Perkins 403F-E17T 404F-E22T Operation And Maintenance Manual Download

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Operation and
Maintenance
Manual

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

ER1

(Engine)

EQ1

(Engine)

EW1

(Engine)

SEBU9075-03 (en-us)

July 2018

Summary of Contents for 403F-E17T 404F-E22T

Page 1: ...Operation and Maintenance Manual 403F E17T 404F E22T and 404F E22TA Industrial Engines ER1 Engine EQ1 Engine EW1 Engine SEBU9075 03 en us July 2018 ...

Page 2: ...ormation that was available at the time that the publication was written The specifications torques pressures measurements adjustments illustrations and other items can change at any time These changes can affect the service that is given to the product Obtain the complete and most current information before you start any job Perkins dealers or Perkins distributors have the most current informatio...

Page 3: ...ronics 21 Product Information Section General Information 23 Product Identification Information 33 Operation Section Lifting and Storage 35 Features and Controls 38 Engine Diagnostics 44 Engine Starting 46 Engine Operation 49 Aftertreatment Operation 51 Cold Weather Operation 52 Engine Stopping 56 Maintenance Section Refill Capacities 57 Maintenance Recommendations 72 Maintenance Interval Schedule...

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 section lists basic safety precautions In addition this section identifies hazardous warning situations Read and understand the basic precautions listed in the safety section before operating or performi...

Page 5: ...r 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 distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment Overhaul Major engine overhaul details are not covered in the Operation and Maintenance Man...

Page 6: ...at secures the warning signs The warning signs that are loosened could drop off the engine Replace any warning sign that is damaged or missing If a warning sign is attached to a part of the engine that is replaced install a new warning sign on the replacement part Your Perkins distributor can provide new warning signs 1 Universal Warning Do not operate or work on this equipment unless you have rea...

Page 7: ...cause fluid penetration and burn hazards High pressure fuel spray may cause a fire hazard Failure to follow these inspection maintenance and service in structions may cause personal injury or death Illustration 3 g02382677 Typical example SEBU9075 03 7 Safety Section Safety Messages ...

Page 8: ...e installed on the air cleaner or close to the air cleaner The location will depend on the application Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals Failure to follow the instructions or heed the warnings could result in serious injury or death 8 SEBU9075 03 Safety Section Safety Messages ...

Page 9: ...ions with care Report all necessary repairs Unless other instructions are provided perform the maintenance under the following conditions The engine is stopped Ensure that the engine cannot be started The protective locks or the controls are in the applied position Engage the secondary brakes or parking brakes Block the vehicle or restrain the vehicle before maintenance or repairs are performed Di...

Page 10: ...k Use all cleaning solutions with care Report all necessary repairs Unless other instructions are provided perform the maintenance under the following conditions The engine is stopped Ensure that the engine cannot be started Disconnect the batteries when maintenance is performed or when the electrical system is serviced Disconnect the battery ground leads Tape the leads in order to help prevent sp...

Page 11: ...ult with your fuel or fuel system supplier to ensure that the delivery system complies with fueling standards for proper grounding and bonding Avoid static electricity risk when fueling Ultra low sulfur diesel fuel ULSD fuel poses a greater static ignition hazard than earlier diesel formula tions with a higher sulfur contents Avoid death or serious injury from fire or explosion Consult with your f...

Page 12: ...any source of water i06276622 Burn Prevention Do not touch any part of an operating engine system The engine the exhaust and the engine aftertreatment system can reach temperatures as high as 650 C 1202 F under normal operating conditions Allow the engine system to cool before any maintenance is performed Relieve all pressure in the air system hydraulic system lubrication system fuel system and th...

Page 13: ...p is cool before removing the filler cap The filler cap must be cool enough to touch with a bare hand Remove the filler cap slowly in order to relieve pressure Cooling system conditioner contains alkali Alkali can cause personal injury Do not allow alkali to contact the skin the eyes or the mouth Oils Skin may be irritated following repeated or prolonged exposure to mineral and synthetic base oils...

