Perkins Engine 402F-05, 403F-07, 403F-11, 403F-15 Service Manual

Operation and Maintenance Manual

SEBU9064

June 2013

402F-05, 403F-07, 403F-11, and 403F-15 Industrial Engines

EG (Engine) EH (Engine) EJ (Engine) EK (Engine)

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. 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 the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. 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.

Failure to heed this warning can lead to premature failures, product damage, personal injury or

death.

SEBU9064 3

Table of Contents

Foreword.............................. ............................. 4

Safety Section

Safety Messages ....................... ....................... 5

General Hazard Information ............... .............. 6

Burn Prevention........................ ........................ 7

Fire Prevention and Explosion Prevention .... ... 8

Crushing Prevention and Cutting Prevention .. . 9

Before Starting Engine ................. .................. 10

Engine Starting ........................ ....................... 10

Engine Stopping ....................... .......................11

Electrical System ...................... .......................11

Maintenance Interval Schedule ........... ........... 54

Warranty Section

Warranty Information................... ................... 82

Reference Information Section

Reference Materials ........................................ 83

Index Section

Index................................ ............................... 84

Product Information Section

General Information.................... .................... 12

Product Identification Information.......... ......... 18

Operation Section

Lifting and Storage..................... ..................... 20

Features and Controls.................. .................. 22

Engine Diagnostics..................... .................... 26

Engine Starting ........................ ....................... 29

Engine Operation...................... ...................... 31

Cold Weather Operation................. ................ 32

Engine Stopping ....................... ...................... 36

Maintenance Section

Refill Capacities....................... ....................... 37

Maintenance Recommendations.......... .......... 51

4 Foreword

SEBU9064

Foreword

Literature Information

This manual contains safety, operation instructions, lubrication and maintenance information. This manual

should be stored in or near the engine area in a literature holder or literature storage area. Read, study and keep it with the literature and engine information.

English is the primary language for all Perkins publications. The English used facilitates translation and consistency.

Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult with your Perkins dealer or your Perkins distributor for the latest available information.

Safety

This safety section lists basic safety precautions. In addition, this section identifies hazardous, warning situations. Read and understand the basic

precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.

Operation

Operating techniques outlined in this manual are basic. They assist with developing the skills and techniques required to operate the engine more efficiently and economically. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities.

The operation section is a reference for operators. Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of electronic diagnostic information.

Maintenance

The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance intervals. Items in the maintenance schedule are

referenced to detailed instructions that follow.

Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary.

The maintenance schedule items are organized for a preventive maintenance management program. If the preventive maintenance program is followed, a periodic tune-up is not required. The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.

Maintenance Intervals

Perform maintenance on items at multiples of the original requirement. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained

as part of the engine's permanent record.

Your authorized Perkins dealer or your Perkins distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment.

Overhaul

Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that interval.

Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer or your Perkins distributor offers a variety of options regarding overhaul programs. If you experience a major engine failure, there are also numerous after failure overhaul options available. Consult with your Perkins dealer or your Perkins distributor for information regarding these options.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer,

birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

SEBU9064

Safety Section

i05333233

Safety Messages

There may be several specific warning signs on your engine. The exact location and a description of the warning signs are reviewed in this section. Become familiar with all warning signs.

Ensure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if the words cannot be read or if the illustrations are not

visible. Use a cloth, water, and soap to clean the warning signs. Do not use solvents, gasoline, or other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the

warning signs.

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.

Safety Section

Safety Messages

(A) Universal Warning

Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death.

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.

6 SEBU9064 Safety Section

General Hazard Information

Illustration 2 g03378379

Typical examples

(A) Location of warning label (1) 402F-05

(2) 403F-07 (3) 403F-11

i02328435

(4) 403F-15

General Hazard Information

Illustration 4 g00702020

Wear a hard hat, protective glasses, and other protective equipment, as required.

