Perkins 415GM Instruction Manual

®
User’s Handbook
GB
Part No N39453
422GM
422TGM
4.4GM 4.4TGM
4.4TWGM &
4.4TW2GM
415GM
4.4TWGM & 4.4TW2GM
Radiator
4.4GM & 4.4TGM
Radiator

N39453 Title
Perkins
415GM
422GM
422TGM
4.4GM
4.4TGM
4.4TWGM
4.4TW2GM
4.4GM Radiator
4.4TGM Radiator
4.4TWGM Radiator
4.4TW2GM Radiator
User’s Handbook
Publication N39453, Issue 7.
© Proprietary information of Wimborne Marine Power Centre, all rights reserved.
The information is correct at the time of print.
Published in December 2013 by Wimborne Marine Power Centre, Wimborne, Dorset, England BH21 7PW
Tel: [phone] Fax: [phone] E -mail: [email protected] www.perkins.com/marine

Title N39453

N39453 Contents
1 General information .................................................................................1
Introduction...................................................................................................................1
How to care for your engine........................................................................................2
General safety precautions ........................................................................................11
Engine guarantee ........................................................................................................12
Engine identication ...................................................................................................12
Perkins companies......................................................................................................14
2 Engine views............................................................................................15
Introduction..................................................................................................................15
Location of engine parts - 415GM..............................................................................16
Front and right side view (A)...........................................................................16
Rear and left side view (B) - 415GM................................................................17
Location of engine parts for the - 422GM..................................................................18
Front and left side view (C) .............................................................................18
Rear and right side view (D) - 422GM .............................................................19
Location of engine parts for the - 422TGM ...............................................................20
Front and right side view (E) ...........................................................................20
Rear and right side view (F) - 422TGM ...........................................................21
Location of engine parts - 4.4GM...............................................................................22
Front and left side view (G) of the engine......................................................22
Rear and right side view (H) of the engine.....................................................23
Location of engine parts - 4.4TGM.............................................................................24
Front and right side view (I) of the engine .....................................................24
Rear and left side view (J) of the engine........................................................25
Location of engine parts - 4.4TWGM and 4.4TW2GM ..............................................26
Front and left side view (K) of the engine ......................................................26
Rear and right side view (L) of the engine .....................................................27
Location of engine parts - 4.4GM & 4.4TGM Radiator..............................................28
Front and left side view (M) of the engine......................................................28
Rear and right side view (N) of the engine.....................................................29
Location of engine parts - 4.4TWGM and 4.4TW2GM Radiator...............................30
Front and left side view (O) of the engine......................................................30
Rear and right side view (P) of the engine.....................................................31
3 Operation instructions............................................................................33
Models - 415GM, 422GM & 422TGM, how to start the engine .................................33
How to start a cold engine with the fuelled starting aid ..........................................33
How to start a warm engine........................................................................................33
How to stop the engine...............................................................................................34
Adjustment of the engine speed range .....................................................................34

Contents N39453
Running-in....................................................................................................................34
Angle of operation.......................................................................................................34
Models - 4.4GM, 4.4TGM, 4.4TWGM, 4.4TW2GM, 4.4GM rad, 4.4TGM rad,
4.4TWGM rad & 4.4TW2GM rad, control panel (optional)........................................35
Control module (optional)...........................................................................................37
Engine wiring harness (optional equipment)............................................................38
How to start the engine...............................................................................................41
How to stop the engine...............................................................................................42
Emergency procedures...............................................................................................43
4 Preventive maintenance, Models...........................................................45
Preventive maintenance periods - 415GM, 422TGM & 422TGM..............................45
Schedules, models - 415GM, 422GM & 422TGM ...........................................46
How to drain the coolant circuit......................................................................47
Engines tted with keel coolers......................................................................47
How to check the specic gravity of the coolant ..........................................48
How to drain the raw water system ................................................................49
How to check the impeller of the raw water pump........................................50
How to check the drive belt.............................................................................51
How to adjust the belt tension ........................................................................51
How to renew the element of the fuel lter ....................................................52
Fuel pre-lter ....................................................................................................52
Atomiser fault ...................................................................................................52
How to renew an atomiser...............................................................................53
How to eliminate air from the fuel system .....................................................54
How to renew the lubricating oil .....................................................................55
How to renew the canister of the lubricating oil lter ..................................56
How to renew the engine breather assembly ................................................57
How to renew the element of the air lter - 415GM and 422GM...................58
How to renew the element of the air lter - 422TGM.....................................59
How to set the valve tip clearances - 415GM.................................................60
How to set the valve tip clearances - 422GM and 422TGM ..........................61
Seacock strainer...............................................................................................62
Corrosion ..........................................................................................................62
Supplementary tools........................................................................................62
Preventive maintenance periods - 4.4GM, 4.4TGM, 4.4TWGM, 4.4TW2GM,
4.4GM rad, 4.4TGM rad, 4.4TWGM rad & 4.4TW2GM rad. .......................................63
Schedules - 4.4GM, 4.4TGM, 4.4TWGM, 4.4TW2GM......................................64
Schedules - 4.4GM rad, 4.4TGM rad, 4.4TWGM rad & 4.4TW2GM rad.........65
How to ll the coolant circuit - 4.4GM, 4.4TGM, 4.4TWGM, 4.4TW2GM..................66
How to ll the coolant circuit - 4.4GM rad, 4.4TGM rad, 4.4TWGM rad &
4.4TW2GM rad..............................................................................................................67
How to drain the coolant circuit - 4.4GM...................................................................68
How to drain the coolant circuit - 4.4TGM.................................................................69
How to drain the coolant circuit - 4.4TWGM & 4.4TW2GM ......................................70
How to drain the coolant circuit - 4.4GM & 4.4TGM rad...........................................71
How to drain the coolant circuit - 4.4TWGM & 4.4TW2GM rad................................72

