Perkins 400 Series Operation And Maintenance Manual
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Perkins 400 Series Operation And Maintenance Manual

Perkins 400 Series Operation And Maintenance Manual

Industrial engine
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Operation and
Maintenance
Manual
400C Industrial Engine
HB (Engine)
HD (Engine)
HH (Engine)
HL (Engine)
HM (Engine)
HN (Engine)
HP (Engine)
HR (Engine)
SEBU7992-05 (en-us)
February 2020

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Summary of Contents for Perkins 400 Series

  • Page 1 SEBU7992-05 (en-us) February 2020 Operation and Maintenance Manual 400C Industrial Engine HB (Engine) HD (Engine) HH (Engine) HL (Engine) HM (Engine) HN (Engine) HP (Engine) HR (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

    SEBU7992-05 Table of Contents Table of Contents Warranty Section Warranty Information........82 Foreword ............4 Index Section Safety Section Index..............83 Safety Messages..........6 General Hazard Information......6 Burn Prevention..........9 Fire Prevention and Explosion Prevention..10 Crushing Prevention and Cutting Prevention.. 12 Before Starting Engine ........

  • 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

    Illustration 3 g00104545 sign on the replacement part. Any Perkins distributor Attach a “Do Not Operate” warning tag or a similar can provide new warning signs. warning tag to the start switch or to the controls...
  • Page 7 SEBU7992-05 Safety Section General Hazard Information Start the engine from the operators station (cab). Never short across the starting motor terminals or the batteries. This action could bypass the engine neutral start system and/or the electrical system could be damaged. Engine exhaust contains products of combustion which may be harmful to your health.
  • Page 8 SEBU7992-05 Safety Section General Hazard Information Obey all local regulations for the disposal of liquids. Static Electricity Hazard when Fueling with Ultra-low Sulfur Diesel Fuel The removal of sulfur and other compounds in ultra- low sulfur diesel fuel (ULSD fuel) decreases the conductivity of ULSD and increases the ability of ULSD to store static charge.

  • Page 9: Burn Prevention

    Dispose of Waste Properly Perkins equipment and replacement parts that are shipped from Perkins engine company limited are asbestos free. Perkins recommends the use of only genuine Perkins replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris.

  • Page 10: Fire Prevention And Explosion Prevention

    Diesel Fuel If the application involves the presence of combustible gases, consult your Perkins dealer and/ or your Perkins distributor for additional information Diesel may be irritating to the eyes, respiratory about suitable protection devices.
  • Page 11 Do not clip any other items to the high- pressure lines. Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for repair or for replacement parts. Check lines, tubes, and hoses carefully. Do not use your bare hand to check for leaks.

  • Page 12: Crushing Prevention And Cutting Prevention

    SEBU7992-05 Safety Section Crushing Prevention and Cutting Prevention • End fittings are displaced. Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the Make sure that all clamps, guards, and heat shields area is free of personnel.

  • Page 13: Engine Stopping

    The 400 Series engines are equipped with a glow plug starting aid in each individual cylinder that heats Uncontrolled electrical circuit paths can result in the intake air in order to improve starting.

