SEBU9064 June 2013 Operation and Maintenance Manual 402F-05, 403F-07, 403F-11, and 403F-15 Industrial Engines EG (Engine) EH (Engine) EJ (Engine) EK (Engine)
These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the most current information available. When replacement parts are required for this product Perkins recommends using Perkins replacement parts.
Operation and Maintenance Manual except for the Operation interval and the maintenance items in that interval. Major repairs should only be carried out by Perkins Operating techniques outlined in this manual are authorized personnel. Your Perkins dealer or your basic. They assist with developing the skills and...
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 dealer or your distributor can provide new warning signs. (A) Universal Warning...
General Hazard Information Illustration 2 g03378379 Typical examples (A) Location of warning label (2) 403F-07 (4) 403F-15 (1) 402F-05 (3) 403F-11 i02328435 General Hazard Information Illustration 4 g00702020 Wear a hard hat, protective glasses, and other protective equipment, as required.
SEBU9064 Safety Section Burn Prevention Never put maintenance fluids into glass containers. Drain all liquids into a suitable container. Obey all local regulations for the disposal of liquids. Use all cleaning solutions with care. Report all necessary repairs. Do not allow unauthorized personnel on the equipment.
Remove the filler cap slowly in If the application involves the presence of order to relieve pressure. combustible gases, consult your Perkins dealer and/ Cooling system conditioner contains alkali. Alkali can or your Perkins distributor for additional information about suitable protection devices.
Repair any lines that are loose or damaged. Leaks Illustration 7 g00704059 can cause fires. Consult your Perkins dealer or your Perkins distributor for repair or for replacement parts. Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not Check lines, tubes and hoses carefully.
SEBU9064 Safety Section Before Starting Engine Unless other maintenance instructions are provided, i02157354 never attempt adjustments while the engine is Engine Starting running. Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is performed.
SEBU9064 Safety Section Engine Stopping Engines that are installed without engine-to-frame i02234873 ground straps can be damaged by electrical Engine Stopping discharge. To ensure that the engine and the engine electrical systems function correctly, an engine-to-frame Stop the engine according to the procedure in the ground strap with a direct path to the battery must be Operation and Maintenance Manual, “Engine used.
SEBU9064 Product Information Section Model View Illustrations Product Information General Information Section i05333703 Model View Illustrations The 403F-15 Engine View Illustration 9 g03378808 Typical example (1) Rear lifting eye (5) Low mounted oil filler cap (9) Oil filter (2) Top oil filler cap (6) Fuel injection pump (10) Electronically controlled actuator (3) Front lifting eye...
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SEBU9064 General Information Model View Illustrations Illustration 10 g03379877 (12) Air intake (15) Solenoid for starter (18) Fan belt (13) Coolant outlet (16) Starting motor (18) Coolant intake connection (14) Exhaust manifold (17) Alternator...
SEBU9064 General Information Model View Illustrations Fuel System Components Illustration 11 g03379882 Typical examples (1) In-line fuel filter (3) Primary fuel filter (5) Secondary fuel filter (2) Electric fuel pump (4) Secondary fuel filter (element type) Note: The electric fuel pump is an option, engines may have a mechanical fuel lift pump installed.
The number 1 cylinder is the front cylinder. Product Description There are four Perkins engines in the 400F series that are below 19Kw power band. These engines are, 402F-05, 403F-07, 403F-11, and the 403F-15. These engines have the following characteristics: •...
Plate Locations and Film Locations Perkins engines are identified by a serial number. This serial number is shown on a serial number plate. The plate is mounted above the fuel injection pump on the right-hand side of the engine block.
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SEBU9064 Product Identification Information Reference Information Total Lubrication System Capacity Total Cooling System Capacity Air Cleaner Element Alternator Belt...
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.
Maintenance Manual, “Fluid recommendations”. 4. Remove the fan 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.
