Perkins 403F-15T Operation And Maintenance Manual
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Perkins 403F-15T Operation And Maintenance Manual

Industrial engines
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SEBU8609-01
January 2013
Operation and
Maintenance
Manual
403F-15T, 404F-22 and 404F-22T
Industrial Engines
EL (Engine)
EN (Engine)
EP (Engine)

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Summary of Contents for Perkins 403F-15T

  • Page 1: Operation And Maintenance

    SEBU8609-01 January 2013 Operation and Maintenance Manual 403F-15T, 404F-22 and 404F-22T Industrial Engines EL (Engine) EN (Engine) EP (Engine)

  • Page 2: Important Safety Information

    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.

  • Page 3: Table Of Contents

    SEBU8609 Table of Contents Table of Contents Refill Capacities..........57 Maintenance Recommendations....70 Foreword............4 Maintenance Interval Schedule ...... 73 Safety Section Warranty Section Safety Messages..........5 Warranty Information ........99 General Hazard Information ......5 Reference Information Section Burn Prevention......

  • Page 4: Foreword

    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...

  • Page 5: 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 dealer or your Illustration 2 g01154807 distributor can provide new warning signs.
  • Page 6 SEBU8609 Safety Section General Hazard Information • Tampering with the engine installation or tampering • The engine is stopped. Ensure that the engine with the OEM supplied wiring can be dangerous. cannot be started. Personal injury, death and/or engine damage •...

  • Page 7: Pressure Air And Water

    SEBU8609 Safety Section General Hazard Information Keep the engine free from foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, and from steps. Never put maintenance fluids into glass containers. Drain all liquids into a suitable container. Obey all local regulations for the disposal of liquids.

  • Page 8: Dispose Of Waste Properly

    • Obey environmental regulations for the disposal of asbestos. Asbestos Information • Stay away from areas that might have asbestos Perkins equipment and replacement parts that are particles in the air. shipped from Perkins are asbestos free. Perkins recommends the use of only genuine Perkins Dispose of Waste Properly replacement parts.

  • Page 9: Burn Prevention

    SEBU8609 Safety Section Burn Prevention Coolant i05200861 When the engine is at operating temperature, the Burn Prevention engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant. Do not touch any part of an operating engine system.

  • Page 10: Fire Prevention And Explosion Prevention

    Personal injury, property damage, or engine damage could result. If the application involves the presence of combustible gases, consult your Perkins dealer and/ or your Perkins distributor for additional information about suitable protection devices. Remove all flammable combustible materials or conductive materials such as fuel, oil, and debris from the engine.

  • Page 11: Crushing Prevention And Cutting Prevention

    Do not bend high-pressure lines. Do not strike high- pressure lines. Do not install any lines that are damaged. Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for replacement parts. Replace the parts if any of the following conditions...

  • Page 12: Mounting And Dismounting

    SEBU8609 Safety Section Mounting and Dismounting i04016709 i02157354 Mounting and Dismounting Engine Starting Do not climb on the engine or the engine aftertreatment. The engine and aftertreatment have not been designed with mounting or dismounting Do not use aerosol types of starting aids such as locations.

  • Page 13: Engine Stopping

    SEBU8609 Safety Section Engine Stopping Grounding Practices i02234873 Engine Stopping Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine components. Use the Emergency Stop Button (if equipped) ONLY in an emergency situation.

  • Page 14: Engine Electronics

    Note: Many of the engine control systems and discharge. display modules that are available for Perkins Engines will work in unison with the Engine To ensure that the engine and the engine electrical Monitoring System.

