Perkins Engine 404A-22SG1 Gas Service Manual

Operation and
Maintenance
Manual

SEBU9073 (en-us)

December 2015

404A-22SG1 Gas Industrial Engine

EX1 1-UP (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.

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3

Table of Contents

Table of Contents

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

Safety Section

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

General Hazard Information.............................. 5

Burn Prevention................................................. 8

Fire Prevention and Explosion Prevention........ 9

Crushing Prevention and Cutting Prevention...11

Mounting and Dismounting ..............................11

Ignition Systems ...............................................11

Before Starting Engine .....................................11

Engine Starting .................................................11

Maintenance Interval Schedule....................... 34

Reference Information Section

Reference Materials ........................................ 51

Index Section

Index................................................................ 53

Engine Stopping .............................................. 12

Electrical System............................................. 12

Product Information Section

Model Views and Specifications...................... 13

Product Identification Information ................... 16

Operation Section

Lifting and Storage .......................................... 17

Gauges and Indicators .................................... 19

Features and Controls..................................... 20

Engine Starting ................................................ 23

Engine Operation ............................................ 26

Engine Stopping .............................................. 27

Maintenance Section

Refill Capacities............................................... 28

4

Foreword

SEBU9073

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.

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Safety Section

i06149155

Safety Messages

SMCS Code: 1000; 7405

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 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. The warning signs that are loosened
could drop off the engine.

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 your distributor
can provide new warning signs.

(A) Universal Warning

5

Safety Section

Safety Messages

Illustration 2 g06012059

Typical example

i06149170

General Hazard Information

SMCS Code: 1000

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

The universe warning label (1) is on the left side of
the engine on the valve mechanism cover

Illustration 3 g00104545

Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
repaired. Attach the warning tags to the engine and
to each operator control station. When appropriate,
disconnect the starting controls.

Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.

6

Safety Section
General Hazard Information

SEBU9073

• Tampering with the engine installation or
tampering with the OEM supplied wiring can be
dangerous. Personal injury, death and/or engine
damage could result.

• Vent the engine exhaust to the outside when the
engine is operated in an enclosed area.

• If the engine is not running, do not release the
secondary brake or the parking brake systems
unless the vehicle is blocked or unless the vehicle
is restrained.

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

• When work is performed around an engine that is
operating, wear protective devices for ears in
order to help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can
snag on controls or on other parts of the engine.

• Ensure that all protective guards and all covers
are secured in place on the engine.

• Never put maintenance fluids into glass
containers. Glass containers can break.

• For initial start-up of a new engine or for starting
an engine that has been serviced, make
provisions to stop the engine if an overspeed
occurs. The stopping of the engine may be
accomplished by shutting off the fuel supply and/
or the air supply to the engine. Ensure that only
the fuel supply line is shut off. Ensure that the fuel
return line is open.

• Start the engine from the operators station (cab).
Never short across the starting motor terminals or
the batteries. This action could bypass the engine
neutral start system and/or the electrical system
could be damaged.

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

Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.

• Filler caps

• Grease fittings

• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, perform the
maintenance under the following conditions:

• The engine is stopped. Ensure that the engine
cannot be started.

• The protective locks or the controls are in the
applied position.

• Engage the secondary brakes or parking brakes.

• Block the vehicle or restrain the vehicle before
maintenance or repairs are performed.

• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.

• Do not attempt any repairs or any adjustments to
the engine while the engine is operating.

• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.

• Pressure taps

• Breathers

• Drain plugs

Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of the
cover plate or the device. Before removing the last
two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.

Illustration 4 g00702020

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

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7

Safety Section

General Hazard Information

• When work is performed around an engine that is
operating, wear protective devices for ears in
order to help prevent damage to hearing.

• Do not wear loose clothing or jewelry that can
snag on controls or on other parts of the engine.

• Ensure that all protective guards and all covers
are secured in place on the engine.

• Never put maintenance fluids into glass
containers. Glass containers can break.

• Use all cleaning solutions with care.

• Report all necessary repairs.

Unless other instructions are provided, perform
the maintenance under the following conditions:

• The engine is stopped. Ensure that the engine
cannot be started.

• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.

• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.

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).

Containing Fluid Spillage

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

maintenance, testing, adjusting, and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.

Dispose of all fluids according to local regulations
and mandates.

Inhalation

Electrostatic Discharge

Before performing any service or repair follow the
instruction:

• Discharge the static electricity on your body to
ground by touching and holding a grounded metal
object.