Do not wear loose clothing or jewelry that can snag

Illustration 3 g00104545

Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment.

on controls or on other parts of the engine.

Make sure that all protective guards and all covers are secured in place on the engine.

Keep the engine free from foreign material. Remove debris, oil, tools, and other items from the deck, from

walkways, and from steps.

SEBU9064

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.

Ensure that the power supply is disconnected before you work on the bus bar or the glow plugs.

Perform maintenance on the engine with the equipment in the servicing position. Refer to the OEM information for the procedure for placing the equipment in the servicing position.

Pressure Air and Water

Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury.

The direct application of pressurized air or pressurized water to the body could result in personal injury.

When pressurized air and/or water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield.

The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly.

Safety Section

Burn Prevention

Illustration 5 g00687600

Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

Containing Fluid Spillage

Care must be taken in order to ensure that fluids are contained during performance of inspection,

maintenance, testing, adjusting and repair of the engine. Make provision to collect the fluid with a suitable container before any compartment is opened or before any component is disassembled.

• Only use the tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids.

• Only use the tools that are suitable for containing fluids and equipment that is suitable for containing fluids.

Obey all local regulations for the disposal of liquids.

Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve the hydraulic pressure.

i02143195

Burn Prevention

Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine. Relieve all pressure in the air system, in the hydraulic system, in the lubrication system, in the fuel system, or in the cooling system before any lines, fittings or related items are disconnected.

Coolant

When the engine is at operating temperature, the 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.

8 SEBU9064 Safety Section

Fire Prevention and Explosion Prevention

Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained.

Check the coolant level after the engine has stopped and the engine has been allowed to cool.

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 in order to relieve pressure.

Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.

Oils

Hot oil and hot lubricating components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not allow hot components to contact the skin.

Batteries

Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended.

i02813488

Fire Prevention and Explosion Prevention

A flash fire may result if the covers for the engine crankcase are removed within fifteen minutes after an

emergency shutdown.

Determine whether the engine will be operated in an environment that allows combustible gases to be drawn into the air inlet system. These gases could cause the engine to overspeed. 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. Do not allow any flammable combustible

materials or conductive materials to accumulate on the engine.

Store fuels and lubricants in correctly marked containers away from unauthorized persons. Store oily rags and any flammable materials in protective containers. Do not smoke in areas that are used for

storing flammable materials.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray in case of a line, a tube, or a seal failure. Exhaust shields must be

installed correctly.

Do not weld on lines or tanks that contain flammable fluids. Do not flame cut lines or tanks that contain flammable fluid. Clean any such lines or tanks

thoroughly with a nonflammable solvent prior to welding or flame cutting.

Wiring must be kept in good condition. All electrical wires must be correctly routed and securely attached. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all electrical connections.

Illustration 6 g00704000

All fuels, most lubricants, and some coolant mixtures are flammable.

Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire. Fire may cause personal injury and property damage.

Eliminate all wiring that is unattached or unnecessary. Do not use any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers.

Arcing or sparking could cause a fire. Secure connections, recommended wiring, and correctly maintained battery cables will help to prevent arcing or sparking.

Inspect all lines and hoses for wear or for deterioration. 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.

Oil filters and fuel filters must be correctly installed. The filter housings must be tightened to the correct torque.

SEBU9064 9

Safety Section

Crushing Prevention and Cutting Prevention

Do not charge a frozen battery. This may cause an explosion.

The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the recommended cables, connections, and battery box covers when the engine is operated.

Fire Extinguisher

Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly. Obey the recommendations on the instruction plate.

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are bent or damaged. Do not clip any other items to the high pressure lines.

Illustration 7 g00704059

Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open flames or sparks. Always stop the engine before refueling.

Illustration 8 g00704135

Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery. Do not smoke in battery charging areas.

Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer.

Incorrect jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specific instructions.

Repair any lines that are loose or damaged. Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for repair or for replacement parts.

Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recommended torque.

