Perkins Engine 403F-15T, 404F-22, 404F-22T Service Manual
Operation and
Maintenance
Manual
SEBU8609-01
January 2013
403F-15T, 404F-22 and 404F-22T
Industrial Engines
EL (Engine)
EN (Engine)
EP (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.
SEBU8609 3
Table of Contents
Table of Contents
Foreword.............................. ............................. 4
Safety Section
Safety Messages ....................... ....................... 5
General Hazard Information ............... .............. 5
Burn Prevention........................ ........................ 9
Fire Prevention and Explosion Prevention ... .. 10
Crushing Prevention and Cutting Prevention . .11
Mounting and Dismounting............... .............. 12
Before Starting Engine ................. .................. 12
Engine Starting ........................ ....................... 12
Engine Stopping ....................... ...................... 13
Refill Capacities....................... ....................... 57
Maintenance Recommendations.......... .......... 70
Maintenance Interval Schedule ........... ........... 73
Warranty Section
Warranty Information................... ................... 99
Reference Information Section
Reference Materials .................. ................... 103
Index Section
Index............................... .............................. 104
Electrical System ...................... ...................... 13
Engine Electronics..................... ..................... 14
Product Information Section
General Information.................... .................... 15
Product Identification Information.......... ......... 26
Operation Section
Lifting and Storage..................... ..................... 28
Features and Controls.................. .................. 30
Engine Diagnostics..................... .................... 43
Engine Starting ........................ ....................... 45
Engine Operation...................... ...................... 48
Cold Weather Operation................. ................ 52
Engine Stopping ....................... ...................... 56
Maintenance Section
4
Foreword
SEBU8609
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.
SEBU8609
Safety Section
5
Safety Section
Safety Messages
i05139549
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. 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 dealer or your
distributor can provide new warning signs.
(1) 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 2 g01154807
Typical example
The location of the universal warning label is located
on the right side of the valve mechanism cover.
Illustration 1 g03256898
(1) Universal Warning
i05139571
General Hazard Information
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.
6 SEBU8609
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.
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
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.
SEBU8609
Keep the engine free from foreign material. Remove
debris, oil, tools, and other items from the deck, from
walkways, and from steps.
Never put maintenance fluids into glass containers.
Drain all liquids into a suitable container.
Obey all local regulations for the disposal of liquids.
Use all cleaning solutions with care.
Report all necessary repairs.
Do not allow unauthorized personnel on the
equipment.
7
Safety Section
General Hazard Information
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.
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.
8 SEBU8609
Safety Section
General Hazard Information
Inhalation
Illustration 6 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 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.
• 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.
Dispose of Waste Properly
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.
If dust that may contain asbestos is present, there are
several guidelines that should be followed:
Illustration 7 g00706404
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
SEBU8609 9
Safety Section
Burn Prevention
i05200861
Burn Prevention
Do not touch any part of an operating engine system.
The engine, the exhaust, and the engine
aftertreatment system can reach temperatures as
high as 650 °C (1202 °F) under normal operating
conditions.
At idle engine speed and/or zero vehicle speed, an
operator can request a manual regeneration. Under
this condition, the exhaust gas temperature can reach
650 °C (1202 °F). Otherwise automatic regeneration
can produce exhaust gas temperatures as high as
650 °C (1202 °F).
Allow the engine system to cool before any
maintenance is performed. Relieve all pressure in the
following systems, hydraulic system, lubrication
system, fuel system, and the cooling system before
related items are disconnected.
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service instructions may cause personal injury or death.
After the engine has stopped, allow if active the
regeneration active lamp to be extinguished before
any service or repair is performed.
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.
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.
Induction System
Sulfuric Acid Burn Hazard may cause serious personal injury or death.
The exhaust gas cooler may contain a small
amount of sulfuric acid. The use of fuel with sulfur
levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid
may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and
clothing on contact. Always wear the appropriate
personal protective equipment (PPE) that is noted
on a material safety data sheet (MSDS) for sulfuric
acid. Always follow the directions for first aid that
are noted on a material safety data sheet (MSDS)
for sulfuric acid.
