SEBU9064 June 2013 Operation and Maintenance Manual 402F-05, 403F-07, 403F-11, and 403F-15 Industrial Engines EG (Engine) EH (Engine) EJ (Engine) EK (Engine)
Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.
SEBU9064 3 Table of Contents Table of Contents Maintenance Interval Schedule ........... ........... 54 Foreword.............................. ............................. 4 Warranty Section Safety Section Warranty Information ................... ................... 82 Safety Messages....................... ....................... 5 Reference Information Section General Hazard Information ............... .............. 6 Reference Materials ........................................
SEBU9064 Foreword Foreword Literature Information This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literature holder or literature storage area. Read, study and keep it with the literature and engine information. English is the primary language for all Perkins publications. The English used facilitates translation and consistency.
SEBU9064 Safety Section Safety Messages Safety Section i05333233 Safety Messages There may be several specific warning signs on your engine. The exact location and a description of the warning signs are reviewed in this section. Become familiar with all warning signs. Ensure that all of the warning signs are legible. Clean the warning signs or replace the warning signs if the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the warning signs.
SEBU9064 Safety Section General Hazard Information Illustration 2 g03378379 Typical examples (A) Location of warning label (1) 402F-05 (2) 403F-07 (3) 403F-11 (4) 403F-15 i02328435 General Hazard Information Illustration 4 g00702020 Wear a hard hat, protective glasses, and other protective equipment, as required.
SEBU9064 Safety Section Burn Prevention Never put maintenance fluids into glass containers. Drain all liquids into a suitable container. Obey all local regulations for the disposal of liquids. Use all cleaning solutions with care. Report all necessary repairs. Do not allow unauthorized personnel on the equipment. Ensure that the power supply is disconnected before you work on the bus bar or the glow plugs. Perform maintenance on the engine with the equipment in the servicing position.
SEBU9064 Safety Section Fire Prevention and Explosion Prevention Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained. A flash fire may result if the covers for the engine crankcase are removed within fifteen minutes after an emergency shutdown. Check the coolant level after the engine has stopped and the engine has been allowed to cool.
SEBU9064 9 Safety Section Crushing Prevention and Cutting Prevention Do not charge a frozen battery. This may cause an explosion. The batteries must be kept clean. The covers (if equipped) must be kept on the cells. Use the recommended cables, connections, and battery box covers when the engine is operated. Fire Extinguisher Make sure that a fire extinguisher is available. Be familiar with the operation of the fire extinguisher. Inspect the fire extinguisher and service the fire extinguisher regularly.
SEBU9064 Safety Section Before Starting Engine Unless other maintenance instructions are provided, never attempt adjustments while the engine is running. i02157354 Engine Starting 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.
SEBU9064 11 Safety Section Engine Stopping i02234873 Engine Stopping Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine components. Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping.
SEBU9064 Product Information Section Model View Illustrations Product Information Section General Information i05333703 Model View Illustrations The 403F-15 Engine View Illustration 9 g03378808 Typical example (1) Rear lifting eye (2) Top oil filler cap (3) Front lifting eye (4) Water pump (5) Low mounted oil filler cap (6) Fuel injection pump (7) Oil gauge (Dipstick) (8) Oil drain plug (9) Oil filter (10) Electronically controlled actuator (11) Injector
SEBU9064 13 General Information Model View Illustrations Illustration 10 (12) Air intake (13) Coolant outlet (14) Exhaust manifold g03379877 (15) Solenoid for starter (16) Starting motor (17) Alternator (18) Fan belt (18) Coolant intake connection
SEBU9064 General Information Model View Illustrations Fuel System Components Illustration 11 g03379882 Typical examples (1) In-line fuel filter (2) Electric fuel pump (3) Primary fuel filter (4) Secondary fuel filter (element type) Note: The electric fuel pump is an option, engines may have a mechanical fuel lift pump installed.
SEBU9064 15 General Information Product Description Components for Electronic Control Illustration 12 (1) Electronic Control Module (ECM) (2) Speed sensor g03379884 (3) Atmospheric Pressure Sensor (Barometric Pressure Sensor) Note: Due to individual applications the atmospheric pressure sensor (3) may appear different from the illustration. i05333638 Product Description There are four Perkins engines in the 400F series that are below 19Kw power band.
