Perkins 402J-05 Systems Operation Testing And Adjusting

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Operation and maintenance manual (114 pages)

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M0087365-02 (en-us)

October 2022

Systems Operation

Testing and Adjusting

402J-05, 403J-07, 403J-11, 403J-11T,

403J-15, 403J-17 and 403J-17T

Industrial Engines

IH (Engine)

IF (Engine)

IG (Engine)

IZ (Engine)

IS (Engine)

IK (Engine)

IJ (Engine)

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Page 1 Systems Operation Testing and Adjusting 402J-05, 403J-07, 403J-11, 403J-11T, 403J-15, 403J-17 and 403J-17T Industrial Engines IH (Engine) IF (Engine) IG (Engine) IZ (Engine) IS (Engine) IK (Engine) IJ (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
Cylinder Head - Inspect ........73 Piston Height - Inspect.........74 Flywheel - Inspect ..........75 Flywheel Housing - Inspect ........76 Gear Group - Inspect...........78 Electrical System Alternator - Test...........79 Battery - Test ............80 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 4: Systems Operation Section
Adjustments to the fuel injection pump timing and high idle should only be made by trained personnel. The fuel injection pumps have mechanical governors that control the engine rpm. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 5 (4) Oil gauge (Dipstick) (7) Fuel shutoff solenoid (2) Coolant temperature sensor (5) Oil filter (8) Secondary fuel filter (3) Water pump (6) Fuel transfer pump (9) Oil filler cap Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 6 Illustration 2 g06555606 Typical example (10) Rear lifting eye (13) Alternator (16) Front lifting eye (11) Water temperature regulator (14) Oil drain plug (12) Starting motor (15) Fan belt Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 7 (9) Oil drain plug (2) Coolant outlet (6) Electric starting motor (10) Coolant intake (3) Rear lifting eye (7) Alternator (11) Water temperature regulator housing (4) Exhaust elbow (8) Drive belt Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 8 (20) Fuel transfer pump (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 9 (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 10 (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 11 (2) Top engine oil filler cap (6) Fuel injection pump (10) Fuel shutoff solenoid (3) Front lifting eye (7) Oil level gauge (Dipstick) (11) Fuel injector (4) Water pump (8) Oil drain plug Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 12 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 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 13 (9) Oil drain plug (2) Coolant outlet (6) Electric starting motor (10) Coolant intake (3) Rear lifting eye (7) Alternator (11) Water temperature regulator housing (4) Exhaust elbow (8) Drive belt Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 14 (20) Fuel transfer pump (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 15: Fuel System Components
Fuel System General Operation of the Fuel System Refer to Systems Operation, “General Information” for locations of the components for the fuel system. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 16 The fuel filter (5) can also function as a water separator. The fuel filter can be drained through a valve that is located at the bottom of the filter housing. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 17 • A leak exists in the low pressure side of the fuel system. In order to release air from the fuel injection pump and the fuel injectors, refer to Testing and Adjusting, “Fuel System - Prime”. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 18 The fuel rack automatically returns to the excess fuel position when the engine is stopped. The excess fuel position aids the cold starting of the engine. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 19: Fuel Injection Pump
A fuel delivery valve (2) for each cylinder acts as a check valve in order to prevent a loss of pressure to the fuel injector. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 20: Fuel Priming Pump
The sequence of the strokes by all the pistons in all the engine cylinders provides constant air flow from the air inlet system during the engine operation. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 21: Cylinder Head And Valves
(11). The energy of the exhaust gas turns the turbine wheel (8). Then, the exhaust gas flows out of the turbine housing (7) through the exhaust outlet (9). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 22: Crankcase Breather
• Crankshaft The oil filter is a spin-on filter that is disposable. • Idler gear • Camshaft • Valve lifters • Pushrods • Rocker arms • Valve springs Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 23: Cooling System
• Pressure cap for the radiator which flows around the relief valve, flows to the oil filter. • Fan for the radiator • Drive pulley (if equipped) for the fan • Water pump Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 24: Basic Engine
