Perkins 403EA-11 Operation And Maintenance Manual
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Perkins 403EA-11 Operation And Maintenance Manual

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M0132847 (en-us)
June 2022
Operation and
Maintenance
Manual
403EA-11, 403EA-11T, 403EA-17,
404EA-22, and 404EA-22T Industrial
Engines
QS (Engine)
QZ (Engine)
QJ (Engine)
QN (Engine)
QP (Engine)

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Summary of Contents for Perkins 403EA-11

  • Page 1 M0132847 (en-us) June 2022 Operation and Maintenance Manual 403EA-11, 403EA-11T, 403EA-17, 404EA-22, and 404EA-22T Industrial Engines QS (Engine) QZ (Engine) QJ (Engine) QN (Engine) QP (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

    M0132847 Table of Contents Maintenance Recommendations ....71 Table of Contents Maintenance Interval Schedule....... 73 Foreword ............4 Warranty Section Safety Section Warranty Information........106 Safety Messages..........6 Reference Information Section General Hazard Information......8 Reference Materials ........107 Burn Prevention..........12 Index Section Fire Prevention and Explosion Prevention..

  • Page 4: Foreword

    Whenever a question constituents are known to the State of arises regarding your engine, or this manual, please consult with your Perkins dealer or your Perkins California to cause cancer, birth defects, distributor for the latest available information.
  • 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 M0132847 Safety Section Safety Messages Illustration 2 g06671757 Typical example of 403EA-11 Industrial Engines Illustration 3 g06671738 Typical example of 403EA-11T Industrial Engines (2) Ether Warning Ether Warning label (2) is installed in different locations. The location will change according to the physical size of the engine.

  • Page 8: General Hazard Information

    M0132847 Safety Section General Hazard Information • Vent the engine exhaust to the outside when the engine is operated in an enclosed area. • If the engine is not running, do not release the secondary brake or the parking brake systems unless the vehicle is blocked or unless the vehicle is restrained.
  • Page 9 Always start and operate the engine in a well ventilated • Perkins recommend that you do not stand next to area and, if in an enclosed area, vent the exhaust an exposed running engine unless it is necessary to the outside.
  • Page 10 M0132847 Safety Section General Hazard Information When pressurized air and/or pressurized water is Dispose of all fluids according to local regulations used for cleaning, wear protective clothing, protective and mandates. shoes, and eye protection. Eye protection includes goggles or a protective face shield. Static Electricity Hazard when The maximum air pressure for cleaning purposes Fueling with Ultra-low Sulfur Diesel...
  • Page 11 (ULSD fuel) poses a greater good hygiene, and adhering to safe work practices static ignition hazard than earlier diesel formula- when handling the equipment or parts. Perkins also tions with a higher sulfur contents. Avoid death recommends the following: or serious injury from fire or explosion.

  • Page 12: Burn Prevention

    M0132847 Safety Section Burn Prevention • Use exhaust ventilation on permanent machining Coolant jobs. When the engine is at operating temperature, the engine coolant is hot. The coolant is also under • Wear an approved respirator if there is no other pressure.

  • Page 13: Fire Prevention And Explosion Prevention

    Appropriate personal If the application involves the presence of protective equipment should be used. Refer to combustible gases, consult your Perkins distributor supplier Material safety Data sheets for detailed for additional information about suitable protection information.
  • Page 14 M0132847 Safety Section Fire Prevention and Explosion Prevention Arcing or sparking could cause a fire. Secure connections, recommended wiring, and properly maintained battery cables will help to prevent arcing or sparking. Ensure that the engine is stopped. Inspect all lines and hoses for wear or for deterioration.

  • Page 15: Crushing Prevention And Cutting Prevention

    Mounting and Dismounting Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Perkins distributor for Inspect the steps, the handholds, and the work area repair or for replacement parts. before mounting the engine. Keep these items clean and keep these items in good repair.

  • Page 16: Engine Starting

    M0132847 Safety Section Engine Starting Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel. Engine exhaust contains products of combustion which may be harmful to your health. Always If equipped, ensure that the lighting system for the start and operate the engine in a well ventilated engine is suitable for the conditions.
  • Page 17 M0132847 Safety Section Electrical System Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical connections before the engine is started. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for specific starting instructions.

