Perkins 403J-E17T Operation And Maintenance Manual
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Perkins 403J-E17T Operation And Maintenance Manual

Industrial engines
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M0094137-02 (en-us)
December 2020
Operation and
Maintenance
Manual
403J-E17T, 404J-E22T, and 404J-E22TA
Industrial Engines
IR (Engine)
IQ (Engine)
IW (Engine)

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  • Page 1 M0094137-02 (en-us) December 2020 Operation and Maintenance Manual 403J-E17T, 404J-E22T, and 404J-E22TA Industrial Engines IR (Engine) IQ (Engine) IW (Engine)
  • Page 2 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 you are authorized to perform this work, and that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.

  • Page 3: Table Of Contents

    M0094137-02 Table of Contents Table of Contents Maintenance Section Refill Capacities..........58 Foreword ............4 Maintenance Recommendations ....76 Safety Section Maintenance Interval Schedule....... 79 Safety Messages..........6 Warranty Section General Hazard Information......10 Warranty Information........119 Burn Prevention..........13 Reference Information Section Fire Prevention and Explosion Prevention..

  • Page 4: Foreword

    State of arises regarding your engine, or this manual, please California to cause cancer, birth defects, consult with your Perkins dealer or your Perkins distributor for the latest available information. and other reproductive harm. WARNING – This product can...
  • Page 5 Perkins distributor offers various options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available. Consult with your Perkins dealer or your Perkins distributor for information regarding these options.

  • Page 6: Safety Section

    Replace any warning sign that is damaged or missing. If a warning sign is attached to a part of the engine that is replaced, install a new warning sign on the replacement part. Your Perkins distributor can provide new warning signs. (1) Universal Warning...
  • Page 7 M0094137-02 Safety Section Safety Messages Illustration 2 g06310205 Typical example (2) Hand (High Pressure) Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service in- structions may cause personal injury or death.
  • Page 8 M0094137-02 Safety Section Safety Messages Illustration 4 g06310206 Typical example The warning label for the Hand (High Pressure) (2) is a wrap around label that is installed on the high- pressure fuel line. (3) Ether Warning An ether warning label should be installed on the air cleaner or close to the air cleaner.
  • Page 9 M0094137-02 Safety Section Safety Messages Illustration 5 g01154809 Illustration 6 g06543925 Typical example of an industrial engine fitted with a Balancer (1) Universal Warning label (2) Hand (High Pressure) label...

  • Page 10: General Hazard Information

    M0094137-02 Safety Section General Hazard Information • After the ECM has powered down, disconnect the i08314780 batteries when maintenance is performed or when General Hazard Information the electrical system is serviced. Disconnect the battery ground leads. Use electrical insulating tape on the leads to help prevent sparks.
  • Page 11 • Wear a hard hat, protective glasses, and other protective equipment, as required. • Perkins recommends that you do not stand next to an exposed running engine unless it is necessary when carrying out daily checks or maintenance procedures.
  • Page 12 Perkins equipment and replacement parts comply with applicable regulations and requirements where Static Electricity Hazard when originally sold. Perkins recommends the use of only Fueling with Ultra-low Sulfur Diesel genuine Perkins replacement parts. Fuel Hexavalent chromium has occasionally been...

  • Page 13: Burn Prevention

    M0094137-02 Safety Section Burn Prevention Use caution. Avoid inhaling dust that might be • Stay away from areas that might have asbestos generated when you handle components that contain particles in the air. asbestos fibers. Inhaling this dust can be hazardous to your health.
  • Page 14 M0094137-02 Safety Section Burn Prevention Allow the pressure to be purged in the air system, in Cooling system conditioner contains alkali. Alkali can the hydraulic system, in the lubrication system, or in cause personal injury. Do not allow alkali to contact the cooling system before any lines, fittings, or the skin, the eyes, or the mouth.

  • Page 15: Fire Prevention And Explosion Prevention

    Material safety Data sheets for detailed property damage, or engine damage could result. information. If the application involves the presence of combustible gases, consult your Perkins dealer and/ Batteries or your Perkins distributor for additional information about suitable protection devices.
  • Page 16 M0094137-02 Safety Section Fire Prevention and Explosion Prevention After the engine has stopped, you must wait for 10 minutes to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed on the engine fuel lines. The 10 minute wait will also allow static charge to dissipate from the low-pressure fuel system.