Page 14: ...lines or tanks that contain flammable fluid Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting Wiring must be kept in good condition Ensure that all electrical wires are correctly installed and securely attached Check all electrical wires daily Repair any wires that are loose or frayed before you operate the engine Clean all electrical connection...

Page 15: ...s Never check the battery charge by placing a metal object across the terminal posts Use a voltmeter or a hydrometer Incorrect jumper cable connections can cause an explosion that can result in injury Refer to the Operation Section of this manual for specific instructions Do not charge a frozen battery A frozen battery may cause an explosion The batteries must be kept clean The covers if equipped ...

Page 16: ... be injured by flying debris i05768982 Mounting and Dismounting Do not climb on the engine or the engine aftertreatment system The engine and aftertreatment system have not been designed with mounting or dismounting locations Refer to the OEM for the location of foot and hand holds for your specific application i06662133 High Pressure Fuel Lines Contact with high pressure fuel may cause fluid pene...

Page 17: ...ghten the connection to stop the leak The connection must only be tightened to the recommended torque Refer to Disassembly and Assembly Fuel injection lines Remove and Fuel injection lines Install If the high pressure fuel lines are torqued correctly and the high pressure fuel lines are leaking the high pressure fuel lines must be replaced Ensure that all clips on the high pressure fuel lines are ...

Page 18: ...86691 1 High pressure line 2 High pressure line 3 High pressure line 4 High pressure line 5 High pressure fuel manifold rail 6 High pressure line 7 Fuel transfer line that is high pressure 18 SEBU9075 03 Safety Section High Pressure Fuel Lines ...

Page 19: ...g or similar warning tag attached to the start switch or to the controls Before starting the engine ensure that no one is on underneath or close to the engine Ensure that the area is free of personnel If equipped ensure that the lighting system for the engine is suitable for the conditions Ensure that all lights work properly if equipped All protective guards and all protective covers must be inst...

Page 20: ...dual cylinder that heats the intake air in order to improve starting Some Perkins engines may have a cold starting system that is controlled by the ECM that allows a controlled flow of ether into the engine The ECM will disconnect the glow plugs before the ether is introduced This system would be installed at the factory i02234873 Engine Stopping Stop the engine according to the procedure in the O...

Page 21: ...he negative battery terminal with a wire that is adequate to handle the full charging current of the alternator The power supply connections and the ground connections for the engine electronics should always be from the isolator to the battery i06276686 Engine Electronics Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal...

Page 22: ...d Rail NOx Reduction System Engine Aftertreatment System The Engine Monitoring package can vary for different engine models and different engine applications However the monitoring system and the engine monitoring control will be similar for all engines Note Many of the engine control systems and display modules that are available for Perkins Engines will work in unison with the Engine Monitoring ...

Page 23: ...s of the engine and the aftertreatment system Due to individual applications your engine and your aftertreatment may appear different from the illustrations Three Cylinder Engine Illustration 18 g06068851 Typical example 1 Location of fuel filter is for shipment only SEBU9075 03 23 Product Information Section General Information ...

Page 24: ...Illustration 19 g06068852 Typical example 24 SEBU9075 03 Product Information Section Model View Illustrations ...

Page 25: ...ye 3 Top oil fill cap 4 Front lifting eye 5 Fan 6 Alternator and fan belt 7 Fuel manifold Fuel rail 8 Lower oil filler cap 9 High pressure fuel pump 10 Oil gauge Dipstick 11 Oil drain plug 12 Oil filter 13 Secondary fuel filter 14 Breather SEBU9075 03 25 Product Information Section Model View Illustrations ...

Page 26: ...ure regulator 16 NOx Reduction System Valve NRS 17 Throttle valve 18 Diesel Oxidation Catalyst DOC 19 Flywheel 20 Flywheel housing 21 Starting motor 22 Turbocharger 23 NRS cooler 24 Alternator 26 SEBU9075 03 Product Information Section Model View Illustrations ...

Page 27: ...nder Engines Illustration 22 g06103572 Typical example 1 Electric fuel priming pump 2 Primary fuel filter water separator 3 Electronic Control Module ECM 4 Engine wiring harnesses SEBU9075 03 27 Product Information Section Model View Illustrations ...