Replace the parts if any of the following conditions are present:

• End fittings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are ballooning.

• Flexible part of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, this will help to prevent vibration, rubbing against other parts, and excessive heat.

i02143194

Crushing Prevention and Cutting Prevention

Support the component correctly when work beneath the component is performed.

10 SEBU9064 Safety Section

Before Starting Engine

Unless other maintenance instructions are provided, never attempt adjustments while the engine is running.

Stay clear of all rotating parts and of all moving parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, reinstall the guards.

Keep objects away from moving fan blades. The fan blades will throw objects or cut objects.

When objects are struck, wear protective glasses in order to avoid injury to the eyes.

Chips or other debris may fly off objects when objects are struck. Before objects are struck, ensure that no one will be injured by flying debris.

i02813489

Before Starting Engine

Before the initial start-up of an engine that is new, serviced or repaired, make provision to shut the engine off, in order to stop an overspeed. This may be accomplished by shutting off the air and/or fuel supply to the engine.

Overspeed shutdown should occur automatically for engines that are controlled electronically. If automatic shutdown does not occur, press the emergency stop button in order to cut the fuel and/or air to the engine.

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel.

If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work correctly, if equipped.

All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.

Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are

provided in order to help prevent personal injury. The circuits are also provided in order to help prevent engine damage.

See the Service Manual for repairs and for adjustments.

i02157354

Engine Starting

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.

If a warning tag is attached to the engine start switch or to the controls, DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.

Start the engine from the operator's compartment or from the engine start switch.

Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Knowing the correct procedure will help to prevent major damage to the engine components. Knowing the procedure will also help to prevent personal injury.

To ensure that the jacket water heater (if equipped) and/or the lube oil heater (if equipped) is working correctly, check the water temperature gauge and the oil temperature gauge during the heater operation.

Engine exhaust contains products of combustion which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside.

Note: The engine is equipped with an automatic device for cold starting for normal conditions of operation. If the engine will be operated in very cold conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with the correct type of starting aid for your region of operation.

The 400 Series engines are equipped with a glow plug starting aid in each individual cylinder that heats the intake air in order to improve starting.

SEBU9064 11

Safety Section

Engine Stopping

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. Do not use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOTstart the engine until the problem that caused the emergency stop has been corrected.

Stop the engine if an overspeed condition occurs during the initial start-up of a new engine or an engine that has been overhauled.

To stop an electronically controlled engine, cut the power to the engine and/or shutting off the air supply to the engine.

i02176668

Engines that are installed without engine-to-frame ground straps can be damaged by electrical discharge.

To ensure that the engine and the engine electrical systems function correctly, an engine-to-frame ground strap with a direct path to the battery must be used. This path may be provided by way of a direct engine ground to the frame.

All grounds should be tight and free of corrosion. The engine alternator must be grounded to the negative “-” battery terminal with a wire that is adequate to handle the full charging current of the alternator.

Electrical System

Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible gases that are produced by some batteries, the negative “−” jump start cable should be connected last from the external power source to the negative “−” terminal of the starting motor. If the starting motor is not equipped with a negative “−” terminal, connect the jump start cable to the engine block.

Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires before the engine is started. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for specific starting instructions.

Grounding Practices

Correct grounding for the engine electrical system is necessary for optimum engine performance and reliability. Incorrect grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths.

Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft bearing journal surfaces, and to aluminum components.