  • Page 17: Crushing Prevention And Cutting Prevention

    The engine and aftertreatment system have not been designed with Leaks can cause fires. Consult your Perkins dealer or mounting or dismounting locations. your Perkins distributor for replacement parts. Refer to the OEM for the location of foot and hand Replace the parts if any of the following conditions holds for your specific application.
  • Page 18 M0094137-02 Safety Section High Pressure Fuel Lines Visually inspect the high-pressure fuel lines before the engine is started. This inspection should be each day. If you inspect the engine in operation, always use the proper inspection procedure to avoid a fluid penetration hazard.
  • Page 19 M0094137-02 Safety Section High Pressure Fuel Lines Four Cylinder engine Illustration 15 g03886691 (1) High-pressure line (4) High-pressure line (7) Fuel transfer line that is high pressure (2) High-pressure line (5) High-pressure fuel manifold (rail) (3) High-pressure line (6) High-pressure line...

  • Page 20: Before Starting Engine

    M0094137-02 Safety Section Before Starting Engine Three Cylinder Engine Illustration 16 g06064715 Typical example (1) High-pressure line (3) High-pressure line (5) High-pressure line (2) High-pressure line (4) High-pressure fuel manifold (6) Fuel transfer line that is high pressure Before starting the engine, ensure that no one is on, i08258438 underneath, or close to the engine.

  • Page 21: Engine Starting

    M0094137-02 Safety Section Engine Starting i07905943 i02234873 Engine Starting Engine Stopping Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid Do not use aerosol types of starting aids such as overheating of the engine and accelerated wear of ether.

  • Page 22: Engine Electronics

    M0094137-02 Safety Section Engine Electronics Grounding Practices Uncontrolled electrical circuit paths can result in damage to the crankshaft bearing journal surfaces and to aluminum components. Engines that are installed without engine-to-frame ground straps can be damaged by electrical discharge. To ensure that the engine and the engine electrical systems function correctly, an engine-to-frame ground strap with a direct path to the battery must be used.
  • Page 23 However, the monitoring system and the engine monitoring control will be similar for all engines. Note: Many of the engine control systems and display modules that are available for Perkins Engines will work in unison with the Engine Monitoring System. Together, the two controls will provide the engine monitoring function for the specific engine application.

  • Page 24: Product Information Section

    M0094137-02 Product Information Section General Information Product Information Section General Information i08101098 Model View Illustrations The following model views show typical features of the engine and the aftertreatment system. Due to individual applications, your engine, and your aftertreatment may appear different from the illustrations.
  • Page 25 M0094137-02 Product Information Section Model View Illustrations Three Cylinder Engine Illustration 19 g06311072 Typical example (1) Location of fuel filter is for shipment only...
  • Page 26 M0094137-02 Product Information Section Model View Illustrations Illustration 20 g06311073 Typical example...
  • Page 27 M0094137-02 Product Information Section Model View Illustrations Four Cylinder Engine Illustration 21 g06310812 Typical example (1) Electronic unit injector (6) Alternator and fan belt (11) Oil drain plug (2) Rear lifting eye (7) Fuel manifold (rail) (12) Oil filter (3) Top oil fill cap (8) Lower oil filler cap (13) Secondary fuel filter (4) Front lifting eye...
  • Page 28 M0094137-02 Product Information Section Model View Illustrations Illustration 22 g06311071 Typical example (15) Water temperature regulator (19) Flywheel housing (23) NRS cooler (16) Throttle valve (20) Starting motor (24) Alternator (17) Clean Emissions Module (CEM) (21) NOx Reduction System (NRS) Valve (18) Flywheel (22) Turbocharger...
  • Page 29 M0094137-02 Product Information Section Model View Illustrations Industrial Engine Views For Engines Equipped With A Balancer Illustration 23 g06543948 Typical example (1) Electronic unit injector (5) Fuel manifold (rail) (9) Oil drain plug (2) Rear lifting eye (6) Lower oil filler cap (10) Oil filter (3) Top oil fill cap (7) Fuel injection pump...
  • Page 30 M0094137-02 Product Information Section Model View Illustrations Illustration 24 g06543949 Typical example (13) Water temperature regulator (16) NOx Reduction System (NRS) Valve (19) NRS cooler (14) Throttle valve (17) Starting motor (20) Oil drain plug (15) Flywheel (18) Turbocharger...
  • Page 31 (2) Primary fuel filter/water separator (4) Engine link wiring harnesses i08108619 Product Description Three Cylinder Engine 403J-E17T The 403J-E17T industrial engine is a turbocharged engine. The engine is electronically governed. The 403J-E17T industrial engine has the following characteristics. • In-line 3 cylinder...
  • Page 32 Both the three and four cylinder engines have the same aftertreatment system. The aftertreatment system is approved for use by Perkins. To be emission-compliant, only the approved Perkins aftertreatment system must be used on a Perkins engine. Clean Emission Module (CEM)
  • Page 33 The soot is removed at an Engines equal rate of which the soot is captured. The ash remains in the DPF. Perkins does not warrant the quality or performance Electronic Engine Features of non-Perkins fluids and filters. When auxiliary devices, accessories, or The engine operating conditions are monitored.