  • Page 18: Product Information Section

    M0132847 Product Information Section Model Views Product Information Section Model Views i08625942 Model View Illustrations Industrial Engine Model Views The following model views show typical features of the engine. Due to individual applications, your engine may appear different from the illustrations.
  • Page 19 M0132847 Product Information Section Model View Illustrations 403EA-11 Engine Illustration 15 g06697704 Typical example (1) Front lifting eye (5) Electric starting motor (9) Coolant intake (2) Coolant outlet (6) Alternator (10) Water temperature regulator housing (3) Air intake (7) Drive belt...
  • Page 20 M0132847 Product Information Section Model View Illustrations Illustration 16 g06697711 Typical example (11) Top oil filler (15) Oil gauge (Dipstick) (19) Secondary fuel filter (12) Water pump (16) Oil drain plug (20) Fuel injector (13) Oil filler (lower) (17) Oil filter (14) Cooling drain plug (18) Fuel transfer pump...
  • Page 21 M0132847 Product Information Section Model View Illustrations 403EA-17 Engine Illustration 17 g03378808 Typical example (1) Rear lifting eye (5) Low mounted oil filler cap (9) Oil filter (2) Top engine oil filler cap (6) Fuel injection pump (10) Governor actuator (3) Front lifting eye (7) Oil level gauge (Dipstick) (11) Fuel injector...
  • Page 22 M0132847 Product Information Section Model View Illustrations Illustration 18 g03379877 Typical example (12) Air intake (15) Starting motor solenoid (18) Fan belt (13) Coolant outlet (16) Electric starting motor (19) Coolant intake connection (14) Exhaust manifold (17) Alternator...
  • Page 23 M0132847 Product Information Section Model View Illustrations 404EA-22T Turbocharged Engine Illustration 19 g06697734 Typical example (1) Front lifting eye (5) Turbocharger (9) Oil drain plug (2) Coolant outlet (6) Electric starting motor (10) Coolant intake (3) Exhaust elbow (7) Alternator (11) Water temperature regulator housing (4) Rear lifting eye (8) Drive belt...
  • Page 24 M0132847 Product Information Section Model View Illustrations Illustration 20 g06697770 Typical example (12) Top oil filler (16) Oil gauge (Dipstick) (20) Secondary fuel filter (13) Water pump (17) Oil drain plug (21) Fuel injector (14) Oil filler (lower) (18) Oil filter (15) Cooling drain plug (19) Fuel transfer pump...
  • Page 25 M0132847 Product Information Section Model View Illustrations Off Engine Components Illustration 21 g06747000 Typical example (1) Hand priming pump (2) Atmospheric pressure sensor...
  • Page 26 The pistons have two compression rings and an oil refer to your Perkins distributor. Some fuel injection control ring. It is important to ensure the correct pumps have mechanical governors that control the piston height so that the piston does not contact the engine rpm.
  • Page 27 (A) Exhaust valves (B) Inlet valves Stroke 81 mm (3.19 inch) Displacement 1.131 L (69.0178 in Table 1 Aspiration Turbocharged 403EA-11 Engine Specifications Maximum Operating Speed Compression Ratio 23:1 3600 rpm (rpm) Firing Order 1-2-3 Cylinders and Arrangement In-Line three cylinder...
  • Page 28 M0132847 Product Information Section Product Description 403EA-17 Engine Illustration 26 g00296424 (A) Exhaust valves (B) Inlet valves Illustration 25 g00852304 (A) Exhaust valves Table 4 (B) Inlet valves 404EA-22 Industrial Engines Table 3 Maximum Operating Speed 2800 RPM 403EA-17 Engine Specifications (rpm) Maximum Operating Speed Cylinders and Arrangement...
  • Page 29 Aftermarket Products and Perkins Engines Perkins does not warrant the quality or performance of non-Perkins fluids and filters. When auxiliary devices, accessories, or consumables (filters, additives) which are made by...

