Perkins 403EA-11 Operation And Maintenance Manual Download Page 23

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404EA-22T Turbocharged Engine

Illustration 19

g06697734

Typical example

(1) Front lifting eye

(2) Coolant outlet

(3) Exhaust elbow

(4) Rear lifting eye

(5) Turbocharger

(6) Electric starting motor

(7) Alternator

(8) Drive belt

(9) Oil drain plug

(10) Coolant intake

(11) Water temperature regulator housing

M0132847

Product Information Section

Model View Illustrations

Summary of Contents for 403EA-11

Page 1: ...Operation and Maintenance Manual 403EA 11 403EA 11T 403EA 17 404EA 22 and 404EA 22T Industrial Engines M0132847 en us June 2022 QS Engine QZ Engine QJ Engine QN Engine QP Engine...

Page 2: ...ard The warnings in this publication and on the product are therefore not all inclusive You must not use this product in any manner different from that considered by this manual without first satisfyi...

Page 3: ...6 Product Information Section Model Views 18 Product Identification Information 30 Operation Section Lifting and Storage 31 Gauges and Indicators 33 Features and Controls 35 Engine Starting 43 Engine...

Page 4: ...s 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 sec...

Page 5: ...ar the engine as a convenient reminder Perkins also recommends that a maintenance record be maintained as part of the permanent record of the engine Your authorized Perkins dealer or your Perkins dist...

Page 6: ...at are loosened could drop off the engine Replace any warning sign that is damaged or missing If a warning sign is attached to a part of the engine that is replaced install a new warning sign on the r...

Page 7: ...and Maintenance Manuals Failure to follow the instructions or heed the warnings could result in serious injury or death Ether Warning label 2 is installed in different locations The location will chan...

Page 8: ...u may only be near a running engine to carry out maintenance procedures that require the engine to be in operation Do not wear loose clothing or jewelry that can snag on controls or on other parts of...

Page 9: ...ustration 6 g00702020 Wear a hard hat protective glasses and other protective equipment as required Perkins recommend that you do not stand next to an exposed running engine unless it is necessary whe...

Page 10: ...r that is familiar with this type of injury Containing Fluid Spillage Care must be taken to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair o...

Page 11: ...es when handling the equipment or parts Perkins also recommends the following Wear appropriate Personal Protective Equipment PPE Wash your hands and face with soap and water prior to eating drinking o...

Page 12: ...part of an operating engine Operating engines exhaust gases could burn do not come in contact with hot gases Allow the engine to cool before any maintenance is performed on the engine Relieve all pre...

Page 13: ...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...

Page 14: ...er to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices Illustration 12 g02298225 Gases from a battery can explode Keep any open flames or s...

Page 15: ...ore objects are struck ensure that no one will be injured by flying debris i08159517 Mounting and Dismounting Inspect the steps the handholds and the work area before mounting the engine Keep these it...

Page 16: ...pped 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...

Page 17: ...trolled 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 dama...

Page 18: ...el View Illustrations Industrial Engine Model Views The following model views show typical features of the engine Due to individual applications your engine may appear different from the illustrations...

Page 19: ...1 Front lifting eye 2 Coolant outlet 3 Air intake 4 Rear lifting eye 5 Electric starting motor 6 Alternator 7 Drive belt 8 Oil drain plug 9 Coolant intake 10 Water temperature regulator housing M01328...

Page 20: ...oil filler 12 Water pump 13 Oil filler lower 14 Cooling drain plug 15 Oil gauge Dipstick 16 Oil drain plug 17 Oil filter 18 Fuel transfer pump 19 Secondary fuel filter 20 Fuel injector 20 M0132847 Pro...

Page 21: ...ye 2 Top engine oil filler cap 3 Front lifting eye 4 Water pump 5 Low mounted oil filler cap 6 Fuel injection pump 7 Oil level gauge Dipstick 8 Oil drain plug 9 Oil filter 10 Governor actuator 11 Fuel...

Page 22: ...example 12 Air intake 13 Coolant outlet 14 Exhaust manifold 15 Starting motor solenoid 16 Electric starting motor 17 Alternator 18 Fan belt 19 Coolant intake connection 22 M0132847 Product Information...