  • Page 34: Product Identification Information

    The engine serial plate (1) is on the left side of the engine to the rear of the engine cylinder block. Perkins distributors need all the numbers on the plate to determine the components that were included with the engine. This information permits accurate identification of replacement part numbers.
  • Page 35 M0094137-02 Product Information Section Reference Information Illustration 31 g02157153 Typical example Illustration 31 is a representation of the label that will be installed next to the fuel filler cap on the fuel tank of the application. i06280422 Reference Information Information for the following items may be needed to order parts.

  • Page 36: Operation Section

    M0094137-02 Operation Section Lifting and Storage Operation Section Engine and Aftertreatment Lifting and Storage i08106118 Product Lifting NOTICE Always inspect lifting eyebolts and all other lifting equipment for damage before performing any lifting. Never bend the eyebolts and the brackets. Never perform product lifting if components are damaged.
  • Page 37 M0094137-02 Operation Section Product Lifting Engine Equipped with a Balancer The support pads in Positions (A) can support a maximum evenly distributed load with a combined weight of 912 kg (2010 lb), refer to Illustration 34 . The support pads in Positions (B) can support a maximum evenly distributed load with a combined weight of 386 kg (851 lb), refer to Illustration 34 .
  • Page 38 The engine must be stored in a water proof building. equipment manufacture for more information. The building must be kept at a constant temperature. Engines that are filled with Perkins ELC will have Engines with Factory Installed coolant protection to an ambient temperature of −36°...
  • Page 39 M0094137-02 Operation Section Engine and Aftertreatment For maintenance procedures refer to this Operation and Maintenance Manual. Aftertreatment No special procedures are required. The exhaust outlet of the aftertreatment should be capped. Before storing, the engine and the aftertreatment must be enclosed in a cover that will provide protection from the environment.

  • Page 40: Features And Controls

    Make necessary repairs before attempting to restart Determine and correct the cause of any significant the engine. change in the readings. Consult your Perkins dealer or your Perkins distributor for assistance. Be familiar with the following items: NOTICE If no oil pressure is indicated, STOP the engine.
  • Page 41 M0094137-02 Operation Section Monitoring System If the engine is operating above the normal range NOTICE and steam becomes apparent, perform the following The Engine Monitoring System is not a guarantee procedure: against catastrophic failures. Programmed delays and derate schedules are designed to minimize false 1.
  • Page 42 2 second delay to verify the condition. If there is a signal for low oil pressure, there will be a 2 second delay to verify the condition. For more information or assistance for repairs, consult your Perkins distributor. i07426635 Monitoring System (Engine Warning Indicators)
  • Page 43 . i07397434 Overspeed The overspeed threshold is the Revolution Per Minute (RPM) listed below for the engines covered by this Operation and Maintenance Manual (OMM). • 403J-E17T 3700 RPM • 404J-E22T 3700 RPM • 404J-E22TA 3700 RPM i07399976...
  • Page 44 M0094137-02 Operation Section Sensors and Electrical Components Illustration 36 g06310720 Typical example (1) Diesel Particulate Filter (DPF) inlet (5) Glow plug (8) Suction control valve for the fuel injection temperature sensor (6) Fuel pressure sensor (fuel rail pressure pump (2) Differential pressure sensor sensor) (9) Oil pressure switch (3) Electronic unit injector...
  • Page 45 M0094137-02 Operation Section Sensors and Electrical Components Illustration 37 g06310761 Typical example (11) Coolant temperature sensor (14) NOx Reduction System (NRS) control (17) Fuel priming pump (12) Throttle valve valve (18) Vent for atmospheric pressure sensor (13) Diesel Oxidation Catalyst (DOC) inlet (15) Starting motor (19) Electronic Control Module (ECM) temperature sensor...

  • Page 46: Engine Diagnostics

    M0094137-02 Operation Section Engine Diagnostics Engine Diagnostics In most cases, stopping the engine will not be necessary because of an intermittent code. However, the operator should retrieve the logged fault codes and the operator should reference the appropriate i05142509 information. in order to identify the nature of the Fault Logging event.