SEBU9064 General Information Product Description 402F-05 Engine 403F-07 Engine Illustration 13 g01108476 Illustration 14 g00852304 (A) Exhaust valves (B) Inlet valves (A) Exhaust valves (B) Inlet valves Table 1 Table 2 402F-05 Engine Specifications 403F-07 Engine Specifications Maximum Operating Speed (rpm) 3600 rpm Maximum Operating Speed (rpm) 3600 rpm Cylinders and Arrangement In-Line 2 cylinder Cylinders and Arrangement In-Line 3 cylinder Bore 67 mm (2.64 inch) Bore 67 mm (2.
SEBU9064 17 General Information Product Description 403F-11 Engine 403F-15 Engine Illustration 15 g00852304 Illustration 16 g00852304 (A) Exhaust valves (B) Inlet valves (A) Exhaust valves (B) Inlet valves Table 3 Table 4 403F-11 Engine Specifications 403F-15 Engine Specifications Maximum Operating Speed (rpm) 3600 rpm Maximum Operating Speed (rpm) 3000 rpm Cylinders and Arrangement In-Line 3 cylinder Cylinders and Arrangement In-Line 3 cylinder Bore 77 mm (3.03 inch) Bore 84 mm (3.
SEBU9064 Product Identification Information Plate Locations and Film Locations Product Identification Information i05333666 Emissions Certification Film i05333660 Plate Locations and Film Locations Perkins engines are identified by a serial number. This serial number is shown on a serial number plate. The plate is mounted above the fuel injection pump on the right-hand side of the engine block. A typical example of an engine number is EK*****N000001X.
SEBU9064 19 Product Identification Information Reference Information Total Lubrication System Capacity Total Cooling System Capacity Air Cleaner Element Alternator Belt
SEBU9064 Operation Section Product Lifting Operation Section Lifting and Storage i05335230 Lifting eyes are designed and installed for specific engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting fixtures obsolete. If alterations are made, ensure that correct lifting devices are provided. Consult your Perkins dealer or your Perkins distributor for information regarding fixtures for correct engine lifting.
SEBU9064 21 Lifting and Storage Product Storage 3. The engine oil will not need to be drained in order to store the engine. Provided the correct specification of engine oil is used the engine can be stored for up to 6 months. For the correct specification of engine oil refer to this Operation and Maintenance Manual, “Fluid recommendations”. 4. Remove the fan belt from the engine.
SEBU9064 Features and Controls Gauges and Indicators Features and Controls 2. Inspect the cooling system for leaks. i05336041 Gauges and Indicators Your engine may not have the same gauges or all of the gauges that are described. For more information about the gauge package, see the OEM information. Gauges provide indications of engine performance. Ensure that the gauges are in good working order. Determine the normal operating range by observing the gauges over a period of time.
SEBU9064 23 Features and Controls Overspeed NOTICE The Engine Monitoring System is not a guarantee against catastrophic failures. Programmed delays and derate schedules are designed to minimize false alarms and provide time for the operator to stop the engine.
SEBU9064 Features and Controls Sensors and Electrical Components Illustration 19 g03381125 Typical examples (1) Oil pressure sensor (2) Coolant temperature sensor (3) Atmosphere pressure sensor (Barometric pressure sensor) Note: Due ti individual applications the atmosphere pressure sensor (3) may appear different from the illustration.
SEBU9064 25 Features and Controls Sensors and Electrical Components Illustration 20 g03381126 Typical examples (7) Alternator (8) Starting motor (9) Glow plugs (10) Electronic control model (Controller) When the keyswitch is in the OFF position, the multi function lamp will not be illuminated. With the keyswitch in the ON position the multi function lamp will flash once. The flash will indicate that the system is powered and ready for operation.
Engine Diagnostics Self-Diagnostics SEBU9064 Engine Diagnostics i05339798 Self-Diagnostics The electronic engines can perform a self-diagnostics test. When the system detects an active problem, a diagnostic lamp is activated. This lamp is a multi function lamp that is located on the electronic control module. The lamp will flash a code that will give am indication of the fault. For more information on the flash codes, refer to this Operation and Maintenance Manual, “Diagnostic Flash Code Retrieval”.