Page 28: ...ors Three Cylinder Turbocharged Engine Illustration 23 g06164176 Typical example 1 Coolant filler cap 2 Heater for breather system 3 Radiator drain plug 4 Inspection cover for alternator and belt adjustment 28 SEBU9075 03 Product Information Section Model View Illustrations ...

Page 29: ... Typical example 1 Coolant filler cap 2 Heater for breather system 3 Inspection cover for alternator and belt adjustment 4 Radiator drain plug 5 Recess for fan belt installation SEBU9075 03 29 Product Information Section Engines with Factory Installed Radiators ...

Page 30: ...Three Cylinder Engine 403F E17T The Perkins 403F E17T industrial engine is a turbocharged engine This engine has a Diesel Oxidation Catalyst DOC aftertreatment system The DOC aftertreatment system does not require a service interval and engine is electronically governed The 403F E17T industrial engine has the following characteristics In line 3 cylinder 4 stroke cycle Two valves per cylinder DOC a...

Page 31: ... Two valves per cylinder DOC aftertreatment Illustration 27 g00296424 A Exhaust valves B Inlet valves The 404F E22Tand 404F E22TA engines may be supplied with a throttle control valve and temperatures sensors in the DOC or without these components installed The difference will be due to the evolution of engine design Table 2 404F E22T and 404F E22TA Industrial Engines Bore 84 mm 3 307 inch Stroke ...

Page 32: ... is demanded The average power that is demanded is based on fuel consumption of the engine over a period of time Reduced hours of operation at full throttle and or operating at reduced throttle settings result in a lower average power demand Reduced hours of operation will increase the length of operating time before an engine overhaul is required The aftertreatment system can be expected to funct...

Page 33: ...er block Perkins distributors need all the numbers on the plate in order to determine the components that were included with the engine This information permits accurate identification of replacement part numbers Perkins Plate Illustration 29 g01094203 Typical example i06591372 Emissions Certification Film Illustration 30 g01478138 Typical example SEBU9075 03 33 Product Information Section Product...

Page 34: ...on for the following items may be needed to order parts Locate the information for your engine Record the information in the appropriate space Make a copy of this list for a record Keep the information for future reference Record for Reference Engine Model Engine Serial number Engine Low Idle rpm Engine Full Load rpm Primary Fuel Filter Secondary Fuel Filter Element Lubrication Oil Filter Element ...

Page 35: ...operly rated for the weight Use a hoist to remove heavy components Use an adjustable lifting beam to lift the engine All supporting members chains and cables should be parallel to each other The chains and cables should be perpendicular to the top of the object that is being lifted To obtain the correct balance for lifting an application adjust the chain lengths Lifting eyes are designed and insta...

Page 36: ...led The fuel tank will require flushing b Fill the fuel system with an ultra low sulfur fuel For more information on acceptable fuels refer to this Operation and Maintenance Manual Fluid recommendations Operate the engine for 15 minutes in order to remove all biodiesel from the system 2 Drain any water from the primary filter water separator Ensure that the fuel tank is full 3 The engine oil will ...

Page 37: ...e storage Log the procedure in the record for the engine Removal from Storage 1 Install the drive belt refer to this Operation and Maintenance Manual Alternator and Fan Belts Inspect Adjust for the tension of the belt 2 Ensure that the engine oil level is correct Ensure that the coolant level is correct Ensure that the fuel system is full and the fuel system is primed Refer to the Operation and Ma...

Page 38: ...sensor indicates high jacket water coolant temperature i06541814 Gauges and Indicators Your engine may not have the same gauges or all 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 ...

Page 39: ...trol lever is at the full throttle position with maximum rated load NOTICE To help prevent engine damage never exceed the high idle rpm Overspeeding can result in serious damage to the engine The engine can be operated at high idle without damage but should never be al lowed to exceed high idle rpm Ammeter This gauge indicates the amount of charge or discharge in the battery charging circuit Opera...