N39453 Contents
Engines tted with keel coolers.................................................................................73
How to check the specic gravity of the coolant .....................................................73
How to drain the raw water system - 4.4GM & 4.4TGM............................................74
How to drain the raw water system - 4.4TWGM & 4.4TW2GM.................................75
How to check the impeller of the raw water pump - 4.4GM, 4.4TGM, 4.4TWGM &
4.4TW2GM ....................................................................................................................76
How to check the drive belt - 4.4GM, 4.4TGM, 4.4TWGM & 4.4TW2GM..................77
How to adjust the belt tension ...................................................................................77
How to check the drive belt - 4.4GM rad, 4.4TGM rad, 4.4TWGM rad &
4.4TW2GM rad..............................................................................................................78
How to adjust the belt tension ........................................................................78
How to renew the element of the fuel lter - 4.4GM, 4.4TGM, 4.4TWGM &
4.4TW2GM ....................................................................................................................79
Fuel pre-lter................................................................................................................79
How to renew the element of the fuel lter - 4.4GM rad, 4.4TGM rad,
4.4TWGM rad & 4.4TW2GM rad..................................................................................80
Fuel pre-lter (optional) ...................................................................................80
Atomiser maintenance................................................................................................81
Atomiser faults .................................................................................................81
How to remove and to t an atomiser .......................................................................82
How to t ......................................................................................................................83
How to eliminate air from the fuel system ................................................................84
How to renew the lubricating oil ................................................................................85
How to renew the canister of the lubricating oil lter..............................................86
Air lter.........................................................................................................................87
Restriction indicator ........................................................................................88
How to check the valve tip clearances...........................................................89
Supplementary tools........................................................................................90
Power take-off...................................................................................................90
5 Engine uids............................................................................................91
Fuel specication ........................................................................................................91
Lubricating oil specication.......................................................................................92
Coolant specication ..................................................................................................93
6 Fault diagnosis ........................................................................................95
Problems and possible causes..................................................................................95
List of possible causes...............................................................................................96
7 Engine preservation................................................................................97
Introduction..................................................................................................................97
Procedure models - 415GM, 422GM, 422TGM, 4.4GM, 4.4TGM, 4.4TWGM &
4.4TW2GM ....................................................................................................................97
How to add coolant to the raw water system for engine preservation purposes .98
Procedure models - 4.4GM rad, 4.4TGM rad, 4.4TWGM rad & 4.4TW2GM rad ......99

Contents N39453
8 Parts and service....................................................................................101
Introduction.................................................................................................................101
Service literature ........................................................................................................101
Training........................................................................................................................101
On-board spares kit....................................................................................................101
POWERPART recommended consumable products ..............................................101
9 General data............................................................................................103
415GM..........................................................................................................................103
422GM..........................................................................................................................104
422TGM........................................................................................................................105
4.4GM...........................................................................................................................106
4.4TGM.........................................................................................................................107
4.4TWGM .....................................................................................................................108
4.4TW2GM ...................................................................................................................109
4.4GM Radiator ........................................................................................................... 110
4.4TGM Radiator......................................................................................................... 111
4.4TWGM Radiator......................................................................................................112
4.4TW2GM Radiator....................................................................................................113

N39453 Chapter 1
Page 1
Introduction
These on-board generating sets and other auxiliary power units are the latest developments from the business
arrangement between Perkins Engines Ltd and Wimborne Marine Power Centre.
Wimborne Marine Power Centre are the managers of the Perkins marine business and all enquires should be
made to Wimborne Marine Power Centre; refer to the company address list.
Over sixty years of diesel production experience, together with the latest technology, have been applied to the
manufacture of your engine to give you reliable and economic power.
To ensure that you use the relevant information for your specic engine type, refer to “Engine identication”.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: This indicates that there is a possible danger to the engine.
Note: Is used where the information is important, but there is not a danger.
General information