  • Page 15: Product Information Section

    Product Information Section General Information i05139695 Model View Illustrations (Engines and Aftertreatment) The following model views show typical features of the engine. Due to individual applications, your engine may appear different from the illustrations. 403F-15T Illustration 13 g03246538 Typical example...
  • Page 16 SEBU8609 General Information Model View Illustrations 404F-22 Illustration 14 g03246558 Typical example...
  • Page 17 SEBU8609 General Information Model View Illustrations 404F-22T Illustration 15 g03246676 (1) Top oil filler (4) Cylinder block drain plug (7) Oil filter (2) Fan (5) Oil gauge (Dipstick) (8) Electric fuel pump (3) Side oil filler (6) Rear oil drain plug (9) Secondary fuel filter...
  • Page 18 SEBU8609 General Information Model View Illustrations Illustration 16 g03246563 (10) Air intake (14) Flywheel housing (18) NOx reduction system cooler (11) Turbocharger (15) Starting motor (19) Coolant outlet (12) Aftertreatment system (16) Solenoid for starting motor (13) Flywheel (17) Front oil drain plug...
  • Page 19 SEBU8609 General Information Model View Illustrations Illustration 17 g03249056 (20) Engine crankcase breather (23) Air pump drive belt (26) Coolant intake (21) Rear lifting eye bracket (24) Alternator (27) Water pump (22) Air pump (25) Fan and alternator drive belt (28) Front lifting eye...
  • Page 20 SEBU8609 General Information Model View Illustrations Aftertreatment System Illustration 18 g03249241 (29) Aftertreatment Regeneration Device (30) Diesel Oxidation Catalyst (DOC) (ARD), also known as the (Burner) (31) Diesel Particulate Filter (DPF)
  • Page 21 SEBU8609 General Information Model View Illustrations Off Engine Parts Illustration 19 g03271819 (32) Electronic Control Unit (ECM) (33) In line fuel filter...

  • Page 22: Product Description

    SEBU8609 General Information Product Description Engine with Low Mounted Air Pump Illustration 20 g03321871 The crankshaft for a three cylinder engine has four i05139813 main bearing journals. The crankshaft for a four Product Description cylinder engine has five main bearing journals. End play is controlled by the thrust washers that are located on the rear main bearing.

  • Page 23: Engine Specifications

    If any adjustments to the fuel injection Bore 84 mm (3.31 inch) pump timing and high idle are required, you must refer to your Perkins distributor your Perkins dealer. Stroke 90 mm (3.54 inch) A gerotor oil pump is located in the center of the idler Displacement 1.496 L (91.291 in...

  • Page 24: Electronic Engine Features

    SEBU8609 General Information Product Description Electronic Engine Features (Table 2, contd) Rotation that is viewed from the The engine operating conditions are monitored. The Counterclockwise flywheel Electronic Control Module (ECM) controls the response of the engine to these conditions and to the Valve Lash Setting (Inlet) 0.20 mm (0.008 inch) demands of the operator.

  • Page 25: Aftermarket Products And Perkins Engines

    Therefore, the defects are NOT covered under the Perkins warranty. Aftertreatment System The aftertreatment system is approved for use by Perkins . In order to be emission-compliant only the approved Perkins aftertreatment system must be used on a Perkins engine.

  • Page 26: Product Identification Information

    The first digit is a production code. 00001 Engine Serial Number Year of Manufacture Perkins dealers or Perkins distributors need all of these numbers in order to determine the components that were included with the engine. This information permits accurate identification of replacement part numbers.

  • Page 27: Reference Information

    Identifying Numbers on Aftertreatment Illustration 27 g02052934 Perkins will supply the fuel label with every engine, refer to illustration 27 . The equipment manufacturer must install the label to the equipment. The label must be attached to the equipment near the inlet of the fuel tank.

  • Page 28: Operation Section

    To remove the engine ONLY, use the lifting eyes that The building must be kept at a constant temperature. are on the engine. 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...

  • Page 29: Open Cooling System

    Maintenance Manual, “Fluid recommendations”. 4. Remove the drive belts 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 30: Features And Controls

    SEBU8609 Features and Controls Alarms and Shutoffs Features and Controls Coolant temperature – The coolant temperature sensor indicates high jacket water coolant temperature. i05142391 Engine oil pressure – The engine oil pressure Alarms and Shutoffs sensor or switch, indicates when oil pressure drops below rated system pressure, at a set engine speed.

  • Page 31: Indicators And Lamps

    NOTICE Determine and correct the cause of any significant To help prevent engine damage, never exceed the change in the readings. Consult your Perkins dealer or your Perkins distributor for assistance. high idle rpm. Overspeeding can result in serious damage to the engine. The engine can be operated at...

  • Page 32: Monitoring System

    Lamps” for more information on Indicator Lamps. For more information or assistance for repairs, If the Warning/Derate/Shutdown mode has been consult your Perkins dealer or your Perkins selected and the warning indicator activates, distributor. bring the engine to a stop whenever possible. De- pending on the application, special precautions should be taken to avoid personal injury.