Page 40: ...e engine will be derated Stop the engine Investigate the fault Level 3 Flashing ON Level 3 Engine condition is abnormal The engine will auto matically shutdown If shutdown is not en abled the engine can operate but may course damage Stop engine immediately Investigate the fault i06542459 Monitoring System If the Shutdown mode has been selected and the warning indicator activates engine shutdown ma...

Page 41: ...engine power Shutdown The orange warning will be Flashing After the warning the engine power will be derated The engine will continue at the rpm of the set derate until a shutdown of the engine occurs After shutdown the red stop lamp will illuminate The engine can be restarted after a shutdown for use in an emergency A shutdown of the engine after been triggered is immediate The engine can be rest...

Page 42: ... 4 Fuel Pressure Sensor Fuel Rail Pressure Sensor 5 Fuel Temperature Sensor 6 Fuel Metering Solenoid for the High Pressure Fuel Pump 7 Crankshaft speed timing sensor 8 Diesel Oxidation Catalyst DOC outlet temperature sensor 9 DOC inlet temperature sensor 42 SEBU9075 03 Operation Section Sensors and Electrical Components ...

Page 43: ...p priming pump 16 Electronic control module 17 Vent for atmospheric pressure sensor 18 Camshaft speed timing sensor 19 Coolant temperature sensor Note Some components may not be installed on some applications The DOC may not be equipped with temperature sensors The throttle valve may not be installed SEBU9075 03 43 Operation Section Sensors and Electrical Components ...

Page 44: ...rvice tool Refer to Troubleshooting Electronic Service Tools for more information i05142509 Fault Logging The system provides the capability of Fault Logging When the Electronic Control Module ECM generates an active diagnostic code the code will be logged in the memory of the ECM The codes that have been logged by the ECM can be identified by the electronic service tool The active codes that have...

Page 45: ...future reference For more information on diagnostic codes refer to the Troubleshooting Guide for this engine i05142533 Configuration Parameters System configuration parameters affect the emissions of the engine or the power of the engine System configuration parameters are programmed at the factory Normally system configuration parameters would never change through the life of the engine System co...

Page 46: ...types of starting aids such as ether Such use could result in an explosion and personal injury The ability to start the engine will be improved at temperatures below 18 C 0 F or at high altitude above 2000 m 6561 ft from the use of a jacket water heater or extra battery capacity When Group 2 diesel fuel is used the following items provide a means of minimizing starting problems and fuel problems i...

Page 47: ...er to Troubleshooting Indicator Lamp Circuit Test 2 Turn the keyswitch to the RUN position Leave the keyswitch in the RUN position until the warning light for the glow plugs is extinguished 3 When the warning light for the glow plugs has been extinguished turn the keyswitch to the START position The starter motor will then crank the engine Note The operating period of the warning light for the glo...

Page 48: ...nual Starting the Engine 5 Immediately after the engine is started disconnect the jump start cables in reverse order After jump starting the alternator may not be able to recharge fully batteries that are severely discharged The batteries must be replaced or charged to the proper voltage with a battery charger after the engine is stopped Many batteries which are considered unusable are still recha...

Page 49: ...e is equipped with an aftertreatment system in order to meet emissions regulations The system uses a Diesel Oxidation Catalyst DOC in order to meet emissions regulations The system is passive and will not require any operation by the engine user The DOC will not require a service interval in order to operate correctly i06283233 Fuel Conservation Practices The efficiency of the engine can affect th...

Page 50: ...sume excess fuel Utilize heat from the jacket water system and the exhaust system when possible Keep cooling system components clean and keep cooling system components in good repair Never operate the engine without water temperature regulators All of these items will help maintain operating temperatures 50 SEBU9075 03 Operation Section Fuel Conservation Practices ...

Page 51: ...scheduled maintenance and will not be included in the Maintenance Interval Schedule In order for the 404F E22 and 403F E17T family of engines to meet emissions regulations the exhaust gases are passed through the DOC There the gases react with the catalyst The aftertreatment system can be expected to function properly for the lifetime of the engine emissions durability period However for the after...