  • Page 47: Engine Starting

    M0094137-02 Operation Section Engine Starting Engine Starting i07907357 Cold Weather Starting i04053911 Before Starting Engine Do not use aerosol types of starting aids such as Perform the required daily maintenance and other ether. Such use could result in an explosion and periodic maintenance before the engine is started.
  • Page 48 M0094137-02 Operation Section Starting the Engine Note: During key ON, the indicator lamps will be NOTICE illuminated for 0.5 of a second to check the lamp Do not engage the starting motor when flywheel is operation. If any of the indicator lamps do not turning.
  • Page 49 M0094137-02 Operation Section Starting with Jump Start Cables 6. Constant speed engines should be allowed to NOTICE reach operating speed with no load. Operate Using a battery source with the same voltage as the engine for 2 minutes before applying load. electric starting motor.
  • Page 50 M0094137-02 Operation Section After Starting Engine i07818134 After Starting Engine After starting, the engine may be held at low speed for up to 30 seconds to allow engine systems to stabilize. The duration will depend on ambient temperature, time since last run and other factors. After starting the engine and allowing the engine to stabilize, increase the engine speed to 1500 RPM for 10 seconds to ensure that the alternator begins to...

  • Page 51: Engine Operation

    Comparing the data over time will help to determine normal readings for each gauge. For the 403J-E17T engine, 905.42 g/kWh was Comparing data over time will also help detect determined to be the CO value during the EU type abnormal operating developments.
  • Page 52 M0094137-02 Operation Section Fuel Conservation Practices These values were recorded in EU type approval • Cold engines consume excess fuel. Utilize heat certificate. This CO measurement results from from the jacket water system and the exhaust testing over a fixed test cycle, under laboratory system, when possible.

  • Page 53: Cold Weather Operation

    Perkins Diesel Engines can operate effectively in cold weather. During cold weather, the starting and • Install the correct specification of engine lubricant the operation of the diesel engine depends the before the beginning of cold weather.
  • Page 54 240 V DC. The output can be 600/1000W. Consult The free operation of the valves and the valve your Perkins dealer or your Perkins distributor for components will be maintained. more information.
  • Page 55 This action ensures maximum coolant flow to the radiator to achieve maximum heat dissipation. Note: Only use grades of fuel that are recommended by Perkins. Refer to this Operation and Maintenance Note: Do not restrict the air flow. Restriction of the air Manual, “Fluid Recommendations”.
  • Page 56 M0094137-02 Operation Section Fuel Related Components in Cold Weather The following components can provide a means of The micron rating and the location of a primary fuel minimizing fuel waxing problems in cold weather: filter is important in cold-weather operation. The In- line filter, primary fuel filter, and the fuel supply line •...

  • Page 57: Engine Stopping

    M0094137-02 Operation Section Engine Stopping Engine Stopping i03756631 After Stopping Engine i06832774 Stopping the Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan. NOTICE •...