  • Page 33: Sensors And Electrical Components

    Overspeed Sensors and Electrical Components (Engine and Aftertreatment) • 403F-15T 3000 RPM • 404F-22 3000 RPM • ARD Aftertreatment Regeneration Devise • 404F-22T 3000 RPM • DOC Diesel Oxidation Catalyst The overspeed is plus 700 RPM above the given speed for engines shown.
  • Page 34 SEBU8609 Features and Controls Sensors and Electrical Components Illustration 30 g03276099 (1) Inlet air temperature sensor (4) Fuel rack solenoid and position sensor (7) Fuel pump/Priming pump (2) Oil pressure switch (5) Glow plugs (3) Secondary speed sensor (6) Resistor for ARD glow plug...
  • Page 35 SEBU8609 Features and Controls Sensors and Electrical Components Illustration 31 g03276102 (8) Air pump (11) Primary speed sensor (14) Solenoid for starting motor (9) Coolant temperature sensor (12) Inlet manifold air pressure sensor (15) Starting motor (10) Alternator (13) NRS control valve...
  • Page 36 SEBU8609 Features and Controls Sensors and Electrical Components Illustration 32 g03279116 (16) ARD glow plug (19) ARD temperature sensor (22) DPF outlet temperature sensor (17) DPF pressure differential sensor (20) DOC intake temperature sensor (23) ECM (18) ARD injectors (21) DPF intake temperature sensor The ECM is remotely mounted.
  • Page 37 SEBU8609 Features and Controls Sensors and Electrical Components Illustration 33 g03279862 (1) Inlet air temperature (3) Secondary speed sensor (2) Oil pressure switch (4) Fuel rack solenoid and position sensor...
  • Page 38 SEBU8609 Features and Controls Sensors and Electrical Components Illustration 34 g03280057 (5) Glow plugs (6) Resistor for ARD glow plug (7) Fuel pump/Priming pump...
  • Page 39 SEBU8609 Features and Controls Sensors and Electrical Components Illustration 35 g03299376 (8) Air pump (10) Alternator (9) Coolant temperature sensor (11) Primary speed sensor...
  • Page 40 SEBU8609 Features and Controls Sensors and Electrical Components Illustration 36 g03299456 (12) Inlet manifold air pressure sensor (14) Solenoid for starting motor (16) ARD glow plug (13) NRS control valve (15) Starting motor...
  • Page 41 SEBU8609 Features and Controls Sensors and Electrical Components Illustration 37 g03299640 (17) DPF pressure differential sensor (18 A) ARD injector 2 (19 A) Alterative position for the ARD (18) ARD injector 1 (19) ARD temperature sensor temperature sensor...
  • Page 42 SEBU8609 Features and Controls Sensors and Electrical Components Illustration 38 g03299676 (20) DOC intake temperature sensor (22) DPF outlet temperature sensor (21) DPF intake temperature sensor (23) ECM...

  • Page 43: Engine Diagnostics

    The system provides the capability of Fault Logging. When the Electronic Control Module (ECM) generates an active diagnostic code, the code will be Perkins electronic engines have the capability to logged in the memory of the ECM. The codes that perform a self-diagnostics test. When the system...

  • Page 44: Configuration Parameters

    SEBU8609 Engine Diagnostics Configuration Parameters In most cases, stopping the engine will not be necessary because of an intermittent code. However, the operator should retrieve the logged fault codes and the operator should reference the appropriate information. in order to identify the nature of the event.

  • Page 45: Engine Starting

    SEBU8609 Engine Starting Before Starting Engine Engine Starting Do not use aerosol types of starting aids such as i04053911 ether. Such use could result in an explosion and Before Starting Engine personal injury. The ability to start the engine will be improved at temperatures below −18 °C (0 °F) from the use of a Perform the required daily maintenance and other jacket water heater or extra battery capacity.

  • Page 46: Starting The Engine

    SEBU8609 Engine Starting Starting the Engine Note: The engine should not be “raced” in order to NOTICE speed up the warm-up process. Do not engage the starting motor when flywheel is 6. Allow the engine to idle for 3 to 5 minutes, or allow turning.

  • Page 47: After Starting Engine

    SEBU8609 Engine Starting After Starting Engine 1. Turn the start switch on the stalled engine to the Note: Gauge readings should be observed and the data should be recorded frequently while the engine OFF position. Turn off all the engine's accessories. is operating.

  • Page 48: Engine Operation

    SEBU8609 Engine Operation Engine Operation Engine Operation The operator will receive information on the status of the ARD from dash lamps and the driver will be able to request a regeneration by using a switch. Refer to this Operation and Maintenance Manual, “Monitoring i05182510 System”...

  • Page 49: Modes Of Regeneration

    SEBU8609 Engine Operation Diesel Particulate Filter Regeneration Regeneration Disable – This Indicator is • Refer to OEM for the applications interlocks illuminated whenever the disable switch required to be engaged before regeneration can is activated or the system has been take place.