12 SEBU9064 Product Information Section

Model View Illustrations

Product Information Section

Model View Illustrations

The 403F-15 Engine View

General Information

i05333703

Illustration 9 g03378808

Typical example

(1) Rear lifting eye (2) Top oil filler cap (3) Front lifting eye (4) Water pump

(5) Low mounted oil filler cap (6) Fuel injection pump (7) Oil gauge (Dipstick) (8) Oil drain plug

(9) Oil filter (10) Electronically controlled actuator (11) Injector

SEBU9064 13

General Information

Model View Illustrations

Illustration 10 g03379877

(12) Air intake (13) Coolant outlet (14) Exhaust manifold

(15) Solenoid for starter (16) Starting motor (17) Alternator

(18) Fan belt (18) Coolant intake connection

14 SEBU9064 General Information

Model View Illustrations

Fuel System Components

Illustration 11 g03379882

Typical examples

(1) In-line fuel filter (2) Electric fuel pump

(3) Primary fuel filter (4) Secondary fuel filter (element type)

(5) Secondary fuel filter

Note: The electric fuel pump is an option, engines may have a mechanical fuel lift pump installed.

SEBU9064 15

General Information

Product Description

Components for Electronic Control

Illustration 12 g03379884

(1) Electronic Control Module (ECM) (2) Speed sensor

Note: Due to individual applications the atmospheric

(3) Atmospheric Pressure Sensor

(Barometric Pressure Sensor)

Engine Specifications

(4) Actuator

pressure sensor (3) may appear different from the illustration.

Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right

i05333638

sides of the engine are determined from the flywheel end. 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:

• In-Line 2 cylinder (402F-05)

• In-Line 3 cylinder (403F-07, 403F-11, and the 403F-15)

• Naturally aspirated

• Fuel Limiter

• 2 Valves in each cylinder

16 SEBU9064 General Information

Product Description

402F-05 Engine

Illustration 13 g01108476

(A) Exhaust valves (B) Inlet valves

Table 1

402F-05 Engine Specifications

Maximum Operating Speed (rpm)

Cylinders and Arrangement In-Line 2 cylinder

3600 rpm

403F-07 Engine

Illustration 14 g00852304

(A) Exhaust valves (B) Inlet valves

Table 2

403F-07 Engine Specifications

Maximum Operating Speed (rpm)

Cylinders and Arrangement In-Line 3 cylinder

3600 rpm

Bore 67 mm (2.64 inch)

Stroke 72 mm (2.83 inch)

Displacement 0.507 L (30.939 in

Aspiration Naturally Aspirated

Compression Ratio

Firing Order

Rotation that is viewed from the flywheel

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust) 0.20 mm (0.008 inch)

Injection

23.5:1

1-2

Counterclockwise

Indirect

Bore 67 mm (2.64 inch)

Stroke 72 mm (2.83 inch)

)

Displacement 0.762 L (46.500 in

Aspiration Naturally Aspirated

Compression Ratio

Firing Order

Rotation that is viewed from the flywheel

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust) 0.20 mm (0.008 inch)

Injection

23.5:1

1-2-3

Counterclockwise

Indirect

)

SEBU9064 17

General Information

Product Description

403F-11 Engine

Illustration 15 g00852304

(A) Exhaust valves (B) Inlet valves

Table 3

403F-11 Engine Specifications

Maximum Operating Speed (rpm)

Cylinders and Arrangement In-Line 3 cylinder

3600 rpm

403F-15 Engine

Illustration 16 g00852304

(A) Exhaust valves (B) Inlet valves

Table 4

403F-15 Engine Specifications

Maximum Operating Speed (rpm)

Cylinders and Arrangement In-Line 3 cylinder

3000 rpm

Bore 77 mm (3.03 inch)

Stroke 81 mm (3.19 inch)

Displacement 1.131 L (69.018 in

Aspiration Naturally Aspirated

Compression Ratio

Firing Order

Rotation that is viewed from the flywheel

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust) 0.20 mm (0.008 inch)

Injection

23:1

1-2-3

Counterclockwise

Indirect

Bore 84 mm (3.31 inch)

Stroke 90 mm (3.54 inch)

)

Displacement 1.496 L (91.291 in

Aspiration Naturally Aspirated

Compression Ratio

Firing Order

Rotation that is viewed from the flywheel

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust) 0.20 mm (0.008 inch)

Injection

22.5:1

1-2-3

Counterclockwise

Indirect

)

18 SEBU9064 Product Identification Information

Plate Locations and Film Locations

Product Identification Information

i05333660

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.

