Perkins 402d 403d 404d Series Operation Maintenance Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:334
DOWNLOADABLE:YES
FILE TYPE:PDF
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DESCRIPTION:
Perkins 402d 403d 404d Series Operation Maintenance Manual
Foreword
Literature Information
This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literature holder or literature storage area. Read, study and keep it with the literature and engine information. English is the primary language for all Perkins publications. The English used facilitates translation and consistency. Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Perkins dealer or your Perkins distributor for the latest available information.
Safety
This safety section lists basic safety precautions. In addition, this section identies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.
Operation
Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efciently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities. The operation section is a reference for operators. Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information.
Maintenance
Maintenance Intervals Perform maintenance on items at multiples of the original requirement. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of the engine’s permanent record. Your authorized Perkins dealer or your Perkins distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment.
- The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance intervals. 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 Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule.
- Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specied in the Maintenance Interval Schedule may be necessary.
- The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.
TABLE OF CONTENTS:
Perkins 402d 403d 404d Series Operation Maintenance Manual
Foreword 4
Safety Section
Safety Messages 5
General Hazard Information 7
Burn Prevention 8
Fire Prevention and Explosion Prevention 8
Crushing Prevention and Cutting Prevention 10
Before Starting Engine 11
Engine Starting 11
Engine Stopping 11
Electrical System 12
Product Information Section
Model Views 13
Product Identication Information 23
Operation Section
Lifting and Storage 25
Gauges and Indicators 28
Features and Controls 29
Engine Starting 30
Engine Operation 33
Engine Stopping 34
Cold Weather Operation 35
Maintenance Section
Rell Capacities 39
Maintenance Interval Schedule 54
Warranty Section
Warranty Information 85
Index Section
Index 86
INDEX DETAILS:
A
After Starting Engine 32
After Stopping Engine 34
Alternator – Inspect 55
Alternator and Fan Belts – Inspect/Adjust 55
Adjustment 55
Inspection 55
Alternator and Fan Belts – Replace 56
B
Battery – Replace 56
Battery Electrolyte Level – Check 57
Battery or Battery Cable – Disconnect 57
Before Starting Engine 11, 30
Burn Prevention 8
Batteries 8
Coolant 8
Oils 8
C
Cold Weather Operation 35
Hints for Cold Weather Operation 35
Idling the Engine 36
Recommendations for Coolant Warm Up 36
Recommendations for the Coolant 35
Viscosity of the Engine Lubrication Oil 35
Cooling System Coolant (Commercial Heavy-Duty) –
Change 58
Drain 58
Fill 59
Flush 58
Cooling System Coolant (ELC) – Change 59
Drain 60
Fill 60
Flush 60
Cooling System Coolant Extender (ELC) – Add 61
Cooling System Coolant Level – Check 61
Engines With a Coolant Recovery Tank 61
Engines Without a Coolant Recovery Tank 62
Cooling System Supplemental Coolant Additive
(SCA) – Test/Add 62
Add the SCA, If Necessary 62
Test for SCA Concentration 62
Crushing Prevention and Cutting Prevention 10
D
Driven Equipment – Check 63
E
Electrical System 12
Grounding Practices 12
Emergency Stopping 34
Emissions Certication Film 23
Emissions Warranty Information 85
Engine – Clean 63
Engine Air Cleaner Element (Dual Element) –
Clean/Replace 64
Cleaning the Primary Air Cleaner Elements 65
Servicing the Air Cleaner Elements 64
Engine Air Cleaner Element (Single Element) –
Inspect/Replace 66
Engine Air Cleaner Service Indicator – Inspect 66
Test the Service Indicator 67
Engine Air Precleaner – Check/Clean 67
Engine Crankcase Breather – Replace 67
Engine Description 16
Engine Specications 17
Engine Identication 23
Engine Lifting 25
Engine Mounts – Inspect 68
Engine Oil and Filter – Change 69
Drain the Engine Oil 69
Fill the Engine Crankcase 70
Replace the Oil Filter 69
Engine Oil Level – Check 68
Engine Operation 33
Engine Starting 11, 30
Engine Stopping 11, 34
Engine Storage 25
Cooling System 26
Exhaust System 27
General Items 27
Induction System 26
Lubrication System 25
Engine Valve Lash – Inspect/Adjust 70
F
Features and Controls 29
Fire Prevention and Explosion Prevention 8
Fire Extinguisher 10
Lines, Tubes and Hoses 10
Fluid Recommendations 41
Cooling System Specications 48
ELC Cooling System Maintenance 50
Engine Oil 42
Fuel Specications 45
General Lubricant Information 41
SEBU8311 87
Index Section
Foreword 4
California Proposition 65 Warning 4
Literature Information 4
Maintenance 4
Maintenance Intervals 4
Operation 4
Overhaul 4
Safety 4
Fuel and the Effect from Cold Weather 37
Fuel Conservation Practices 33
Fuel Injector – Test/Change 71
Identication of a suspect Fuel Injector 71
Fuel Related Components in Cold Weather 38
Fuel Filters 38
Fuel Heaters 38
Fuel Tanks 38
Fuel Shutoff 29
Fuel System – Prime 72
Fuel lters 72
Primary lter 72
Priming the system 73
Fuel System Filter – Replace 76
Fuel Filter with Canister 76
Fuel Filter with Element 77
Fuel Filter with Priming Pump 77
Fuel System Primary Filter/Water Separator –
Drain 78
Fuel Tank Water and Sediment – Drain 79
Drain the Water and the Sediment 79
Fuel Storage Tanks 79
Fuel Tank 79
G
Gauges and Indicators 28
General Hazard Information 7
Containing Fluid Spillage 8
Fluid Penetration 7
Pressure Air and Water 7
H
Hoses and Clamps – Inspect/Replace 79
Replace the Hoses and the Clamps 80
I
Important Safety Information 2
L
Lifting and Storage 25
M
Maintenance Interval Schedule 54
Maintenance Section 39
Model View Illustrations 13
Model Views 13
O
Operation Section 25
P
Product Identication Information 23
Product Information Section 13
R
Radiator – Clean 80
Reference Numbers 23
Record for Reference 23
Rell Capacities 39
Cooling System 40
Lubrication System 39
S
Safety Messages 5
(A) Universal Warning 5
Safety Section 5
Serial Number Plate 23
Severe Service Application – Check 81
Environmental Factors 82
Incorrect Maintenance Procedures 82
Incorrect Operating Procedures 82
Starting Motor – Inspect 82
Starting the Engine 30
Starting with Jump Start Cables 31
Stopping the Engine 34
T
Table of Contents 3
Turbocharger – Inspect (If Equipped) 82
Inspecting 83
Removal and Installation 82
W
Walk-Around Inspection 83
Inspect the Engine for Leaks and for Loose
Connections 83
Warranty Information 85
Warranty Section 85
Water Pump – Inspect 84
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
Dylan Miller –
would use again, thanks