  • Page 50: Fuel Conservation Practices

    Use only the recommended fuels. Refer to the The efficiency of the engine can affect the fuel Operations and Maintenance Manual, “Fuel economy. Perkins design and technology in Recommendations”for further information. manufacturing provides maximum fuel efficiency in all applications. Follow the recommended procedures in •...
  • Page 51 SEBU8609 Engine Operation Fuel Conservation Practices • Observe the service indicator frequently. Keep the air cleaner elements clean. • Ensure that the turbocharger is operating correctly. For more information refer to this Operation and Maintenance Manual, “Turbocharger - Inspect” • Maintain a good electrical system. One faulty battery cell will overwork the alternator.

  • Page 52: Cold Weather Operation

    • 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.

  • Page 53: Viscosity Of The Engine Lubrication Oil

    Lubrication will be improved. There will be less acid 240 V dc. The output can be 750/1000W. Consult and less sludge in the oil. This condition will provide your Perkins dealer or your Perkins distributor for longer service life for the engine bearings, the piston more information.
  • Page 54 Note: Group 3 fuels reduce the life of the engine. The components for operation from −25° to -40°C use of Group 3 fuels is not covered by the Perkins (−13° to -72.°F). warranty. Group 3 fuels include Low Temperature Fuels and i02322217 Aviation Kerosene Fuels .

  • Page 55: Fuel Filters

    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.

  • Page 56: Engine Stopping

    SEBU8609 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 •...

  • Page 57: Maintenance Section

    This capacity information will be needed in Section” for more information on Lubricant order to determine the amount of coolant that is Specifications. required for the Total Cooling System. 403F-15T Engine 403F-15T Engine Table 6 Table 8 403F-15T Engine...

  • Page 58: General Coolant Information

    SEBU8609 Refill Capacities Fluid Recommendations 404F-22T Engine Many engine failures are related to the cooling system. The following problems are related to cooling system failures: Overheating, leakage of the water Table 10 pump and plugged radiators or heat exchangers. 404F-22T Engine Refill Capacities These failures can be avoided with correct cooling system maintenance.

  • Page 59: Coolant Recommendations

    Supplement Coolant Additive • ASTM American Society for Testing and Glycol Materials Glycol in the coolant helps to provide protection The following two coolants are used in Perkins against the following conditions: diesel engines: • Boiling Preferred – Perkins ELC • Freezing Acceptable –...

  • Page 60: Elc Cooling System Maintenance

    (SCA). Use the interval that occurs first. The cooling system must also be flushed out at this time. When using Perkins ELC, do not use standard SCA's or SCA filters. Perkins provides ELC for use in the following ELC Cooling System Cleaning applications: •...
  • Page 61 Flush the system with clean water. Fill the system with the Perkins ELC. 4. Use Perkins cleaner to clean the system. Follow the instruction on the label. • Drain a portion of the cooling system into a suitable container according to local regulations.

  • Page 62: General Lubricant Information

    SCA that is needed. • ECF-3 Engine Crankcase Fluid Use the equation that is in Table 17 to determine the amount of Perkins SCA that is required, if Licensing necessary: The Engine Oil Licensing and Certification System Table 17...

  • Page 63: Engine Oil

    “Fluid Recommendations/ Note: These engine oils are not approved by Engine Oil” topic (Maintenance Section). Perkins and these engine oils must not be used: Engine Oil CC, CD, CD-2, CF-4, CG-4, CH-4 and CI-4. Lubricant Viscosity Recommendations...

  • Page 64: Aftermarket Oil Additives

    An infrared analysis is used to compare the properties of new oil to the Perkins does not recommend the use of aftermarket additives in oil. It is not necessary to use aftermarket properties of the used oil sample. This analysis...

  • Page 65: Diesel Fuel Requirements

    20 . • Glossary NOTICE • ISO International Standards Organization The footnotes are of the key part Perkins Specifica- tion for Distillate Diesel Fuel Table. Read ALL of the • ASTMAmerican Society for Testing and Materials footnotes. • HFRRHigh Frequency Reciprocating Rig for Lubricity testing of diesel fuels •...
  • Page 66 SEBU8609 Refill Capacities Fluid Recommendations Table 20 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...