Chapter 1 N39453
Page 2
How to care for your engine
Warning! Read the “Safety precautions” and remember them. They are given for your protection and must be
applied at all times.
Caution: Do not clean an engine while it runs. If cold cleaning uids are applied to a hot engine, certain
components on the engine may be damaged.
This handbook has been written to assist you to maintain and operate your engine correctly.
To obtain the best performance and the longest life from your engine, you must ensure that the maintenance
operations are done at the intervals indicated in “Preventive maintenance”. If the engine works in a very dusty
environment or other adverse conditions, certain maintenance intervals will have to be reduced. Renew the
lter canister and lubricating oil regularly in order to ensure that the inside of your engine remains clean.
Ensure that all adjustments and repairs are done by personnel who have had the correct training. Perkins
distributors have this type of personnel available. You can also obtain parts and service from your Perkins
distributor. If you do not know the address of your nearest distributor, enquire at Wimborne Marine Power
Centre,.
The “left side” and “right side” of the engine apply when the engine is seen from the ywheel end.

N39453 Chapter 1
Page 3

Chapter 1 N39453
Page 4

N39453 Chapter 1
Page 5

Chapter 1 N39453
Page 6

N39453 Chapter 1
Page 7

Chapter 1 N39453
Page 8

N39453 Chapter 1
Page 9

Chapter 1 N39453
Page 10

N39453 Chapter 1
Page 11
General safety precautions
These safety precautions are important. You must refer also to the local regulations in the country of use.
Some items only refer to specic applications.
• Only use these engines in the type of application for which they have been designed.
• Do not change the specication of the engine.
• Do not smoke when you put fuel in the tank.
• Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
• Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
• Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct
training; even then extreme care must be used to prevent injury).
• Do not make adjustments that you do not understand.
• Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
• Other persons must be kept at a safe distance while the engine, auxiliary equipment or boat is in
operation.
• Do not permit loose clothing or long hair near moving parts.
Keep away from moving parts during engine operation. Warning! Some moving parts cannot be seen clearly
while the engine runs.
• Do not operate the engine if a safety guard has been removed.
• Do not remove the ller cap or any component of the cooling system while the engine is hot and while the
coolant is under pressure, because dangerous hot coolant can be discharged.
• Do not use salt water or any other coolant which can cause corrosion in the closed circuit of the cooling
system.
• Do not allow sparks or re near the battery (especially when the battery is on charge) because the gases
from the electrolyte are highly ammable. The battery uid is dangerous to the skin and especially to the
eyes.
• Disconnect the battery terminals before a repair is made to the electrical system.
• Only one person must control the engine.
• Ensure that the engine is operated only from the control panel or from the operators position.
• If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
• Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons.
Protect your hands with gloves or a special solution to protect the skin.
• Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets of clothing.
• Discard used lubricating oil and coolant in accordance with local regulations to prevent contamination.
• Use extreme care if emergency repairs must be made at sea or in adverse conditions.
• The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or
with the eyes.
• Always close the seacock before the removal of any component of the raw water circuit.
• Always use a safety cage to protect the operator when a component is to be pressure tested in a container
of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to
be pressure tested.
• Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
• The latest marine engines have a cover tted to give some protection from the alternator fan and the drive
belt. Ensure that this cover is tted before the engine is started.
• Fit only genuine Perkins parts.

Chapter 1 N39453
Page 12
Engine guarantee
If a claim under guarantee is necessary, the boat owner should make a guarantee claim on the nearest Perkins
marine distributor or an approved dealer.
If it is difcult to nd a Perkins distributor or an approved dealer, consult the Service Department of Wimborne
Marine Power Centre, Wimborne.
The engine identication number is shown at two locations on the engine:
Models 415GM, 422GM and 422TGM: stamped on a plate (I1) at the front right side of the cylinder block
under the fuel injection pipes. The other is shown on a label (I2) tted to the top of the timing case.
Models 4.4GM, 4.4TGM, 4.4TWGM and 4.4TW2GM: stamped on a plate at the right side of the cylinder block
(J1) and shown on a label (K1) tted to the front of the timing case.
Models 4.4GM rad, 4.4TGM rad, 4.4TWGM rad and 4.4TW2GM rad: stamped on a plate at the right side of
the cylinder block (L1) and shown on a label (M1) tted to the front of the timing case.
An example of a 4.4TGM Radiator engine number is: RG30879U123456L.
The components of the engine number are as follows:
RG30879U123456L
RG Type code letters
30879 Build list number
U Built in the UK
123456 Engine serial number
L Year of manufacture
If you need parts, service or information for your engine, you must give the complete engine number to your
Perkins distributor.
Engine identication
• 415GM - identication letters HL
• 422GM - identication letters HP
• 422TGM - identication letters HR
• 4.4GM - identication letters RE
• 4.4TGM - identication letters RG
• 4.4TWGM - identication letters RJ
• 4.4TW2GM - identication letters RJ
• 4.4GM Radiator - identication letters RE
• 4.4TGM Radiator - identication letters RG
• 4.4TWGM Radiator - identication letters RJ
• 4.4TW2GM Radiator - identication letters RJ