Perkins 402F-05 Operation And Maintenance Manual Download Page 16

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402F-05 Engine

Illustration 13

g01108476

(A) Exhaust valves
(B) Inlet valves

Table 1

402F-05 Engine Specifications

Maximum Operating Speed
(rpm)

3600 rpm

Cylinders and Arrangement

In-Line 2 cylinder

Bore

67 mm (2.64 inch)

Stroke

72 mm (2.83 inch)

Displacement

0.507 L (30.939 in

)

Aspiration

Naturally Aspirated

Compression Ratio

23.5:1

Firing Order

1-2

Rotation that is viewed from the
flywheel

Counterclockwise

Valve Lash Setting (Inlet)

0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection

Indirect

403F-07 Engine

Illustration 14

g00852304

(A) Exhaust valves
(B) Inlet valves

Table 2

403F-07 Engine Specifications

Maximum Operating Speed
(rpm)

3600 rpm

Cylinders and Arrangement

In-Line 3 cylinder

Bore

67 mm (2.64 inch)

Stroke

72 mm (2.83 inch)

Displacement

0.762 L (46.500 in

)

Aspiration

Naturally Aspirated

Compression Ratio

23.5:1

Firing Order

1-2-3

Rotation that is viewed from the
flywheel

Counterclockwise

Valve Lash Setting (Inlet)

0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection

Indirect

SEBU9064

General Information
Product Description

Summary of Contents for 402F-05

Page 1: ...Operation and Maintenance Manual 402F 05 403F 07 403F 11 and 403F 15 Industrial Engines EG Engine EH Engine EJ Engine EK Engine SEBU9064 June 2013 ...

Page 2: ...ning 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 o...

Page 3: ...ation Section General Information 12 Product Identification Information 18 Operation Section Lifting and Storage 20 Features and Controls 22 Engine Diagnostics 26 Engine Starting 29 Engine Operation 31 Cold Weather Operation 32 Engine Stopping 36 Maintenance Section Refill Capacities 37 Maintenance Recommendations 51 Maintenance Interval Schedule 54 Warranty Section Warranty Information 82 Referen...

Page 4: ...nced 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 t...

Page 5: ...the adhesive that secures the warning signs 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 A Universal Warning Do not operate or work on this equipment unless you have read and understand the instruction...

Page 6: ...ent or before you repair the equipment 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 Keep the engine free from foreign material Remove debris oil tools and othe...

Page 7: ...ntil 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 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 sever...

Page 8: ...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 fl...

Page 9: ...er regularly Obey the recommendations on the instruction plate Lines Tubes and Hoses Do not bend high pressure lines Do not strike high pressure lines Do not install any lines that are bent or damaged Do not clip any other items to the high pressure lines Repair any lines that are loose or damaged Leaks can cause fires Consult your Perkins dealer or your Perkins distributor for repair or for repla...

Page 10: ...to help prevent engine damage See the Service Manual for repairs and for adjustments 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 NOTstart the engine or move the controls Consult with the person that attached the warning tag be...

Page 11: ...of the starting motor If the starting motor is not equipped with a negative terminal connect the jump start cable to the engine block Check the electrical wires daily for wires that are loose or frayed Tighten all loose electrical wires before the engine is started Repair all frayed electrical wires before the engine is started See the Operation and Maintenance Manual for specific starting instruc...

Page 12: ...n 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 12 SEBU9064 Product Information Section Model View Illustrations ...

Page 13: ... g03379877 12 Air intake 13 Coolant outlet 14 Exhaust manifold 15 Solenoid for starter 16 Starting motor 17 Alternator 18 Fan belt 18 Coolant intake connection SEBU9064 13 General Information Model View Illustrations ...

Page 14: ...line fuel filter 2 Electric fuel pump 3 Primary fuel filter 4 Secondary fuel filter element type 5 Secondary fuel filter Note The electric fuel pump is an option engines may have a mechanical fuel lift pump installed 14 SEBU9064 General Information Model View Illustrations ...

Page 15: ...00F series that are below 19Kw power band These engines are 402F 05 403F 07 403F 11 and the 403F 15 These engines have the following characteristics In Line 2 cylinder 402F 05 In Line 3 cylinder 403F 07 403F 11 and the 403F 15 Naturally aspirated Fuel Limiter 2 Valves in each cylinder Engine Specifications Note The front end of the engine is opposite the flywheel end of the engine The left and the...