A typical example of an engine number is EK*****N000001X.

E Engine family

K Type of engine

***** The list number of the engine

N Country of manufacture

0 The first digit is a production code.

i05333666

Emissions Certification Film

00001 Engine Serial Number

X 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.

Illustration 17 g03378752

Typical example

i05335976

Reference Information

Information for the following items may be needed to order parts. Locate the information for your engine. Record the information in the appropriate space. Make a copy of this list for a record. Keep the information for future reference.

Record for Reference

Engine Model

Engine Serial Number

ECM Serial Number

Engine Low Idle rpm

Engine Full Load rpm

In-Line Fuel Filter

Primary Fuel Filter

Secondary Fuel Filter Element

Lubrication Oil Filter Element

Auxiliary Oil Filter Element

SEBU9064 19

Product Identification Information

Reference Information

Total Lubrication System Capacity

Total Cooling System Capacity

Air Cleaner Element

Alternator Belt

20 SEBU9064 Operation Section

Product Lifting

Operation Section

Lifting and Storage

Product Lifting

i05335230

Lifting eyes are designed and installed for specific engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting fixtures obsolete. 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.

i05335259

Product Storage

Perkins are not responsible for damage which may occur when an engine is in storage after a period in service.

Your Perkins dealer or your Perkins distributor can assist in preparing the engine for extended storage periods.

Condition for Storage

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.

Illustration 18 g03380038

Typical example

(1) Rear lifting eye (2) Front lifting eye

NOTICE Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees.

When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight.

Use a hoist to remove heavy components. Use an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted.

Some removals require lifting the fixtures in order to obtain correct balance and safety.

To remove the engine ONLY, use the lifting eyes that are on the engine.

Storage Period

An engine can be stored for up to 6 months provided all the recommendation are adhered to.

Storage Procedure

Keep a record of the procedure that has been completed on the engine.

Note: Do not store an engine that has biodiesel in the fuel system.

1. Ensure that the engine is clean and dry.

a. If the engine has been operated using

biodiesel, the system must be drained and new filters installed. The fuel tank will require flushing.

b. Fill the fuel system with an ultra low sulfur fuel.

For more information on acceptable fuels refer to this Operation and Maintenance Manual, “Fluid recommendations”. Operate the engine for 15 minutes in order to remove all biodiesel from the system.

2. Drain any water from the primary filter water separator. Ensure that the fuel tank is full.

SEBU9064 21

Lifting and Storage

Product Storage

3. The engine oil will not need to be drained in order to store the engine. Provided the correct specification of engine oil is used the engine can be stored for up to 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.

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. Allow the coolant to drain. Install the drain plugs. Place a vapor phase inhibitor into the system. The coolant system must be sealed once the vapor phase inhibitor has been introduced. The effect of the vapor phase inhibitor will be lost if the cooling system is open to the atmosphere.

For maintenance procedures ref to this Operation and Maintenance Manual.

Monthly Checks

The crankshaft must be rotated in order to change the spring loading on the valve train. Rotate the crankshaft more than 180 degrees. Visibly check for damage or corrosion to the engine.

Ensure that the engine is covered completely before storage. Log the procedure in the record for the engine.

22 SEBU9064 Features and Controls

Gauges and Indicators

Features and Controls

i05336041

Gauges and Indicators

Your engine may not have the same gauges or all of the gauges that are described. For more information about the gauge package, see the OEM information.

Gauges provide indications of engine performance. Ensure that the gauges are in good working order. Determine the normal operating range by observing the gauges over a period of time.

Noticeable changes in gauge readings indicate potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the readings are within specifications. Determine and correct the cause of any significant change in the readings. Consult your Perkins dealer or your Perkins distributor for assistance.