  • Page 30: Product Identification Information

    Lubrication Oil Filter Element No. engine to the rear of the engine cylinder block. Auxiliary Oil Filter Element No. Perkins distributors need all the numbers on the plate to determine the components that were included with Supplemental Coolant Additive Maintenance the engine.

  • Page 31: Operation Section

    The engine must be stored in a water proof building. The building must be kept at a constant temperature. Engines that are filled with Perkins ELC will have coolant protection to an ambient temperature of −36° C (−32.8° F). The engine must not be subjected to extreme variations in temperature and humidity.
  • Page 32 Maintenance Manual, “Fluid recommendations”. 4. Remove the drive belt from the engine. Sealed Coolant System Ensure that the cooling system is filled with Perkins ELC, or an antifreeze that meets “ASTM D6210” specification. Open Cooling System Ensure that all cooling drain plugs have been opened.

  • Page 33: Gauges And Indicators

    Determine and correct the cause of any significant 1. Reduce the load on the engine. change in the readings. Consult your Perkins dealer or your Perkins distributor for assistance. 2. Determine if the engine must be shut down...
  • Page 34 M0132847 Operation Section Gauges and Indicators Service Hour Meter – The gauge indicates total operating hours of the engine. Indicator Lamps • Shutdown lamp • Warning lamp • Low oil pressure lamp • Wait to start lamp (Glow plug warning lamp) For information, refer to this manual, “Monitoring System (Table for the Indicator Lamps)”...

  • Page 35: Features And Controls

    • Oil pressure switch • Coolant temperature sensor/switch • Atmospheric pressure sensor (Barometric pressure sensor) • Speed sensor • Governor actuator Sensor Locations for the Engine 403EA-11 Engine Note: In the following illustrations, some components have been removed to improve visibility.
  • Page 36 M0132847 Operation Section Sensors and Electrical Components Illustration 31 g06697388 Typical example (1) Coolant temperature sensor/switch...
  • Page 37 M0132847 Operation Section Sensors and Electrical Components Illustration 32 g06747150 Typical example (2) Speed sensor (3) Governor actuator (4) Oil pressure switch...
  • Page 38 M0132847 Operation Section Sensors and Electrical Components 403EA-11T Engine Illustration 33 g06697927 Typical example (1) Coolant temperature sensor/switch Illustration 34 g06747151 Typical example (2) Governor actuator (3) Oil pressure switch (4) Speed sensor...
  • Page 39 M0132847 Operation Section Sensors and Electrical Components 404EA-22T Turbocharged Engine Illustration 35 g06697297 Typical example (1) Coolant temperature sensor/switch (2) Inlet manifold temperature and pressure sensor (if equipped)
  • Page 40 M0132847 Operation Section Sensors and Electrical Components Illustration 36 g06747162 Typical example (3) Governor actuator (4) Oil pressure switch (5) Speed sensor...
  • Page 41 M0132847 Operation Section Engine Shutoffs and Engine Alarms Detailed views Illustration 37 g06731659 Typical examples (1) Oil pressure sensor (3) Inlet air temperature sensor (if equipped) (2) Coolant temperature sensor/switch (4) Governor actuator Be familiar with the following items: i02672017 •...
  • Page 42 • 403EA-17 2600 Revolution Per Minute (RPM) Refer to the Service Manual for more information on • 404EA-22 3600 Revolution Per Minute testing procedures or consult your Perkins dealer. (RPM) • 404EA-22T Turbocharged engine 3000 i08681759 Revolution Per Minute (RPM) Fuel Shutoff The fuel shutoff actuator is on the fuel injection pump.