Pressurized Air and Water

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

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

Illustration 5 g00702022

Exhaust

Use caution. Exhaust fumes can be hazardous to
health. If you operate the equipment in an enclosed

area, adequate ventilation is necessary.

Asbestos Information

Perkins equipment and replacement parts that are
shipped from Perkins engine company limited are
asbestos free. Perkins recommends the use of only
genuine Perkins replacement parts. Use the following
guidelines when you handle any replacement parts
that contain asbestos or when you handle asbestos
debris.

Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.

8

Safety Section
Burn Prevention

SEBU9073

If dust that may contain asbestos is present, there
are several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestos
materials.

• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.

• Use exhaust ventilation on permanent machining
jobs.

• Wear an approved respirator if there is no other
way to control the dust.

• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.

• Obey environmental regulations for the disposal of
asbestos.

• Stay away from areas that might have asbestos
particles in the air.

Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.

i06149208

Burn Prevention

SMCS Code: 1000

Allow the engine system to cool before any
maintenance is performed. Relieve all pressure in the
air system, hydraulic system, lubrication system, fuel
system, and the cooling system before the related
items are disconnected.

Allow the pressure to be purged in the air system, in
the hydraulic system, in the lubrication 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.

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

Dispose of Waste Properly

Illustration 6 g00706404

Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.

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.

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9

Safety Section

Fire Prevention and Explosion Prevention

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

Oils

Skin may be irritated following repeated or prolonged
exposure to mineral and synthetic base oils. Refer to
your suppliers Material Safety Data Sheets for
detailed information. Hot oil and lubricating
components can cause personal injury. Do not allow
hot oil to contact the skin. Appropriate personal
protective equipment should be used.

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.

i06149211

Fire Prevention and Explosion
Prevention

SMCS Code: 1000

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 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 line, 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.

Illustration 7 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.

After the emergency stop button is operated, ensure
that you allow 15 minutes, before the engine covers
are removed.

Wiring must be kept in good condition. Ensure that all
electrical wires are correctly installed 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.

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.

Ensure that the engine is stopped. Inspect all lines
and hoses for wear or for deterioration. Ensure that

the hoses are correctly routed. The lines and hoses
must have adequate support and secure clamps.

Oil filters and fuel filters must be installed correctly.
The filter housings must be tightened to the correct
torque. Refer to the Disassembly and Assembly
manual for more information.

10

Safety Section
Fire Prevention and Explosion Prevention

Illustration 8 g00704059

SEBU9073

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.

Do not charge a frozen battery. A frozen battery 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.

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.

Avoid static electricity risk when fueling. Consult your
fuel or fuel system supplier to ensure that the delivery
system is in compliance with fueling standards for
proper grounding and bonding practices.

Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike high­pressure lines. Do not install any lines that are
damaged.

Leaks can cause fires. Consult your Perkins
distributor for replacement parts.

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 parts of the hoses are kinked.

• Outer covers have embedded armoring.

• End fittings are displaced.

Illustration 9 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.

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11

Safety Section

Crushing Prevention and Cutting Prevention

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

i06149222

Crushing Prevention and
Cutting Prevention

SMCS Code: 1000

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

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.

i06149224

Ensure that the power supply is isolated before any
service or repairs are performed.

i03560601

Before Starting Engine

SMCS Code: 1000

NOTICE

For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.

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

to the outside.

Inspect the engine for potential hazards.

Do not start the engine or move any of the controls if
there is a “DO NOT OPERATE” warning tag or similar
warning tag attached to the start switch or to the
controls.

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

Mounting and Dismounting

SMCS Code: 1000

Do not climb on the engine . The engine has not
been designed with mounting or dismounting
locations.

Refer to the OEM for the location of foot and hand
holds for your specific application.

i06210914

Ignition Systems

SMCS Code: 1550

Ignition systems can cause electrical shocks. Avoid
contacting the ignition system components and
wiring.

If the control is in the AUTOMATIC or START position
the ignition system may discharge, and a spark plug
will operate. The spark plug will ignite any gas that
has accumulated in that cylinder. The crankshaft and
the driven equipment can move. Personal injury may
result. Gas that has accumulated in the exhaust

system can also be ignited.

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

i06149227

Engine Starting

SMCS Code: 1000

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.

12

Safety Section
Engine Stopping

SEBU9073

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.

Start the engine from the operators 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 that the correct procedure will help
to prevent major damage to the engine components.
Knowing that 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. Also,
check 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.

i02234873

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.