NOTICE If no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded, STOP the engine. Engine damage can result.

Engine Oil Pressure – The oil pressure should be greatest after a cold engine is

started. The typical engine oil pressure with SAE10W30 is 207 to 413 kPa (30 to 60 psi) at rated rpm.

A lower oil pressure is normal at low idle. If the load is stable and the gauge reading changes, perform the following procedure:

1. Remove the load.

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

Jacket Water Coolant Temperature –

Typical temperature range is 71 to 96°C

(160 to 205°F). The maximum allowable temperature with the pressurized cooling system at 90 kPa (13 psi) is 125° C (257° F). Higher temperatures may occur under certain conditions. The water temperature reading may vary according to load. The reading should never exceed the boiling point for the pressurized system that is being used.

If the engine is operating above the normal range and steam becomes apparent, perform the following procedure:

1. Reduce the load and the engine rpm.

2. Inspect the cooling system for leaks.

3. Determine if the engine must be shut down

immediately or if the engine can be cooled by reducing the load.

Tachometer – This gauge indicates engine speed (rpm). When the throttle

controller is moved to the full throttle position without load, the engine is running at high idle. The engine is running at the full load rpm when the throttle controller is at the full throttle position with maximum rated load.

NOTICE To help prevent engine damage, never exceed the high idle rpm. Overspeeding can result in serious damage to the engine. The engine can be operated at high idle without damage, but should never be allowed to exceed high idle rpm.

Ammeter – This gauge indicates the amount of charge or discharge in the battery charging circuit. Operation of the

indicator should be to the right side of ““0”” (zero).

Fuel Level – This gauge indicates the fuel level in the fuel tank. The fuel level gauge operates when the ““START/

STOP”” switch is in the ““ON”” position.

Service Hour Meter – The gauge indicates operating time of the engine.

Indicators and Lamps

The following indicator lamps can be installed, for more information refer to the Original Equipment Manufacturer (OEM)

• Shutdown lamp

• Warning lamp

• Low-pressure oil lamp

A multi function lamp is installed on the electric control module.

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Monitoring System

SEBU9064 23

Features and Controls

Overspeed

NOTICE The Engine Monitoring System is not a guarantee against catastrophic failures. Programmed delays and derate schedules are designed to minimize false alarms and provide time for the operator to stop the engine.

The following parameters are monitored:

• Coolant temperature

• Oil pressure

• Engine speed

• Atmospheric pressure (Barometric pressure)

The coolant temperature, oil pressure, and the engine speed can trigger an engine shutdown.

• Atmospheric pressure (Barometric pressure) can

trigger an engine de-rate.

The atmospheric pressure sensor (Barometric pressure sensor) can de-rate the engine. Operating the engine and increasing the altitude will de-rate the engine in accordance with emission regulations. The start of the de-rate will be determined by the flash file that is installed.

• Oil pressure sensor

• Coolant temperature sensor

• Atmospheric pressure sensor (Barometric pressure sensor)

• Speed sensor

• Throttle actuator

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Overspeed

• 402F-05 3600 Revolutions Per Minute (RPM)

• 403F-07 3600 RPM

• 403F-11 3600 RPM

• 403F-15 3000 RPM

The overspeed is plus 700 RPM above the given speed for engines shown.

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Sensors and Electrical Components

The following sensors or switches are installed on the 402F-05, 403F-07, 403F-11, and the 403F-15

engines:

24 SEBU9064 Features and Controls

Sensors and Electrical Components

Illustration 19 g03381125

Typical examples

(1) Oil pressure sensor (2) Coolant temperature sensor

Note: Due ti individual applications the atmosphere

(3) Atmosphere pressure sensor (Barometric

pressure sensor)

• Alternator

(4) Speed sensor (5) Throttle actuator

pressure sensor (3) may appear different from the illustration.