  • Page 43: Engine Starting

    M0132847 Operation Section Engine Starting • Do not start the engine or move any of the controls Engine Starting if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the controls. i01486758 Before Starting Engine •...
  • Page 44 M0132847 Operation Section Cold Weather Starting Note: During key ON, the indicator lamps will be 1. Disengage any driven equipment. illuminated for 0.5 of a second to check the lamp Note: During key ON, the indicator lamps will be operation. If any of the indicator lamps do not illuminated for 0.5 of a second to check the lamp illuminate check the bulb.
  • Page 45 M0132847 Operation Section Starting with Jump Start Cables i08704508 NOTICE Using a battery source with the same voltage as the Starting with Jump Start electric starting motor. Use ONLY equal voltage for jump starting. The use of higher voltage will damage Cables the electrical system.
  • Page 46 M0132847 Operation Section After Starting Engine 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 charge the battery. Note: In ambient temperatures from 0° to 48°C (0°...

  • Page 47: Engine Operation

    M0132847 Operation Section Engine Operation 4. Increase the rpm to the rated rpm. Check for fluid Engine Operation leaks and air leaks. The engine may be operated at full rated rpm and at full load when the jacket i08473863 water temperature reaches 60°C (140°F). Engine Operation i01646335 Engaging the Driven...
  • Page 48 M0132847 Operation Section Fuel Conservation Practices • Avoid spilling fuel. Fuel expands when the fuel is warmed up. The fuel may overflow from the fuel tank. Inspect fuel lines for leaks. Repair the fuel lines, as needed. • Be aware of the properties of the different fuels. Use only the recommended fuels.

  • Page 49: Engine Stopping

    M0132847 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 50: 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 51 240 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 52 Perkins recommends a warning device for the inlet head. This action ensures maximum coolant flow to the radiator to achieve maximum heat dissipation.
  • Page 53 M0132847 Operation Section Fuel Related Components in Cold Weather Pour point is the last temperature before the fuel flow Drain the water and sediment from any fuel storage stops and waxing of the fuel will start. tank at the following intervals: weekly, service intervals and refueling of the fuel tank.

  • Page 54: Maintenance Section

    Specifications. Crankcase Oil Sump (1.90 US gal) (2.25 US gal) 403EA-11 Engine Total Lubrication System More than one style of sump may be used on these engines. Table 7 Use these values to estimate the refill capacity. Use the engine oil level gauge to fill the engine to the correct oil level.
  • Page 55 Certain abbreviations follow the nomenclature of “SAE J754”. Some classifications follow “SAE J183” abbreviations, and some classifications follow the (continued) “EMA Recommended Guideline on Diesel Engine Oil”. In addition to Perkins definitions, there are other definitions that will be of assistance in purchasing lubricants.
  • Page 56 Oil for all Perkins engines. Perkins unique oil support off-road applications, including Perkins formulations have been developed to provide full Engines. DO NOT use API FA-4 oil for Perkins performance and maximum service life of your engines. These engine oils are not approved by...
  • Page 57 Aftermarket Oil Additives deterioration of the oil during use. This analysis Perkins does not recommend the use of aftermarket also allows technicians to verify the performance additives in oil. Aftermarket additives are not...
  • Page 58 • Formation of mineral deposits Coolant is normally composed of three elements: Water, additives, and glycol. • Rust Refer to Perkins Diesel Engines Fluids • Scale Recommendations, M0113102 for additional information that relates to coolant. • Foaming of the coolant Many additives are depleted during engine operation.
  • Page 59 Do not use propylene glycol in concentrations that exceed 50 percent glycol because of the reduced The Perkins industrial engines with a NOx reduc- heat transfer capability of propylene glycol. Use ethyl- tion system must be operated with a minimum...
  • Page 60 Note: If the cooling system is already using ELC, agents with low amounts of nitrite. Perkins ELC has cleaning agents are not required to be used at the been formulated with the correct amount of these specified coolant change interval.
  • Page 61 An SCA that is liquid may be needed at 500-hour Perkins. intervals. NOTICE 6. Fill the cooling system with the Perkins Premixed Do not mix types and brands of coolant. ELC. Operate the engine. Ensure that all coolant valves open then stop the engine. When cool Do not mix brands and types of SCAs.
  • Page 62 Use a non-foaming detergent to clean Example Of The Equation For Adding The SCA To The Heavy- oil contamination, consult your Perkins dealer for Duty Coolant At The Initial Fill suitable product.
  • Page 63 M0132847 Maintenance Section General Fuel Information • CFR Co-ordinating Fuel Research NOTICE The footnotes are key part of the Perkins "Specifica- • ULSD Ultra Low Sulfur Diesel tion for Distillate Diesel Fuel" Table. Read ALL of the footnotes. • RME Rape Methyl Ester •...
  • Page 64 M0132847 Maintenance Section General Fuel Information Table 22 "Perkins Specification for Distillate Diesel Fuel" Property UNITS Requirements “ASTM”Test “ISO/Other”Test Aromatics %Volume 35% maximum “D1319” “ISO 3837” %Weight 0.01% maximum “D482” “ISO 6245” Carbon Residue on 10% %Weight 0.20% maximum “D524”...
  • Page 65 EPA and other appropriate regulatory agencies. 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.
  • Page 66 “EU Off-Road Diesel fuel. Acceptable from 2011 MUST have less than 10 PPM sulfur level” All the fuels must comply with the specification in the table for the Perkins Specification Distillate Diesel Fuel. Perkins recommends kinematic viscosities of 1.4 and Diesel Fuel Characteristics 4.5 mm2/sec that is delivered to the fuel injection...
  • Page 67 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 68 EN 15751. If the test shows that the fuel has degraded, fuel tank must be drained and engine • Perkins recommend the use of oil analysis to flashed by running with the fresh high-quality diesel check the quality of the engine oil if biodiesel fuel fuel.
  • Page 69 Perkins. Manual” Fluid Recommendations If biodiesel or biodiesel blends of fuel are to be used, Perkins require the use of Perkins fuel cleaner. The Fuel for Cold-Weather Operation use of the fuel is to remove deposits within the fuel system that is created with the use of biodiesel.
  • Page 70 Maintenance Section General Fuel Information Detailed instructions on the rate of which the fuel • Perkins recommends the use of bulk fuel filter / cleaner must be used are on the container. coalescer units which clean the fuel of both...

