standard oil filter. Engines equipped with auxiliary oil filters will require

Ask for extra oil. For the capacity of the auxiliary oil filter, see the original

Technical parameters of the original equipment manufacturer.

Engine crankcase fill capacity reflects approximate crankcase capacity

Or the sum of the oil pan and the capacity of the standard oil filter. Auxiliary oil filter

The cleaner requires additional oil. About the capacity of the auxiliary oil filter

For size, refer to the technical specifications of the original equipment manufacturer. About Run

For more information on lubricant technical parameters, refer to Operation and Maintenance Manual

Booklet, "Maintenance Section".

(2) The total capacity of the lubrication system is equal to the capacity of the crankcase oil sump and the factory installed oil filter

The sum of the capacity of the cleaner and other filters installed in the lubrication system. Fill in this line

The total capacity of the lubrication system.

403D-15 and 403D-15T engines

Table 14

402D-05 engine

403D-15 and 403D-15T engines

Filling capacity

Table 11

Cabin or system

lowest

highest

402D-05 engine

Filling capacity

4.5 L

(4.8 qt)

6 L

(6.3 qt)

Crankcase oil sump

(1)

Cabin or system

lowest

highest

Total lubrication system capacity

(2)

1.61 L

(1.7 qt)

2.01 L

(2.1 qt)

Crankcase oil sump

(1)

(1) These values are approximate capacities of the crankcase sump, including factory-installed

Capacity of standard oil filter. Engines equipped with auxiliary oil filters will require

Ask for extra oil. For the capacity of the auxiliary oil filter, see the original

Technical parameters of the original equipment manufacturer.

Total lubrication system capacity

(2)

(1) These values are approximate capacities of the crankcase sump, including factory-installed

(2) The total capacity of the lubrication system is equal to the capacity of the crankcase oil sump and the factory installed oil filter

The sum of the capacity of the cleaner and other filters installed in the lubrication system. Fill in this line

The total capacity of the lubrication system.

Capacity of standard oil filter. Engines equipped with auxiliary oil filters will require

Ask for extra oil. For the capacity of the auxiliary oil filter, see the original

Technical parameters of the original equipment manufacturer.

(2) The total capacity of the lubrication system is equal to the capacity of the crankcase oil sump and the factory installed oil filter

The sum of the capacity of the cleaner and other filters installed in the lubrication system. Fill in this line

The total capacity of the lubrication system.

403D-17 engine

Table 15

403D-07 engine

403D-17 engine

Filling capacity

Table 12

Cabin or system

lowest

highest

403C-07 engine

Filling capacity

4.5 L

(4.8 qt)

6 L

(6.3 qt)

Crankcase oil sump

(1)

Cabin or system

lowest

highest

Total lubrication system capacity

(2)

2.35 L

(2.5 qt)

3.05 L

(3.2 qt)

Crankcase oil sump

(1)

(1) These values are approximate capacities of the crankcase sump, including factory-installed

Capacity of standard oil filter. Engines equipped with auxiliary oil filters will require

Ask for extra oil. For the capacity of the auxiliary oil filter, see the original

Technical parameters of the original equipment manufacturer.

Total lubrication system capacity

(2)

(1) These values are approximate capacities of the crankcase sump, including factory-installed

(2) The total capacity of the lubrication system is equal to the capacity of the crankcase oil sump and the factory installed oil filter

The sum of the capacity of the cleaner and other filters installed in the lubrication system. Fill in this line

The total capacity of the lubrication system.

Capacity of standard oil filter. Engines equipped with auxiliary oil filters will require

Ask for extra oil. For the capacity of the auxiliary oil filter, see the original

Technical parameters of the original equipment manufacturer.

(2) The total capacity of the lubrication system is equal to the capacity of the crankcase oil sump and the factory installed oil filter

The sum of the capacity of the cleaner and other filters installed in the lubrication system. Fill in this line

The total capacity of the lubrication system.

This document is printed from SPI². Not for RESALE

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