Electrical components install on the 402F-05, 403F-

• Starting motor

• Glow plugs

07, 403F-11, and the 403F-15 engines:

• Electronic control governor (Location will depend on the application)

• Electric fuel pump

SEBU9064 25

Features and Controls

Sensors and Electrical Components

Illustration 20 g03381126

Typical examples

(7) Alternator (8) Starting motor

(9) Glow plugs (10) Electronic control model (Controller)

(11) Fuel pump (12) Multi function lamp

When the keyswitch is in the OFF position, the multi function lamp will not be illuminated. With the keyswitch in the ON position the multi function lamp will flash once. The flash will indicate that the system is powered and ready for operation.

The multi function lamp can be used as a diagnostic lamp. For information as a diagnostic lamp refer to this Operation and Maintenance Manual, “Diagnostic Lamp”.

26 SEBU9064 Engine Diagnostics

Self-Diagnostics

Engine Diagnostics

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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. The lamp will flash a code that will give am indication of the fault. For more information on the

flash codes, refer to this Operation and Maintenance Manual, “Diagnostic Flash Code Retrieval”.

i05339090

Diagnostic Lamp

The multi function lamp on the electronic control module can operate as a diagnostic lamp. The diagnostic function is used to indicate the existence of an active fault. The active fault is transmitted as a flash code.

For information on flash codes refer to this Operation and Maintenance Manual, “Diagnostic Flash Code Retrieval”.

i05339103

Diagnostic Flash Code Retrieval

The multi function lamp will flash a two-digit code in a given sequence in order to show the flash code diagnostic massage. By counting the number of flashes in a given sequence you can determine the flash code.

After the flash code as finished, the flash code sequence will continual to be repeated. If a second

flash code has been activated, then the system will repeat both codes in the given sequence.

Four short flashes will indicate a flash code of 04. Three long flashes of one second each followed by

one short flash will indicate a flash code of 31.

If there is more than one code to be indicated, the system will flash the first code then after a delay

interval the next code is flashed.

SEBU9064 27

Engine Diagnostics

Diagnostic Flash Code Retrieval

Table 5

Flash Codes with Key ON (Engine not in Operation)

Flash Code Description Engine status Operator Action

13 Oil pressure switch malfunction.

Disconnection of Oil pressure switch. Disconnection of Oil pressure harness.

22 Pressure sensor malfunction.

Disconnection of Pressure sensor connector. Disconnection of Pressure sensor harness.

33 Actuator position sensor

malfunction. Disconnection of Actuator position sensor connector. Disconnection of Actuator position sensor harness.

04 Actuator drive malfunction.

Disconnection of Speed sensor connector. Disconnection of Speed sensor harness.

Table 6

Flash Codes During Engine Cranking

Flash Code Description Engine status Operator Action

Engine will start, but the engine will shut down after 180 seconds

Engine will start, but the engine go to limp home mode.

Engine will not start. Check harness connection. If the

Check harness connection. If the fault remains contact your Perkins dealer or your Perkins distributor.

fault remains contact your Perkins dealer or your Perkins distributor.

13 Speed sensor malfunction.

Disconnection of Speed sensor connector. Disconnection of Speed sensor harness.

Table 7

Flash Codes with Engine in Operation

Flash Code Description Engine status Operator Action

31 Oil pressure decline.

Weak signal from oil pressure switch. Short-circuiting.

22 Pressure sensor malfunction.

Disconnection of Pressure sensor connector. Disconnection of Pressure sensor harness.

33 Actuator position sensor

malfunction. Disconnection of Actuator position sensor connector. Disconnection of Actuator position sensor harness.

Engine will not start. Check harness connection. If the

fault remains contact your Perkins dealer or your Perkins distributor.

Engine will go to limp home mode but the engine may shut down.

The engine will go into limp home mode.

Check engine oil. Check harness connection. If the fault remains contact your Perkins dealer or your Perkins distributor.

Check harness connection. If the fault remains contact your Perkins dealer or your Perkins distributor.

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