SEBU9073 (en-us)
December 2015
Operation and
Maintenance
Manual
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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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 |
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 |
|
|
3 |
|
Table of Contents |
Maintenance Interval Schedule |
....................... 34 |
Reference Information Section |
|
Reference Materials ........................................ |
51 |
Index Section |
|
Index................................................................ |
53 |
Refill Capacities............................................... |
28 |
4
Foreword
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.
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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
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 ( |
is on1the left side)of |
the engine on the valve mechanism cover
5
Safety Section
Safety Messages
Illustration 2 |
g06012059 |
Typical example
i06149170
General Hazard Information
SMCS Code: 1000
Illustration 3 |
g00104545 |
Attach a “ NotDoOperate 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.
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Safety Section
General Hazard Information
•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.
•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.
•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
•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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•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.
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.
7
Safety Section
General Hazard Information
The maximum air pressure for cleaning purposes |
) |
. |
|
must be below 205 kPa ( |
psi 30The maximum |
||
water pressure for cleaning purposes must be below |
|
||
275 kPa ( psi 40 |
) |
. |
|
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
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
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 “ CFR291910.1001
•Obey environmental regulations for the disposal of asbestos.
•Stay away from areas that might have asbestos particles in the air.
Dispose of Waste Properly
Illustration 6 |
g00706404 |
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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.
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.
Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations.
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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
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.
9
Safety Section
Fire Prevention and Explosion Prevention
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.
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.
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Safety Section
Fire Prevention and Explosion Prevention
Illustration 8 |
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.
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.
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.
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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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
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.
11
Safety Section
Crushing Prevention and Cutting Prevention
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 “ NOTDOOPERATE 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.
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 NOTstart the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.
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Safety Section
Engine Stopping
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 “ EngineStarting 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
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 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
Electrical System
SMCS Code: 1000; 1400
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.
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 “ batteryterminal” with a wire that is adequate to handle the full charging current of the alternator.
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Product Information Section
Model Views and Specifications
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.
Illustration 10 |
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g03848732 |
|
Typical example |
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|
|
|
|
|
( |
Coolant1 filler)pressure cap |
( |
Control4 |
) |
( |
Breather7 outlet) hose |
( |
Top2oil filler cap) |
( |
Mixer5 |
) |
( |
Alternator8 ) |
( |
Control3 throttle) |
( |
Starting6 motor) |
( |
Thermostat9 housing) |
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14 |
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Product Information Section
Product Description
Illustration 11 |
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g03848772 |
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Typical example |
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(10) |
Ignition coil |
(15) |
Electronic control module |
(20) |
Air cleaner |
(11) Fan belt |
(16) |
Wiring harness |
(21) |
Engine rear lifting eye |
|
(12) |
Lower oil filler |
(17) |
Oil drain plug |
(22) |
Engine front lifting eye |
(13) |
Oil gauge (Dipstick) |
(18) |
Flywheel housing |
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|
(14) |
Oil filter |
(19) |
Flywheel |
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i06149296
Product Description
SMCS Code: 1000; 4450; 4491
The Perkins 404A-22SG1 is a gas fueled constant speed industrial engine.
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)
•Valve Lash Setting (Exhaust) 0.20 mm (0.00787 inch)
•Compression Ratio 9: 1
•Firing Order 1-3-4-2
•RPM 1500/1800
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Illustration 12 |
g00296424 |
|
( |
ExhaustA valves) |
|
( |
InletB 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.
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
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 NOTcovered under the Perkins warranty.
Perkins does not warrant the quality or performance of non-Perkins fluids and filters.
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Product Information Section
Product Identification Information
Product Identification
Information
Serial Number Plate
i06156142
Plate Locations and Film
Locations
SMCS Code: 1000; 4450
Illustration 14 |
g01094203 |
Typical example
Illustration 13 |
g03831850 |
Typical example
( Engine1 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
Operation Section
Lifting and Storage
i06205337
Product Lifting
SMCS Code: 1000; 7002
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.
17
Operation Section
Lifting and Storage
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 ( −F32The.8° engine) must not. be subjected to extreme variations in temperature and humidity.
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 “ ASTMD6210 specification.
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