Page 16: ...008 inch Valve Lash Setting Exhaust 0 20 mm 0 008 inch Injection Indirect 403F 07 Engine Illustration 14 g00852304 A Exhaust valves B Inlet valves Table 2 403F 07 Engine Specifications Maximum Operating Speed rpm 3600 rpm Cylinders and Arrangement In Line 3 cylinder Bore 67 mm 2 64 inch Stroke 72 mm 2 83 inch Displacement 0 762 L 46 500 in3 Aspiration Naturally Aspirated Compression Ratio 23 5 1 F...

Page 17: ...008 inch Valve Lash Setting Exhaust 0 20 mm 0 008 inch Injection Indirect 403F 15 Engine Illustration 16 g00852304 A Exhaust valves B Inlet valves Table 4 403F 15 Engine Specifications Maximum Operating Speed rpm 3000 rpm Cylinders and Arrangement In Line 3 cylinder Bore 84 mm 3 31 inch Stroke 90 mm 3 54 inch Displacement 1 496 L 91 291 in3 Aspiration Naturally Aspirated Compression Ratio 22 5 1 F...

Page 18: ...he components that were included with the engine This information permits accurate identification of replacement part numbers i05333666 Emissions Certification Film Illustration 17 g03378752 Typical example i05335976 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 co...

Page 19: ...Total Lubrication System Capacity Total Cooling System Capacity Air Cleaner Element Alternator Belt SEBU9064 19 Product Identification Information Reference Information ...

Page 20: ...on regarding fixtures for correct engine lifting i05335259 Product Storage 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 ...

Page 21: ... 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 Monthly Checks The crankshaft mu...

Page 22: ...itions The water temperature reading may vary according to load The reading should never exceed the boiling point for the pressurized system that is being used If the engine is operating above the normal range and steam becomes apparent perform the following procedure 1 Reduce the load and the engine rpm 2 Inspect the cooling system for leaks 3 Determine if the engine must be shut down immediately...

Page 23: ...tric pressure sensor can de rate the engine Operating the engine and increasing the altitude will de rate the engine in accordance with emission regulations The start of the de rate will be determined by the flash file that is installed i05336156 Overspeed 402F 05 3600 Revolutions Per Minute RPM 403F 07 3600 RPM 403F 11 3600 RPM 403F 15 3000 RPM The overspeed is plus 700 RPM above the given speed ...

Page 24: ...ote Due ti individual applications the atmosphere pressure sensor 3 may appear different from the illustration Electrical components install on the 402F 05 403F 07 403F 11 and the 403F 15 engines Alternator Starting motor Glow plugs Electronic control governor Location will depend on the application Electric fuel pump 24 SEBU9064 Features and Controls Sensors and Electrical Components ...

Page 25: ...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 The multi function lamp can be used as a diagnostic lamp For information as a diagnostic lamp refer to this Operation and Maintenance Manual Diagnostic Lamp SEBU9064 25 Features and Controls Sensors and Electr...

Page 26: ...de For information on flash codes refer to this Operation and Maintenance Manual Diagnostic Flash Code Retrieval i05339103 Diagnostic Flash Code Retrieval The multi function lamp will flash a two digit code in a given sequence in order to show the flash code diagnostic massage By counting the number of flashes in a given sequence you can determine the flash code After the flash code as finished th...

Page 27: ...our Perkins dealer or your Perkins distributor Table 6 Flash Codes During Engine Cranking Flash Code Description Engine status Operator Action 13 Speed sensor malfunction Disconnection of Speed sensor connector Disconnection of Speed sensor harness Engine will not start Check harness connection If the fault remains contact your Perkins dealer or your Perkins distributor Table 7 Flash Codes with En...

Page 28: ...sor connector Disconnection of Speed sensor harness The engine will go into limp home mode Check harness connection If the fault remains contact your Perkins dealer or your Perkins distributor 1 Checking engine oil is part of the daily engine check Operating an engine will a low level of engine oil can damage your engine For more information on diagnostic messages and diagnostic tools contact your...

Page 29: ...i05339804 Starting the Engine Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury Note Do not adjust the engine speed control during start up The electronic control module ECM will control the engine speed during start up 1 Disengage any equipment that is driven by the engine 2 Turn the keyswitch to the RUN position Check that the multi...

Page 30: ...ustible gases that are produced by some batteries Note The engine electronic control module must be powered before the starting motor is operated or damage can occur 4 Start the engine in the normal operating procedure Refer to this Operation and Maintenance Manual Starting the Engine 5 Immediately after the engine is started disconnect the jump start cables in reverse order After jump starting th...