  • Page 14: Product Information Section

    Model Views i02810676 Model View Illustrations The following model views show typical features of the 400 series engines. Due to individual applications, your engine may appear different from the illustrations. Note: Individual components are detailed on the 404C-22T turbocharged engine only.
  • Page 15 SEBU7992-05 Product Information Section Model View Illustrations Illustration 12 g01109212 Typical view of the 403C-11 engine...
  • Page 16 SEBU7992-05 Product Information Section Model View Illustrations Illustration 13 g01402021 Typical view of the 403C-17 engine...
  • Page 17 SEBU7992-05 Product Information Section Model View Illustrations Illustration 14 g01097209 Front and left side view of the 404C-22T Engine (1) Engine oil filler cap (7) Exhaust manifold (13) Engine oil drain plug (2) Coolant temperature switch (8) Turbocharger (14) Engine oil pan (3) Crankcase breather (9) Starting motor solenoid (15) Crankshaft pulley...
  • Page 18 The 400 series engines are diesel engines that are controlled with a mechanically actuated fuel injection The crankshaft for a two cylinder engine has two pump.
  • Page 19 SEBU7992-05 Product Information Section Engine Description 402C-05 Engine The timing gears are stamped with timing marks in order to ensure the correct assembly of the gears. When the No. 1 piston is at top center compression stroke, the teeth that are stamped on the crankshaft gear and the camshaft gear will be in alignment with the idler gear.
  • Page 20 SEBU7992-05 Product Information Section Engine Description 403C-07 Engine 403C-11 Engine Illustration 17 g00852304 Illustration 18 g00852304 (A) Exhaust valves (A) Exhaust valves (B) Inlet valves (B) Inlet valves Table 2 Table 3 403C-07 Engine Specifications 403C-11 Engine Specifications Maximum Operating Speed Maximum Operating Speed 3600 rpm 3600 rpm...
  • Page 21 SEBU7992-05 Product Information Section Engine Description 403C-15 Engine 403C-17 Engine Illustration 19 g00852304 Illustration 20 g00852304 (A) Exhaust valves (A) Exhaust valves (B) Inlet valves (B) Inlet valves Table 4 Table 5 403C-15 Engine Specifications 403C-17 Engine Specifications Maximum Operating Speed Maximum Operating Speed 3000 rpm 2600 rpm...
  • Page 22 SEBU7992-05 Product Information Section Engine Description 404C-15 Engine 404C-22 Engine Illustration 21 g00296424 Illustration 22 g00296424 (A) Exhaust valves (A) Exhaust valves (B) Inlet valves (B) Inlet valves Table 6 Table 7 404C-15 Engine Specifications 404C-22 Engine Specifications Maximum Operating Speed Maximum Operating Speed 3000 rpm 3000 rpm...
  • Page 23 SEBU7992-05 Product Information Section Engine Description 404C-22T Engine Illustration 23 g00296424 (A) Exhaust valves (B) Inlet valves Table 8 404C-22T Engine Specifications Maximum Operating Speed 3000 rpm (rpm) Cylinders and Arrangement In-Line four cylinder Bore 84.0 mm (3.31 inch) Stroke 100.0 mm (3.94 inch) Displacement 2.216 L (135.229 in...

  • Page 24: Product Identification Information

    Reference Numbers Engine Identification Information for the following items may be needed to Perkins engines are identified by a serial number. order parts. Locate the information for your engine. This number is shown on a serial number plate that is Record the information in the appropriate space.
  • Page 25 SEBU7992-05 Product Information Section Emissions Certification Film Illustration 25 g06438512...

  • Page 26: Operation Section

    If alterations are made, ensure that correct lifting devices are provided. Consult your Perkins dealer or your Perkins distributor for information regarding fixtures for correct engine lifting. i02134814...
  • Page 27 Note: Certain corrosion inhibitors could cause damage to some engine components. Contact the Service Department of Perkins for advice. 8. Operate the engine for a short period in order to circulate the lubricating oil and the coolant in the engine.
  • Page 28 When the engine protection has been completed in accordance with these instructions, this ensures that no corrosion will occur. Perkins are not responsible for damage which may occur when an engine is in storage after a period in service.

  • Page 29: Gauges And Indicators

    Ammeter – This gauge indicates the Determine and correct the cause of any significant amount of charge or discharge in the change in the readings. Consult your Perkins dealer battery charging circuit. Operation of or your Perkins distributor for assistance.

  • Page 30: Features And Controls

    SEBU7992-05 Operation Section Features and Controls Features and Controls i00705809 Fuel Shutoff The fuel shutoff solenoid is located on the governor or the fuel shutoff solenoid is located on the fuel injection pump. When the fuel shutoff solenoid is activated, the solenoid moves the fuel rack “OFF” . The fuel shutoff solenoid moves the fuel rack directly or the fuel shutoff solenoid moves the fuel rack through the governor.

  • Page 31: Engine Starting

    SEBU7992-05 Operation Section Engine Starting Engine Starting • Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or i02194223 to the controls. Before Starting Engine •...
  • Page 32 SEBU7992-05 Operation Section Starting with Jump Start Cables 1. Before the engine is started, move the throttle Note: If it is possible, first diagnose the reason for the starting failure. Make any necessary repairs. If the lever to the 30 PERCENT OPEN position. engine will not start only due to the condition of the battery, either charge the battery, or start the engine NOTICE...
  • Page 33 SEBU7992-05 Operation Section After Starting Engine i06791278 After Starting Engine Note: In temperatures from 0°C to 60°C (32°F to 140°F), the warm-up time is approximately 3 minutes. In temperatures below 0°C (32°F), extra warm-up time may be required. When the engine idles during warm-up, observe the following conditions: •...

  • Page 34: Engine Operation

    Fuel Conservation Practices The efficiency of the engine can affect the fuel economy. Perkins design and technology in manufacturing provides maximum fuel efficiency in all applications. Follow the recommended procedures in order to attain optimum performance for the life of the engine.