  • Page 58: Maintenance Section

    Total Lubrication System in this row. Engines Equipped with a Balancer Oil Illustration 38 g06544043 Typical example (1) Standard Oil Pan Table 4 403J-E17T Engine Refill Capacities Compartment or System Minimum Maximum 4.8 L 6.3 L Crankcase Oil Sump (1.27 US gal)
  • Page 59 • CTL Coal to liquid required for the Total Cooling System. • DPF Diesel Particulate Filter Table 7 403J-E17T Engine • EPA Environmental Protection Agency of Refill Capacities the United States Compartment or System US gallons Liters •...
  • Page 60 Contact your local Perkins distributor for the most up-to-date recommendations. Diesel Fuel Requirements Perkins is not in a position to continuously evaluate and monitor all worldwide distillate diesel fuel specifications that are published by governments and technological societies.
  • Page 61 M0094137-02 Maintenance Section General Fuel Information (Table 10, contd) Distillation °C 50% at 250° C (482° F) “D86” “ISO 3405” minimum 90% at 350° C (662° F) maximum Density at 15 °C (59 °F) kg/M 800 minimum and 860 No equivalent test “ISO 3675”“ISO 12185”...
  • Page 62 M0094137-02 Maintenance Section General Fuel Information NOTICE Operating with fuels that do not meet the Perkins rec- ommendations can cause the following effects: Start- ing difficulty, reduced fuel filter service life, poor combustion, deposits in the fuel injectors, signifi- cantly reduce service life of the fuel system. Also, the creation of deposits in the combustion chamber and reduced service life of the engine.
  • Page 63 Refer to the Recommendation for Biodiesel and Using B20 section of this “Operation and Maintenance Manual” Fluid Recommendations for more information. All the fuels must comply with the specification in the table for the Perkins Specification Distillate Diesel Fuel. Diesel Fuel Characteristics Perkins recommends kinematic viscosities of between 1.4 and 4.5 mm...
  • Page 64 Protection Agency (EPA) and European Certification wear scar diameter than 0.52 mm (0.0205 inch) will fuels. Perkins does not certify engines on any other lead to reduced service life and premature failure of fuel. The user of the engine has the responsibility of the fuel system.
  • Page 65 20 hours or more as per EN 15751. If the test shows that the fuel has • Perkins recommend the use of oil analysis to degraded, fuel tank must be drained and engine check the quality of the engine oil if biodiesel fuel flushed by running with the fresh high-quality diesel fuel.
  • Page 66 Note: Some anti-corrosion additives can lead to to use as a directed replacement to petroleum diesel injector fouling, this fouling can cause the injector to or as a blendstock for petroleum diesel fuel in Perkins operate incorrectly. diesel engines provided they meet latest edition of the paraffinic diesel fuel specification “CENTS...
  • Page 67 Note: Perkins fuel cleaner is compatible with existing water or less. and U.S. EPA Tier 4 nonroad certified diesel engine • Perkins recommends the use of bulk fuel filter / emission control catalysts and particulate filters. coalescer units which clean the fuel of both...
  • Page 68 M0094137-02 Maintenance Section Fluid Recommendations Water Consult your local Perkins distributor for additional information on Perkins designed and produced filtration products. NOTICE Never use water alone as coolant. Water alone is cor- rosive and does not provide any protection against i07911116 boiling or freezing.
  • Page 69 Coolant Recommendations −51 °C (−60 °F) 60 Percent The following three glycol-based coolants are recommended for use in Perkins diesel engines: NOTICE Preferred – Perkins ELC Do not use propylene glycol in concentrations that exceed 50 percent glycol because of the reduced heat transfer capability of propylene glycol.
  • Page 70 ASTM D3306 specification. This type of contains organic corrosion inhibitors and antifoam coolant/antifreeze is made for light automotive agents with low amounts of nitrite. Perkins ELC has applications. been formulated with the correct amount of these additives to provide superior corrosion protection for all metals in engine cooling systems.
  • Page 71 8. Repeat Steps 6 and repeat steps 7 until the 2. Dispose of the coolant according to local system is completely clean. regulations. 9. Fill the cooling system with the Perkins Premixed 3. Flush the system with distilled or deionized water ELC. to remove any debris.
  • Page 72 Check the antifreeze (glycol concentration) to ensure adequate protection against boiling or freezing. Heavy-duty antifreezes of all types require periodic Perkins recommends the use of a refractometer for additions of SCA. checking the glycol concentration. Do not use a hydrometer.
  • Page 73 The system must be thoroughly flushed with distilled Association des Constructers European Automobiles or deionized water after use of cleaning agents. (ACEA) is recognized by Perkins. For detailed information about this system, see the latest edition of the “API publication No. 1509”. Engine oils that bear the API symbol are authorized by API.
  • Page 74 Refer to illustration 42 (maximum temperature) to “EMA Recommended Guideline on Diesel Engine select the oil viscosity for engine operation at the Oil”. In addition to Perkins definitions, there are other highest ambient temperature that is anticipated. definitions that will be of assistance in purchasing lubricants.
  • Page 75 This analysis with the finished oil. This failure could produce sludge also allows technicians to verify the performance in the crankcase. Perkins discourages the use of of the oil according to the specification during the aftermarket additives in finished oils.

  • Page 76: Maintenance Recommendations

    Consult the OEM of the equip- To relieve the pressure from the coolant system, turn ment or your Perkins dealer regarding welding on a chassis frame or rail. off the engine. Allow the cooling system pressure cap to cool.
  • Page 77 M0094137-02 Maintenance Section Welding on Engines with Electronic Controls 1. Stop the engine. Turn the switched power to the OFF position. 2. Ensure that the fuel supply to the engine is turned off. 3. Disconnect the negative battery cable from the battery.
  • Page 78 Necessary engine. Perkins maintains standards for the following adjustments should be made. engine parameters: • Performance such as power range, speed range,...

  • Page 79: Maintenance Interval Schedule

    M0094137-02 Maintenance Section Maintenance Interval Schedule “ Radiator - Clean“ ......115 i08108977 Maintenance Interval Schedule Every 1000 Service Hours “Alternator and Fan Belts - Replace“...

  • Page 80: Alternator And Fan Belts - Replace

    Make repairs, if necessary. i02322311 Alternator - Inspect Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and correct battery charging. Check the ammeter (if equipped) during engine operation in order to ensure correct battery performance and/or correct performance of the electrical system.
  • Page 81 M0094137-02 Maintenance Section Multi-V Stretch Belt 5. Rotate alternator (4) towards the cylinder block to remove the alternator belt. Discard the alternator belt. Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 44 g06473107 Typical example...
  • Page 82 M0094137-02 Maintenance Section Multi-V Stretch Belt Illustration 47 g06474305 1. Position the new alternator belt onto the alternator pulley. Refer to Operation and Maintenance Manual, “Alternator and Fan Belts - Replace” for the correct procedure. Illustration 48 g06474149 2. Use a suitable tool to position the alternator away from the cylinder block engage the cut-out in 3.