10 SEBU8609
Safety Section
Fire Prevention and Explosion Prevention
i04047444
Fire Prevention and Explosion
Prevention
Illustration 8 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.
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 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.
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. The hoses
must be correctly routed. The lines and hoses must
have adequate support and secure clamps.
Oil filters and fuel filters must be correctly installed.
The filter housings must be tightened to the correct
torque. Refer to the Disassembly and Assembly
manual for more information.
After the emergency stop button has been operated,
ensure that you allow 15 minutes, before the engine
covers are removed.
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.
Illustration 9 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.
SEBU8609 11
Safety Section
Crushing Prevention and Cutting Prevention
• High-pressure fuel line or lines are removed.
• 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.
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.
Regeneration
Illustration 10 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.
Do not charge a frozen battery. Charge 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.
The exhaust gas temperature during regeneration will
be elevated. Follow proper fire prevention instructions
and use the disable switch function when appropriate.
i02143194
Crushing Prevention and
Cutting Prevention
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.
Leaks can cause fires. Consult your Perkins dealer
or your Perkins distributor for replacement parts.
Replace the parts if any of the following conditions
are present:
12 SEBU8609
Safety Section
Mounting and Dismounting
i04016709
Mounting and Dismounting
Do not climb on the engine or the engine
aftertreatment. The engine and aftertreatment have
not been designed with mounting or dismounting
locations.
Refer to the OEM for the location of foot and hand
holds for your specific application.
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.
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.
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 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.
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.
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.
SEBU8609 13
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.
i04047709
Electrical System
Grounding Practices
Illustration 11 g02324975
Typical example
Ground to battery
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 “−” cable should be connected last from the
external power source to the primary position for
grounding.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical
connections 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.
Illustration 12 g02324976
Typical example
Alternate ground to battery
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.
14 SEBU8609
Safety Section
Engine Electronics
Uncontrolled electrical circuit paths can result in
damage to the 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.
The connections for the 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.
The power supply connections and the ground
connections for the engine electronics should always
be from the isolator to the battery.
i05181812
Engine Electronics
The Engine Monitoring package can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Note: Many of the engine control systems and
display modules that are available for Perkins
Engines will work in unison with the Engine
Monitoring System. Together, the two controls will
provide the engine monitoring function for the specific
engine application. Refer to the Troubleshooting for
more information on the Engine Monitoring System.
Tampering with the electronic system installation
or the OEM wiring installation can be dangerous
and could result in personal injury or death and/or
engine damage.
This engine has a comprehensive, programmable
Engine Monitoring System. The Electronic Control
Module (ECM) has the ability to monitor the engine
operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
initiate an immediate action.
The following actions are available for engine
monitoring control:
• Warning
• Derate
• Shutdown
The following monitored engine operating conditions
and components have the ability to limit engine speed
and/or the engine power:
• Oil Pressure Switch
• Coolant Temperature Sensor
• Engine Aftertreatment System
SEBU8609 15
Product Information Section
Model View Illustrations
Product Information
Section
General Information
i05139695
Model View Illustrations
(Engines and Aftertreatment)
The following model views show typical features of
the engine. Due to individual applications, your
engine may appear different from the illustrations.