Page 52: ...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 and the lubrication system for the engine do not lose heat immediately upon shutdown This means that an engine can be shutdown for a period and the retained heat within the engine will allow the engi...

Page 53: ...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 up an engine that has cooled below normal operating temperatures due to inactivity This warm up should be performed before the engine is returned to full operation During operationin very cold temperatur...

Page 54: ...ge the crankcase ventilation system If the engine is operated in temperatures of 18 C 0 4 F or lower measures must be taken to prevent freezing and plugging of the breather system Insulated hoses and an insulated canister assembly should be installed A heater unit must also be installed into the breather system Both measures are required to protect the engine when working in temperatures of 18 C 0...

Page 55: ...tly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Drain the water and sediment from any fuel storage tank at the following intervals weekly service intervals and refueling of the fuel tank Draining will help prevent water and or sediment from being pumped from the fuel storage tank and into the engine fuel tank Fue...

Page 56: ...M 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 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 MA...

Page 57: ...e 5 contd 1 More than one style of sump may be used on these engines Use these values to estimate the refill capacity Use the engine oil level gauge to fill the engine to the correct oil level Record the result in this table These values are the approximate ca pacities for the Crankcase Oil Sump which includes the stand ard factory installed oil filters Engines with auxiliary oil filters will requ...

Page 58: ... following specifica tion of engine oil Failure to use the appropriate specification of engine oil will reduce the life of your engine Failure to use the appropriate speci fication of engine oil will also reduce the life of your aftertreatment system Table 9 Oil Specification API CJ 4 ACEA E9 ECF 3 API CJ 4 and ACEA E9 oil categories have the following chemical limits 0 1 percent maximum sulfated ...

Page 59: ...These additive packages are blended into the base oils at precise percentages to help provide finished oils with performance characteristics that meet industry standards There are no industry standard tests that evaluate the performance or the compatibility of aftermarket additives in finished oil Aftermarket additives may not be compatible with the finished oils additive package which could lower...

Page 60: ...formation 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 respon sible 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 Diesel Fuel Requirements Perkins is not in a position to ...

Page 61: ...nimum and 4 5 maximum D445 ISO 3405 Water and sediment weight 0 05 maximum D1796 ISO 3734 Water weight 0 05 maximum D1744 No equivalent test Sediment weight 0 05 maximum D473 ISO 3735 Gums and Resins 5 mg 100mL 10 mg per 100 mL maximum D381 ISO 6246 Lubricity correctedwear scar diameter at 60 C 140 F 6 mm 0 52 maximum D6079 ISO 12156 1 Fuel Cleanliness 7 ISO 18 16 13 D7619 ISO 4406 Trace Metals 8 ...

Page 62: ...ropean Certification Perkins does not certify diesel engines on any other fuel Note The owner and the operator of the engine has the responsibility of using the fuel that is prescribed by the EPA and other appropriate regulatory agencies NOTICE Operating with fuels that do not meet the Perkins rec ommendations can cause the following effects Start ing difficulty reduced fuel filter service life po...

Page 63: ...ng of the fuel may be required to maintain 1 4 cSt or greater viscosity at the fuel injection pump Fuels with a high viscosity might require fuel heaters to lower the viscosity to 4 5 cSt at the fuel injection pump Density Density is the mass of the fuel per unit volume at a specific temperature This parameter has a direct influence on engine performance and a direct influence on emissions This in...

Page 64: ...te The percentages given are volume based The U S distillate diesel fuel specification ASTM D975 09a includes up to B5 5 percent biodiesel European distillate diesel fuel specification EN590 2010 includes up B7 7 percent biodiesel Note Engines that are manufactured by Perkins are certified by use of the prescribed Environmental Protection Agency EPA and European Certification fuels Perkins does no...

Page 65: ...llowing Standby Generator sets and certain emergency vehicles Perkins strongly recommended that seasonally operated engines have the fuel systems including fuel tanks flashed with conventional diesel fuel before prolonged shutdown periods An example of an application that should seasonally flush the fuel system is a combine harvester Microbial contamination and growth can cause corrosion in the fu...