Page 31: ...that the engine is operated i05339949 Fuel Conservation Practices The efficiency of the engine can affect the fuel economy Perkins design and technology in manufacturing provides maximum fuel efficiency in all applications Follow the recommended procedures in order to attain optimum performance for the life of the engine Avoid spilling fuel Fuel expands when the fuel is warmed up The fuel may over...

Page 32: ...alves from sticking The cooling system and the lubrication system for the engine do not lose heat immediately upon shutdown This means that an engine can be shut down for a period and the engine can still have the ability to start readily Install the correct specification of engine lubricant before the beginning of cold weather Refer to this Operation and Maintenance Manual Fluid Recommendations f...

Page 33: ...ompletely burned in the combustion chamber This fuel and oil causes soft carbon deposits to form on the valve stems Generally the deposits do not cause problems and the deposits are burned off during operation at normal engine operating temperatures When starting and stopping an engine many times without being operated in order to warm up completely the carbon deposits become thicker This starting...

Page 34: ...R to ISO 12156 1 Group 2 fuels are considered acceptable for issues of warranty This group of fuels may reduce the life of the engine the engines maximum power and the engines fuel efficiency When Group 2 diesel fuels are used the following components provide a means of minimizing problems in cold weather Glow plugs Engine coolant heaters which may be an Original Equipment Manufacture OEM option F...

Page 35: ... the following intervals weekly oil changes and refueling of the fuel tank This procedure will help prevent water and or sediment from being pumped from the fuel storage tank and into the engine fuel tank Fuel Filters The engine must have an in line fuel filter installed between the fuel tank and the electric operated fuel lift pump After you change the fuel filter always prime the fuel system in ...

Page 36: ...or the external system that support the engine operation are secured after the engine is stopped i03756631 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 Check the crankcase oil level Maintain the oil level between the MIN mark and the MAX mark on the engine oil level gauge If ne...

Page 37: ...er filters added to the lubrication system Enter the value for the capacity of the Total Lubrication System in this row 403F 11 Engine Table 10 403F 11 Engine Refill Capacities Compartment or System Minimum Maximum Crankcase Oil Sump 1 3 4 L 3 6 qt 4 4 L 4 7 qt Total Lubrication System 2 1 These values are the approximate capacities for the crankcase oil sump which includes the standard factory in...

Page 38: ...is row 2 The Total Cooling System capacity includes the capacity of the Engine plus the External System Enter the value for the ca pacity of the Total Cooling System in this row 403F 15 Engines Table 15 403F 15 Engines Refill Capacities Compartment or System Liters Quarts Engine Only 2 6 2 7 External System Per OEM 1 Total Cooling System 2 1 The External System includes a radiator or an expansion ...

Page 39: ...Additives help to protect the metal surfaces of the cooling system A lack of coolant additives or insufficient amounts of additives enable the following conditions to occur Corrosion Formation of mineral deposits Rust Scale Foaming of the coolant Many additives are depleted during engine operation These additives must be replaced periodically Additives must be added at the correct concentration Ov...

Page 40: ...s may be used Table 19 Coolant Service Life Coolant Type Service Life 1 Perkins ELC 6 000 Service Hours or Three Years Commercial Heavy Duty Anti freeze that meets ASTM D6210 3000 Service Hours or Two Years A Perkins approved SCA inhibitor 3000 Service Hours or Two Years 1 Use the interval that occurs first The cooling system must also be flushed out at this time ELC Perkins provides ELC for use i...

Page 41: ...iners before opening any compartment or disas sembling any component containing fluids Dispose of all fluids according to local regulations and mandates 1 Drain the coolant into a suitable container 2 Dispose of the coolant according to local regulations 3 Flush the system with clean water in order to remove any debris 4 Use Perkins cleaner to clean the system Follow the instruction on the label 5...

Page 42: ...of SCA at the initial fill Read the label or the instructions that are provided by the OEM of the product Use the equation that is in Table 20 to determine the amount of Perkins SCA that is required when the cooling system is initially filled Table 20 Equation For Adding The SCA To The Heavy Duty Coolant At The Initial Fill V 0 045 X V is the total volume of the cooling system X is the amount of S...

Page 43: ...ailed information about this system see the latest edition of the API publication No 1509 Engine oils that bear the API symbol are authorized by API Illustration 21 g03383033 Typical API symbol Terminology Certain abbreviations follow the nomenclature of SAE J754 Some classifications follow SAE J183 abbreviations and some classifications follow the EMA Recommended Guideline on Diesel Engine Oil In...