403F-15T
Illustration 13 g03246538
Typical example
16 SEBU8609
General Information
Model View Illustrations
404F-22
Illustration 14 g03246558
Typical example
SEBU8609 17
General Information
Model View Illustrations
404F-22T
Illustration 15 g03246676
(1) Top oil filler
(2) Fan
(3) Side oil filler
(4) Cylinder block drain plug
(5) Oil gauge (Dipstick)
(6) Rear oil drain plug
(7) Oil filter
(8) Electric fuel pump
(9) Secondary fuel filter
18 SEBU8609
General Information
Model View Illustrations
Illustration 16 g03246563
(10) Air intake
(11) Turbocharger
(12) Aftertreatment system
(13) Flywheel
(14) Flywheel housing
(15) Starting motor
(16) Solenoid for starting motor
(17) Front oil drain plug
(18) NOx reduction system cooler
(19) Coolant outlet
SEBU8609 19
General Information
Model View Illustrations
Illustration 17 g03249056
(20) Engine crankcase breather
(21) Rear lifting eye bracket
(22) Air pump
(23) Air pump drive belt
(24) Alternator
(25) Fan and alternator drive belt
(26) Coolant intake
(27) Water pump
(28) Front lifting eye
20 SEBU8609
General Information
Model View Illustrations
Aftertreatment System
Illustration 18 g03249241
(29) Aftertreatment RegenerationDevice
(ARD), also known as the (Burner)
(30) Diesel Oxidation Catalyst (DOC)
(31) Diesel Particulate Filter (DPF)
SEBU8609 21
General Information
Model View Illustrations
Off Engine Parts
Illustration 19 g03271819
(32) Electronic Control Unit (ECM)
(33) In line fuel filter
22 SEBU8609
General Information
Product Description
Engine with Low Mounted Air Pump
Illustration 20 g03321871
i05139813
Product Description
The 400F models are indirect injection engines. The
fuel injection pump is operated by a solenoid that is
controlled by a Pulse Width Modulation (PWM) signal
from the ECM.
The cylinder head assembly has one inlet valve and
one exhaust valve for each cylinder. Each cylinder
valve has a single valve spring.
The pistons have two compression rings and an oil
control ring. It is important to ensure the correct piston
height so that the piston does not contact the cylinder
head. The correct piston height also ensures efficient
combustion of fuel that is necessary in order to
conform to requirements for emissions.
The crankshaft for a three cylinder engine has four
main bearing journals. The crankshaft for a four
cylinder engine has five main bearing journals. End
play is controlled by the thrust washers that are
located on the rear main bearing.
The timing gears are stamped with timing marks in
order to ensure the correct assembly of the gears.
With the timing marks on the crankshaft gear
camshaft gear and the idler gear aligned No. 1 piston
will be at top center compression stroke.
The crankshaft gear turns the idler gear which then
turns the camshaft gear and the gear for the engine
oil pump.
The fuel injection pump is mounted in the cylinder
block. The fuel injection pump is operated by the
camshaft. The fuel pump is located on the right-hand
side of the cylinder block. The fuel pump is electrically
operated.
SEBU8609 23
General Information
Product Description
The fuel injection pump conforms to requirements for
emissions. If any adjustments to the fuel injection
pump timing and high idle are required, you must
refer to your Perkins distributor your Perkins dealer.
A gerotor oil pump is located in the center of the idler
gear. The engine oil pump sends lubricating oil to the
main oil gallery through a pressure relief valve and an
engine oil filter. The rocker arms receive pressurized
oil through an externally located oil line that runs from
the main oil gallery to the cylinder head.
Coolant from the bottom of the radiator passes
through the belt driven centrifugal water pump. The
coolant is cooled by the radiator and the temperature
is regulated by a water temperature regulator.
Engine efficiency, efficiency of emission controls, and
engine performance depend on adherence to correct
operation and maintenance recommendations.
Engine performance and efficiency also depend on
the use of recommended fuels, lubrication oils, and
coolants. Refer to the Operation and Maintenance
Manual, “Maintenance Interval Schedule” for more
information on maintenance items.
Engine Specifications
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right side
of the engine are determined from the flywheel end.
The No. 1 cylinder is the front cylinder.