  • Page 71: Maintenance Recommendations

    High pressure fuel Refer to the standards for the engine or consult your spray may cause a fire hazard. Failure to follow Perkins distributor to determine if the engine is these inspection, maintenance and service in- operating within the defined parameters.
  • Page 72 • Operating outside the intended application • Operating with fuel which does not meet the standards for distillate diesel fuel as stated in Perkins Diesel Engines Fluids Recommendations, M0113102 • Operating with a blend of distillate fuel which contains more than 20 percent biodiesel Incorrect Maintenance Procedures •...

  • Page 73: Maintenance Interval Schedule

    M0132847 Maintenance Section Maintenance Interval Schedule “ Engine Protective Devices - Check“ ... 96 i08675040 “ Fuel System Filter - Replace“ ....100 Maintenance Interval Schedule “...
  • Page 74 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 75 Used Belt Span (mm) Tension (Nm) Tension (Nm) Frequency (Hz) Frequency (Hz) and (lb) and (lb) 403EA-11 Naturally 167 mm - 205 mm 190-200 Hz 400 N (90 lb) 160-170 Hz 300 N (67 lb) Aspirated 425 to 456 N...
  • Page 76 Alternator and Fan Belts - Replace (Single-V Belt) Removal Procedure 1. If the engine is equipped with fan guards, remove the fan guards. Refer to your Perkins distributor for further assistance. Illustration 47 g06540190 Typical example 1. Position alternator belt (6) onto alternator (3), the water pump pulley, and the crankshaft pulley.
  • Page 77 M0132847 Maintenance Section Battery - Recycle For applications that require multiple drive belts, 4. The NEGATIVE “-” cable connects the NEGATIVE replace the belts in matched sets. “-” battery terminal to the ground plane. Disconnect the cable from the NEGATIVE “-” battery terminal.
  • Page 78 M0132847 Maintenance Section Battery or Battery Cable - Disconnect Clean the battery case with one of the following NOTICE cleaning solutions: Keep all parts clean from contaminants. • Use a solution of 0.1 kg (0.2 lb) baking soda Contaminants may cause rapid wear and shortened component life.
  • Page 79 NOTICE Dispose of used engine coolant or recycle. Various methods have been proposed to reclaim used cool- ant for reuse in engine cooling systems. The full distil- lation procedure is the only method acceptable by Perkins to reclaim the coolant.
  • Page 80 M0132847 Maintenance Section Coolant (ELC) - Change For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or your Perkins distributor. Drain Plugs for Factory Installed Radiators Illustration 49 g06164641 Typical example (2) Three cylinder radiator drain plug...
  • Page 81 M0132847 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 82 • The fuel has entered the cooling system and the engine damage. coolant is contaminated. Perkins engines incorporate a shunt design cooling Note: When the cooling system is cleaned, only system and require operating the engine with a water clean water is needed.
  • Page 83 NOTICE Dispose of used engine coolant or recycle. Various methods have been proposed to reclaim used cool- ant for reuse in engine cooling systems. The full distil- lation procedure is the only method acceptable by Perkins to reclaim the coolant.
  • Page 84 M0132847 Maintenance Section Coolant (Commercial Heavy-Duty) - Change For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or your Perkins distributor. Drain Plugs for Factory Installed Radiators Illustration 52 g06164641 Typical example (2) Three cylinder radiator drain plug...
  • Page 85 M0132847 Maintenance Section Coolant (Commercial Heavy-Duty) - 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 86 M0132847 Maintenance Section Cooling System Coolant Level - Check 7. Start the engine. Inspect the cooling system for leaks and for correct operating temperature. i06914881 Cooling System Coolant Level - Check Pressurized System: Hot coolant can cause seri- ous burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool.
  • Page 87 M0132847 Maintenance Section Cooling System Coolant Level - Check Factory Installed Radiators Illustration 54 g06165264 Typical example • The coolant level (A) is for factory installed • The coolant level (C) is for factory installed radiator with the three cylinder engine. radiator with the four cylinder turbocharged aftercooled engine.
  • Page 88 M0132847 Maintenance Section Cooling System Supplemental Coolant Additive (SCA) - Test/Add Clean the cooling system filler cap and check the Use a Coolant Conditioner Test Kit in order to check the concentration of the SCA. condition of the filler cap gasket (1). Replace the cooling system filler cap if the filler cap gasket (1) or the sealing surface (2) are damaged.