Determine and correct the cause of any significant change in the readings. Consult your Perkins dealer or your Perkins distributor for assistance. Ammeter – This gauge indicates the...
3600 RPM • 403F-15 3000 RPM The overspeed is plus 700 RPM above the given speed for engines shown. i05336173 Sensors and Electrical Components The following sensors or switches are installed on the 402F-05, 403F-07, 403F-11, and the 403F-15 engines:...
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• Alternator pressure sensor (3) may appear different from the • Starting motor illustration. Electrical components install on the 402F-05, 403F- • Glow plugs 07, 403F-11, and the 403F-15 engines: • Electronic control governor (Location will depend on the application)
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SEBU9064 Features and Controls Sensors and Electrical Components Illustration 20 g03381126 Typical examples (7) Alternator (9) Glow plugs (11) Fuel pump (8) Starting motor (10) Electronic control model (Controller) (12) Multi function lamp When the keyswitch is in the OFF position, the multi function lamp will not be illuminated.
SEBU9064 Engine Diagnostics Self-Diagnostics Engine Diagnostics i05339798 Self-Diagnostics The electronic engines can perform a self-diagnostics test. When the system detects an active problem, a diagnostic lamp is activated. This lamp is a multi function lamp that is located on the electronic control module.
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Oil pressure switch malfunction. Engine will start, but the engine will Check harness connection. If the shut down after 180 seconds Disconnection of Oil pressure fault remains contact your Perkins switch. dealer or your Perkins distributor. Disconnection of Oil pressure harness.
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Checking engine oil is part of the daily engine check. Operating an engine will a low level of engine oil can damage your engine. For more information on diagnostic messages and diagnostic tools contact your Perkins dealer or your Perkins distributor.
SEBU9064 Engine Starting Before Starting Engine Engine Starting i05339804 Starting the Engine i04053911 Before Starting Engine Perform the required daily maintenance and other Do not use aerosol types of starting aids such as periodic maintenance before the engine is started. ether.
SEBU9064 Engine Starting Starting with Jump Start Cables 5. Immediately after the engine is started, disconnect i05339814 the jump-start cables in reverse order. Starting with Jump Start After jump starting, the alternator may not be able to Cables fully recharge batteries that are severely discharged. The batteries must be replaced or charged to the proper voltage with a battery charger after the engine is stopped.
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.
• The cooling system and the lubrication system for Perkins Diesel Engines can operate effectively in the engine do not lose heat immediately upon cold weather. During cold weather, the starting and shutdown.
240 V dc. The output can be 750/1000W. Consult rings, and other parts. However, limit unnecessary your Perkins dealer or your Perkins distributor for idle time to 10 minutes in order to reduce wear and more information.
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−25° to -40°C (−13° to -72.°F). Note: Group 3 fuels reduce the life of the engine. The use of Group 3 fuels is not covered by the Perkins warranty. i05340086 Fuel and the Effect from Cold Group 3 fuels include Low Temperature Fuels and Aviation Kerosene Fuels .
Maintenance Manual in the Maintenance Section for more information on priming the fuel system. 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.
SEBU9064 Engine Stopping Stopping the Engine Engine Stopping i03756631 After Stopping Engine i02334873 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 •...
These values are the approximate capacities for the crankcase oil sump which includes the standard factory installed oil filters. 402F-05 Engine Engines with auxiliary oil filters will require additional oil. Refer to the OEM specifications for the capacity of the auxiliary oil Table 8 filter.
SEBU9064 Refill Capacities Fluid Recommendations 402F-05 Engine 403F-15 Engines Table 12 Table 15 402F-05 Engine 403F-15 Engines Refill Capacities Refill Capacities Compartment or System Compartment or System Liters Quarts Liters Quarts Engine Only Engine Only External System Per OEM External System Per OEM...
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Chloride (Cl) 40 mg/L • Cavitation of the water pump Sulfate (SO 100 mg/L For optimum performance, Perkins recommends a 1:1 mixture of a water/glycol solution. 170 mg/L Total Hardness Note: Use a mixture that will provide protection 340 mg/L Total Solids against the lowest ambient temperature.
