Perkins Engine 404F-E22T, 404F-E22TA, 403F-E17T Service Manual

Operation and Maintenance Manual

SEBU9075-01 (en-us)

November 2016

404F-E22T, 404F-E22TA and 403F-E17T Industrial Engines

ER1 (Engine) EQ1 (Engine) EW1 (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.............................. 8

Burn Prevention................................................11

Fire Prevention and Explosion Prevention...... 13

Crushing Prevention and Cutting Prevention.. 15

Mounting and Dismounting ............................. 15

High Pressure Fuel Lines................................ 15

Before Starting Engine .................................... 18

Engine Starting................................................ 18

Engine Stopping .............................................. 51

Maintenance Section

Refill Capacities............................................... 52

Maintenance Recommendations .................... 67

Maintenance Interval Schedule....................... 70

Warranty Section

Warranty Information....................................... 93

Reference Information Section

Reference Materials ........................................ 94

Index Section

Index................................................................ 95

Engine Stopping .............................................. 19

Electrical System............................................. 19

Engine Electronics........................................... 20

Product Information Section

General Information ........................................ 22

Product Identification Information ................... 29

Operation Section

Lifting and Storage .......................................... 31

Features and Controls..................................... 33

Engine Diagnostics ......................................... 39

Engine Starting................................................ 41

Engine Operation ............................................ 44

Aftertreatment Operation................................. 46

Cold Weather Operation ................................. 47

4 Foreword

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Foreword

Literature Information

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

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

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

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

Safety

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

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

Operation

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

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

Maintenance

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

referenced to detailed instructions that follow.

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

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

Maintenance Intervals

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

maintained as part of the engine's permanent record.

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

Overhaul

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

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

California Proposition 65 Warning

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

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

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Safety Section

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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 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.

Safety Section

Safety Messages

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 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 1 g01154807

Typical example

The Universal Warning label (1) is on the side of the valve mechanism cover. Refer to illustration 2 .

6 Safety Section

Safety Messages

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Illustration 2 g03881406

(2) Hand (High Pressure)

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.

Illustration 3 g02382677

Typical example

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Safety Section

Safety Messages

Illustration 4 g03881407

The warning label for the Hand (High Pressure) (2) is a wrap around label that is installed on the highpressure fuel line.

Ether Warning

An ether warning label should be installed on the air cleaner or close to the air cleaner. The location will

depend on the application.

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.

8 Safety Section

General Hazard Information

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• 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.

Illustration 5 g01154809

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General Hazard Information

Illustration 6 g00104545

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

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

• 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.

• 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. If equipped, allow the diesel exhaust fluid to be purged before disconnecting the battery.

• If equipped, disconnect the connectors for the unit injectors that are located on the valve cover base. This action will help prevent personal injury from the high voltage to the unit injectors. Do not come in contact with the unit injector terminals while the engine is operating.

• 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.

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Safety Section

General Hazard Information

• 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.

• 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.

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.

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).

Illustration 7 g00702020

• 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.

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.

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.

10 Safety Section

General Hazard Information

Illustration 8 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.

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Avoid static electricity risk when fueling. Ultralow sulfur diesel fuel (ULSD fuel) poses a greater static ignition hazard than earlier diesel formulations with a higher sulfur contents. Avoid death or serious injury from fire or explosion. Consult with your fuel or fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices.

Inhalation

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.

Static Electricity Hazard when Fueling with Ultra-low Sulfur Diesel Fuel

The removal of sulfur and other compounds in ultralow sulfur diesel fuel (ULSD fuel) decreases the conductivity of ULSD and increases the ability of ULSD to store static charge. Refineries may have treated the fuel with a static dissipating additive. Many factors can reduce the effectiveness of the additive over time. Static charges can build up in ULSD fuel while the fuel is flowing through fuel delivery systems. Static electricity discharge when combustible vapors are present could result in a fire or explosion. Ensure that the entire system used to refuel your machine (fuel supply tank, transfer pump, transfer hose, nozzle, and others) is properly grounded and bonded. Consult with your fuel or fuel system supplier to ensure that the delivery system complies with fueling standards for proper grounding and bonding.

Illustration 9 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.

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

• Never use compressed air for cleaning.