  • Page 35: Engine Stopping

    SEBU7992-05 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 36: Cold Weather Operation

    Cold Weather Operation • Install the correct specification of engine lubricant before the beginning of cold weather. Perkins Diesel Engines can operate effectively in • Check all rubber parts (hoses, fan drive belts.) cold weather. During cold weather, the starting and weekly.
  • Page 37 An electric block heater can be activated once the • Pushrods may become bent. engine is stopped. An effective block heater is typically a 1250/1500 W unit. Consult your Perkins • Other damage to valve train components can dealer or your Perkins distributor for more result.
  • Page 38 Pour point is the last temperature before the fuel flow dissipation. stops and waxing of the fuel will start. Note: Perkins discourages the use of all air flow Be aware of these properties when diesel fuel is restriction devices such as radiator shutters.
  • Page 39 SEBU7992-05 Operation Section Fuel Related Components in Cold Weather i01903588 Fuel Related Components in Cold Weather Fuel Tanks Condensation can form in partially filled fuel tanks. Top off the fuel tanks after you operate the engine. Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks.

  • Page 40: Maintenance Section

    SEBU7992-05 Maintenance Section Refill Capacities Maintenance Section (Table 10, contd) These values are the approximate capacities for the crankcase oil sump which includes the standard factory installed oil filters. Engines with auxiliary oil filters will require additional oil. Refer Refill Capacities to the OEM specifications for the capacity of the auxiliary oil filter.
  • Page 41 SEBU7992-05 Maintenance Section Refill Capacities 404C-15 Engine 402C-05 Engine Table 13 Table 15 404C-15 Engine 402C-05 Engine Refill Capacities Refill Capacities Compartment or System Compartment or System Minimum Maximum Liters Quarts 4.1 L 6.5 L Engine Only Crankcase Oil Sump (4.3 qt) (6.9 qt) External System Per OEM...
  • Page 42 The Engine Oil Licensing and Certification System by 404C-15 Engine the American Petroleum Institute (API) is recognized Refill Capacities by Perkins. For detailed information about this Compartment or System system, see the latest edition of the “API publication Quarts Liters No.
  • Page 43 The classifications CD-2 and American Petroleum Institute CF- the base stock and with the viscosity grade of the 2 are for two-cycle diesel engines. Perkins does not sell en- gines that utilize CD-2 and API CF-2 oils. finished commercial oil. The use of “API Base Oil Interchange Guidelines”...
  • Page 44 1.5 percent: intervals. API CH-4 oils are recommended for conditions that demand a premium oil. Your Perkins • Choose an oil with the highest TBN that meets dealer or your Perkins distributor has specific one of these classifications: EMA DHD-1 and API guidelines for optimizing oil change intervals.
  • Page 45 Aftermarket Oil Additives Re-refined Base Stock Oils Perkins does not recommend the use of aftermarket Re-refined base stock oils are acceptable for use in additives in oil. It is not necessary to use aftermarket Perkins engines if these oils meet the performance additives to achieve the engine's maximum service requirements that are specified by Perkins.
  • Page 46 To achieve the best performance from a Perkins engine, conform to the following guidelines: Fuel Specifications • Select the correct oil, or a commercial oil that Fuel Recommendations meets the “EMA Recommended Guideline on...
  • Page 47 Table 25 Group 3 (aviation kerosene fuels): Specification Perkins Specifications for Distillate Diesel Fuel Performance of the engine may be reduced if these Specifications Requirements fuels are used.
  • Page 48 Cloud Point est expected ambi- ent temperature. NOTICE Operating with fuels that do not meet the Perkins rec- Copper Strip No. 3 maximum ommendations can cause the following effects: Start- “D130” Corrosion...
  • Page 49 If distilled water or deionized water is not available, use water with the properties that are listed in Table 27 . General Coolant Information Table 27 Perkins Minimum Acceptable Water Requirements NOTICE Never add coolant to an overheated engine. Engine Property Maximum Limit damage could result.
  • Page 50 To check the concentration of glycol in the coolant, measure the specific gravity of the coolant. • Heavy-duty diesel engines Coolant Recommendations • Automotive applications The following two coolants are used in Perkins diesel engines: Preferred – Perkins Extended Life Coolant (ELC)
  • Page 51 Extended Life Coolant contains organic corrosion inhibitors and antifoam (ELC). agents with low amounts of nitrite. Perkins ELC has been formulated with the correct amount of these Do not use standard supplemental coolant additive additives to provide superior corrosion protection for (SCA).
  • Page 52 8. Repeat Steps 6 and 7 until the system is Supplemental Coolant Additive (SCA). completely clean. Additions of SCA are based on the results of the test. 9. Fill the cooling system with the Perkins Premixed An SCA that is liquid may be needed at 500-hour intervals. ELC.
  • Page 53 SCA that is needed. Use the equation that is in Table 34 to determine the amount of Perkins SCA that is required, if necessary: NOTICE Cleaning agents for industrial cooling system must Table 34 not be used.