The piston pin is off-center to reduce the noise level. The pistons have two compression rings and an oil control ring. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 25 The idler gear contains the oil pump. The idler gear • Linkage for the fuel injection pump turns the gear for the tachometer. • Fuel Control lever for the governor • Throttle Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 26: Engine Electrical System
• Cables If the engine has a disconnect switch, the starting circuit can operate only after the disconnect switch is • Wires for the battery put in the “ON” position. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 27 The starting switch is in operation only when the start switch is activated. The charging circuit is connected through the ammeter. The starting circuit is not connected through the ammeter. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 28 M0087365-02 Systems Operation Section Automatic Shutdown System Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 29 (15) Automatic shutdown device (4) Battery (10) Fuse (16) Electrical connector (5) Electric starting motor (11) Ignition switch (17) Delay fuse (6) Warning lamp (oil pressure) (12) Signal for glow plugs Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 30 (4) Electric starting motor (10) Fuse (16) Electrical connector (5) Warning lamp (oil pressure) (11) Ignition switch (17) Delay fuse (6) Engine oil pressure switch (12) Signal for glow plug Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 31 (8) Coolant temperature switch (13) Fuel shutoff solenoid (4) Electric starting motor (9) Fuse (14) Automatic shutdown device (5) Warning lamp (oil pressure) (10) Ignition switch (15) Electrical connector Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 32 (9) Coolant temperature switch (15) Automatic shutdown device (4) Electric starting motor (10) Fuse (16) Electrical connector (5) Tachometer (11) Ignition switch (6) Warning lamp (oil pressure) (12) Signal for glow plug Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 33: Electrical Connector
Note: The rated current draw of the engine oil pressure switch is 0.42 amperes (5 watts maximum bulb). Note: If necessary, a delay fuse should be used for replacement. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 34: Starting System Components
The regulator then uses switches to control the current to the field windings. This controls the voltage output in order to meet the electrical demand of the system. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 35: Other Components
The solenoid will now take a smaller amount of current from the battery. Heat that is created by the solenoid will be kept at an acceptable level. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 36: Testing And Adjusting Section
(3) Excessive air bubbles in the fuel are not acceptable. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 37: Finding Top Center Position For No. 1 Piston
Old This procedure sets the No. 1 piston at the top center shims should not be used. position on the compression stroke. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 38: Fuel Injector - Test
The dirt can also Perform the following procedures in order to distort the spray pattern of the nozzle. determine if a fuel injector does not work correctly. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 39: Leakage Test
3. Look for any leakage in the connection from the adapter to the fuel injector (2). If leakage is visible, make sure that the components are tightened to the correct torque. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 40 (5) Fuel Collector (6) Filter The pressure adjustment must be correct before you test the spray pattern. This procedure tests for the correct spray pattern for the fuel injectors. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 41: Fuel Quality - Test
• Cetane number of the fuel • Fuel should be sprayed evenly in a 360 degree pattern around the nozzle. • Air in the fuel Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 42: Fuel System - Prime
Typical example 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 43 There are three types of fuel filter that may be installed on the engine. • Element • Canister • Spin-on filter with fuel priming pump Illustration 46 g01327361 Typical example of a canister (4) Vent screw Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 44: Priming The System
Refer to illustration 48 . • Hand priming pump • In-line hand priming pump • Electrical priming pump • Transfer pump that is operated by the starting motor Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 45 (6) Hand priming pump (8) Electrical priming pump (7) In-line priming pump (9) Fuel transfer pump with hand priming Illustration 49 g06523835 (10) Connector bolt (11) Fuel return line (12) Connector bolt Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 46: Fuel Transfer Pump
