Operation andMaintenanceManual
403F-15T, 404F-22 and 404F-22TIndustrial Engines
EL (Engine)EN (Engine)EP (Engine)
SEBU8609-01
January 2013
Страница 1: ...Operation and Maintenance Manual 403F 15T 404F 22 and 404F 22T Industrial Engines EL Engine EN Engine EP Engine SEBU8609 01 January 2013...
Страница 2: ...ing 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 canno...
Страница 3: ...ronics 14 Product Information Section General Information 15 Product Identification Information 26 Operation Section Lifting and Storage 28 Features and Controls 30 Engine Diagnostics 43 Engine Starti...
Страница 4: ...ced 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...
Страница 5: ...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 1 Universa...
Страница 6: ...akes Block the vehicle or restrain the vehicle before maintenance or repairs are performed Disconnect the batteries when maintenance is performed or when the electrical system is serviced Disconnect t...
Страница 7: ...er the engine has been stopped The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly Do not remove any hydraulic components or...
Страница 8: ...s present there are several guidelines that should be followed Never use compressed air for cleaning Avoid brushing materials that contain asbestos Avoid grinding materials that contain asbestos Use a...
Страница 9: ...during service of the en gine The sulfuric acid will burn the eyes skin and clothing on contact Always wear the appropriate personal protective equipment PPE that is noted on a material safety data s...
Страница 10: ...uel spray in case of a line a tube or a seal failure Exhaust shields must be installed correctly Do not weld on lines or tanks that contain flammable fluids Do not flame cut lines or tanks that contai...
Страница 11: ...pressure fuel line or lines are removed End fittings are damaged or leaking Outer coverings are chafed or cut Wires are exposed Outer coverings are ballooning Flexible parts of the hoses are kinked O...
Страница 12: ...er 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 per...
Страница 13: ...the battery when the charging unit is operating A spark can cause the combustible gases that are produced by some batteries to ignite To help prevent sparks from igniting combustible gases that are p...
Страница 14: ...y or death and or engine damage This engine has a comprehensive programmable Engine Monitoring System The Electronic Control Module ECM has the ability to monitor the engine operating conditions If an...
Страница 15: ...nes and Aftertreatment The following model views show typical features of the engine Due to individual applications your engine may appear different from the illustrations 403F 15T Illustration 13 g03...
Страница 16: ...404F 22 Illustration 14 g03246558 Typical example 16 SEBU8609 General Information Model View Illustrations...
Страница 17: ...676 1 Top oil filler 2 Fan 3 Side oil filler 4 Cylinder block drain plug 5 Oil gauge Dipstick 6 Rear oil drain plug 7 Oil filter 8 Electric fuel pump 9 Secondary fuel filter SEBU8609 17 General Inform...
Страница 18: ...bocharger 12 Aftertreatment system 13 Flywheel 14 Flywheel housing 15 Starting motor 16 Solenoid for starting motor 17 Front oil drain plug 18 NOx reduction system cooler 19 Coolant outlet 18 SEBU8609...
Страница 19: ...rankcase breather 21 Rear lifting eye bracket 22 Air pump 23 Air pump drive belt 24 Alternator 25 Fan and alternator drive belt 26 Coolant intake 27 Water pump 28 Front lifting eye SEBU8609 19 General...
Страница 20: ...em Illustration 18 g03249241 29 Aftertreatment Regeneration Device ARD also known as the Burner 30 Diesel Oxidation Catalyst DOC 31 Diesel Particulate Filter DPF 20 SEBU8609 General Information Model...
Страница 21: ...Off Engine Parts Illustration 19 g03271819 32 Electronic Control Unit ECM 33 In line fuel filter SEBU8609 21 General Information Model View Illustrations...
Страница 22: ...ments for emissions The crankshaft for a three cylinder engine has four main bearing journals The crankshaft for a four cylinder engine has five main bearing journals End play is controlled by the thr...
Страница 23: ...Maintenance Interval Schedule for more information on maintenance items Engine Specifications Note The front end of the engine is opposite the flywheel end of the engine The left and the right side of...
Страница 24: ...rols topic Operation Section Engine Diagnostics The engine has built in diagnostics in order to ensure that the engine systems are functioning correctly The operator will be alerted to the condition b...
Страница 25: ...is not affected simply because of such use However failures that result from the installation or use of other manufacturers devices accessories or consumables are NOT Perkins defects Therefore the def...
Страница 26: ...gine family P Type of engine The list number of the engine U Country of manufacture 0 The first digit is a production code 00001 Engine Serial Number V Year of Manufacture Perkins dealers or Perkins d...
Страница 27: ...n will ensure compliance of the label i05157330 Reference Information Information for the following items may be needed to order parts Locate the information for your engine Record the information in...
Страница 28: ...tions are made ensure that correct lifting devices are provided Consult your Perkins dealer or your Perkins distributor for information regarding fixtures for correct engine lifting Lifting Eyes with...