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Safety Section

Burn Prevention

• 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

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

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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.

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.

After the engine has stopped, wait for 10 minutes in order to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed on the engine fuel lines. The 10 minute wait will also allow static charge to dissipate from the low-pressure fuel system.

Illustration 10 g00706404

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

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.

12 Safety Section

Burn Prevention

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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 sul-

fur 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.

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, aftertreatment system 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.

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.

Diesel Fuel

Diesel may be irritating to the eyes, respiratory system, and skin. Prolonged exposure to diesel may cause various skin conditions. Appropriate personal protective equipment should be used. Refer to supplier Material safety Data sheets for detailed information.

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.

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.

Aftertreatment System

Allow the aftertreatment to cool down before any maintenance or repair is performed.

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Safety Section

Fire Prevention and Explosion Prevention

i05670934

Fire Prevention and Explosion Prevention

Illustration 11 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.

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.

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.

After the engine has stopped, you must wait for 10 minutes in order to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed on the engine fuel lines. The 10 minute wait will also allow static charge to dissipate from the low-pressure fuel system.

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

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.

14 Safety Section

Fire Prevention and Explosion Prevention

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Illustration 12 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. Ultra-low Sulfur Diesel fuel (ULSD fuel) poses a greater static ignition hazard than earlier diesel formulations with a higher sulfur content. Avoid death or serious injury from fire or explosion. 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.

Illustration 13 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. 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.

Ether

Ether is flammable and poisonous.

Do not smoke while you are replacing an ether cylinder or while you are using an ether spray.

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Safety Section

Crushing Prevention and Cutting Prevention

Do not store ether cylinders in living areas or in the engine compartment. Do not store ether cylinders in direct sunlight or in temperatures above 49° C (120° F). Keep ether cylinders away from open flames or sparks.

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 dealer or your Perkins distributor for replacement parts.

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

• 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.

i02143194

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.

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Mounting and Dismounting

Do not climb on the engine or the engine aftertreatment system. The engine and aftertreatment system 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.

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High Pressure Fuel Lines

The high-pressure fuel lines are the fuel lines that are between the high-pressure fuel pump and the highpressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head. These fuel lines are different from fuel lines on other fuel

systems.

The different is because of the following items:

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.

• The high-pressure fuel lines are constantly charged with high pressure.

• The internal pressures of the high-pressure fuel lines are higher than other types of fuel system.

• The high-pressure fuel lines are formed to shape and then strengthened by a special process.

Do not step on the high-pressure fuel lines. Do not deflect the high-pressure fuel lines. Do not bend or strike the high-pressure fuel lines. Deformation or damage of the high-pressure fuel lines may cause a point of weakness and potential failure.

Do not check the high-pressure fuel lines with the engine or the starting motor in operation. After the engine has stopped, you must wait for 10 minutes to allow the fuel pressure to be purged from the highpressure fuel lines before any service or repair is performed on the engine fuel lines. The 10 minute wait will also allow static charge to dissipate from the low-pressure fuel system.

16 Safety Section

High Pressure Fuel Lines

Do not loosen the high-pressure fuel lines to remove air from the fuel system. This procedure is not required.

Visually inspect the high-pressure fuel lines before the engine is started. This inspection should be each day.

If you inspect the engine in operation, always use the proper inspection procedure to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”.

• Inspect the high-pressure fuel lines for damage, deformation, a nick, a cut, a crease, or a dent.

• Do not operate the engine with a fuel leak. If there is a leak, do not tighten the connection to stop the leak. The connection must only be tightened to the recommended torque. Refer to Disassembly and Assembly, “Fuel injection lines - Remove and Fuel injection lines - Install”.

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• If the high-pressure fuel lines are torqued correctly and the high-pressure fuel lines are leaking, the high-pressure fuel lines must be replaced.

• Ensure that all clips on the high-pressure fuel lines are in place. Do not operate the engine with clips that are damaged, missing, or loose.

• Do not attach any other item to the high-pressure fuel lines.

• Loosened high-pressure fuel lines must be replaced. Also removed high-pressure fuel lines must be replaced. Refer to Disassembly and assembly manual, “Fuel Injection Lines - Install”.