However, ELC contains organic corrosion inhibitors and antifoam Preferred – Perkins ELC agents with low amounts of nitrite. Perkins ELC has been formulated with the correct amount of these additives in order to provide superior corrosion Acceptable –...
ELC. Lowering the proportion of antifreeze lowers the proportion of 4. Use Perkins cleaner to clean the system. Follow additive. This action will lower the ability of the the instruction on the label. coolant to protect the system from pitting, from cavitation, from erosion, and from deposits.
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Cooling System (V) Factor that is Required (X) Use the equation that is in Table 20 to determine the amount of Perkins SCA that is required when the 15 L (4 US gal) × 0.014 0.2 L (7 oz) cooling system is initially filled.
EMA Recommended Guideline on Diesel Engine Oil. Because of government regulations regarding the In addition to Perkins definitions, there are other certification of exhaust emissions from the engine, the definitions that will be of assistance in purchasing lubricant recommendations must be followed.
Note: These engine oils are not approved by order to help provide finished oils with performance Perkins and these engine oils must not be used: characteristics that meet industry standards. CC, CD, CD-2, CF-4, CG-4, CH-4 and CI-4.
An infrared analysis is used to compare the properties of new oil to the Perkins is not in a position to continuously evaluate properties of the used oil sample. This analysis and monitor all worldwide distillate diesel fuel...
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SEBU9064 Refill Capacities Fluid Recommendations Table 25 Perkins Specification for Distillate Diesel Fuel Property UNITS Requirements ASTMTest ISOTest Aromatics %Volume 35% maximum D1319 ISO3837 %Weight 0.01% maximum D482 ISO6245 Carbon Residue on 10% %Weight 0.35% maximum D524 ISO4262 Bottoms Cetane Number...
“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 . Diesel Fuel Characteristics Cetane numbers in excess of 45 are normally expected from current diesel fuel.
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15 °C (59 °F). Perkins recommends a value of density of 841 kg/m Biodiesel is a fuel that can be defined as mono-alkyl in order to obtain the correct power output. Lighter esters of fatty acids .
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Note: Engines that are manufactured by Perkins are certified by use of the prescribed Environmental • Perkins recommend the use of oil analysis in Protection Agency (EPA) and European Certification order to check the quality of the engine oil if fuels.
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If biodiesel or biodiesel blends of fuel are to be used, Perkins require the use of Perkins fuel cleaner. The of the fuel filter. Consult your supplier of fuel for assistance in selecting appropriate anti-microbial...
SEBU9064 Maintenance Recommendations System Pressure Release Maintenance Components for the driven equipment should also be considered. When possible, remove the component Recommendations that requires welding. When welding on an engine that is equipped with an ECM and removal of the component is not possible, the following procedure i04056177 must be followed.
• Installation • The temperature of the fluid in the engine Refer to the standards for the engine or consult your Perkins dealer or your Perkins distributor in order to Illustration 23 g01075639 determine if the engine is operating within the defined Use the example above.
SEBU9064 Maintenance Recommendations Severe Service Application Buildup – Compounds, elements, corrosive chemicals, and salt can damage some components. Altitude – Problems can arise when the engine is operated at altitudes that are higher than the intended settings for that application. Necessary adjustments should be made.
Alternator - Inspect “Fuel System Primary Filter - Replace” ....74 “Fuel System Secondary Filter - Replace” ....76 Perkins recommends a scheduled inspection of the alternator. Inspect the alternator for loose Every 500 Service Hours or 1 Year connections and correct battery charging. Check the ammeter (if equipped) during engine operation in “Battery Electrolyte Level - Check”...
SEBU9064 Maintenance Recommendations Alternator and Fan Belts - Inspect/Adjust Check the alternator and the battery charger for Install the gauge (1) at the center of the belt between correct operation. If the batteries are correctly the alternator and the crankshaft pulley and check the charged, the ammeter reading should be very near belt tension.