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

Engine Stopping

SMCS Code: 1000

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 NOT start 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

Electrical System

SMCS Code: 1000; 1400

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.

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.

SEBU9073

Product Information
Section

Model Views and
Specifications

i06198554

Model View Illustrations

SMCS Code: 1000

The following model views show typical features of
the engine. Due to individual applications, your
engine may appear different from the illustrations.

13

Product Information Section

Model Views and Specifications

Illustration 10 g03848732

Typical example

(1) Coolant filler pressure cap
(2) Top oil filler cap
(3) Control throttle

(4) Control
(5) Mixer
(6) Starting motor

(7) Breather outlet hose
(8) Alternator
(9) Thermostat housing

14

Product Information Section
Product Description

SEBU9073

Illustration 11 g03848772

Typical example

(10) Ignition coil
(11) Fan belt
(12) Lower oil filler
(13) Oil gauge (Dipstick)
(14) Oil filter

(15) Electronic control module
(16) Wiring harness
(17) Oil drain plug
(18) Flywheel housing
(19) Flywheel

i06149296

• Valve Lash Setting (Exhaust) 0.20 mm

(20) Air cleaner
(21) Engine rear lifting eye
(22) Engine front lifting eye

(0.00787 inch)

Product Description

• Compression Ratio 9: 1

SMCS Code: 1000; 4450; 4491

• Firing Order 1-3-4-2

The Perkins 404A-22SG1 is a gas fueled constant
speed industrial engine.

• RPM 1500/1800

The 404A-22SG1 has the following characteristics:

• In-line four cylinder

• Two valves per cylinder

• Four stroke cycle

• Valve Lash Setting (Inlet) 0.20 mm (0.00787 inch)

SEBU9073

Illustration 12 g00296424

(A) Exhaust valves
(B) Inlet valves

The front end of the engine is opposite the flywheel
end of the engine. The left and the right side of the
engine is determined from the flywheel end. The No.
1 cylinder is the front cylinder.

15

Product Information Section

Product Description

When auxiliary devices, accessories, or
consumables (filters, additives, catalysts,) which are
made by other manufacturers are used on Perkins
products, the Perkins warranty is not affected simply
because of such use.

However, failures that result from the installation or
use of other manufacturers devices, accessories, or
consumables are NOT Perkins defects. Therefore,
the defects are NOT covered under the Perkins
warranty.

Ignition System

• ECM

• 4 Ignition coils

• Crankshaft position sensor and camshaft position
sensor

• Spark Plug

Gas System

• Fuel filter

• Electric fuel vapor lock off solenoid valve

• Fuel pressure regulator

• Fuel trim valve

• Gas/air mixer

Engine Service Life

Engine efficiency and maximum utilization of engine
performance depend on the adherence to proper
operation and maintenance recommendations. In
addition, use recommended fuels, coolants, and

lubricants. Use the Operation and Maintenance
Manual as a guide for required engine maintenance.

Aftermarket Products and Perkins
Engines

Perkins does not warrant the quality or performance
of non-Perkins fluids and filters.

16

Product Information Section
Product Identification Information

SEBU9073

Product Identification
Information

Plate Locations and Film
Locations

SMCS Code: 1000; 4450

Serial Number Plate

i06156142

Illustration 14 g01094203

Typical example

Illustration 13 g03831850

Typical example

(1) Engine serial plate location

Perkins engines are identified by a serial number.
This number is shown on a serial number plate that is
mounted above the fuel injection pump on the right­hand side of the engine block.

An example of an engine number is
EX*****U000001A.

E Engine family

X Type of engine

***** The list number of the engine

U Country of manufacture

0 The first digit is a production code.

00001 Engine Serial Number

A Year of Manufacture

Perkins dealers or Perkins distributors need all these
numbers to determine the components that were

included with the engine. This information permits
accurate identification of replacement part numbers.

SEBU9073

17

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

Product Lifting

SMCS Code: 1000; 7002

i06205337

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 distributor for information regarding fixtures
for correct engine lifting.

i06152951

Product Storage

SMCS Code: 1000; 7002

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

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 15 g03851874

Typical example

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.

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.

The lifting eyes should be used to lift only the engine
and radiator as supplied by Perkins.

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.

1. Ensure that the engine is clean and dry.

2. Ensure that all open ports on the fuel system are

capped so that no ingress of fluid or dirt can enter
the fuel system.

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 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.