(Table 1, contd)
Bore 84 mm (3.31 inch)
Stroke 90 mm (3.54 inch)
Displacement 1.496 L (91.291 in
Aspiration
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
(1)
Turbocharged
(1)
T
22.5:1
1-2-3
Counterclockwise
Indirect
404F-22 Engine
3
)
403F-15T Engine
Illustration 21 g00852304
(A) Exhaust valves
(B) Inlet valves
Table 1
403F-15T Engine Specifications
Maximum Operating Speed
(rpm)
Cylinders and Arrangement In-Line 3 cylinder
2800 rpm
Illustration 22 g00296424
(A) Exhaust valves
(B) Inlet valves
Table 2
404F-22 Engine Specifications
Maximum Operating Speed
(rpm)
Cylinders and Arrangement In-Line 4 cylinder
Bore 84.0 mm (3.31 inch)
Stroke 100.0 mm (3.94 inch)
Displacement 2.216 L (135.229 in
Aspiration
Compression Ratio
Firing Order
3000 rpm
(1)
NA
23.3:1
1-3-4-2
3
)
(continued)
(continued)
24 SEBU8609
General Information
Product Description
(Table 2, contd)
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
(1)
Naturally Aspirated
Counterclockwise
Indirect
404F-22T Engine
Illustration 23 g00296424
(A) Exhaust valves
(B) Inlet valves
Table 3
404F-22T Engine Specifications
Maximum Operating Speed
(rpm)
Cylinders and Arrangement In-Line 4 cylinder
Bore 84.0 mm (3.31 inch)
Stroke 100.0 mm (3.94 inch)
Displacement 2.216 L (135.229 in
Aspiration
3000 rpm
(1)
T
3
)
Electronic Engine Features
The engine operating conditions are monitored. The
Electronic Control Module (ECM) controls the
response of the engine to these conditions and to the
demands of the operator. These conditions and
operator demands determine the precise control of
fuel injection by the ECM. The electronic engine
control system provides the following features:
• Engine monitoring
• Engine speed governing
• System diagnostics
• Aftertreatment Regeneration
• NOx reduction system control on the 404F-22T
engine
For more information on electronic engine features,
refer to the Operation and Maintenance Manual,
“Features and Controls” topic (Operation Section).
Engine Diagnostics
The engine has built-in diagnostics in order to ensure
that the engine systems are functioning correctly. The
operator will be alerted to the condition by a “Stop or
Warning” lamp. Under certain conditions, the engine
horsepower and the vehicle speed may be limited.
The electronic service tool may be used to display the
diagnostic codes.
There are four types of diagnostic codes: active code,
logged code, active event and logged event.
Most of the diagnostic codes are logged and stored in
the ECM. For additional information, refer to the
Operation and Maintenance Manual, “Engine
Diagnostics” topic (Operation Section).
The ECM provides an electronic governor that
controls the injector output in order to maintain the
desired engine rpm.
Engine Service Life
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
(1)
Turbocharged
23.5:1
1-3-4-2
Counterclockwise
Indirect
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.
Expected engine life is generally predicted by the
average power that is demanded. The average power
that is demanded is based on fuel consumption of the
engine over a period of time. Reduced hours of
operation at full throttle and/or operating at reduced
throttle settings result in a lower average power
demand. Reduced hours of operation will increase
the length of operating time before an engine
overhaul is required.
SEBU8609 25
General Information
Product Description
Aftermarket Products and Perkins
Engines
Perkins does not warrant the quality or performance
of non-Perkins fluids and filters.
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.
Aftertreatment System
The aftertreatment system is approved for use by
Perkins . In order to be emission-compliant only the
approved Perkins aftertreatment system must be
used on a Perkins engine.
26 SEBU8609
Product Identification Information
Plate Locations and Film Locations
Product Identification
Information
Plate Locations and Film
Locations
i05140083
An example of an engine number is
ER*****U000001V.
ER Engine family
P 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
V 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.
i05140229
Emissions Certification Film
Illustration 24 g02335396
Typical example
(1) serial number plate
Perkins engines are identified by a serial number.
This number is shown on a serial number plate. The
serial number plate is mounted above the fuel
injection pump on the right-hand side of the engine
block.
Illustration 25 g01094203
Typical example
Illustration 26 g02269574
Typical example
The emissions label, refer to illustration 26 is
installed on the front cover of the engine.
SEBU8609 27
Product Identification Information
Reference Information
Identifying Numbers on Aftertreatment
Illustration 27 g02052934
Perkins will supply the fuel label with every engine,
refer to illustration 27 . The equipment manufacturer
must install the label to the equipment. The label must
be attached to the equipment near the inlet of the fuel
tank. This action will comply with the EPA regulations.