SEBU9064 Maintenance Recommendations Alternator and Fan Belts - Replace 2. Move the alternator in order to increase or decrease the belt tension. 3. Tighten adjusting bolt (1) and tighten mounting bolts and nut (2). Tighten bolt (3). Tighten all fixing to a torque of 25 N·m (221 lb in) i05341723 Alternator and Fan Belts -...
SEBU9064 Maintenance Recommendations Battery - Replace 4. Install new belt (5) and adjust the alternator to the Note: Always recycle a battery. Never discard a battery. Dispose of used batteries to an appropriate required tension. recycling facility. 5. Tighten bolt (1) and tighten bolt and nut (2). Tighten 5.
This is a good opportunity to replace For information regarding the disposal and the the water pump, the water temperature regulator, and recycling of used coolant, consult your Perkins the hoses, if necessary. dealer or your Perkins distributor.
SEBU9064 Maintenance Recommendations Coolant (ELC) - Change 5. Clean the cooling system filler cap. Inspect the NOTICE gasket that is on the cooling system filler cap. If the Do not fill the cooling system faster than 5 L gasket that is on the cooling system filler cap is (1.3 US gal) per minute to avoid air locks.
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Coolant (ELC) - Change Note: Inspect the water pump and the water For information regarding the disposal and the recycling of used coolant, consult your Perkins temperature regulator after the cooling system has dealer or your Perkins distributor. been drained. This is a good opportunity to replace...
Engines With a Coolant Recovery Tank Note: The cooling system may not have been provided by Perkins . The procedure that follows is for typical cooling systems. Refer to the OEM information for the correct procedures. Check the coolant level when the engine is stopped and cool.
1. Remove the cooling system filler cap slowly in Perkins engines incorporate a shunt design cooling system and require operating the engine with a water order to relieve pressure. temperature regulator installed.
SEBU9064 Maintenance Recommendations Cooling System Supplemental Coolant Additive (SCA) - Test/Add i03644948 NOTICE When any servicing or repair of the engine cooling Cooling System Supplemental system is performed the procedure must be per- Coolant Additive (SCA) - Test/ formed with the engine on level ground. This will allow you to accurately check the coolant level.
Steam cleaning the engine will remove accumulated Note: The air filter system may not have been oil and grease. A clean engine provides the following provided by Perkins . The procedure that follows is benefits: for a typical air filter system. Refer to the OEM information for the correct procedure.
SEBU9064 Maintenance Recommendations Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace Cleaning the Primary Air Cleaner The primary air cleaner element can be used up to six times if the element is properly cleaned and properly Elements inspected. The primary air cleaner element should be replaced at least one time per year.
SEBU9064 Maintenance Recommendations Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace Inspecting the Primary Air Cleaner Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more Elements than three times. Use filtered, dry air with a maximum pressure of 207 kPa (30 psi).
SEBU9064 Maintenance Recommendations Engine Air Cleaner Service Indicator - Inspect • Check for ease of resetting. The service indicator NOTICE should reset in less than three pushes. Never service the air cleaner element with the engine running since this will allow dirt to enter the engine. •...
Engine Mounts - Inspect Note: The engine mounts may not have been supplied by Perkins . Refer to the OEM information for further information on the engine mounts and the correct bolt torque. Inspect the engine mounts for deterioration and for correct bolt torque.
SEBU9064 Maintenance Recommendations Engine Oil and Filter - Change i05336039 Engine Oil and Filter - Change Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. NOTICE Care must be taken to ensure that fluids are con- tained during performance of inspection, mainte- nance, testing, adjusting and repair of the product.
Replace the Oil Filter 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 bearings, crankshaft, etc., as a result of the larger waste particles from unfiltered oil entering the engine lubricating system.