Page 44: ...It is not necessary to use aftermarket additives in order to achieve the engines maximum service life or rated performance Fully formulated finished oils consist of base oils and of commercial additive packages These additive packages are blended into the base oils at precise percentages in order to help provide finished oils with performance characteristics that meet industry standards There are ...

Page 45: ... States PPM Parts Per Million General Information NOTICE Every attempt is made to provide accurate up to date information By use of this document you agree that Perkins Engines Company Limited is not responsible for errors or omissions NOTICE These recommendations are subject to change with out notice Contact your local Perkins distributor for the most up to date recommendations The fuel informati...

Page 46: ...on includes the requirements for Ultra Low Sulfur Diesel ULSD ULSD fuel will have 15 ppm 0 0015 sulfur Refer to ASTM D5453 ASTM D2622 or ISO 20846 ISO 20884 test methods 2 A fuel with a higher cetane number is recommended in order to operate at a higher altitude or in cold weather 3 Via standards tables the equivalent API gravity for the minimum density of 801 kg m3 kilograms per cubic meter is 45...

Page 47: ...el Fuel DERV ASDM D975 GRADE 1D S15 North American Light Distillate Diesel fuel with less than 15 PPM sulfur level ASTM D975 GRADE 2D S15 North American Middle Distillate general purpose Diesel fuel with less than 15 PPM sulfur level JIS K2204 Japanese Diesel Fuel Must meet the requirements that are stated in the section Lubricity BS 2869 or equivalent EU Off Road Diesel fuel Acceptable from 2011 ...

Page 48: ...ons can require a fuel with a specific sulfur limit The sulfur content of the fuel and the fuel quality must comply with all existing local regulations for emissions By using the test methods ASTM D5453 ASTM D2622 or ISO 20846 ISO 20884 the content of sulfur in ultra low sulfur ULSD fuel must be below 15 PPM 0 0015 The lubricity of these fuels must not exceed wear scar diameter of 0 52 mm 0 0205 i...

Page 49: ...d certified or that is accredited and certified by a comparable biodiesel quality body to meet similar biodiesel quality standards is required Engine Service Requirements Aggressive properties of biodiesel fuel may cause debris in the fuel tank and fuel lines The aggressive properties of biodiesel will clean the fuel tank and fuel lines This cleaning of the fuel system can prematurely block of the...

Page 50: ...physical properties of the fuel The diesel fuel ASTM D975 1 D used in the United States of America may be used in very cold temperatures that are below 18 C 0 4 F Aftermarket Fuel Additives Supplemental diesel fuel additives are not generally recommended This recommendation is due to potential damage to the fuel system or the engine Your fuel supplier or the fuel manufacturer will add the appropri...

Page 51: ...lectronic Control Module ECM on the engine Clean Emissions Module CEM Sensors Associated components 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...

Page 52: ...aintenance Coolant type and maintenance Environmental qualities Installation The temperature of the fluid in the engine Refer to the standards for the engine or consult your Perkins dealer or your Perkins distributor in order to determine if the engine is operating within the defined parameters Severe service operation can accelerate component wear Engines that operate under severe conditions may ...

Page 53: ...ssary adjustments should be made Incorrect Operating Procedures Extended operation at low idle Frequent hot shutdowns Operating at excessive loads Operating at excessive speeds Operating outside the intended application Incorrect Maintenance Procedures Extending the maintenance intervals Failure to use recommended fuel lubricants and coolant antifreeze SEBU9064 53 Maintenance Recommendations Sever...

Page 54: ...r Cleaner Element Dual Element Inspect Clean Replace 64 Engine Air Cleaner Element Single Element Inspect Clean Replace 66 Engine Oil and Filter Change 69 Hoses and Clamps Inspect Replace 78 Radiator Clean 79 Every 1000 Service Hours Alternator and Fan Belts Replace 56 Engine Valve Lash Check 71 Every 2000 Service Hours Alternator Inspect 54 Engine Crankcase Breather Replace 68 Engine Mounts Inspe...

Page 55: ...t of a matched set will cause the new belt to carry more load because the older belt is stretched The additional load on the new belt could cause the new belt to break If the belts are too loose vibration causes unnecessary wear on the belts and pulleys Loose belts may slip enough to cause overheating To check accurately the belt tension a suitable gauge should be used Illustration 24 g03383147 Ty...

