Perkins 402J-05 Operation And Maintenance Manual
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Perkins 402J-05 Operation And Maintenance Manual

Operation and maintenance manual
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M0087369-08 (en-us)
April 2021
Operation and
Maintenance
Manual
402J-05, 403J-07, 403J-11, 403J-11T,
403J-15, 403J-17, 403J-17T and 404J-
22 Industrial Engines
IH (Engine)
IF (Engine)
IG (Engine)
IZ (Engine)
IS (Engine)
IK (Engine)
IJ (Engine)
IN (Engine)
Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE

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Summary of Contents for Perkins 402J-05

  • Page 1 Manual 402J-05, 403J-07, 403J-11, 403J-11T, 403J-15, 403J-17, 403J-17T and 404J- 22 Industrial Engines IH (Engine) IF (Engine) IG (Engine) IZ (Engine) IS (Engine) IK (Engine) IJ (Engine) IN (Engine) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • 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

    Features and Controls........37 Engine Starting..........40 Engine Operation ..........43 Cold Weather Operation ......... 45 Engine Stopping ..........49 Maintenance Section Refill Capacities..........50 Maintenance Recommendations ....68 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 4: Foreword

    English is the primary language for all Perkins freezing cold operating conditions, more frequent publications. The English used facilitates translation lubrication, and maintenance than is specified in the and consistency. Maintenance Interval Schedule may be necessary. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 5 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. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 6: Safety Section

    Illustration 1 g01154807 Typical example Warning label (A) is installed in different locations. The location will change according to the physical size of the engine. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 7 Note: The 403J-17T engine and the 403J-17 engine warning label are on the valve mechanism cover. Illustration 3 g06221728 Typical example (A) Location of warning label (5) 403J-11T and 403J-17T Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 8: General Hazard Information

    Ensure that only the fuel supply line is shut off. Ensure that the fuel return line is open. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 9 Refer to the OEM information for any procedures that are required to relieve the hydraulic pressure. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 10 Exhaust debris. Use caution. Exhaust fumes can be hazardous to health. If you operate the equipment in an enclosed area, adequate ventilation is necessary. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 11: Burn Prevention

    Ensure that the filler cap is cool before removing the filler cap. The filler cap must be cool enough to touch with a bare hand. Remove the filler cap slowly to relieve pressure. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 12: Fire Prevention And Explosion Prevention

    The hoses must be correctly routed. The lines and hoses must have adequate support and secure clamps. Tighten all connections to the recommended torque. Leaks can cause fires. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 13 Never check the battery charge by placing a metal • Flexible parts of the hoses are kinked. object across the terminal posts. Use a voltmeter or a hydrometer. • Outer covers have embedded armoring. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 14: Crushing Prevention And Cutting Prevention

    This may be accomplished by shutting off the around the parts carefully. air and/or fuel supply to the engine. Start the engine from the operator's compartment or from the engine start switch. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 15: Engine Stopping

    To stop an electronically controlled engine, cut the power to the engine and/or shutting off the air supply to the engine. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 16: Product Information Section