The equipment manufacturer may install another fuel
label . If another fuel label is used, the equipment
manufacturer must send a drawing or a photo of the
label to Perkins. This action will ensure compliance of
the label.
i05157330
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
Engine rpm
In-Line fuel filter
Fuel Filter Element
Lubrication Oil Filter
Crankcase Breather Element
Total Lubrication System Capacity
Total Cooling System Capacity
Air Cleaner Element
Fan Belt
Belt for Air Pump
28 SEBU8609
Operation Section
Product Lifting
Operation Section
Lifting and Storage
Product Lifting
i05140249
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.
Lifting Eyes with Top Mounted
Aftertreatment
Illustration 28 g03274116
Typical example
(1) Front lifting eye
(2) Rear lifting eyes
Note: The engine assembly has three lifting eyes,
refer to illustration 28 .
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.
To remove the engine ONLY, use the lifting eyes that
are on the engine.
Illustration 29 g03321882
(1) Front lifting eye
(2) Rear lifting eye
i04053009
Product Storage
(Engine and Aftertreatment)
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.
SEBU8609 29
Lifting and Storage
Product Storage
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.
Aftertreatment
No special procedures are required. The exhaust
outlet of the aftertreatment should be capped. Before
storing, the engine and the aftertreatment must be
enclosed in a cover.
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 and
aftertreatment.
Ensure that the engine and aftertreatment are
covered completely before storage. Log the
procedure in the record for the engine.
2. Drain any water from the primary filter water
separator. Ensure that the fuel tank is full.
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.
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.
30 SEBU8609
Features and Controls
Alarms and Shutoffs
Features and Controls
i05142391
Alarms and Shutoffs
• ECM Electronic Control Module
• DOC Diesel Oxidation Catalyst
• DPF Diesel Particulate Filter
• ARD Aftertreatment Regeneration Device
Shutoffs
The shutoffs are electrically operated or mechanically
operated. The electrically operated shutoffs are
controlled by the ECM.
Shutoffs are set at critical levels for the following
items:
• Operating temperature
• Operating RPM
• Overspeed
• Aftertreatment regeneration
The particular shutoff may need to be reset before the
engine will start.
Coolant temperature – The coolant temperature
sensor indicates high jacket water coolant
temperature.
Engine oil pressure – The engine oil pressure
sensor or switch, indicates when oil pressure drops
below rated system pressure, at a set engine speed.
Boost pressure (Intake manifold pressure – The
intake manifold pressure sensor checks the rated
pressure in the engine manifold.
Intake manifold air temperature – The intake
manifold air temperature sensor indicates high intake
air temperature.
Atmospheric pressure – The atmospheric pressure
sensor checks the air pressure in the location that the
engine is operating.
Aftertreatment Alarms
DOC inlet temperature – The inlet temperature
sensor checks the operating temperature.
DPF inlet temperature – The inlet temperature
sensor checks the operating temperature.
DPF outlet temperature – The outlet temperature
sensor checks the operating temperature.
Delta P sensor (Differential pressure) – The sensor
checks the differential pressure within the system.
ARD temperature – The sensor checks the
temperature within the burner in the ARD system
NOTICE
Always determine the cause of the engine shutdown.
Make necessary repairs before attempting to restart
the engine.
Be familiar with the following items:
• Types and locations of shutoff
• Conditions which cause each shutoff to function
• The resetting procedure that is required to restart
the engine
Alarms
The alarms are electrically operated. The operations
of the alarms are controlled by the ECM.
The alarm is operated by a sensor or by a switch.
When the sensor or the switch is activated, a signal is
sent to the ECM. An event code is created by the
ECM. The ECM will send a signal in order to
illuminate the lamp. Some application may have a
display panel in order to alert the operator.
Your engine may be equipped with the following
sensors or switches:
Testing
Turning the keyswitch to the ON position will check
the indicator lights on the control panel. All the
indicator lights will be illuminated for 2 seconds after
the keyswitch is operated. Replace suspect bulbs
immediately.
If any lamps stay illuminated or flashes, the fault must
be investigated immediately. The fault will create a
diagnostic code.
Refer to Troubleshooting, “Diagnostic Trouble Code”
for more information.
i05140291
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.
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