Page 56: ...w belt could cause the new belt to break Note When new belts are installed check the belt tension again after 20 hours of engine operation Removal and Installation Procedure Refer to the original equipment manufacture for removal and installation of the fan guards Illustration 27 g03383665 Typical example Illustration 28 g03383666 Typical example 1 Loosen adjusting bolt 1 and mounting bolt and nut...

Page 57: ...om the POSITIVE battery terminal Note Always recycle a battery Never discard a battery Dispose of used batteries to an appropriate recycling facility 5 Remove the used battery 6 Install the new battery Note Before the cables are connected ensure that the engine start switch is OFF 7 Connect the cable from the starting motor to the POSITIVE battery terminal 8 Connect the NEGATIVE cable to the NEGAT...

Page 58: ...gulator and the hoses if necessary Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pressure 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any p...

Page 59: ...aintain the coolant level in the expansion bottle if equipped at the correct level 5 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damag...

Page 60: ...th clean water in order to remove any debris 2 Close the drain cock or install the drain plug in the engine Close the drain cock or install the drain plug on the radiator 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 ...

Page 61: ...opped and cool NOTICE When any servicing or repair of the engine cooling system is performed the procedure must be per formed with the engine on level ground Level ground will allow you to check accurately the coolant level This checking will also help in avoiding the risk of in troducing an air lock into the coolant system 1 Observe the coolant level in the coolant recovery tank Maintain the cool...

Page 62: ...g or overcooling of the engine A water temperature regulator that fails in the closed position can cause excessive overheating Excessive overheating could result in cracking of the cylinder head or piston seizure problems A water temperature regulator that fails in the open position will cause the engine operating temperature to be too low during partial load operation Low engine operating tempera...

Page 63: ...Loosen the cooling system pressure cap slowly in order to relieve the pressure NOTICE When any servicing or repair of the engine cooling system is performed the procedure must be per formed with the engine on level ground This will allow you to accurately check the coolant level This will al so help in avoiding the risk of introducing an air lock into the coolant system 1 Slowly loosen the cooling...

Page 64: ...ture wear and damage to en gine components Air cleaner elements help to pre vent airborne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Elements Note The air filter system may not have been provided by Perkins The procedure that follows is for a typical air filter syst...

Page 65: ...cleaner element is cleaned check for rips or tears in the filter material 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 NOTICE Do not tap or strike the air cleaner element Do not wash the primary air cleaner element Use low pressure 207 kPa 30 psi maximum pres surized air or vacuum cleaning t...

Page 66: ...Air Cleaner Elements Illustration 36 g00281693 Inspect the clean dry primary air cleaner element Use a 60 W blue light in a dark room or in a similar facility Place the blue light in the primary air cleaner element Rotate the primary air cleaner element Inspect the primary air cleaner element for tears and or holes Inspect the primary air cleaner element for light that may show through the filter ...

Page 67: ... air cleaner element should be replaced when one of the following conditions occur The yellow diaphragm enters the red zone The red piston locks in the visible position Test the Service Indicator Service indicators are important instruments Check for ease of resetting The service indicator should reset in less than three pushes Check the movement of the yellow core when the engine is accelerated t...

Page 68: ... breather assembly into the cavity 5 of the valve mechanism cover 5 Install a new spring 3 6 Install the breather cover 2 and the four screws 1 Tighten the screws i02323089 Engine Mounts Inspect Note The engine mounts may not have been supplied by Perkins Refer to the OEM information for further information on the engine mounts and the correct bolt torque Inspect the engine mounts for deterioratio...

Page 69: ...containing fluids Dispose of all fluids according to local regulations and mandates NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with the draining cold oil Drain the crankcase ...

Page 70: ...inder heads Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter Consult your Perkins dealer or your Perkins distributor in order to arrange for a further analysis if an excessive amount of debris is found in the oil filter Illustration 41 g03380736 Typical example 3 Clean the sealing surface of the cylinder block 4 Apply clean engine oil to the new ...

Page 71: ...help provide maximum engine life The maintenance for the valve lash is important in order to keep the engine compliant NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual or your au thorized Perkins dealer or your Perkins distributor for the complete valve lash adjustment procedure Operation of Perkins engines with incorrect valve lash can reduce eng...

Page 72: ...ponents 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 Note Refer to Systems Operation Testing and Adjusting Cleanliness of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system NOTICE Ensure that the ...