    (4) Oil gauge (Dipstick) (7) Stop Solenoid (2) Water Temperature Sensor (5) Oil Filter (8) Secondary Fuel Filter (3) Water Pump (6) Mechanical Fuel Pump (Low Pressure) (9) Oil Filler Cap Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 17 Typical example (10) Rear Engine Lifting Eye (13) Alternator (16) Front Engine Lifting Eye (11) Coolant Temperature Regulator (14) Oil Drain Plug (12) Starting Motor (15) Fan Belt Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 18 (8) Engine oil cooler (13) Secondary fuel filter (4) Water pump (9) Oil drain plug (14) Stop solenoid (not shown) (5) Low mounted oil filler cap (10) Oil filter (15) Crankcase breather Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 19 Illustration 16 g06573853 Typical example (16) Rear lifting eye (19) Oil drain plug (22) Air intake (17) Exhaust elbow (20) Alternator (23) Breather tube heater (18) Starting motor (21) Turbocharger Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 20 Product Information Section Model View Illustrations Illustration 17 g06573867 Typical example (20) Water temperature sensor (22) Water inlet (24) Water outlet (21) Fan belt (23) Water temperature regulator housing Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 21 (2) Front lifting eye (6) Oil drain plug (10) Fuel injector (3) Low mounted oil filler cap (7) Oil filter (11) Glow plug (4) Fuel injection pump (8) Coolant drain Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 22 (13) Rear lifting eye (17) Starting motor (21) Coolant outlet (14) Coolant temperature switch (18) Alternator (22) Oil pressure switch (15) Coolant temperature sensor (19) Fan belt (23) Air intake Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 23 (2) Top oil filler cap (6) Fuel injection pump (10) Stop solenoid (3) Front lifting eye (7) Oil gauge (Dipstick) (11) Injector (4) Water pump (8) Oil drain plug Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 24 Illustration 21 g03379877 Typical example (12) Air intake (15) Solenoid for starter (18) Fan belt (13) Coolant outlet (16) Starting motor (19) Coolant intake connection (14) Exhaust manifold (17) Alternator Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 25 (9) Oil drain plug (2) Coolant outlet (6) Starting motor (10) Coolant Intake (3) Rear lifting eye (7) Alternator (11) Water temperature regulator housing (4) Exhaust elbow (8) Fan belt (Thermostat housing) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 26 (20) Fuel pump (Mechanical) (13) Air intake (17) Oil gauge (Dipstick) (21) Secondary fuel filter (14) Water pump (18) Oil drain plug (22) Fuel injector (15) Oil filler (lower) (19) Oil filter Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 27 The 403J-11G Industrial Open Power Unit (IOPU) Engine View Illustration 24 g06470243 Typical example (1) Air filter assembly (3) Coolant overflow hose (2) Engine air cleaner service indicator (4) Radiator cap Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 28 (5) Coolant drain valve (guard removed for (6) Air filter assembly valve clarity) Fuel System Components Illustration 26 g03379882 Typical examples (1) In-line fuel filter (2) Electric fuel pump Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 29 67 mm (2.64 inch) Stroke 72 mm (2.83 inch) Table 1 402J-05 Engine Specifications Displacement 0.762 L (46.500 in Maximum Operating Speed Aspiration Naturally Aspirated 3600 rpm (rpm) (continued) (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 30 Firing Order 1-2-3 Rotation that is viewed from the Counterclockwise flywheel Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) Valve Lash Setting (Exhaust) 0.20 mm (0.008 inch) Injection Indirect Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 31 0.20 mm (0.008 inch) Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) Valve Lash Setting (Exhaust) 0.20 mm (0.008 inch) Valve Lash Setting (Exhaust) 0.20 mm (0.008 inch) Injection Injection Indirect Indirect Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 32 Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) Valve Lash Setting (Exhaust) 0.20 mm (0.008 inch) Valve Lash Setting (Exhaust) 0.20 mm (0.008 inch) Injection Injection Indirect Indirect Naturally Aspirated Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 33: Product Identification Information

    Illustration 36 g02157153 Typical example Illustration 36 is a representation of the label that will be installed next to the fuel filler cap on the fuel tank of the application. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 34 Primary Fuel Filter Secondary Fuel Filter Element Lubrication Oil Filter Element (If Equipped) Auxiliary Oil Filter Element Total Lubrication System Capacity Total Cooling System Capacity Air Cleaner Element Alternator Belt Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 35: 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. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 36 6 months. For the correct specification of engine oil refer to this Operation and Maintenance Manual, “Fluid recommendations”. 4. Remove the fan belt from the engine. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 37: Features And Controls

    • 403J-11T 2800 RPM procedure: • 403J-15 2800 RPM 1. Reduce the load and the engine rpm. • 403J-17 2800 RPM 2. Inspect the cooling system for leaks. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 38 Components The following sensors or switches are installed on the 402J-05, 403J-07, 403J-11, 403J-11T, 403J-15, 403J-17, 403J-17T and the 404J-22 engines: • Oil pressure switch • Coolant temperature sensor Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 39 (4) Stop solenoid (7) Electric fuel pump (2) Coolant temperature sensor (5) Glow plug (3) Oil pressure sensor (6) Starting motor Note: Some engines will have a mechanical fuel pump installed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 40: Engine Starting