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Four Cylinder engine

Safety Section

High Pressure Fuel Lines

Illustration 14 g03886691

(1) High-pressure line (2) High-pressure line (3) High-pressure line

(4) High-pressure line (5) High-pressure fuel manifold (rail) (6) High-pressure line

(7) Fuel transfer line that is high pressure

18 Safety Section

Before Starting Engine

Three Cylinder Engine

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Illustration 15 g06064715

Typical example

(1) High-pressure line (2) High-pressure line

(3) High-pressure line (4) High-pressure fuel manifold

i03560601

If equipped, ensure that the lighting system for the

(5) High-pressure line (6) Fuel transfer line that is high pressure

engine is suitable for the conditions. Ensure that all

Before Starting Engine

lights work properly, if equipped.

All protective guards and all protective covers must be installed if the engine must be started in order to

For initial start-up of a new or rebuilt engine, and for

NOTICE

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.

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

Engine exhaust contains products of combustion

adjustments.

which may be harmful to your health. Always start and operate the engine in a well ventilated

i03996487

area and, if in an enclosed area, vent the exhaust to the outside.

Engine Starting

Inspect the engine for potential hazards.

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

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

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

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Safety Section

Engine Stopping

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 operators compartment or from the engine start switch.

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

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

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

Note: The engine is equipped with a device for cold starting. 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.

Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected.

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

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

i06276654

Electrical System

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

To help prevent sparks from igniting combustible gases that are produced by some batteries, the negative “−” 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.

These engines are equipped with a glow plug starting aid in each individual cylinder that heats the intake air in order to improve starting. Some Perkins engines may have a cold starting system that is controlled by the ECM that allows a controlled flow of ether into the

engine. The ECM will disconnect the glow plugs before the ether is introduced. This system would be installed at the factory.

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.

20 Safety Section

Engine Electronics

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Grounding Practices

Illustration 16 g03881462

Typical example Ground to battery

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.

i06276686

Engine Electronics

Illustration 17 g03881463

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.

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.

Electrical Shock Hazard. The electronic unit injectors use DC voltage. The ECM sends this voltage to the electronic unit injectors. Do not come in contact with the harness connector for the elec-

tronic unit injectors while the engine is operating. Failure to follow this instruction could result in

personal injury or death.

This engine has a comprehensive, programmable Engine Monitoring System. The Electronic Control Module (ECM) will 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

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The following monitored engine operating conditions and components have the ability to limit engine speed and/or the engine power:

• Engine Coolant Temperature

• Engine Oil Pressure

• Intake Manifold Air Temperature

• Intake Manifold Air Pressure

• Engine Speed Sensors

• Fuel Temperature

• Aftertreatment Temperature Sensors (if installed)

• Electronic Unit Injectors

• Engine Intake Throttle Valve (if installed)

• Supply Voltage to Sensors

Safety Section

Engine Electronics

• Fuel Pressure in Manifold (Rail)

• NOx Reduction System

• Engine Aftertreatment System

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.

22 Product Information Section

General Information

Product Information Section

General Information

i06674280

Model View Illustrations

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

Three Cylinder Engine

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Illustration 18 g06068851

Typical example

(1) Location of fuel filter is for shipment only

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Product Information Section

Model View Illustrations

Illustration 19 g06068852

Typical example

24 Product Information Section

Model View Illustrations

Four Cylinder Engine

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Illustration 20 g06103579

Typical example

(1) Electronic unit injector (2) Rear lifting eye (3) Top oil fill cap (4) Front lifting eye (5) Fan

(6) Alternator and fan belt (7) Fuel manifold (Fuel rail) (8) Lower oil filler cap (9) High-pressure fuel pump (10) Oil gauge (Dipstick)

(11) Oil drain plug (12) Oil filter (13) Secondary fuel filter (14) Breather

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Product Information Section

Model View Illustrations

Illustration 21 g06103622

Typical example

(15) Water temperature regulator (16) NOx Reduction System Valve (NRS) (17) Throttle valve (18) Diesel Oxidation Catalyst (DOC)

(19) Flywheel (20) Flywheel housing (21) Starting motor (22) Turbocharger

(23) NRS cooler (24) Alternator

26 Product Information Section

Product Description

Off Engine Components for Three and Four Cylinder Engines

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Illustration 22 g06103572

Typical example

(1) Electric fuel priming pump (2) Primary fuel filter/water separator

(3) Electronic Control Module (ECM) (4) Engine wiring harnesses

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Product Description

Three Cylinder Engine 403F-E17T

The Perkins 403F-E17T industrial engine is a , turbocharged engine This engine has a Diesel Oxidation Catalyst (DOC) aftertreatment system. The DOC aftertreatment system does not require a service interval and engine is electronically governed.