  • Page 89 Servicing the Air Cleaner Elements Personal injury or death can result from high voltage. Note: The air filter system may not have been provided by Perkins. The procedure that follows, is Moisture create paths electrical for a typical air filter system.
  • Page 90 M0132847 Maintenance Section Engine Air Cleaner Service Indicator - Inspect Replace the dirty air cleaner elements with clean air 3. Remove end cover (4) from air cleaner body (2). If cleaner elements. Before installation, the new air necessary, clean end cover and ensure that the cleaner elements should be thoroughly checked for vacuum valve (5) is clean and free from dirt.
  • Page 91 M0132847 Maintenance Section Engine Air Precleaner - Check/Clean Observe the service indicator. The air cleaner Note: When a new service indicator is installed, element should be cleaned or the air cleaner element excessive force may crack the top of the service should be replaced when one of the following indicator.
  • Page 92 (1) Screws for the breather cover recommended torques. (2) Breather cover (3) Spring When the engine mounts are supplied by Perkins the (4) Diaphragm and plate maintenance procedure will be supplied in the (5) Spacer for turbocharged engines only Disassembly and Assembly manual for your engine.
  • Page 93 Perkins recommends using a sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when a sampling valve is used.
  • Page 94 250 hours. If the engine is operated in severe service conditions, i08673384 Perkins recommends the use of engine oil sampling. Refer to this Operation and Maintenance Manual, Engine Oil and Filter - Change Fluid Recommendations, General Lubricant Information and see section Oil Analysis for more information.
  • Page 95 Fill the Engine Crankcase 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- 1. Remove the oil filler cap. Refer to the Operation ings, crankshaft, etc., as a result of the larger waste...
  • Page 96 To prevent damage to the engine, only authorized service personnel or your Perkins distributor should perform the tests. Consult your Perkins distributor or refer to the Service Manual for more information. i06299296 Engine Valve Lash - Check Ensure that the engine cannot be started while this maintenance is being performed.
  • Page 97 Regular maintenance of the fuel injectors is will require checking. The gap between the edge of recommended by Perkins. The fuel injectors must be the cover and the tip of the fan blade (A) must be removed and tested by an authorized agent. The fuel checked in four equally spaced positions.
  • Page 98 1. Ensure that the fuel valve is open. The fuel valve for the fuel filter that has a canister may be located Consult your authorized Perkins dealer or your away from the engine. Refer to the OEM Perkins distributor for further assistance.
  • Page 99 M0132847 Maintenance Section Fuel System - Prime Illustration 67 g06677660 Connector that is installed on 3 cylinder engines (2) Fuel return hose for the injector (3) Connector bolt Illustration 66 g06518138 Lift pump hand priming option (if equipped). Loose part hand priming option. 3.
  • Page 100 M0132847 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 30 seconds.
  • Page 101 M0132847 Maintenance Section Fuel System Primary Filter/Water Separator - Drain The fuel system will need to be primed after the new filter is installed. Refer to this Operation and Maintenance Manual, “Fuel System - Prime”. i08471398 Fuel System Primary Filter/ Water Separator - Drain Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire.
  • Page 102 M0132847 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 103 (if equipped). debris. Clean the radiator, if necessary. The coolant system and the hoses for the coolant system are not usually supplied by Perkins. The following text describes a typical method of replacing coolant hoses. Refer to the OEM information for Personal injury can result from air pressure.
  • Page 104 Test” for more information on the checking procedure contamination. and for specifications consult your Perkins dealer or your Perkins distributor for assistance. NOTICE For any type of leak (coolant, lube, or fuel) clean up i07824273 the fluid.
  • Page 105 M0132847 Maintenance Section Water Pump - Inspect • Inspect the lubrication system for leaks at the front Visually inspect the water pump for leaks. Renew the water pump seal or the water pump if there is an crankshaft seal, the rear crankshaft seal, the oil excessive leakage of coolant.