    NOTICE Do not crank the engine for more than 30 seconds. Allow the electric starting motor to cool for two mi- nutes before cranking the engine again. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 41 1. Turn the start switch on the stalled engine to the speed with no load for 2 minutes. OFF position. Turn off all the engines accessories. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 42 Comparing the data over time will help to determine normal readings for each gauge. Comparing data over time will also help detect abnormal operating developments. Significant changes in the readings should be investigated. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 43: Engine Operation

    One faulty battery cell will overwork the alternator. express any guarantee of the performance of a This fault will consume excess power and excess particular engine. fuel. • The belt should be in good condition. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 44 Keep cooling system components clean and keep cooling system components in good repair. Never operate the engine without water temperature regulators. All of these items will help maintain operating temperatures. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 45: Cold Weather Operation

    Provide cooling system protection for the lowest expected outside temperature. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” for the recommended coolant mixture. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 46 This starting and stopping can cause the following problems: • Valves become stuck. • Pushrods may become bent. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 47 Note: Group 3 fuels reduce the life of the engine. The cab should be insulated to reduce heat loss to the outside air. use of Group 3 fuels is not covered by the Perkins warranty. i05340086 Group 3 fuels include Low Temperature Fuels and Fuel and the Effect from Cold Aviation Kerosene Fuels.
  • Page 48 Fuel Heaters Fuel heaters help to prevent fuel filters from plugging in cold weather due to waxing. For further information on fuel heaters, consult your Perkins dealer or distributor. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 49: Engine Stopping

    For more information about the emergency stop button, refer to the OEM information. Ensure that any components for the external system that support the engine operation are secured after the engine is stopped. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 50: Maintenance Section

    Engines with auxiliary oil filters will require more oil. Refer to Total Lubrication System the OEM specifications for the capacity of the auxiliary oil filter. (continued) (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 51 The Total Cooling System capacity includes the capacity of the Engine plus the External System. Enter the value for the ca- pacity of the Total Cooling System in this row. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 52 Total Cooling System in this row. Refill Capacities Compartment or System Quarts Liters Engine Only Engine and Radiator Industrial Open Power Unit (IOPU) External System Per OEM Total Cooling System (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 53 170 mg/L must be either protected to the lowest outside tem- Total Hardness perature or drained completely to prevent damage. 340 mg/L Total Solids Acidity pH of 5.5 to 9.0 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 54 Note: 100 percent pure glycol will freeze at a meets the ASTM D3306 specification. This type of temperature of −13 °C (8.6 °F). coolant/antifreeze is made for light automotive applications. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 55 As needed, add the coolant mixture to fill the system to the specified level. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 56 ONE of V is the total volume of the cooling system. the following procedures: X is the amount of SCA that is required. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 57 Typical API symbol Cleaning the System of Heavy-Duty Antifreeze • Clean the cooling system after used coolant is drained or before the cooling system is filled with new coolant. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 58 The correct SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start-up, and the maximum ambient temperature during engine operation. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 59 • ULSD Ultra Low Sulfur Diesel • Tests are conducted to detect contamination of the oil by water, glycol, or fuel. • v/v (volume of solute)/(volume of solution) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 60 45 minimum in European Union Cloud Point °C The cloud point must not “D2500” “ISO 3015” exceed the lowest expected ambient temperature. Copper Strip Corrosion No. 3 maximum “D130” “ISO 2160” (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 61 Additional limit for fuel containing FAME. Fuel containing more than 2% v/v FAME must meet both tests. Note: The owner and the operator of the engine has the responsibility of using the fuel that is prescribed by the EPA and other appropriate regulatory agencies. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 62 “Japanese Diesel Fuel” Must meet the requirements that are stated in the lubricity section of this “Operation and Maintenance Manual” Fluid Recommendations. “BS 2869: 2010 CLASS A2 or EU equivalent” UK Off-Road Diesel fuel (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • 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 United States. This biodiesel is standards is required. derived from soybean oil. Soybean oil or rapeseed oil are the primary feedstocks. These fuels are together known as Fatty Acid Methyl Esters (FAME). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 65 The oxidation process can cause the more information refer to Perkins Diesel Fuel formation of deposits therefore these materials must Cleaner. not be used for fuel tanks and fuel lines. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 66 These deposits can create a loss of used at temperatures as low as −44 °C (−47.2 °F). power and engine performance. Refer to “EN590” for a detailed discretion of the physical properties of the fuel. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 67 • Cover, protect, and ensure cleanliness of all connection hoses, fittings, and dispensing nozzles. Consult your local Perkins distributor for additional information on Perkins designed and produced filtration products. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 68: Maintenance Recommendations