  • Page 54: Maintenance Interval Schedule

    “ Alternator and Fan Belts - Inspect/Adjust” ..56 Note: The frequency that the engine oil is changed will be affected if the load factor for the engine is greater than 40 percent. Consult your Perkins Every 500 Service Hours distributor if assistance is required to calculate the load factor for your engine.
  • Page 55 SEBU7992-05 Maintenance Section Maintenance Interval Schedule “ Water Pump - Inspect”..... . 81 Every 3000 Service Hours or 2 Years “...
  • Page 56 Maintenance Section Alternator - Inspect 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 57 SEBU7992-05 Maintenance Section Alternator and Fan Belts - Replace 2. Move the alternator in order to increase or i02322315 decrease the belt tension. Battery - Replace 3. Tighten the adjusting bolt (1). Tighten the mounting bolts (2). Refer to the Specifications Manual for the correct torque settings.
  • Page 58 SEBU7992-05 Maintenance Section Battery Electrolyte Level - Check i02747977 i07819485 Battery Electrolyte Level - Battery or Battery Cable - Check Disconnect When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge.
  • Page 59 SEBU7992-05 Maintenance Section Cooling System Coolant (Commercial Heavy-Duty) - Change 1. Stop the engine and allow the engine to cool. i08038786 Loosen the cooling system filler cap slowly to Cooling System Coolant relieve any pressure. Remove the cooling system filler cap. (Commercial Heavy-Duty) - Change NOTICE...
  • Page 60 Do not install the cooling system filler cap. For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer 4. Start and run the engine at low idle. Increase the or your Perkins distributor. engine rpm to high idle. Run the engine at high...
  • Page 61 SEBU7992-05 Maintenance Section Cooling System Coolant (ELC) - Change NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist: •...
  • Page 62 Close the drain cock or install the drain Note: The cooling system may not have been plug on the radiator. provided by Perkins. The procedure that follows is for typical cooling systems. Refer to the OEM NOTICE information for the correct procedures.
  • Page 63 SEBU7992-05 Maintenance Section Cooling System Coolant Level - Check 1. Observe the coolant level in the coolant recovery Note: The coolant will expand as the coolant heats up during normal engine operation. The additional tank. Maintain the coolant level to “COLD FULL” volume will be forced into the coolant recovery tank mark on the coolant recovery tank.
  • Page 64 SEBU7992-05 Maintenance Section Cooling System Supplemental Coolant Additive (SCA) - Test/Add 4. Inspect the cooling system for leaks. NOTICE When any servicing or repair of the engine cooling system is performed the procedure must be per- i03644948 formed with the engine on level ground. This will al- Cooling System Supplemental low you to accurately check the coolant level.
  • Page 65 Note: The air filter system may not have been Steam cleaning the engine will remove accumulated provided by Perkins. The procedure that follows is for oil and grease. A clean engine provides the following a typical air filter system. Refer to the OEM benefits: information for the correct procedure.
  • Page 66 SEBU7992-05 Maintenance Section Engine Air Cleaner Service Indicator - Inspect 6. Install end cover (4) to air cleaner body (2) and secure end cover. If necessary, reset the air service indicator, refer to this Operation and Maintenance Manual, Engine Air Cleaner Service Indicator - Inspect for more information.
  • Page 67 SEBU7992-05 Maintenance Section Engine Crankcase Breather - Replace • Check the movement of the yellow core when the engine is accelerated to the engine rated speed. The yellow core should latch at the greatest vacuum that is attained. If the service indicator does not reset easily, or if the yellow core does not latch at the greatest vacuum, the service indicator should be replaced.
  • Page 68 Refer to the OEM information for the recommended torques. NOTICE When the engine mounts are supplied by Perkins the Care must be taken to ensure that fluids are con- maintenance procedure will be supplied in the tained during performance of inspection, mainte- Disassembly and Assembly manual for your engine.
  • Page 69 34 N·m (300.93 lb in) NOTICE Perkins oil filters are built to Perkins specifications. Use of an oil filter not recommended by Perkins could result in severe engine damage to the engine bear- ings, crankshaft, etc., as a result of the larger waste particles from unfiltered oil entering the engine lubri- cating system.
  • Page 70 Fill the crankcase with the oil filter. Consult your Perkins dealer or your correct amount of oil. Refer to the Operation and Perkins distributor to arrange for a further analysis...
  • Page 71 Only qualified service personel should perform this maintenance. Refer to the Service Manual or your au- Regular maintenance of the fuel injectors is thorized Perkins dealer or your Perkins distributor for recommended by Perkins. The fuel injectors must be the complete valve lash adjustment procedure.
  • Page 72 Do not loosen the union nut more than half a turn. There will be little effect on the engine speed when the union nut to the faulty fuel injector is loosened. Consult your authorized Perkins dealer or your Perkins distributor for further assistance. i08037197 Illustration 48...
  • Page 73 SEBU7992-05 Maintenance Section Fuel System - Prime Illustration 51 g01122126 Connector that is installed on 2 and 3 cylinder engines (4) Connector bolt (5) Fuel return hose for the injector Illustration 50 g06518138 Lift pump hand priming option. Loose part hand priming option. 3.
  • Page 74 SEBU7992-05 Maintenance Section Fuel System Filter - Replace 6. Operate the hand primer. When fuel free from air flows from the connector tighten the connector bolt. 7. Try to start the engine. Note: Do not operate the starting motor for more than 15 seconds.
  • Page 75 SEBU7992-05 Maintenance Section Fuel System Filter - Replace Illustration 55 g01122130 2. Clean the outside of the fuel filter assembly. 3. Loosen the locking ring (3). 4. Remove the casing for the filter (2) and the element. Illustration 54 g00917937 6.
  • Page 76 Engine damage may result. The fuel filter/water separator (if equipped) is not usually supplied by Perkins. The following text describes a typical fuel filter/water separator. Refer to the OEM information for further information on the fuel filter/water separator.
  • Page 77 SEBU7992-05 Maintenance Section Fuel Tank Water and Sediment - Drain Some fuel tanks use supply pipes that allow water NOTICE and sediment to settle below the end of the fuel The water separator is under suction during normal supply pipe. Some fuel tanks use supply lines that engine operation.
  • Page 78 • Anticipated expansion and contraction of the hose • Anticipated expansion and contraction of the fittings The radiator is not usually supplied by Perkins. The following text describes a typical cleaning procedure Replace the Hoses and the Clamps for the radiator. Refer to the OEM information for further information on cleaning the radiator.
  • Page 79 • The temperature of the fluid in the engine • Failure to use recommended fuel, lubricants and Refer to the standards for the engine or consult your coolant/antifreeze Perkins dealer or your Perkins distributor in order to determine if the engine is operating within the defined i07888480 parameters.
  • Page 80 Adjusting Manual, “Electric Starting System - Assembly Manual, “Turbocharger - Remove and Test” for more information on the checking procedure Turbocharger - Install” for further information. and for specifications consult your Perkins dealer or your Perkins distributor for assistance. Inspecting i02184788...
  • Page 81 “Water Pump - Remove and Install” for more and parts contract. information or consult your Perkins dealer or your Perkins distributor. Visually inspect the water pump for leaks. Renew the water pump seal or the water pump if there is an •...

