Operation and Maintenance Manual - Diesel …

1 SEBU8311-01 April 2008 Operation andMaintenanceManual402D-403D-404D Industrial EngineGG(Engine)GH(Engine)GJ(Engine)GK(E ngine)GL(Engine)GM(Engine)GN(Engine)GP(E ngine)GQ(Engine)GS(Engine)This document has been printed from SPI . Not for ResaleImportant Safety InformationMost accidents that involve product Operation , Maintenance and repair are caused by failure toobserve basic safety rules or precautions. An accident can often be avoided by recognizing potentiallyhazardous situations before an accident occurs. A person must be alert to potential hazards. Thisperson should also have the necessary training, skills and tools to perform these functions Operation , lubrication, Maintenance or repair of this product can be dangerous andcould result in injury or not operate or perform any lubrication, Maintenance or repair on this product, until you haveread and understood the Operation , lubrication, Maintenance and repair precautions and warnings are provided in this Manual and on the product.

2 If these hazardwarnings are not heeded, bodily injury or death could occur to you or to other hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as DANGER , WARNING or CAUTION . The Safety Alert WARNING label is shown meaning of this safety alert symbol is as follows:Attention! Become Alert! Your Safety is message that appears under the warning explains the hazard and can be either written orpictorially that may cause product damage are identified by NOTICE labels on the product and inthis cannot anticipate every possible circumstance that might involve a potential hazard.

3 Thewarnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,work method or operating technique that is not specifically recommended by Perkins is used,you must satisfy yourself that it is safe for you and for others. You should also ensure that theproduct will not be damaged or be made unsafe by the Operation , lubrication, Maintenance orrepair procedures that you information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time.

4 These changes canaffect the service that is given to the product. Obtain the complete and most current information beforeyou start any job. Perkins dealers or Perkins distributors have the most current information replacement parts are required for thisproduct Perkins recommends using Perkins replacement to heed this warning can lead to prema-ture failures, product damage, personal injury document has been printed from SPI . Not for ResaleSEBU8311-013 Table of ContentsTable of ContentsForeword .. 4 Safety SectionSafety Messages .. 5 General Hazard Information .. 7 Burn Prevention .. 8 Fire Prevention and Explosion Prevention.

5 8 Crushing Prevention and Cutting Prevention .. 10 Before Starting Engine .. 11 Engine Starting .. 11 Engine Stopping .. 11 Electrical System .. 12 Product Information SectionModel Views .. 13 Product Identification Information .. 23 Operation SectionLifting 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 SectionRefill Capacities .. 39 Maintenance Interval Schedule .. 58 Warranty SectionWarranty Information .. 89 Index SectionIndex .. 90 This document has been printed from SPI . Not for Resale4 SEBU8311-01 ForewordForewordLiterature InformationThis Manual contains safety, Operation instructions ,lubrication and Maintenance information.

6 Thismanual should be stored in or near the engine areain a literature holder or literature storage area. Read,study and keep it with the literature and is the primary language for all Perkinspublications. The English used facilitates translationand photographs or illustrations in this manualshow detailsor attachments that may be differentfrom your engine. Guards and covers may havebeen removed for illustrative purposes. Continuingimprovement and advancement of product designmay have caused changes to your engine which arenot included in this Manual . Whenever a questionarises regarding your engine, or this Manual , pleaseconsult with your Perkins dealer or your Perkinsdistributor for the latest available safety section lists basic safety addition, this section identifies hazardous,warning situations.

7 Read and understand the basicprecautions listed in the safety section beforeoperating or performing lubrication, Maintenance andrepair onthis techniques outlined in this Manual arebasic. They assist with developing the skills andtechniques required to operate the engine moreefficiently and economically. Skill and techniquesdevelopas the operator gains knowledge of theengine and its Operation section is a reference for and illustrations guide the operatorthrough procedures of inspecting, starting, operatingand stopping the engine. This section also includes adiscussion of electronic diagnostic Maintenance section is a guide to engine illustrated, step-by-step instructions are groupedby service hours and/or calendar time maintenanceintervals.

8 Items in the Maintenance schedule arereferenced to detailed instructions that service should be performed at theappropriate intervals as indicated in the MaintenanceInterval Schedule. The actual operating environmentof the engine also governs the Maintenance IntervalSchedule. Therefore, under extremely severe,dusty, wet or freezing cold operating conditions,more frequent lubrication and Maintenance than isspecified in the Maintenance Interval Schedule maybe Maintenance schedule items are organized fora preventive Maintenance management program. Ifthe preventive Maintenance program is followed, aperiodic tune-up is not required.

9 The implementationof a preventive Maintenance management programshould minimize operating costs through costavoidances resulting from reductions in unscheduleddowntime and IntervalsPerform Maintenance on items at multiples ofthe original requirement. We recommend that themaintenance schedules be reproduced and displayednear the engine as a convenient reminder. We alsorecommend that a Maintenance record be maintainedas part ofthe engine s permanent authorized Perkins dealer or your Perkinsdistributor can assist you in adjusting yourmaintenance schedule to meet the needs of youroperating engine overhaul details are not covered inthe Operation and Maintenance Manual exceptfor the interval and the Maintenance items in thatinterval.

10 Major repairs should only be carried out byPerkins authorized personnel. Your Perkins dealeror your Perkins distributor offers a variety of optionsregarding overhaul programs. If you experiencea major engine failure, there are also numerousafter failure overhaul options available. Consult withyour Perkins dealer or your Perkins distributor forinformation regarding these Proposition 65 WarningDiesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birthdefects, and other reproductive harm. Batteryposts, terminals and related accessories contain leadand lead hands after document has been printed from SPI.