Perkins 402d 403d 404d Engine Systems Operation Testing Manual
Perkins 400 Series 402d, 403d, 404d Industrial Engine Systems, Operation, Testing And Adjusting Manual (gg, Gh, Gj, Gk, Gl, Gm, Gn, Gp, Gq, Gs)
General Maintenance
Troubleshooting
Engine Service / Repair
Transmission Service / Repair
Brake System
Wiring Diagram
Electrical System
Suspension
Periodic Lubrication
Steering
Cooling System
Fuel Injection
Fuel System
Emission System
Heater/ Air Conditional
Engine Control System
Chassis / Body
Restraint System
Interior
Differential / Drive
Axle
Perkins 402d 403d 404d Engine Systems Operation Testing Manual
Operating Manual Contents:
SAFETY HINT
Before operating the machine
During operating the machine
During maintenance
Parking
SPECIFICATIONS
Major components
Specifications
Working range
Weight
Lifting capacities
Bucket selection guide
Undercarriage
Specification for major components
Recommended oils
CONTROL DEVICE
Cab device
Cluster
Switches
Levers and pedals
Air conditioner and heater
OPERATION
Suggestion for new machine
Check before starting the engine
Starting and stop the engine
Operation of the working device
Traveling of the machine
Efficient working method
Operation in the special work sites
Normal operation of excavator
Attachment lowering Pattern
Storage
RCV lever operating pattern
TRANSPORTATION
Preparation for transportation
Dimension and weight
Loading the machine
Fixing the machine
Loading and unloading by crane
MAINTENANCE
Instructions
Tightening torque
Specification of fuel, coolant and lubricants
Maintenance check list
Maintenance chart
Service instruction
Electrical system
Air conditioner and heater
To perform basic service on a Perkins 400 Series engine, you can follow these general steps:
1. Review the manual: Obtain the engine’s service manual specific to your model of the Perkins 400 Series. The manual provides detailed instructions and specifications for servicing and maintaining the engine. It will be a valuable resource throughout the process.
2. Safety precautions: Before starting any service or maintenance work, ensure that the engine is shut off, and take necessary safety precautions such as wearing protective gloves and eyewear.
3. Check fluid levels: Verify the levels of engine oil, coolant, and fuel. Top up or replace fluids as needed, following the instructions in the manual. Ensure you use the recommended fluids and adhere to the specified levels.
4. Change the engine oil and filter: Locate the oil drain plug and remove it to drain the old oil into a suitable container. Once drained completely, replace the drain plug and install a new oil filter. Refill the engine with the recommended oil, considering the correct capacity mentioned in the manual.
5. Replace the fuel filter: Locate the fuel filter housing and carefully remove the old filter. Clean the housing, lubricate the rubber gasket of the new filter with a bit of clean fuel, and install it securely. Ensure the filter is properly tightened but avoid overtightening.
6. Inspect and clean the air filter: Remove the air filter cover and inspect the air filter element. If it appears dirty or clogged, replace it with a new one. If it is reusable, clean it according to the instructions in the manual. Ensure the air filter is properly seated and the cover is securely closed after cleaning or replacement.
7. Check and tighten connections: Inspect all electrical and hose connections, ensuring they are secure and in good condition. Tighten any loose connections as necessary.
8. Inspect belts and pulleys: Check the condition and tension of the engine belts. Replace any worn-out or damaged belts, and adjust the tension according to the specifications in the manual. Examine the pulleys for signs of wear or misalignment and address any issues accordingly.
9. Check battery condition: Inspect the battery terminals for corrosion or loose connections. Clean the terminals if necessary and ensure they are tightened securely. Test the battery’s voltage using a multimeter to ensure it is within the acceptable range.
10. Perform a general visual inspection: Examine the engine for any signs of leaks, loose or damaged components, or abnormal wear. Address any issues identified or consult a professional technician for assistance.
Remember, these are general guidelines, and the specific steps may vary based on the model and configuration of your Perkins 400 Series engine. Always refer to the service manual for accurate instructions and consult with a professional if you are unsure about any aspect of servicing your engine.