  • Page 83: Alternator And Fan Belts - Replace

    2. Loosen bolt (1) and bolt (2) (not shown) on the (Single-V Belt) adjuster link. 3. Loosen nut (4) (not shown) and bolt (5). Removal Procedure 1. If the engine is equipped with fan guards, remove the fan guards. Refer to your Perkins dealer for further assistance.

  • Page 84: Battery - Replace

    25 N·m (221 lb in). 6. Install the new battery. 5. If the engine is equipped with fan guards, install the fan guards. Refer to your Perkins dealer for further Note: Before the cables are connected, ensure that the engine start switch is OFF.

  • Page 85: Battery Or Battery Cable - Disconnect

    M0094137-02 Maintenance Section Battery Electrolyte Level - Check 8. Connect the NEGATIVE “-” cable to the i07819485 NEGATIVE “-” battery terminal. Battery or Battery Cable - Disconnect i02747977 Battery Electrolyte Level - Check The battery cables or the batteries should not be When the engine is not run for long periods of time or removed with the battery cover in place.

  • Page 86: Coolant (Commercial Heavy-Duty) - Change

    M0094137-02 Maintenance Section Coolant (Commercial Heavy-Duty) - Change If the belt is too loose, vibration causes unnecessary wear on the belt and pulleys. A loose belt may slip enough to cause overheating. The correct tension for a new belt is 400 N (90 lb) to 489 N (110 lb).
  • Page 87 M0094137-02 Maintenance Section Coolant (Commercial Heavy-Duty) - Change Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This inspection is a good opportunity to replace the water pump, the water temperature regulator, and the hoses, if necessary. Drain Pressurized System: Hot coolant can cause seri- ous burns.
  • Page 88 1. Flush the cooling system with clean water and a at least 82 °C (180 °F). suitable cleaning agent to remove any debris. Refer to your Perkins dealer or distributor for suitable cleaning agents. 2. Install connection hose. Clean the drain plugs.

  • Page 89: Coolant (Elc) - Change

    M0094137-02 Maintenance Section Coolant (ELC) - Change NOTICE Improper or incomplete rinsing of the cooling system can result in damage to copper and other metal components. To avoid damage to the cooling system, make sure to completely flush the cooling system with clear water. Continue to flush the system until all signs of the cleaning agent are gone.
  • Page 90 M0094137-02 Maintenance Section Coolant (ELC) - Change • The engine overheats frequently. • Foaming is observed. • The oil has entered the cooling system and the coolant is contaminated. • The fuel has entered the cooling system and the coolant is contaminated. Note: When the cooling system is cleaned, only clean water is needed when the ELC is drained and replaced.
  • Page 91 M0094137-02 Maintenance Section Coolant (ELC) - Change For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or Perkins distributor. Drain Plugs for Factory Installed Radiators Illustration 58 g06164641 Typical example (2) Three cylinder radiator drain plug...

  • Page 92: Coolant Level - Check

    M0094137-02 Maintenance Section Coolant Level - Check 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly to relieve any pressure. Remove the cooling system filler cap. Remove the cooling system drain plugs. Allow the water to drain.
  • Page 93 M0094137-02 Maintenance Section Coolant Level - Check Check the coolant level when the engine is stopped and cool. NOTICE When any servicing or repair of the engine cooling system is performed, the procedure must be per- formed with the engine on level ground. This proce- dure will allow you to check accurately the coolant level.

  • Page 94: Coolant Temperature Regulator - Replace

    (1). Replace the engine damage. cooling system filler cap if the filler cap gasket (2) or Perkins engines incorporate a shunt design cooling the sealing surface (1) are damaged. system and require operating the engine with a water The radiator filler cap should be check at regular temperature regulator installed.

  • Page 95: Crankcase Breather (Canister) - Replace

    • The installation of the filter element is critical to the correct operation of the engine. • The quality of the filter element that is installed is very important, Perkins recommend using genuine Perkins filters. • The filter element protects the engine from excessive quantities of oil from entering the induction system.
  • Page 96 M0094137-02 Maintenance Section Crankcase Breather (Canister) - Replace Illustration 63 g03331704 Illustration 64 g06477300 Typical example 8. Install hose (4) and clip (3). Ensure that the hose is correctly orientated. 4. Remove filter element (5) and remove O ring seal (6) and discard.

  • Page 97: Engine - Clean

    Servicing the Air Cleaner Elements • Maximum heat transfer characteristics Note: The air filter system may not have been provided by Perkins. The procedure that follows, is • Ease of maintenance for a typical air filter system. Refer to the OEM Note: Caution must be used to prevent electrical information for the correct procedure.