Page 66: ...ad to injector fouling this fouling can cause the injector to operate incorrectly Contact your fuel supplier for those circumstances when fuel additives are required Your fuel supplier can recommend the appropriate fuel additive and the correct level of treatment Note For the best results your fuel supplier should treat the fuel when additives are required The treated fuel must meet the requiremen...

Page 67: ...the fuel to the fuel tank In addition filtration at the dispensing point should remove water to ensure that fuel is dispensed at 500 ppm water or less Perkins recommends the use of bulk fuel filter coalescer units which clean the fuel of both particulate contamination and water in a single pass Ensure that you use Perkins Advanced Efficiency Fuel Filters Change your fuel filters per recommended se...

Page 68: ...a water If distilled water or deionized water is not available use water with the properties that are listed in Table 12 Table 12 Acceptable Water Property Maximum Limit Chloride Cl 40 mg L Sulfate SO4 100 mg L Total Hardness 170 mg L Total Solids 340 mg L Acidity pH of 5 5 to 9 0 For a water analysis consult one of the following sources Local water utility company Agricultural agent Independent l...

Page 69: ...of water and glycol will provide optimum heavy duty performance as an antifreeze This ratio may be increased to 1 2 water to glycol if extra freezing protection is required A mixture of SCA inhibitor and water is acceptable but will not give the same level of corrosion boiling and freezing protection as ELC Perkins recommends a 6 percent to 8 percent concentration of SCA in those cooling systems D...

Page 70: ...bilizes As needed add the coolant mixture to fill the system to the specified level Changing to Perkins ELC To change from heavy duty antifreeze to the Perkins ELC perform the following steps NOTICE Care must be taken to ensure that all fluids are con tained during performance of inspection mainte nance testing adjusting and the repair of the product Be prepared to collect the fluid with suitable ...

Page 71: ... filled Table 16 Equation For Adding The SCA To The Heavy Duty Coolant At The Initial Fill V 0 07 X V is the total volume of the cooling system X is the amount of SCA that is required Table 17 is an example for using the equation that is in Table 16 Table 17 Example Of The Equation For Adding The SCA To The Heavy Duty Coolant At The Initial Fill Total Volume of the Cooling System V Multiplication ...

Page 72: ...ot loosen the high pressure fuel lines in order to remove air from the fuel system Engine Oil To relieve pressure from the lubricating system turn off the engine i06296009 Welding on Engines with Electronic Controls NOTICE Because the strength of the frame may decrease some manufacturers do not recommend welding onto a chassis frame or rail Consult the OEM of the equip ment or your Perkins dealer ...

Page 73: ...tronic component 8 Minimum distance between the component that is being welded and any electrical electronic component 9 The component that is being welded 10 Current path of the welder 11 Ground clamp for the welder 5 Connect the welding ground cable directly to the part that will be welded Place the ground cable as close as possible to the weld in order to reduce the possibility of welding curre...

Page 74: ...edures and incorrect maintenance procedures can be factors which contribute to a severe service application Environmental Factors Ambient temperatures The engine may be exposed to extended operation in extremely cold environments or hot environments Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in very cold temperatures Extremely hot intake air r...

Page 75: ...91 Fuel System Primary Filter Water Separator Element Replace 95 Fuel System Secondary Filter Replace 96 Hoses and Clamps Inspect Replace 98 Radiator Clean 99 Every 1000 Service Hours Alternator and Fan Belts Replace 76 Engine Valve Lash Check 92 Turbocharger Inspect 100 Every 1500 Service Hours Crankcase Breather Canister Replace 87 Every 2000 Service Hours Alternator Inspect 76 Engine Mounts Ins...

Page 76: ...nnections and correct battery charging Check the ammeter if equipped during engine operation in order to ensure correct battery performance and or correct performance of the electrical system Make repairs as required 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 cha...

Page 77: ...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 NEGATIVE battery terminal i02747977 Battery Electrolyte Level Check When the engine is not run for long periods of time or when the engine is run for short...