1. Ensure that fuel valve (2) for the fuel filter that has an element is in the ON position. Refer to illustration 45 . 2. Loosen vent screw (3), (4), or (5) on the fuel filter. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 47: Gear Group (Front) - Time
Table 4 Required Tools Tool Part Number Part Description 21825617 Dial Indicator graduated in 0.01 mm (0.0004 inch) (continued) Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 48 7. Release locknut (3). Turn high idle trimmer screw (2) for four turns counterclockwise and tighten locknut (3). 8. Accelerate the engine to high idle. Use Tooling (F) and record the engine rpm as “Speed B” . Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 49 Disassembly and Assembly, “Crankshaft Pulley - Remove” Illustration 55 g01494273 5. Install Tooling (E) to lever assembly (9). Tighten tooling (E) to a torque of 0.4 N·m (3.540 lb in). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 50 13. Push Tooling (A) into Tooling (B) for a further 2 mm (0.0787 inch). Lock Tooling (B) in order to retain Tooling (A) in position. Set Tooling (A) to read 2.00 ± 0.01 mm (0.0787 ± 0.0004 inch). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 51 Disassembly and Assembly, “Housing (Front) - Remove” for the correct procedure. 4. Disassemble the original front housing. Refer to Disassembly and Assembly, “Housing (Front) - Disassemble” for the correct procedure. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 52 3. Use an allen wrench (13) to rotate the allen head screw. Observe the reading on the dial indicator. Adjust the allen head screw until the indicator reads 2.00 ± 0.01 mm (0.0787 ± 0.0004 inch). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 53 8. Install the replacement front housing (7) Refer to Disassembly and Assembly, “Housing (Front) - Install” for the correct procedure. Illustration 64 g01494273 6. Remove Tooling (E) from lever assembly (9). Illustration 66 g01494533 Typical example Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 54 11. Release locknut (3). Set the high idle trimmer screw (2) to the fully out position. Turn the screw clockwise for two turns. Tighten locknut (3). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 55: Air Inlet And Exhaust System
If the end of housing the shroud has a skin of plastic, remove the skin of • Inspection of the wastegate plastic. Ensure that all of the debris is removed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 56 Replace the damage. Replace the turbocharger. oil drain line if there is any sign of damage to the oil drain line. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 57: Compression - Test
2. Remove the boost line from the wastegate. Connect an air supply to the wastegate that can be Illustration 69 g00564993 adjusted accurately. Checking compression of the engine Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 58: Engine Valve Lash - Inspect/Adjust
Hot engine components can cause burns. Allow front housing must be installed. additional time for the engine to cool before measuring valve clearance. Valve Lash Setting The valve lash setting is for a cold engine. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 59 No. 1 cylinder and the exhaust valve for No. 2 cylinder. c. After each adjustment, tighten the valve adjustment screw locknut while adjustment screw (2) is being held from turning. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 60: Valve Depth - Inspect
Set the position of the the minimum, the maximum, and the service wear needle of the dial indicator to zero. limits for the valve depth below the cylinder head face. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 61 Determine if the distance is greater than the maximum clearance of the valve in the valve guide. Refer to Specifications, “Cylinder Head Valves” for the maximum clearance of the valve in the valve guide. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 62: Lubrication System
2. Disassemble the engine oil pump. Refer to Disassembly and Assembly, “Engine Oil Pump - Remove” for additional information. Do not remove bushing (9) from idler gear (10) unless damage is observed. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 63: Excessive Bearing Wear - Inspect
5. Use feeler gauge (12) to measure the distance an oil passage. between C-clip (1) and collar (2). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 64: Inspection Procedure
• Leaks past the seal rings in the turbocharger shaft • Overfilling of the crankcase • Wrong oil level gauge or guide tube • Sustained operation at light loads Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 65: Cooling System
Check the radiator for debris, dirt, or restriction. deposits on the inside of the core. Debris, dirt, or deposits will restrict the flow of coolant through the radiator. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 66: Cooling System - Inspect