OFF. This will fill the oil filters before maintenance. Refer to the Service Manual or your au- starting the engine. Do not crank the engine for more thorized Perkins dealer or your Perkins distributor than 30 seconds. for the complete valve lash adjustment procedure.
SEBU9064 Maintenance Recommendations Fan Clearance - Check i05153591 i05161054 Fan Clearance - Check Fuel Filter (In-Line) - Replace Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.
Regular maintenance of the fuel injectors is tighten the union nut for the high pressure pipe to recommended by Perkins . The fuel injectors must be each fuel injector. Do not loosen the union nut more removed and tested by an authorized agent. The fuel than half a turn.
SEBU9064 Maintenance Recommendations Fuel System - Prime i04145953 Fuel System - Prime Turn the keyswitch to the ON position for 2 minutes in order to prime the fuel system. Turn keyswitch to OFF position, then turn on again. The engine is primed and ready to start.
SEBU9064 Maintenance Recommendations Fuel System Primary Filter/Water Separator - Drain i02627223 Fuel System Primary Filter/ Water Separator - Drain Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.
SEBU9064 Maintenance Recommendations Fuel System Secondary Filter - Replace i05337334 Fuel System Secondary Filter - Replace Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements.
SEBU9064 Maintenance Recommendations Fuel System Secondary Filter - Replace 6. Fasten the assembly to the fuel filter base with setscrew (2). The fuel system will need to be primed after the new filter is installed. Refer to this Operation and Maintenance Manual, “Fuel System - Prime”.
SEBU9064 Maintenance Recommendations Fuel Tank Water and Sediment - Drain Fuel Storage Tanks i02335436 Fuel Tank Water and Sediment Drain the water and the sediment from the fuel storage tank at the following intervals: - Drain • Weekly • Service intervals NOTICE •...
Radiator - Clean • Anticipated expansion and contraction of the fittings The radiator is not usually supplied by Perkins . The Replace the Hoses and the Clamps following text describes a typical cleaning procedure for the radiator. Refer to the OEM information for further information on cleaning the radiator.
For the removal of the Test” for more information on the checking procedure water pump and the installation of water pump and/or and for specifications or consult your Perkins dealer seal, refer to the Disassembly and Assembly Manual, or your Perkins distributor for assistance.
SEBU9064 Maintenance Recommendations Water Pump - Inspect • Drain the water and the sediment from the fuel tank on a daily basis in order to ensure that only clean fuel enters the fuel system. • Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires.
Emissions Warranty. For a full warranty statement contact your Perkins dealer or your Perkins distributor. For customers that have a valid user name and password, for perkins. com . Login then go to TIPSS, and the warranty information can be accessed.
Why buy an Extended Service Contract? 1. No surprises - total protection from unexpected repair cost (parts, labor, and travel). 2. Enjoy longer lasting product support from Perkins global network. 3. Genuine Perkins parts ensure continued engine performance. 4. Highly trained technicians carry out all repairs.
SEBU9064 Index Section Index After Starting Engine........30 Diagnostic Flash Code Retrieval ..... 26 After Stopping Engine........36 Diagnostic Lamp..........26 Alternator - Inspect .......... 54 Driven Equipment - Check....... 63 Alternator and Fan Belts - Inspect/Adjust ..55 Adjustment........... 55 Inspection.............
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SEBU9064 Index Section Fluid Recommendations.......38, 43, 45 Diesel Fuel Characteristics ......47 Hoses and Clamps - Inspect/Replace ..... 78 Diesel Fuel Requirements ......45 Replace the Hoses and the Clamps .... 79 ELC Cooling System Maintenance....40 Engine Oil ............ 43 General Coolant Information......
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SEBU9064 Index Section Radiator - Clean..........79 Reference Information........18 Record for Reference........18 Reference Information Section ......83 Reference Materials ........83 Refill Capacities..........37 Cooling System..........37 Lubrication System ........37 Safety Messages..........5 (A) Universal Warning........5 Safety Section ...........
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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...
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