    • Operational Altitude • Operating at excessive loads • Maintenance intervals • Operating at excessive speeds • Oil selection and maintenance • Coolant type and maintenance • Environmental qualities Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 69 M0087369-08 Maintenance Section Severe Service Application • Operating outside the intended application Incorrect Maintenance Procedures • Extending the maintenance intervals • Failure to use recommended fuel, lubricants, and coolant/antifreeze Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 70: Maintenance Interval Schedule

    “ Fuel System Primary Filter - Replace“ ..97 “ Fuel System Secondary Filter - Replace“..99 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 71 Loose belts may slip enough to cause overheating. To check accurately the belt tension, a suitable gauge should be used. Illustration 45 g06582287 Typical example Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 72 (60 to 80 lb) 400 to 489 N 267 to 356 N 404-22 236 mm - 247 mm 130-150 Hz 110 -130 Hz (90 to 110 lb) (60 to 80 lb) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 73 Illustration 48 g03383665 1. Loosen adjusting bolt (1) and mounting bolt and Typical example nut (2). Loosen bolt (3). 2. Move the alternator to increase or decrease the belt tension. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 74 3. Remove the belt (5). 5. Remove the used battery. 4. Install new belt (5) and adjust the alternator to the 6. Install the new battery. required tension. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 75 Thoroughly rinse the battery case with clean stop the engine and wait until the cooling system water. components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 76 Cooling system air locks may result in engine engine. damage. 3. Remove the drain plug or open the drain tap on the radiator. 4. Allow the coolant to drain. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 77 Dispose of all fluids according to Local regulations and mandates. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 78 Cooling system air locks may result in engine 3. Remove the drain plug or open the drain tap on the damage. radiator. 4. Allow the coolant to drain. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 79 Level ground will allow you to check accurately the coolant level. This checking will also help in avoiding the risk of in- troducing an air lock into the coolant system. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 80 Note: If only the water temperature regulators are replaced, drain the coolant from the cooling system to a level that is below the water temperature regulator housing. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 81 To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 82 Do not replace the air cleaner filter elements in a dirty environment, as dirt can enter the air system when the elements are removed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 83 (Not Shown) and install new primary air filter element (3). Service indicators are important instruments. • Check for ease of resetting. The service indicator should reset in less than three pushes. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 84 (6) Screws for baffle plate (7) Baffle plate (8) Gauze (9) Vent hole 1. Loosen the screws (1) and remove the breather cover (2) from the valve mechanism cover. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 85 (4) and gauze (9). Check the condition of baffle plate (8) and replace, if necessary. 5. Clean the vent hole (11) and the cavity (10) in the valve mechanism cover. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 86 2. Remove the oil filler cap and add oil, if necessary. Clean the oil filler cap. Install the oil filler cap. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 87 “Severe Service Application” for more information on reducing the engine oil and filter change period. For severe service applications the recommended oil and filter change period is 250 hours. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 88 2. Clean oil drain plug (6). 3. Install drain plug (6) to engine oil pan outlet (5). Tighten the drain plug to a torque of 26 N·m (230.12 lb in). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 89 The maintenance for the valve lash is important damage. in order to keep the engine compliant. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 90 (0.07874 inch). If it is not possible to achieve the minimum fan tip clearance, inspect the radiator mounts. Refer to this Operation and Maintenance Manual, “Engine Mounts - Inspect” for further information. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 91 1. Turn the fuel supply valve (if equipped) to the OFF start. position. Remove clamp (3) and remove clamp (6). 2. Remove inlet hose (4) and remove outlet hose (5) • Not enough power from in-line filter (1). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 92 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. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 93 Illustration 72 g06221845 1. If equipped, operate the hand priming pump (2) until fuel free from air comes from the vent screw (1). Then close vent screw (1) by hand. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 94 • Hand priming pump • In-line hand priming pump • Electrical priming pump • Transfer pump that is operated by the starting motor Illustration 75 g01327361 Canister (4) Vent screw Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 95 1. Ensure that fuel valve (2) for the fuel filter that has an element is in the ON position. Refer to To identify the hand priming pump, refer to illustration illustration 74 . 77 . Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 96 Stop the fuel transfer pump. To identify the electrical priming pump, refer to 4. Loosen connection (10 or 12) at the fuel injection illustration 77 . pump. Refer to illustration 78 . Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 97 Clean up any spilled fuel. Clean the outside body 5. Remove the filter element (2) from the fuel filter of the filter assembly. base (1). Discard the filter element (2). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 98 Tighten the filter bowl (4) by hand. Typical example 1. Open drain (1). Catch the draining fluid in a suitable container. Dispose of the drained fluid correctly. 2. Close drain (1). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 99 Typical example 5. Assemble the following items: new seals (8), new seal (7), new canister (3), and bowl (10). Place washer (5) and new seal (6) on setscrew (2). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 100 Refer to Operation and Maintenance Manual, “Fuel System - Prime”. Fuel Filter with Priming Pump 1. Close the fuel supply valve. 2. Clean the outside of the fuel filter assembly. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 101 • Cracking hoses for the coolant system. • Softness • Loose clamps Replace hoses that are cracked or soft. Tighten any loose clamps. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 102 • Incorrect mounting of the radiator Inspect the radiator for these items: Damaged fins, • Deterioration of the radiator mounts corrosion, dirt, grease, insects, leaves, oil and other debris. Clean the radiator, if necessary. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 103 (2) for deterioration, wear, and damage. by a significant engine performance loss (exhaust smoke or engine rpm up at no load), do not continue engine operation until the turbocharger is renewed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 104 Note: The water pump seal is lubricated by the coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and the parts contract. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 105 A failed water pump may cause severe engine overheating problems that could result in the following conditions: • Cracks in the cylinder head • A piston seizure • Other potential damage to the engine Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 106: Warranty Section