SEBU9064 27 Engine Diagnostics Diagnostic Flash Code Retrieval Table 5 Flash Codes with Key ON (Engine not in Operation) Flash Code Description Engine status Operator Action 13 Oil pressure switch malfunction. Disconnection of Oil pressure switch. Disconnection of Oil pressure harness. Engine will start, but the engine will Check harness connection. If the shut down after 180 seconds fault remains contact your Perkins dealer or your Perkins distributor. 22 Pressure sensor malfunction.
Engine Diagnostics Diagnostic Flash Code Retrieval SEBU9064 (Table 7, contd) 04 Actuator drive malfunction. Disconnection of Speed sensor connector. Disconnection of Speed sensor harness. The engine will shut down. Check harness connection. If the fault remains contact your Perkins dealer or your Perkins distributor. 15 Speed sensor malfunction. Disconnection of Speed sensor connector. Disconnection of Speed sensor harness. The engine will go into limp home mode. Check harness connection.
SEBU9064 29 Engine Starting Before Starting Engine Engine Starting i05339804 i04053911 Starting the Engine Before Starting Engine Perform the required daily maintenance and other periodic maintenance before the engine is started. Inspect the engine compartment. This inspection can help prevent major repairs at a later date. Refer to the Operation and Maintenance Manual, “Maintenance Interval Schedule” for more information. • Ensure that the engine has an adequate fuel supply.
SEBU9064 Engine Starting Starting with Jump Start Cables i05339814 Starting with Jump Start Cables Improper jump start cable connections can cause an explosion resulting in personal injury. Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jump start cable ends to contact each other or the engine. NOTICE Using a battery source with the same voltage as the electric starting motor. Use ONLY equal voltage for jump starting.
SEBU9064 31 Engine Operation Engine Operation Engine Operation i05339869 Engine Operation • Be aware of the properties of the different fuels. Use only the recommended fuels. Refer to the Operations and Maintenance Manual, “Fuel Recommendations”for further information. • Avoid unnecessary idling. Shut off the engine rather than idle for long periods of time. General Engine Operation Correct operation and maintenance are key factors in obtaining the maximum life and economy of the engine.
SEBU9064 Cold Weather Operation Cold Weather Operation Cold Weather Operation i05339996 Cold Weather Operation Perkins Diesel Engines can operate effectively in cold weather.
SEBU9064 33 Cold Weather Operation Cold Weather Operation Viscosity of the Engine Lubrication Oil Correct engine oil viscosity is essential. Oil viscosity affects lubrication properties and wear protection that the oil provides for the engine. Refer to this Operation and Maintenance Manual, “Fluid Recommendations” for the recommended viscosity of oil. Recommendations for the Coolant Provide cooling system protection for the lowest expected outside temperature.
SEBU9064 Cold Weather Operation Fuel and the Effect from Cold Weather Note: Do not restrict the air flow. Restriction of the air flow can damage the fuel system. Perkins discourages the use of all air flow restriction devices such as radiator shutters. Restriction of the air flow can result in the following: high exhaust temperatures, power loss, excessive fan usage and reduction in fuel economy. A cab heater is beneficial in very cold weather.
SEBU9064 35 Cold Weather Operation Fuel Related Components in Cold Weather i05200880 Fuel Related Components in Cold Weather Fuel Tanks Condensation can form in partially filled fuel tanks. Top off the fuel tanks after you operate the engine. Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks. Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe.
SEBU9064 Engine Stopping Stopping the Engine Engine Stopping i03756631 i02334873 Stopping the Engine After Stopping Engine Note: Before you check the engine oil, do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan. NOTICE Stopping the engine immediately after it has been working under load, can result in overheating and accelerated wear of the engine components. • Check the crankcase oil level.
SEBU9064 37 Maintenance Section Refill Capacities Maintenance Section Refill Capacities i05335983 Refill Capacities (Table 9, contd) (1) These values are the approximate capacities for the crankcase oil sump which includes the standard factory installed oil filters. Engines with auxiliary oil filters will require additional oil. Refer to the OEM specifications for the capacity of the auxiliary oil filter.
SEBU9064 Refill Capacities Fluid Recommendations 402F-05 Engine 403F-15 Engines Table 12 Table 15 402F-05 Engine Refill Capacities Compartment or System Engine Only 403F-15 Engines Refill Capacities Liters Quarts 1.1 1.2 Compartment or System Engine Only External System Per OEM(1) External System Per OEM(1) Total Cooling System(2) Total Cooling System(2) (1) (2) The External System includes a radiator or an expansion tank with the following components: heat exchanger and piping.