The 403F-E17T industrial engine have the following characteristics.

• In-line 3 cylinder

• 4 stroke cycle

• Two valves per cylinder

• DOC aftertreatment

Illustration 23 g00852304

(A) Exhaust valves (B) Inlet valves

Table 1

403F-E17T Engine Specifications

Maximum Operating Speed (rpm)

Cylinders and Arrangement In-Line three cylinder engine

2800 RPM

(continued)

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Product Information Section

Product Description

(Table 1, contd)

Bore 84 mm (3.31 inch)

Stroke 100 mm (3.94 inch)

Displacement 1.66 L (101.3 in

Aspiration Turbocharged

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)

18:1

1-2-3

Counterclockwise

)

Four Cylinder Engine 404F-E22T and 404F-E22TA

Two variants of Perkins 404F-E22T and 404F-E22TA industrial engine are available, the turbocharged

engine and the turbocharged charge cooled engine. Both engine variants have a Diesel Oxidation Catalyst (DOC) aftertreatment system. The DOC aftertreatment system does not require a service interval. Both engine variants are electronically governed.

The 404F-E22T and 404F-E22TA industrial engines have the following characteristics.

• In-line 4 cylinder

The 404F-E22T and 404F-E22TA engines may be supplied with a throttle control valve and temperatures sensors in the DOC or without these components installed. The difference will be due to the evolution of engine design.

Table 2

404F-E22T and 404F-E22TA Industrial Engines

Bore 84 mm (3.307 inch)

Stroke 100 mm (3.937 inch)

Displacement 2.216 L (135.22861 cubic inch)

Compression Ratio 18: 1

Aspiration Turbocharged and Turbo-

charged charge/air cooled

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

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

Firing Order 1-3-4-2

Rotation (flywheel end) Counterclockwise

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:

• 4 stroke cycle

• Two valves per cylinder

• DOC aftertreatment

Illustration 24 g00296424

(A) Exhaust valves (B) Inlet valves

• Engine monitoring

• Engine speed governing

• Injection timing control

• System diagnostics

Engine Diagnostics

The engine has built-in diagnostics 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 Diagnostic Code, Logged Diagnostic Code, Active Event Code and logged Event Code.

28 Product Information Section

Product Description

The ECM provides an electronic governor that controls the injector output to maintain the desired engine rpm.

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.

Expectedengine 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.

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The aftertreatment system can be expected to function properly for the useful life of the engine (emissions durability period), as defined by regulation, subject to prescribed maintenance requirements being followed.

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.

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Product Information Section

Product Identification Information

Plate Locations and Film Locations

Serial Number Plate

Perkins Plate

i06279352

Illustration 26 g01094203

Typical example

i06591372

Emissions Certification Film

Illustration 25 g03882431

The engine serial plate (1) is located on the left side of the engine to the rear of the engine cylinder block.

Perkins distributors need all the numbers on the plate in order to determine the components that were included with the engine. This information permits accurate identification of replacement part numbers.

Illustration 27 g01478138

Typical example

30 Product Information Section

Reference Information

Illustration 28 g06038952

Typical example

Refer to illustration 28 . The equipment manufacturer must install the label to the equipment. This procedure is recommended by Perkins Shibaura Engines Limited. The label must be attached to the equipment near the fuel inlet to comply with the EPA regulations. The equipment manufacturer may install another fuel label.

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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 Low Idle rpm

Engine Full Load rpm

Primary Fuel Filter

Secondary Fuel Filter Element

Lubrication Oil Filter Element

Auxiliary Oil Filter Element (if Equipped)

Total Lubrication System Capacity

Total Cooling System Capacity

Air Cleaner Element

Drive Belt

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