  • Page 98: Engine Air Cleaner Service Indicator - Inspect

    M0094137-02 Maintenance Section Engine Air Cleaner Service Indicator - Inspect Air Cleaners 4. Remove primary air filter element (3) and if equipped, remove the secondary air filter element Some application can have dual elements. The dual (Not Shown). Discard all old air filter elements. air cleaner contains a primary air cleaner element and a secondary air cleaner element.

  • Page 99: Engine Air Precleaner - Check/Clean

    Refer to the OEM information for the recommended torques. Engine Air Precleaner - Check/ Clean When the engine mounts are supplied by Perkins the maintenance procedure will be supplied in the Disassembly and Assembly manual for your engine. i06862328...

  • Page 100: Engine Oil And Filter - Change

    M0094137-02 Maintenance Section Engine Oil and Filter - Change Note: Ensure that there is sufficient quantity of oil in NOTICE the engine before taking a sample of oil with the Operating your engine when the oil level is above the engine in operation.
  • Page 101 M0094137-02 Maintenance Section Engine Oil and Filter - Change 4. Tighten oil drain plug (1) to a torque of 24 N·m (212 lb in). Remove container below oil drain plug (1) and discard waste oil in accordance with local regulations. Note: A drain valve may be installed.
  • Page 102 Perkins oil filters are built to Perkins specifications. Use of an oil filter not recommended by Perkins could 3. Apply clean engine oil to the new oil filter seal (2). result in severe engine damage to the engine bear- ings, crankshaft, etc., as a result of the larger waste...

  • Page 103: Engine Valve Lash - Check

    M0094137-02 Maintenance Section Engine Valve Lash - Check 4. Install the oil filter (3). Tighten the oil filter by hand. 3. Start the engine and run the engine at “LOW IDLE” Do not overtighten the oil filter. for 2 minutes. Perform this procedure to ensure that the lubrication system has oil and that the oil Fill the Engine Crankcase filters are filled.

  • Page 104: Fuel System - Prime

    M0094137-02 Maintenance Section Fan Clearance - Check Three Cylinder Refer to Systems Operation, Testing and Adjusting, “Engine Valve Lash - Inspect/Adjust” for the correct sequence of adjustment. • (A) equals 5 mm (0.19685 inch) for the three cylinder engine i06912959 Four Cylinder Turbocharged Fan Clearance - Check •...
  • Page 105 M0094137-02 Maintenance Section Fuel System - Prime 4. The keyswitch will allow the electric priming pump to operate. When fuel free from air comes from the vent screw (2), tighten the vent screw to a torque of 24 N·m (212. lb in). Then, operate the electric priming pump for 2 minutes.

  • Page 106: Fuel System Primary Filter (Water Separator) Element - Replace

    M0094137-02 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace Hand Priming (If Equipped) NOTICE Ensure that the engine is stopped before any servic- ing or repair is performed. Remove the Element 1. Turn the fuel supply valve (if equipped) to the OFF position before performing this maintenance.
  • Page 107 M0094137-02 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace 8. Install filter bowl (5) to filter (2) and tighten the filter 2. Clean the outside body of the fuel filter assembly. bowl to a torque of 10 N·m (88 lb in). 3.
  • Page 108 M0094137-02 Maintenance Section Primary Fuel Filter With Water In Fuel (WIF) Sensor 15. Clean filter bowl (9). Install the New Filter Element Illustration 81 g06446785 Typical example 11. Rotate filter bowl (9) counterclockwise and remove the filter bowl from the fuel filter assembly. Illustration 82 g06446785 Typical example...

  • Page 109: Fuel System Primary Filter/Water Separator - Drain

    M0094137-02 Maintenance Section Fuel System Primary Filter/Water Separator - Drain 9. Turn the fuel supply valve (if equipped) to the ON position after performing this maintenance. i07820721 Fuel System Primary Filter/ Water Separator - Drain (Primary Fuel Filter With Water In Fuel (WIF) Sensor) Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire.

  • Page 110: Fuel System Primary Filter/Water Separator - Drain

    M0094137-02 Maintenance Section Fuel System Primary Filter/Water Separator - Drain i07905847 Fuel System Primary Filter/ Water Separator - Drain Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.

  • Page 111: Fuel System Secondary Filter - Replace

    M0094137-02 Maintenance Section Fuel System Secondary Filter - Replace NOTICE The water separator is under suction during normal engine operation. Ensure that the drain valve is tight- ened securely to help prevent air from entering the fuel system. i08106019 Fuel System Secondary Filter - Replace Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire.
  • Page 112 M0094137-02 Maintenance Section Fuel System Secondary Filter - Replace Install the Filter Element Illustration 87 g06545420 Illustration 89 g03891817 1. Install filter element (3) into filter base (2). 2. Install a new O ring seal (4) to filter bowl (5) and install filter bowl (5) to filter base (2).