SEBU9064 39 Refill Capacities Fluid Recommendations Many engine failures are related to the cooling system. The following problems are related to cooling system failures: Overheating, leakage of the water pump and plugged radiators or heat exchangers. These failures can be avoided with correct cooling system maintenance. Cooling system maintenance is as important as maintenance of the fuel system and the lubrication system.
SEBU9064 Refill Capacities Fluid Recommendations NOTICE Do not use propylene glycol in concentrations that exceed 50 percent glycol because of the reduced heat transfer capability of propylene glycol. Use ethylene glycol in conditions that require additional protection against boiling or freezing.
SEBU9064 41 Refill Capacities Fluid Recommendations In order to maintain the correct balance between the antifreeze and the additives, you must maintain the recommended concentration of ELC. Lowering the proportion of antifreeze lowers the proportion of additive. This action will lower the ability of the coolant to protect the system from pitting, from cavitation, from erosion, and from deposits.
SEBU9064 Refill Capacities Fluid Recommendations • Drain the cooling system into a suitable container. Dispose of the coolant according to local regulations. Flush the system with clean water. Fill the system with the Perkins ELC. • Drain a portion of the cooling system into a suitable container according to local regulations. Then, fill the cooling system with premixed ELC. This procedure should lower the contamination to less than 10 percent.
SEBU9064 43 Refill Capacities Fluid Recommendations Cleaning the System of Heavy-Duty Antifreeze Perkins cooling system cleaners are designed to clean the cooling system of harmful scale and corrosion. Perkins cooling system cleaners dissolve mineral scale, corrosion products, light oil contamination, and sludge. • Clean the cooling system after used coolant is drained or before the cooling system is filled with new coolant.
SEBU9064 Refill Capacities Fluid Recommendations Maintenance intervals for engines that use biodiesel – The oil change interval can be adversely affected by the use of biodiesel. Use oil analysis in order to monitor the condition of the engine oil. Use oil analysis also in order to determine the oil change interval that is optimum. Note: These engine oils are not approved by Perkins and these engine oils must not be used: CC, CD, CD-2, CF-4, CG-4, CH-4 and CI-4.
SEBU9064 Refill Capacities Fluid Recommendations • The Wear Rate Analysis monitors the wear of the engines metals. The amount of wear metal and type of wear metal that is in the oil is analyzed. The increase in the rate of engine wear metal in the oil is as important as the quantity of engine wear metal in the oil. • Tests are conducted in order to detect contamination of the oil by water, glycol, or fuel. • The Oil Condition Analysis determines the loss of the oils lubricating properties.
SEBU9064 Refill Capacities Fluid Recommendations Table 25 Perkins Specification for Distillate Diesel Fuel(1) Property UNITS Requirements ASTMTest ISOTest Aromatics %Volume 35% maximum D1319 ISO3837 Ash %Weight 0.01% maximum D482 ISO6245 Carbon Residue on 10% Bottoms %Weight 0.35% maximum D524 ISO4262 Cetane Number (2) - 40 minimum D613/D6890 ISO5165 Cloud Point °C The cloud point must not ex- D2500 ceed the lowest expected ambient temperature.
SEBU9064 Refill Capacities Fluid Recommendations Engines that are manufactured by Perkins are certified with the fuel that is prescribed by the United States Environmental Protection Agency . Engines that are manufactured by Perkins are certified with the fuel that is prescribed by the European Certification. Perkins does not certify diesel engines on any other fuel.
SEBU9064 Refill Capacities Fluid Recommendations Viscosity Viscosity is the property of a liquid of offering resistance to shear or flow. Viscosity decreases with increasing temperature. This decrease in viscosity follows a logarithmic relationship for normal fossil fuel. The common reference is to kinematic viscosity. kinematic viscosity is the quotient of the dynamic viscosity that is divided by the density.
SEBU9064 49 Refill Capacities Fluid Recommendations Raw pressed vegetable oils are NOT acceptable for use as a fuel in any concentration in compression engines . Without esterification, these oils solidify in the crankcase and the fuel tank. These fuels may not be compatible with many of the elastomers that are used in engines that are manufactured today. In original forms, these oils are not suitable for use as a fuel in compression engines .