Page 78: ...cidental starting 7 Proceed with necessary system repairs 8 In order to connect the battery connect the positive connection before the negative connector i06287591 Belts Inspect Adjust Inspection To maximize the engine performance inspect the belt for wear and for cracking Replace a belt that is worn or damaged If the belt is too loose vibration causes unnecessary wear on the belt and pulleys A lo...

Page 79: ...water pump the water temperature regulator 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 c...

Page 80: ... of 6 N m 53 lb in Flush 1 Flush the cooling system with clean water and a suitable cleaning agent to remove any debris Refer to your Perkins dealer or distributor for suitable cleaning agents 2 Install connection hose Clean the drain plugs Install the drain plugs Tighten drain plug securely NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling syst...

Page 81: ... open the engine thermostat This operation will allow any air in the system to be purged Decrease the engine speed to low idle Stop the engine 3 Maintain the coolant level at the maximum mark that is correct for your application Refer to this Operation and Maintenance Manual Coolant Level Check for more information Illustration 44 g06165279 Typical example 4 Clean the cooling system filler cap and...

Page 82: ...round The engine must be level to check the coolant level The engine must be level to avoid the risk of introducing an air lock into the coolant system 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...

Page 83: ... of 4 N m 35 4 lb in Torque drain plug 4 to a torque of 6 N m 53 lb in Flush 1 Flush the cooling system with distilled or deionized water to remove any debris 2 Install the connection hose Clean the drain plugs and install the drain plugs Tighten the drain plugs securely 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 resu...

Page 84: ...op the engine 3 Maintain the coolant level at the maximum mark that is correct for your application For more information refer to this Operation and Maintenance Manual Coolant Level Check Illustration 47 g06165279 Typical example 4 Clean the cooling system filler cap and check the condition of the filler cap gasket 2 Replace the cooling system filler cap if the filler cap gasket 2 and sealing surf...

Page 85: ... engine on level ground This proce dure will allow you to check accurately the coolant level This procedure will also help in avoiding the risk of introducing an air lock into the coolant system Remove the cooling system filler cap slowly to relieve the pressure within the cooling system For the correct coolant level refer to the OEM information Factory Installed Radiators Illustration 48 g0616526...

Page 86: ...erature 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 temperatures during partial loads could cause an e...

Page 87: ...very important The quality of the filter element that is installed is very important The filter element protects the engine from excessive quantities of oil from entering the induction system The filter element also protects the engine aftertreatment system Note Excessive quantities of oil that enter the induction system of the engine can rapidly increase the engine speed without control Illustrat...

Page 88: ... quantity accumu lates on the engine Periodic cleaning of the engine is recommended Steam cleaning the engine will remove accumulated oil and grease A clean engine provides the following benefits Easy detection of fluid leaks Maximum heat transfer characteristics Ease of maintenance Note Caution must be used to prevent electrical components from being damaged by excessive water when the engine is ...

Page 89: ...ferent service indicator Some engines are equipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises If your engine is equipped wi...

Page 90: ...nts for deterioration and for correct bolt torque Engine vibration can be caused by the following conditions Incorrect mounting of the engine Deterioration of the engine mounts Loose engine mounts Any engine mount that shows deterioration should be replaced Refer to the OEM information for the recommended torques i06862328 Engine Oil Level Check Hot oil and hot components can cause personal injury...

Page 91: ... Drain the Engine Oil After the engine has been run at the normal operating temperature stop the engine Use one of the following methods to drain the engine crankcase oil If the engine is equipped with a drain valve turn the drain valve knob counterclockwise to drain the oil After the oil has drained turn the drain valve knob clockwise to close the drain valve If the engine is not equipped with a ...

Page 92: ...X marks on the oil level gauge i06299296 Engine Valve Lash Check Ensure that the engine cannot be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before measuring adjusting valve lash clearance NOTICE Only qualified service personn...

Page 93: ...cooler can be cleaned using a soft lint free cloth and deionized water All components must be dried before installation For more information on installation refer to Disassembly and Assembly Exhaust Gas Recirculation Valve Remove and Install Also refer to Disassembly and Assembly Exhaust Cooler NRS Remove and Install The electronic service tool will need to be connected to reset the maintenance ti...