Page 23: ...ront lifting eye 2 Coolant outlet 3 Exhaust elbow 4 Rear lifting eye 5 Turbocharger 6 Electric starting motor 7 Alternator 8 Drive belt 9 Oil drain plug 10 Coolant intake 11 Water temperature regulato...

Page 24: ...oil filler 13 Water pump 14 Oil filler lower 15 Cooling drain plug 16 Oil gauge Dipstick 17 Oil drain plug 18 Oil filter 19 Fuel transfer pump 20 Secondary fuel filter 21 Fuel injector 24 M0132847 Pro...

Page 25: ...Off Engine Components Illustration 21 g06747000 Typical example 1 Hand priming pump 2 Atmospheric pressure sensor M0132847 25 Product Information Section Model View Illustrations...

Page 26: ...rear main bearing The timing gears are stamped with timing marks to ensure the correct assembly of the gears When the No 1 piston is at top center compression stroke the teeth that are stamped on the...

Page 27: ...gine are determined from the flywheel end The No 1 cylinder is the front cylinder 403EA 11 Engine Illustration 23 g00852304 A Exhaust valves B Inlet valves Table 1 403EA 11 Engine Specifications Maxim...

Page 28: ...he following characteristics In line 4 cylinder 4 stroke cycle Two valves per cylinder Illustration 26 g00296424 A Exhaust valves B Inlet valves Table 4 404EA 22 Industrial Engines Maximum Operating S...

Page 29: ...for required engine maintenance Expected engine life is generally predicted by the average power that is demanded The average power that is demanded is based on fuel consumption of the engine over a p...

Page 30: ...d to order parts Locate the information for your engine Record the information on the appropriate space Make a copy of this list for a record Retain the information for future reference Record for Ref...

Page 31: ...ne arrangement Alterations to the lifting eyes and or the engine make the lifting eyes and the lifting fixtures obsolete If alterations are made ensure that proper lifting devices are provided Illustr...

Page 32: ...Fluid recommendations 4 Remove the drive belt from the engine Sealed Coolant System Ensure that the cooling system is filled with Perkins ELC or an antifreeze that meets ASTM D6210 specification Open...

Page 33: ...2 Stop the engine 3 Check and maintain the oil level Jacket Water Coolant Temperature Typical temperature range is 82 to 96 C 147 6 to 172 8 F The maximum allowable temperature with the pressurized co...

Page 34: ...is detected the lamp will be illuminated The reason for the illumination of the low pressure lamp should be investigated immediately The glow plug warning lamp will flash to show that the engine is be...

Page 35: ...mmediately OFF OFF No Fault Engine operating normally None i08645089 Sensors and Electrical Components The illustrations within the section show the typical locations of the sensors and other electric...

Page 36: ...Illustration 31 g06697388 Typical example 1 Coolant temperature sensor switch 36 M0132847 Operation Section Sensors and Electrical Components...

Page 37: ...Illustration 32 g06747150 Typical example 2 Speed sensor 3 Governor actuator 4 Oil pressure switch M0132847 37 Operation Section Sensors and Electrical Components...

Page 38: ...33 g06697927 Typical example 1 Coolant temperature sensor switch Illustration 34 g06747151 Typical example 2 Governor actuator 3 Oil pressure switch 4 Speed sensor 38 M0132847 Operation Section Senso...

Page 39: ...harged Engine Illustration 35 g06697297 Typical example 1 Coolant temperature sensor switch 2 Inlet manifold temperature and pressure sensor if equipped M0132847 39 Operation Section Sensors and Elect...

Page 40: ...Illustration 36 g06747162 Typical example 3 Governor actuator 4 Oil pressure switch 5 Speed sensor 40 M0132847 Operation Section Sensors and Electrical Components...

Page 41: ...the cause of the engine shutdown Make necessary repairs before attempting to restart the engine Be familiar with the following items Types and locations of shutoff Conditions which cause each shutoff...

Page 42: ...e switch to the ON position in order to check the indicator lights for proper operation Replace faulty bulbs immediately NOTICE During testing abnormal operating conditions must be simulated Perform t...