SEBU9064 Refill Capacities Fluid Recommendations General Requirements Aftermarket Fuel Additives Biodiesel has poor oxidation stability, which can result in long-term problems in the storage of biodiesel. Biodiesel fuel should be used within 6 months of manufacture. Equipment should not be stored with the B20 biodiesel blends in the fuel system for longer than 3 months. Supplemental diesel fuel additives are not generally recommended .
SEBU9064 51 Maintenance Recommendations System Pressure Release Maintenance Recommendations i04056177 System Pressure Release Components for the driven equipment should also be considered. When possible, remove the component that requires welding. When welding on an engine that is equipped with an ECM and removal of the component is not possible, the following procedure must be followed. This procedure minimizes the risk to the electronic components. 1. Stop the engine.
Maintenance Recommendations Severe Service Application SEBU9064 i04150276 Severe Service Application Severe service is the application of an engine that exceeds the current published standards for that engine.
SEBU9064 Buildup – Compounds, elements, corrosive chemicals, and salt can damage some components. Altitude – Problems can arise when the engine is operated at altitudes that are higher than the intended settings for that application. Necessary adjustments should be made.
SEBU9064 Maintenance Recommendations Maintenance Interval Schedule i05335244 Maintenance Interval Schedule “Engine Air Cleaner Element (Single Element) Inspect/Clean/Replace” ...........................................66 “Engine Oil and Filter - Change”..............................69 “Hoses and Clamps - Inspect/Replace”...................78 When Required “Radiator - Clean” ....................................................79 “Battery - Replace”..................................................
SEBU9064 Maintenance Recommendations Alternator and Fan Belts - Inspect/Adjust Check the alternator and the battery charger for correct operation. If the batteries are correctly charged, the ammeter reading should be very near zero. All batteries should be kept charged. The batteries should be kept warm because temperature affects the cranking power. If the battery is too cold, the battery will not crank the engine.
Maintenance Recommendations Alternator and Fan Belts - Replace SEBU9064 2. Move the alternator in order to increase or decrease the belt tension. 3. Tighten adjusting bolt (1) and tighten mounting bolts and nut (2). Tighten bolt (3). Tighten all fixing to a torque of 25 N·m (221 lb in) i05341723 Alternator and Fan Belts Replace For applications that require multiple drive belts, replace the belts in matched sets.
SEBU9064 Maintenance Recommendations Battery - Replace 4. Install new belt (5) and adjust the alternator to the required tension. 5. Tighten bolt (1) and tighten bolt and nut (2). Tighten bolt (3). Tighten all bolts and nuts to a torque of 25 N·m (221 lb in). Refer to this Operation and Maintenance Manual, “Alternator and Fan Belts - Inspect/Adjust” for the tension of the belt. i02322315 Battery - Replace Note: Always recycle a battery. Never discard a battery.
Maintenance Recommendations Coolant (Commercial Heavy-Duty) - Change SEBU9064 i05336023 Coolant (Commercial HeavyDuty) - Change 1. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product.
SEBU9064 NOTICE Do not fill the cooling system faster than 5 L (1.3 US gal) per minute to avoid air locks. Cooling system air locks may result in engine damage. 3. Fill the cooling system with clean water. Install the cooling system filler cap. 4. Start and run the engine at low idle until the temperature reaches 49 to 66 °C (120 to 150 °F). 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove the cooling system filler cap.
Maintenance Recommendations Coolant (ELC) - Change SEBU9064 Note: Inspect the water pump and the water temperature regulator after the cooling system has been drained. This is a good opportunity to replace the water pump, the water temperature regulator, and the hoses, if necessary. For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or your Perkins distributor. Drain 1. Flush the cooling system with clean water in order to remove any debris.
SEBU9064 61 Maintenance Recommendations Coolant Level - Check 3. Start and run the engine at low idle. Increase the engine rpm to high idle. Run the engine at high idle for 1 minute in order to purge the air from the cavities of the engine block. Stop the engine. 4. Check the coolant level. Maintain the coolant level within 13 mm (0.5 inch) below the bottom of the pipe for filling. Maintain the coolant level in the expansion bottle (if equipped) at the correct level. 5.