  • Page 67: Diesel Fuel Characteristics

    “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.
  • Page 68 Biodiesel is a fuel that can be defined as mono-alkyl esters of fatty acids . Biodiesel is a fuel that can be Perkins recommends a value of density of 841 kg/m made from various feedstock. The most commonly in order to obtain the correct power output. Lighter...
  • Page 69 If biodiesel or biodiesel blends of fuel are to be used, biodiesel and 95 percent distillate diesel fuel. Perkins require the use of Perkins fuel cleaner. The use of the fuel is in order to remove deposits within Note: The percentages given are volume-based.

  • Page 70: Maintenance Recommendations

    SEBU8609 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.

  • Page 71: Severe Service Application

    • 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 41 g01075639 determine if the engine is operating within the defined Use the example above.

  • Page 72: Incorrect Operating Procedures

    SEBU8609 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.

  • Page 73: Maintenance Interval Schedule

    Alternator - Inspect “Fuel System Secondary Filter - Replace” ....92 Every 500 Service Hours or 1 Year Perkins recommends a scheduled inspection of the “Battery Electrolyte Level - Check” ......75 alternator. Inspect the alternator for loose connections and correct battery charging. Check the “Cooling System Supplemental Coolant Additive...

  • Page 74: Alternator And Fan Belts - Inspect/Adjust

    SEBU8609 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.

  • Page 75: Battery - Replace

    SEBU8609 Maintenance Recommendations Alternator and Fan Belts - Replace i05162326 Alternator and Fan Belts - The battery cables or the batteries should not be Replace removed with the battery cover in place. The bat- tery cover should be removed before any servic- ing is attempted.

  • Page 76: Battery Or Battery Cable - Disconnect

    SEBU8609 Maintenance Recommendations Battery or Battery Cable - Disconnect 4. Clean all disconnected connection and battery terminals. All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a 5. Use a fine grade of sandpaper to clean the face shield and protective clothing when working terminals and the cable clamps.

  • Page 77: Belts - Inspect/Replace

    SEBU8609 Maintenance Recommendations Belts - Inspect/Replace Adjust Replace Belt The belt should only be replaced if the belt is worn or damaged. i05162435 Belts - Inspect/Replace (Air Pump belt) The air pump belt must be replaced at 1000 hours. Refer to Disassembly and Assembly, “Belt (Air Pump) - Remove and Install”...
  • Page 78 Coolant (Commercial Heavy-Duty) - 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 inspection is a good opportunity to...

  • Page 79: Coolant (Elc) - Change

    SEBU8609 Maintenance Recommendations Coolant (ELC) - Change 3. Start and run the engine at low idle. Increase the • The engine overheats frequently. engine rpm to high idle. Run the engine at high idle • Foaming is observed. for 1 minute in order to purge the air from the cavities of the engine block.

  • Page 80: Coolant Level - Check

    Close the drain cock or install the drain Note: The cooling system may not have been plug on the radiator. provided by Perkins . The procedure that follows is for typical cooling systems. Refer to the OEM information for the correct procedures.

  • Page 81: Engines Without A Coolant Recovery Tank

    SEBU8609 Maintenance Recommendations Coolant Level - Check 4. Clean the filler cap and the receptacle. Reinstall NOTICE the filler cap and inspect the cooling system for When any servicing or repair of the engine cooling leaks. system is performed, the procedure must be per- formed with the engine on level ground.

  • Page 82: Cooling System Supplemental Coolant Additive (Sca) - Test/Add

    Perkins engines incorporate a shunt design cooling cooling system, reducing the engine's heat transfer system and require operating the engine with a water characteristics. Reduced heat transfer could cause temperature regulator installed.

  • Page 83: Crankcase Breather (Canister) - Replace

    SEBU8609 Maintenance Recommendations Crankcase Breather (Canister) - Replace • The filter element within the crankcase breather NOTICE must be serviced at the prescribed service interval. When any servicing or repair of the engine cooling system is performed the procedure must be per- •...

  • Page 84: Diesel Particulate Filter - Clean

    Typical example Note: Improper cleaning or repair of the Diesel Particulate Filter (DPF) can damage the DPF and the engine aftertreatment system. Contact your Perkins dealer for more information. The DPF is enclosed within the assembly (1). For information on removal of the DPF, refer to...

  • Page 85: Engine - Clean

    SEBU8609 Maintenance Recommendations Engine - Clean Aftertreatment • The DPF on the three cylinder engine is different from the four cylinder engine. During the engine cleaning process, ensure that water or cleaning fluids cannot enter the • Only ultra low sulfur diesel fuel can be used in an aftertreatment system.