    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. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 107: Reference Information Section

    Reference Materials Reference Information Section Reference Materials i05204675 Maintenance Log Table 38 Engine Model Customer Identifier Arrangement Number Serial Number Service Quantity Of Service Item Date Authorization Hours Fuel (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 108 Technicians. The Support Service is equipped, and available around the clock to get your engine running again with the minimum of downtime. Buying an ESC means that you get all this for free. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

  • Page 109: Index

    Fluid Recommendations ......53, 57 Test for SCA Concentration ......81 ELC Cooling System Maintenance....55 Crushing Prevention and Cutting Prevention.. 14 Engine Oil ............ 57 General Coolant Information ....... 53 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 110 Product Description......... 29 Ultra-low Sulfur Diesel Fuel ....... 10 Engine Specifications ........29 General Information ........16 Product Identification Information ....33 Product Information Section......16 Product Lifting ..........35 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 111 Removal and Installation ......104 Walk-Around Inspection ........ 104 Inspect the Engine for Leaks and for Loose Connections ..........104 Warranty Information........106 Warranty Section ........... 106 Water Pump - Inspect........105 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 112 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 113 Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number: Dealer Information Name: Branch: Address: Dealer Contact Phone Number Hours Sales: Parts: Service: Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
  • Page 114 M0087369 ©2021 Perkins Engines Company Limited All Rights Reserved April 2021 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

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