Maintenance Recommendations Coolant Temperature Regulator - Replace SEBU9064 Engines Without a Coolant Recovery Tank i05160120 Check the coolant level when the engine is stopped and cool. Coolant Temperature Regulator - Replace Replace the water temperature regulator before the water temperature regulator fails. This is a recommended preventive maintenance practice. Replacing the water temperature regulator reduces the chances for unscheduled downtime.
SEBU9064 63 Maintenance Recommendations Cooling System Supplemental Coolant Additive (SCA) - Test/Add i03644948 Cooling System Supplemental Coolant Additive (SCA) - Test/ Add Cooling system coolant additive contains alkali. To help prevent personal injury, avoid contact with the skin and the eyes. Do not drink cooling system coolant additive. Test for SCA Concentration Heavy-Duty Coolant/Antifreeze and SCA NOTICE Do not exceed the recommended six percent supplemental coolant additive concentration.
Maintenance Recommendations Engine - Clean SEBU9064 i05335960 Engine - Clean Engine Air Cleaner Element (Dual Element) - Inspect/Clean/ Replace Personal injury or death can result from high voltage. Moisture can conductivity. create i04150582 paths of electrical Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls “ DO NOT OPERATE”” . NOTICE Accumulated grease and oil on an engine is a fire hazard. Keep the engine clean.
SEBU9064 65 Maintenance Recommendations Engine Air Cleaner Element (Dual Element) - Inspect/Clean/Replace The primary air cleaner element can be used up to six times if the element is properly cleaned and properly inspected. The primary air cleaner element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings. The secondary air cleaner element is not serviceable.
Maintenance Recommendations Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than three times. Use filtered, dry air with a maximum pressure of 207 kPa (30 psi). Pressurized air will not remove deposits of carbon and oil.
SEBU9064 67 Maintenance Recommendations Engine Air Cleaner Service Indicator - Inspect NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine. A wide variety of air cleaners may be installed for use with this engine. Consult the OEM information for the correct procedure to replace the air cleaner. i02335405 Engine Air Cleaner Service Indicator - Inspect Some engines may be equipped with a different service indicator.
Maintenance Recommendations Engine Crankcase Breather - Replace SEBU9064 i05335963 Engine Crankcase Breather Replace NOTICE Make sure that the components of the breather assembly are installed correctly. Engine damage may occur if the breather assembly is not working correctly. NOTICE Keep all parts clean from contaminants. 4. Install a new diaphragm and plate (4) for the breather assembly into the cavity (5) of the valve mechanism cover.
SEBU9064 69 Maintenance Recommendations Engine Oil and Filter - Change i05336039 Engine Oil and Filter - Change Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product.
Maintenance Recommendations Engine Oil and Filter - Change SEBU9064 Replace the Oil Filter NOTICE Perkins oil filters are built to Perkins specifications. Use of an oil filter not recommended by Perkins could result in severe engine damage to the engine bearings, crankshaft, etc., as a result of the larger waste particles from unfiltered oil entering the engine lubricating system. Only use oil filters recommended by Perkins . 1. Remove the oil filter with a suitable tool.
SEBU9064 71 Maintenance Recommendations Engine Valve Lash - Check NOTICE To prevent crankshaft bearing damage, crank the engine with the fuel OFF. This will fill the oil filters before starting the engine. Do not crank the engine for more than 30 seconds. 2. Start the engine and run the engine at “LOW IDLE” for 2 minutes. Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled. Inspect the oil filter for oil leaks. 3.
Maintenance Recommendations Fan Clearance - Check SEBU9064 i05153591 Fan Clearance - Check i05161054 Fuel Filter (In-Line) - Replace Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.
SEBU9064 73 Maintenance Recommendations Fuel Injector - Test/Change 3. If installed, remove clamp (2) and remove in-line filter (1) from application. • The engine will not start or the engine is difficult to start. 4. Install new in-line filter (1) and install clamp (2). • Not enough power 5. Install inlet hose (4) and install clamp (3). Install outlet hose (5) and install clamp (6). • The engine misfires or the engine runs erratically. 6. Turn the fuel supply valve (if equipped) to the ON position.