Page 43: ...the exhaust to the outside 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 Ensure t...

Page 44: ...sulation Use the procedure that follows for cold weather starting 1 Disengage any driven equipment Note During key ON the indicator lamps will be illuminated for 0 5 of a second to check the lamp oper...

Page 45: ...damage the electrical system Do not reverse the battery cables The alternator can be damaged Attach ground cable last and remove first Turn all electrical accessories OFF before attaching the jump st...

Page 46: ...r leaks at idle rpm and at one half full rpm no load on the engine before operating the engine under load This check may not be possible in some applications Allow the engine to idle for 3 to 5 minute...

Page 47: ...the warm up period 3 Perform another walk around inspection Check the engine for fluid leaks and air leaks 4 Increase the rpm to the rated rpm Check for fluid leaks and air leaks The engine may be op...

Page 48: ...ates proper functioning Maintain a good electrical system One faulty battery cell will overwork the alternator and can consume excess power and excess fuel Ensure that the belts are correctly adjusted...

Page 49: ...n refer to the OEM information Ensure that any components for the external system that support the engine operation are secured after the engine is stopped i03756631 After Stopping Engine Note Before...

Page 50: ...ow loads until a minimum coolant operating temperature of 80 C 176 F is achieved Achieving operating temperature will help prevent the intake valves and exhaust valves from sticking The cooling system...

Page 51: ...e application of a light load parasitic load will help in achieving the minimum operating temperature The minimum coolant operating temperature is 80 C 176 F Recommendations for Coolant Warm Up Warm u...

Page 52: ...talled A heater unit must also be installed into the breather system Both measures are required to protect the engine when working in temperatures of 25 C 13 F or lower i07926238 Radiator Restrictions...

Page 53: ...ially 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 su...

Page 54: ...Oil Sump which includes the stand ard factory installed oil filters Engines with auxiliary oil filters will require more oil Refer to the OEM specifications for the ca pacity of the auxiliary oil filt...

Page 55: ...ncludes a radiator or an expansion tank with the following components heat exchanger and piping Re fer to the OEM specifications Enter the value for the capacity of the External System in this row con...

Page 56: ...particulate matter There is a small percentage of particulate matter that is left behind as the soot is burnt This matter will eventually block the filter causing loss of performance and increased fue...

Page 57: ...e the engine Use new oil and install a new oil filter Perform maintenance at the intervals that are specified in the Operation and Maintenance Manual Maintenance Interval Schedule Oil analysis Some en...

Page 58: ...otect the engine Distilled water or deionized water is recommended for use in engine cooling systems DO NOT use the following types of water in cooling systems Hard water softened water that has been...

Page 59: ...and Materials ELC extended life coolant A coolant that relies on organic inhibitors for corrosion and cavitation protection Also called OATcoolant Organic Acid Technology SCA supplemental coolant add...

Page 60: ...Maintenance Correct additions to the Extended Life Coolant NOTICE Use only Perkins products for pre mixed coolants Mixing Extended Life Coolant with other products re duces the Extended Life Coolant s...

Page 61: ...mination exceeds 10 percent of the total system capacity perform ONE of the following procedures Drain the cooling system into a suitable container Dispose of the coolant according to local regulation...

Page 62: ...tenance Total Volume of the Cooling System V Multiplication Factor Amount of SCA that is Required X 15 L 4 US gal 0 023 0 35 L 11 7 oz Cleaning the System of Heavy Duty Antifreeze Note Before corrosio...

Page 63: ...s Diesel Engines Fluids Recommendations M0113102 for additional information that relates to fuel Diesel Fuel Requirements Perkins is not in a position to continuously evaluate and monitor all worldwid...

Page 64: ...um of 80 reflec tance after aging for 180 mi nutes at 150 C 302 F D6468 No equivalent test Pour Point C 6 C 42 8 F minimum be low ambient temperature D97 ISO 3016 Sulfur 3 mass 0 0010 Stage V Europe a...

Page 65: ...ss level for fuel as dispensed into machine or engine fuel tank is ISO 18 16 13 or cleaner as per ISO 4406 Refer to the Contamination Control Recommendations for Fuels 8 Examples of trace metals inclu...