  • Page 113: Fuel System Secondary Filter/Water Separator

    M0094137-02 Maintenance Section Fuel System Secondary Filter/Water Separator - Drain Install the Canister Fuel Filter Illustration 91 g06014499 Typical example Illustration 90 g06545420 1. Place a suitable container below filter. Open drain valve (1) and allow fluid to drain. 1. Ensure that O-ring seal (2) is in position on fuel filter (3).

  • Page 114: Hoses And Clamps - Inspect/Replace

    M0094137-02 Maintenance Section Hoses and Clamps - Inspect/Replace Water can be introduced into the fuel tank when the If a bulk storage tank has been refilled or moved fuel tank is being filled. recently, allow adequate time for the sediment to settle before filling the engine fuel tank.
  • Page 115 Radiator - Clean • Type of fitting material • Anticipated expansion and contraction of the hose The radiator is not usually supplied by Perkins. The • Anticipated expansion and contraction of the following text describes a typical cleaning procedure fittings for the radiator.

  • Page 116: Walk-Around Inspection

    Adjusting Manual, “Electric Starting System - Test” for more information on the checking procedure and for specifications consult your Perkins dealer or NOTICE your Perkins distributor for assistance. For any type of leak (coolant, lube, or fuel) clean up the fluid.
  • Page 117 M0094137-02 Maintenance Section Walk-Around Inspection • Inspect the piping for the air intake system and the After the engine has stopped, wait 10 minutes to allow the fuel pressure to be purged from the high- elbows for cracks and for loose clamps. Ensure pressure fuel lines before any service or repair is that hoses and tubes are not contacting other performed.

  • Page 118: Water Pump - Inspect

    M0094137-02 Maintenance Section Water Pump - Inspect Engine Aftertreatment Check that all clamps, clips, and cable straps are secure and in good condition. i01907756 Water Pump - Inspect A failed water pump may cause severe engine overheating problems that could result in the following conditions: •...

  • Page 119: Warranty Section

    Emissions Warranty. For a full warranty statement contact your Perkins dealer or your Perkins distributor. For customers that have a valid user name and password, for perkins. com. Login then go to TIPSS, and the warranty information can be accessed.

  • Page 120: Reference Information Section

    M0094137-02 Reference Information Section Reference Materials Reference Information Section Reference Materials i05204675 Maintenance Log Table 21 Engine Model Customer Identifier Arrangement Number Serial Number Service Quantity Of Service Item Date Authorization Hours Fuel (continued)
  • Page 121 Contact your local Perkins Distributor Engine Protection Plans now and the distributor can provide you with a quote in minutes. You can locate your nearest Perkins (Extended Service Contract) Distributor by visiting: www.perkins.com Extended Service Contracts-purchased in minutes, NOTICE protected for years.

  • Page 122: Index

    M0094137-02 Index Section Index Drain Plugs for Factory Installed Radiators............ 88 After Starting Engine ........50 Fill ..............89 After Stopping Engine ........57 Flush ............88 Aftercooler Core - Inspect ....... 80 Coolant (ELC) - Change........89 Alarms and Shutoffs ........40 Drain ............
  • Page 123 M0094137-02 Index Section Engine Operation with Active Diagnostic Fuel System Primary Filter (Water Codes ............46 Separator) Element - Replace..... 106 Engine Operation with Intermittent Remove the Element ......... 106 Diagnostic Codes .......... 46 Fuel System Primary Filter (Water Engine Protection Plans (Extended Service Separator) Element - Replace (Primary Contract)............
  • Page 124 M0094137-02 Index Section Three Cylinder Engine 403J-E17T ....31 Product Identification Information ....34 Maintenance Interval Schedule....... 79 Product Information Section......24 Commissioning ..........79 Product Lifting ..........36 Daily ............. 79 Aftertreatment Systems for Engine Equipped Every 1000 Service Hours......79 with a Balancer ..........
  • Page 125 M0094137-02 Index Section Turbocharger - Inspect ........116 Walk-Around Inspection .........116 High-Pressure Fuel Lines ......117 Inspect the Engine for Leaks and for Loose Connections ..........116 Warranty Information........119 Warranty Section..........119 Water Pump - Inspect........118 Welding on Engines with Electronic Controls ............76...
  • Page 127 Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number:...
  • Page 128 M0094137 ©2020 Perkins Engines Company Limited All Rights Reserved December 2020...

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