SEBU9064 Maintenance Recommendations Fuel System - Prime i04145953 Fuel System - Prime Turn the keyswitch to the ON position for 2 minutes in order to prime the fuel system. Turn keyswitch to OFF position, then turn on again. The engine is primed and ready to start. i05337705 Fuel System Primary Filter Replace Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
SEBU9064 Maintenance Recommendations Fuel System Primary Filter/Water Separator - Drain i02627223 Fuel System Primary Filter/ Water Separator - Drain Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. NOTICE The water separator is not a filter. The water separator separates water from the fuel.
Maintenance Recommendations Fuel System Secondary Filter - Replace SEBU9064 i05337334 Fuel System Secondary Filter Replace Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected.
SEBU9064 Maintenance Recommendations Fuel System Secondary Filter - Replace 6. Fasten the assembly to the fuel filter base with setscrew (2). The fuel system will need to be primed after the new filter is installed. Refer to this Operation and Maintenance Manual, “Fuel System - Prime”. Fuel Filter with Element 1. Close the fuel supply valve (1). Illustration 50 g01334893 Typical example 2. Clean the outside of the fuel filter assembly. 3. Loosen the locking ring (2). 4.
Maintenance Recommendations Fuel Tank Water and Sediment - Drain SEBU9064 i02335436 Fuel Tank Water and Sediment - Drain Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank at the following intervals: • Weekly • Service intervals NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product.
SEBU9064 A constant torque hose clamp can be used in place of any standard hose clamp. Ensure that the constant torque hose clamp is the same size as the standard clamp. Due to extreme temperature changes, the hose will harden. Hardening of the hoses will cause hose clamps to loosen. This can result in leaks. A constant torque hose clamp will help to prevent loose hose clamps. Each installation application can be different.
Maintenance Recommendations Starting Motor - Inspect SEBU9064 If the radiator is blocked internally, refer to the OEM Manual for information regarding flushing the cooling system. After cleaning the radiator, start the engine. Allow the engine to operate at low idle speed for three to five minutes. Accelerate the engine to high idle. This will help in the removal of debris and the drying of the core. Slowly reduce the engine speed to low idle and then stop the engine.
SEBU9064 81 Maintenance Recommendations Water Pump - Inspect • Drain the water and the sediment from the fuel tank on a daily basis in order to ensure that only clean fuel enters the fuel system. • Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires. • Inspect the ground strap for a good connection and for good condition. • Disconnect any battery chargers that are not protected against the current drain of the starting motor.
SEBU9064 Warranty Section Emissions Warranty Information Warranty Section Warranty Information i05341027 Emissions Warranty Information This engine may be certified to comply with exhaust emission standards and gaseous emission standards that are prescribed by the law at the time of manufacture. This engine may be covered by an Emissions Warranty. For a full warranty statement contact your Perkins dealer or your Perkins distributor. For customers that have a valid user name and password, for perkins.
SEBU9064 83 Reference Information Section Engine Protection Plans Reference Information Section www.perkins.com NOTICE Dependant upon engine type and application. Reference Materials i04224089 Engine Protection Plans (Extended Service Contract) Extended Service Contracts-purchased in minutes, protected for years. Extended Service Contracts (ESC) protect you from the stress that unexpected repair work brings to your life by covering the cost of getting your engine up and running again.
SEBU9064 Index Section Index A D After Starting Engine........................................ 30 After Stopping Engine...................................... 36 Alternator - Inspect .......................................... 54 Alternator and Fan Belts - Inspect/Adjust ........ 55 Adjustment................................................... 55 Inspection..................................................... 55 Alternator and Fan Belts - Replace..................
SEBU9064 85 Index Section Fluid Recommendations.......................38, 43, 45 Diesel Fuel Characteristics ......................... 47 Diesel Fuel Requirements ........................... 45 ELC Cooling System Maintenance.............. 40 Engine Oil .................................................... 43 General Coolant Information........................ 38 General Information ..................................... 45 General Lubricant Information ..................... 43 Foreword......................
Index Section R Radiator - Clean............................................... 79 Reference Information..................................... 18 Record for Reference................................... 18 Reference Information Section ........................ 83 Reference Materials ........................................ 83 Refill Capacities............................................... 37 Cooling System............................................ 37 Lubrication System .................................
Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual.
©2013 Perkins Engines Company Limited All Rights Reserved Printed in U.K.