Page 66: ...Fuel must have sufficient viscosity to lubricate the fuel system in both extremely cold temperatures and extremely hot temperatures If the kinematic viscosity of the fuel is lower than 1 4 cSt at the...

Page 67: ...oncentration 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...

Page 68: ...Cleaner and Perkins Biodiesel fuel contains metal contaminants sodium potassium calcium and or magnesium that form ash products upon combustion in the diesel engine The ash can have an impact on the...

Page 69: ...sical 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 NOTICE Perkin...

Page 70: ...eaner in particular for engines with common rail and unit injection systems When you refuel the tank filter the fuel through a 4 m absolute filter Beta 4 75 up to 200 to reach the recommended cleanlin...

Page 71: ...emove air pressure from the fuel system Engine Oil To relieve pressure from the lubricating system turn off the engine i08671082 Severe Service Application Severe service is the application of an engi...

Page 72: ...the intended settings for that application Necessary adjustments should be made Incorrect Operating Procedures Extended operation at low idle Frequent hot shutdowns Frequent stop starts exceeding 10 e...

Page 73: ...Test Add 88 Every 500 Service Hours Fan Clearance Check 97 Every 500 Service Hours or 1 Year Battery Electrolyte Level Check 77 Engine Air Cleaner Element Replace 89 Engine Oil and Filter Change 94 E...

Page 74: ...s Inspect Adjust Inspection To maximize the engine performance inspect the belts for wear and for cracking Replace belts that are worn or damaged For applications that require multiple drive belts rep...

Page 75: ...03EA 11 Naturally Aspirated 167 mm 205 mm 190 200 Hz 400 N 90 lb 160 170 Hz 300 N 67 lb 403EA 11 Turbocharged 167 mm 205 mm 222 229 Hz 425 to 456 N 95 5 to 102 5 lb 205 214 Hz 364 to 395 N 82 to 89 lb...

Page 76: ...sition alternator belt 6 onto alternator 3 the water pump pulley and the crankshaft pulley Ensure that the alternator belt is correctly positioned onto the alternator pulley the water pump pulley and...

Page 77: ...nd plane Disconnect the cable from the NEGATIVE battery terminal 5 The POSITIVE cable connects the POSITIVE battery terminal to the starting motor Disconnect the cable from the POSITIVE battery termin...

Page 78: ...roduct Be prepared to collect the fluid with suitable contain ers before opening any compartment or disassem bling any component containing fluids Dispose of all fluids according to Local regulations...

Page 79: ...ling system is not equipped with a drain valve remove one of the drain plug 1 Allow the coolant to drain into a suitable container NOTICE Dispose of used engine coolant or recycle Various methods have...

Page 80: ...of 6 N m 53 lb in Flush 1 Flush the cooling system with clean water to remove any debris 2 Install the drain plug or close the drain tap if equipped on the engine Close the drain cock or install the d...

Page 81: ...ns Do not install the cooling system filler cap 4 Start and run the engine at low idle Increase the engine rpm to high idle Run the engine at high idle for one minute to purge the air from the cavitie...

Page 82: ...d surface Refer to the Disassembly and Assembly Manual Water Temperature Regulator Remove and Install for the replacement procedure of the water temperature regulator or consult your Perkins dealer or...

Page 83: ...illage 2 Open the cooling system drain valve if equipped If the cooling system is not equipped with a drain valve remove one of the drain plug 1 Allow the coolant to drain into a suitable container NO...

Page 84: ...53 lb in Flush 1 Flush the cooling system with clean water to remove any debris 2 Install the drain plug to the engine or close the drain tap if equipped 3 Close the drain tap or install the drain plu...

Page 85: ...cooling system specifications Do not install the cooling system filler cap 4 Start and run the engine at low idle Increase the engine rpm to high idle Run the engine at high idle for one minute to pu...

Page 86: ...the coolant level when the engine is stopped 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 Thi...

Page 87: ...is for factory installed radiator with the four cylinder turbocharged engine Once the level has been reached add 0 5 L 0 13210 US gal of coolant The coolant level C is for factory installed radiator w...