  • Page 86: Engine Air Precleaner - Check/Clean

    Note: The engine mounts may not have been Service indicators are important instruments. supplied by Perkins . Refer to the OEM information for further information on the engine mounts and the • Check for ease of resetting. The service indicator correct bolt torque.

  • Page 87: Engine Oil And Filter - Change

    SEBU8609 Maintenance Recommendations Engine Oil and Filter - Change i05153469 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.

  • Page 88: Replace The Oil Filter

    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.

  • Page 89: Engine Valve Lash - Check

    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.

  • Page 90: Fan Clearance - Check

    SEBU8609 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.

  • Page 91: Fuel Injector - Test/Change

    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.

  • Page 92: Fuel System - Prime

    SEBU8609 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.

  • Page 93: Fuel Storage Tanks

    SEBU8609 Maintenance Recommendations Fuel Tank Water and Sediment - Drain 6. Fasten the assembly to the fuel filter base with Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel setscrew (2). supply pipe.

  • Page 94: Hoses And Clamps - Inspect/Replace

    SEBU8609 Maintenance Recommendations Hoses and Clamps - Inspect/Replace • Cracking • Softness • Loose clamps Replace hoses that are cracked or soft. Tighten any loose clamps. NOTICE Do not bend or strike high pressure lines. Do not in- stall bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses.

  • Page 95: Radiator - Clean

    Make repairs, if necessary. i02335774 Radiator - Clean The radiator is not usually supplied by Perkins . The following text describes a typical cleaning procedure for the radiator. Refer to the OEM information for further information on cleaning the radiator.

  • Page 96: Removal And Installation

    If the actuator linkage is moved or disturbed, Test” for more information on the checking procedure the engine may not comply with emissions legislation. and for specifications or consult your Perkins dealer or your Perkins distributor for assistance. i05157183...

  • Page 97: Walk-Around Inspection

    Disassembly and Assembly Manual, “Water Pump - Remove and Install” for more information or consult your Perkins dealer or your i02177973 Perkins distributor. Walk-Around Inspection •...

  • Page 98: Water Pump - Inspect

    SEBU8609 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.

  • Page 99: Warranty Section

    Federal Emission Control Warranty Warranty Section As a condition of reimbursement, replaced parts and receipted invoices must be presented at a place of business of a Perkins distributor or your Perkins dealer or other establishment authorized by Perkins Warranty Information Engine Company limited...

  • Page 100: California Emission Control Warranty Statement

    • The costs in order to investigate complaints which Perkins Engines Company Limited warrants to the initial owner and to the subsequent owner of the 400F are not caused by a defect in Perkins Engine diesel engines that such an engine is: Company limited material or Perkins Engine Company limited workmanship.

  • Page 101: Emissions Warranty Information

    • The costs in order to investigate complaints which the following regulations apply: US EPA Tier 4 are not caused by a defect in Perkins Engines Interim, EU Stage IIIB or Japanese MLIT Step 4. If an Company Limited material or Perkins Engines engine is operated in regions of the world where Company Limited workmanship.
  • Page 102 Erratic behavior of the engine may indicate a need for in order to ensure the proper operation of the repair to the ECM. Your Perkins distributor/dealer is emission control systems. The use of genuine equipped with the necessary tools, personnel, and Perkins components is recommended.

  • Page 103: Reference Information Section

    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.

  • Page 104: Index

    SEBU8609 Index Section Index Coolant (ELC) - Change ........79 Drain ............79 After Starting Engine........47 Fill..............80 After Stopping Engine........56 Flush ............80 Alarms and Shutoffs ........30 Coolant Level - Check ........80 Alarms............30 Engines With a Coolant Recovery Tank..80 Shutoffs............
  • Page 105 SEBU8609 Index Section Engine Oil Level - Check ......... 86 Fuel System - Prime ........92 Engine Operation..........48 Fuel System Secondary Filter - Replace ..92 Engine Operation and Active Regeneration Fuel Filter with Canister ....... 92 ..............48 Fuel Tank Water and Sediment - Drain....
  • Page 106 Coolant System..........70 Engine Oil ............ 70 Fuel System ..........70 Plate Locations and Film Locations....26 Product Description ......... 22 Aftermarket Products and Perkins Engines Table of Contents..........3 ..............25 Turbocharger - Inspect (If Equipped)....96 Electronic Engine Features......24 Inspecting.............
  • Page 107 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...
  • Page 108 ©2013Perkins Engines Company Limited All Rights Reserved...

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