Page 73: ...h the fuel injectors occurs Some of the problems that may indicate that new fuel injectors are needed are listed below The engine will not start or the engine is difficult to start Not enough power The engine misfires or the engine runs erratically High fuel consumption Black exhaust smoke The engine knocks or there is vibration in the engine Excessive engine temperature For further information on...

Page 74: ...hat the engine is stopped before any servic ing or repair is performed Remove the Element 1 Turn the fuel supply valve if equipped to the OFF position before performing this maintenance 2 Place a suitable container under the water separator in order to catch any fuel that might spill Clean up any spilled fuel Clean the outside body of the filter assembly Illustration 45 g03381282 Typical example 3...

Page 75: ...ents 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 separa tor separates water from the fuel The engine should never be allowed to run with the water separator more than half full Engine damage may result Illustration 47 g01316965 ...

Page 76: ...fluid with suitable containers before opening any compartment or disassembling any component containing fluids Dispose of all fluids according to local regulations and mandates Note The primary filter element must be replaced at the same time as the secondary filter element Refer to Operation and Maintenance Manual Fuel System Primary Filter Water Separator Element Replace Fuel Filter with Caniste...

Page 77: ...ined into a suitable container Illustration 51 g01334895 Typical example Note Do not fill the fuel filter with fuel The fuel will not be filtered and the fuel could be contaminated Contaminated fuel can damage your fuel system 5 Assemble the following items seal 5 filter element 6 and casing 3 6 Install the assembled items to the filter base 4 7 Install the locking ring 2 to the filter head Rotate...

Page 78: ...es that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank at the following intervals Weekly Service intervals R...

Page 79: ...he correct coolant see this Operation and Maintenance Manual Fluid Recommendations 8 Refill the cooling system Refer to the OEM information for further information on refilling the cooling system 9 Clean the cooling system filler cap Inspect the cooling system filler cap s seals Replace the cooling system filler cap if the seals are damaged Install the cooling system filler cap 10 Start the engine...

Page 80: ...viced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the flu id levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and or oil on an...

Page 81: ... any gauges that are cracked Replace any gauge that can not be calibrated i01907756 Water Pump Inspect A failed water pump may cause severe engine overheating problems that could result in the following conditions Cracks in the cylinder head A piston seizure Other potential damage to the engine Note The water pump seal is lubricated by the coolant in the cooling system It is normal for a small amo...

Page 82: ...re 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 com Login then go to TIPSS and the warranty information can be accessed 82 SEBU9064 Warranty Section Emissions Warranty Information ...

Page 83: ...ine performance 4 Highly trained technicians carry out all repairs 5 Transferable coverage should you sell your machine Flexible coverage provides the right level of protection for your Perkins Engine Coverage can be extended to 2 years 1 000 hours right up to 10 year 40 000 You can buy an ESC at any time during standard warranty even the last day Each Perkins Distributor has highly trained and ex...

Page 84: ...evention and Cutting Prevention 9 D Diagnostic Flash Code Retrieval 26 Diagnostic Lamp 26 Driven Equipment Check 63 E Electrical System 11 Grounding Practices 11 Emergency Stopping 36 Emissions Certification Film 18 Emissions Warranty Information 82 Engine Clean 64 Engine Air Cleaner Element Dual Element Inspect Clean Replace 64 Cleaning the Primary Air Cleaner Elements 65 Servicing the Air Cleane...

Page 85: ... 78 Fuel Tank 78 G Gauges and Indicators 22 Indicators and Lamps 22 General Hazard Information 6 Containing Fluid Spillage 7 Fluid Penetration 7 Pressure Air and Water 7 General Information 12 H Hoses and Clamps Inspect Replace 78 Replace the Hoses and the Clamps 79 I Important Safety Information 2 L Lifting and Storage 20 M Maintenance Interval Schedule 54 Commissioning 54 Daily 54 Every 1000 Ser...

Page 86: ...on 52 Environmental Factors 52 Incorrect Maintenance Procedures 53 Incorrect Operating Procedures 53 Starting Motor Inspect 80 Starting the Engine 29 Starting with Jump Start Cables 30 Stopping the Engine 36 System Pressure Release 51 Coolant System 51 Engine Oil 51 Fuel System 51 T Table of Contents 3 W Walk Around Inspection 80 Inspect the Engine for Leaks and for Loose Connections 80 Warranty I...

Page 87: ...Maintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Information Customer Equipment Number Dealer Equipment Number Dealer Information Name Branch Address Dealer Contact Phone Number Hours Sales Parts Service ...

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Summary of Contents for 402F-05

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