Page 94: ...uel system the air must be purged from the fuel system before the engine can be started Air can enter the fuel system when the following events occur The fuel tank is empty or the fuel tank has been partially drained The low pressure fuel lines are disconnected A leak exists in the low pressure fuel system The fuel filter has been replaced Use the following procedures to remove air from the fuel s...

Page 95: ...u inspect the engine in operation always use the proper inspection procedure to avoid a fluid penetration hazard Refer to Operation and Maintenance Manual General hazard Information If the engine will not start refer to Troubleshooting Engine Cranks but will not Start i06299386 Fuel System Primary Filter Water Separator Element Replace Fuel leaked or spilled onto hot surfaces or electri cal compon...

Page 96: ...ter 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 63 g01316965 Typical example 1 Open drain 1 Catch the draining fluid in a suitable container Dispose of the drained fluid correctly 2 Close drain 1 use hand pressure only Also drain water from the secondary fuel filter R...

Page 97: ...4 from filter bowl 5 Discard the old O ring seal 6 Ensure the filter bowl 5 is clean and free from dirt Install the Filter Element 1 Install filter element 3 into filter base 2 2 Install a new O ring seal 4 to filter bowl 5 and install filter bowl 5 to filter base 2 Do not use a tool to install the filter assembly Use hand pressure only to tighten filter bowl 3 Turn the fuel supply valve if equipp...

Page 98: ...rating the engine in order 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 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...

Page 99: ...er The coolant can be reused 3 Drain the coolant from the cooling system to a 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 the correct coolant see this Operation and Maintenance Manual Fluid Recommendations 8 Refill the cooling system Refer to the...

Page 100: ...mpressor housing Over time this buildup can contribute to loss of engine power increased black smoke and overall loss of engine efficiency If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel can cause damageto the pistons the valves and the cylinder head Refer to Systems Operation T...

Page 101: ...ation hazard Refer to Operation and Maintenance Manual General hazard Information Visually inspect the high pressure fuel lines for damage or signs of fuel leakage Replace any damaged high pressure fuel lines or high pressure fuel lines that have leaked Ensure that all clips on the high pressure fuel lines are in place and that the clips are not loose Inspect the rest of the fuel system for leaks ...

Page 102: ...equipped so as to conform at the time of sale to all applicable regulations adopted by the California Air Resources Board ARB b Free from defects in materials and workmanship which cause the failure of an emission related component to be identical in all material respects to the component as described in the engine manufacturer s application for certification for the warranty period 3 New non road...

Page 103: ...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 104: ...d 84 Coolant Level Check 85 Factory Installed Radiators 85 Radiator Cap 86 Coolant Temperature Regulator Replace 86 Crankcase Breather Canister Replace 87 Crushing Prevention and Cutting Prevention 16 D Diagnostic Lamp 44 Diesel Particulate Filter Regeneration 51 E Electrical System 20 Grounding Practices 21 Emergency Stopping 56 Emissions Certification Film 33 Emissions Warranty Information 102 E...

Page 105: ...arator Drain 96 Fuel System Secondary Filter Replace 96 Remove the Filter Element 97 Fuel System Secondary Filter Water Separator Drain 97 Fuel Tank Water and Sediment Drain 98 Drain the Water and the Sediment 98 Fuel Storage Tanks 98 Fuel Tank 98 G Gauges and Indicators 38 General Hazard Information 9 Containing Fluid Spillage 11 Dispose of Waste Properly 12 Fluid Penetration 10 Inhalation 11 Pre...

Page 106: ...rage Engine and Aftertreatment 36 Condition for Storage 36 R Radiator Clean 99 Reference Information 34 Record for Reference 34 Reference Information Section 103 Reference Materials 103 Refill Capacities 57 Cooling System 57 Lubrication System 57 S Safety Messages 6 1 Universal Warning 6 2 Hand High Pressure 7 Ether Warning 8 Safety Section 6 Self Diagnostics 44 Sensors and Electrical Components 4...

Page 107: ...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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Perkins 403F-E17T 404F-E22T, Operation And Maintenance Manual

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