  • Page 82: Warranty Section

    This engine may be covered by an Emissions Warranty. Consult your authorized Perkins dealer or distributor to determine if your engine is emissions certified and if your engine is subject to an Emissions...

  • Page 83: Index

    SEBU7992-05 Index Section Index After Starting Engine ........33 Driven Equipment - Check ......64 After Stopping Engine ........35 Alternator - Inspect .......... 56 Alternator and Fan Belts - Inspect/Adjust ..56 Electrical System..........13 Adjustment........... 56 Grounding Practices ........13 Inspection ............
  • Page 84 SEBU7992-05 Index Section Fuel Specifications ........46 General Lubricant Information..... 42 Lifting and Storage .......... 26 Foreword ............4 California Proposition 65 Warning ....4 Literature Information ........4 Maintenance ..........4 Maintenance Interval Schedule....... 54 Maintenance Intervals ........5 Daily .............
  • Page 85 SEBU7992-05 Index Section Stopping the Engine ........35 Table of Contents ..........3 Turbocharger - Inspect (If Equipped) ....80 Inspecting ............ 80 Removal and Installation ......80 Walk-Around Inspection ........80 Inspect the Engine for Leaks and for Loose Connections ..........
  • Page 87 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 88 SEBU7992 ©2020 Perkins Engines Company Limited All Rights Reserved February 2020...

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