  • Page 106: Warranty Section

    1 through Tier 4 marine auxiliary engines < 37 kW, “Warranty supplement - Emission warranty parts” but excluding locomotive and other marine available at the Perkins engines website. Consult engines) operated and serviced in the state of your authorized Perkins distributor to determine if...

  • Page 107: Reference Information Section

    (parts, labor, and travel). situation. This should result in a lower engine 2. Enjoy longer lasting product support from Perkins operating cost. global network. Records should be kept for the following items: 3.
  • Page 108 M0132847 Reference Information Section Maintenance Log • Maintenance log i05204675 Maintenance Log Table 25 Engine Model Customer Identifier Arrangement Number Serial Number Service Quantity Of Service Item Date Authorization Hours Fuel...

  • Page 109: Index

    M0132847 Index Section Index Factory Installed Radiators......87 Radiator Cap..........87 After Starting Engine ........45 Cooling System Supplemental Coolant After Stopping Engine ........49 Additive (SCA) - Test/Add......88 Alternator - Inspect .......... 74 Add the SCA, If Necessary ......88 Alternator and Fan Belts - Inspect/Adjust ..
  • Page 110 M0132847 Index Section Engine Valve Lash - Check ......96 Engine Warm-up ..........47 Gauges and Indicators ........33 Indicator Lamps ........... 34 General Hazard Information......8 Containing Fluid Spillage......10 Fan Clearance - Check ........97 Dispose of Waste Properly ......12 Four Cylinder Turbocharged......
  • Page 111 Turbocharger - Inspect ........104 Plate Locations and Film Locations ....30 Serial Number Plate........30 Product Description ......... 26 Aftermarket Products and Perkins Walk-Around Inspection ........ 104 Engines ............29 Inspect the Engine for Leaks and for Loose Engine Specifications ........27 Connections ..........
  • Page 113 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 114 M0132847 ©2022 Perkins Engines Company Limited All Rights Reserved June 2022...

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