1. Check the coolant level in the cooling system. 2. Look for leaks in the system. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 67 Remove any deposits that are found on these items, and remove any material that is found on these items. 3. Install the pressure cap onto a suitable pressurizing Pump. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 68: Water Temperature Regulator - Test
The inside of the cooling system has leakage only minutes. if the following conditions exist: • The reading on the gauge goes down. • You do NOT observe any outside leakage. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 69: Water Pump - Inspect
The water pump bearing may eventually fail due to insufficient c. Pressurize the cooling system using radiator/ lubrication. shunt tank filler neck adaptor and a source of Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 70 If no leak is observed, after repeated hot shutdowns on a stationary application, it is likely the leak is related to the operation of the application. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 71: Basic Engine
Note: On 403J-17T engine, the pistons have a tapered top groove and the piston ring is wedged. The clearance for the top piston ring cannot be checked by the above method when this occurs. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 72: Connecting Rod Bearings - Inspect
± 0.08 mm (± 0.0031 inch). 3. Inspect the piston pin bearing and the piston pin for wear and other damage. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 73: Cylinder Block - Inspect
3. Inspect the bottom surface of the cylinder head for pitting, corrosion, and cracks. Inspect the area around the valve seats and the holes for the fuel injectors. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 74: Piston Height - Inspect
Illustration 88 g00907448 rod and installed in the original cylinder. Typical example Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 75: Flywheel - Inspect
(1.0 inch) of the radius of the flywheel. The radius of the flywheel is measured from the axis of the crankshaft to the contact point of the dial indicator. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 76: Flywheel Runout
3. Turn the flywheel while the dial indicator is set at Part Part Name 0.0 mm (0.00 inch) at location (A). Read the dial Number indicator at locations (B), (C), and (D). 21825617 Dial Indicator Group Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 77 Checking bore runout of the flywheel housing 2. Turn the flywheel while the dial indicator is set at 0.0 mm (0.00 inch) at location (A). Read the dial indicator at locations (B), (C), and (D). Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 78: Gear Group - Inspect
Refer to Illustration 96 . If the backlash measurement is greater than the maximum, install new gears. Note: Refer to Specifications, “Gear Group (Front)” for the minimum and maximum backlash measurements. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 79: Electrical System
14.0 ± 0.5 volts. Refer to the amperes. The actual length of time for the Fault Conditions And Possible Causes in Table 11 decrease to 10 amperes depends on the following conditions: Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 80: Battery - Test
There are no adjustments on maintenance free batteries. A large amount of water would be more than one ounce of water per cell per week or per every 100 service hours. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 81: Electric Starting System - Test
Check of the circuit breaker and wiring. If there is a voltage reading, the problem is in the start switch or in the wires for the start switch. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 82: Fuel Shutoff Solenoid - Test
3. Use a suitable digital multimeter to measure the current through the fuel shutoff solenoid. Connect the battery, the fuel shutoff solenoid, and the leads of the multimeter in series. Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 83: Glow Plugs - Test
(1). Connect the cable for the power supply to the glow plugs. 402J-05, and 403J-07 ....1.0 ohm 403J-11, 403J-11T, 403J-15, 403J-17, and 403J- 17T .
Page 84 M0087365-02 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 85: Index
Excessive Engine Oil Consumption - Inspect..64 Engine Oil Leaks into the Combustion Area of the Cylinders ............64 Engine Oil Leaks on the Outside of the Engine ...64 Main Bearings - Inspect ........72 Introduction .............64 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 86 Inspection of the Turbine Wheel and the Turbine Housing............56 Inspection of the Wastegate......57 Water Pump - Inspect ..........69 Water Temperature Regulator - Test .....68 Introduction .............68 References .............68 Test Preparation ..........68 Test Procedure ..........68 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...
Page 87 Copyright of Perkins Engine Company Limited. NOT FOR REPRINTING OR RESALE...

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403j-07 403j-11 403j-11t 403j-15 403j-17 403j-17t

Perkins 402J-05 Systems Operation Testing And Adjusting

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