Page 88: ...fer could cause cracking of the cylinder head and other high tempera ture components Excessive supplemental coolant additive concentration could also result in radiator tube blockage overheating and o...

Page 89: ...zzle of the cleaner at any electrical connectors or the junction of cables into the rear of the connectors Avoid electrical components such as the alternator and starter Protect the fuel injection pum...

Page 90: ...lve 5 is clean and free from dirt Check the vacuum valve 5 for wear or damage replace if necessary 4 Remove primary air filter element 3 and if equipped remove the secondary air filter element Not Sho...

Page 91: ...frequently in environments that are severely dusty Replace the service indicator annually regardless of the operating conditions Replace the service indicator when the engine is overhauled and whenev...

Page 92: ...cer 5 for turbocharged engines 7 Install a new spring 3 8 Install the breather cover 2 and the four screws 1 Tighten the screws i07819538 Engine Mounts Inspect Note The engine mounts may not have been...

Page 93: ...positioned on the oil filter head or the oil sampling valve is positioned on the cylinder block Perkins recommends using a sampling valve in order to obtain oil samples The quality and the consistency...

Page 94: ...tem with the new oil Oil and Filter Change Intervals The standard engine oil and engine oil filter change period is 500 hours There are several other factors that can alter the standard engine oil and...

Page 95: ...oil filter 1 Tighten the oil filter until the oil filter seal contacts the cylinder block or the oil cooler Tighten the oil filter by hand according to the instructions that are shown on the oil filt...

Page 96: ...ur Perkins distributor should perform the tests Consult your Perkins distributor or refer to the Service Manual for more information i06299296 Engine Valve Lash Check Ensure that the engine cannot be...

Page 97: ...high pressure Under this amount of pressure the test fluid can pierce the skin and cause serious injury to the operator Al ways keep the tip of the fuel injection nozzle pointed away from the operato...

Page 98: ...ed when the union nut to the faulty fuel injector is loosened Consult your authorized Perkins dealer or your Perkins distributor for further assistance i08471258 Fuel System Prime If air enters the fu...

Page 99: ...Illustration 67 g06677660 Connector that is installed on 3 cylinder engines 2 Fuel return hose for the injector 3 Connector bolt Illustration 68 g06677651 Connector that is installed on 4 cylinder en...

Page 100: ...ound a fuel system component that will be disconnected Fit a suitable cover over any disconnected fuel system components NOTICE Care must be taken to ensure that fluids are con tained during performan...

Page 101: ...l 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 separat...

Page 102: ...er to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow w...

Page 103: ...level that is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose 6 Replace the old hose with a new hose 7 Install the hose clamps with a torque wrench Note For t...

Page 104: ...nformation i02177973 Walk Around Inspection Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these check...

Page 105: ...ctions 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...

Page 106: ...rer s application for certification for the warranty period 3 New non road diesel engines installed in construction machines conforming to theSouth Korean regulations for construction machines manufac...

Page 107: ...visiting www perkins com NOTICE Dependant upon engine type and application i05204672 Maintenance Records Perkins recommends the retention of accurate maintenance records Accurate maintenance records...

Page 108: ...204675 Maintenance Log Table 25 Engine Model Customer Identifier Serial Number Arrangement Number Service Hours Quantity Of Fuel Service Item Date Authorization 108 M0132847 Reference Information Sect...

Page 109: ...tor Cap 87 Cooling System Supplemental Coolant Additive SCA Test Add 88 Add the SCA If Necessary 88 Test for SCA Concentration 88 Crushing Prevention and Cutting Prevention 15 D Driven Equipment Check...

Page 110: ...Filter Water Separator Drain 101 Fuel Tank Water and Sediment Drain 102 Drain the Water and the Sediment 102 Fuel Storage Tanks 102 Fuel Tank 102 G Gauges and Indicators 33 Indicator Lamps 34 General...

Page 111: ...Messages 6 1 Universal Warning 6 2 Ether Warning 7 Safety Section 6 Sensors and Electrical Components 35 Sensor Locations for the Engine 35 Severe Service Application 71 Environmental Factors 71 Incor...

Page 112: ......

Page 113: ...aintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Inf...

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Summary of Contents for 403EA-11

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