Страница 29: ...d Maintenance Manual Fluid recommendations 4 Remove the drive belts from the engine Sealed Coolant System Ensure that the cooling system is filled with Perkins ELC or an antifreeze that meets ASTM D62...
Страница 30: ...engine oil pressure sensor or switch indicates when oil pressure drops below rated system pressure at a set engine speed Boost pressure Intake manifold pressure The intake manifold pressure sensor che...
Страница 31: ...e engine must be shut down immediately or if the engine can be cooled by reducing the load Tachometer This gauge indicates engine speed rpm When the throttle control lever is moved to the full throttl...
Страница 32: ...e power will be derated The warning lamp will begin to flash when the derating occurs The engine will be derated if the engine exceeds preset operational limits The engine derate is achieved by restri...
Страница 33: ...is present The engine is operat ing but one or more diagnostic codes are present As soon as possible the diagnostic code should be investigated Level 2 Flashing OFF Level 2 The ECM has detected an ab...
Страница 34: ...mperature sensor 2 Oil pressure switch 3 Secondary speed sensor 4 Fuel rack solenoid and position sensor 5 Glow plugs 6 Resistor for ARD glow plug 7 Fuel pump Priming pump 34 SEBU8609 Features and Con...
Страница 35: ...oolant temperature sensor 10 Alternator 11 Primary speed sensor 12 Inlet manifold air pressure sensor 13 NRS control valve 14 Solenoid for starting motor 15 Starting motor SEBU8609 35 Features and Con...
Страница 36: ...jectors 19 ARD temperature sensor 20 DOC intake temperature sensor 21 DPF intake temperature sensor 22 DPF outlet temperature sensor 23 ECM The ECM is remotely mounted The position of ECM will depend...
Страница 37: ...ustration 33 g03279862 1 Inlet air temperature 2 Oil pressure switch 3 Secondary speed sensor 4 Fuel rack solenoid and position sensor SEBU8609 37 Features and Controls Sensors and Electrical Componen...
Страница 38: ...Illustration 34 g03280057 5 Glow plugs 6 Resistor for ARD glow plug 7 Fuel pump Priming pump 38 SEBU8609 Features and Controls Sensors and Electrical Components...
Страница 39: ...Illustration 35 g03299376 8 Air pump 9 Coolant temperature sensor 10 Alternator 11 Primary speed sensor SEBU8609 39 Features and Controls Sensors and Electrical Components...
Страница 40: ...ion 36 g03299456 12 Inlet manifold air pressure sensor 13 NRS control valve 14 Solenoid for starting motor 15 Starting motor 16 ARD glow plug 40 SEBU8609 Features and Controls Sensors and Electrical C...
Страница 41: ...17 DPF pressure differential sensor 18 ARD injector 1 18 A ARD injector 2 19 ARD temperature sensor 19 A Alterative position for the ARD temperature sensor SEBU8609 41 Features and Controls Sensors a...
Страница 42: ...Illustration 38 g03299676 20 DOC intake temperature sensor 21 DPF intake temperature sensor 22 DPF outlet temperature sensor 23 ECM 42 SEBU8609 Features and Controls Sensors and Electrical Components...
Страница 43: ...on 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 E...
Страница 44: ...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...
Страница 45: ...ould result in an explosion and personal injury The ability to start the engine will be improved at temperatures below 18 C 0 F from the use of a jacket water heater or extra battery capacity When Gro...
Страница 46: ...The operating period of the warning light for the glow plugs will change due to the ambient air temperature NOTICE Do not engage the starting motor when flywheel is turning Do not start the engine un...
Страница 47: ...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 rechargeable Refer...
Страница 48: ...or regeneration to occur The exhaust gas provides heat for the regeneration process There are two types of regeneration Passive Regeneration The engine conditions are sufficient for regeneration The r...
Страница 49: ...ress in the bottom of the switch for 2 seconds in order to disable regeneration An indicator light on the switch will become active The disable indicator will illuminate Note To re enable the regenera...
Страница 50: ...STOP warning indi cator will indicate that the engine will be derated and will be shut down After 30 seconds the en gine will automatically shut down The engine can be restarted but will only run for...
Страница 51: ...he Systems Operation Testing and Adjusting V Belt Test for further information Ensure that all of the connections of the hoses are tight The connections should not leak Ensure that the driven equipmen...
Страница 52: ...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 shut...
Страница 53: ...ber 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 te...
Страница 54: ...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 engine s maximum power and the engine s fuel efficiency When Group...
Страница 55: ...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 t...
Страница 56: ...r 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 le...
Страница 57: ...xiliary oil filters will require additional oil Refer to the OEM specifications for the ca pacity of the auxiliary oil filter 2 The Total Lubrication System includes the capacity for the Crankcase Oil...
Страница 58: ...per operating temperature Cooling system prob lems can develop without water temperature regulators Many engine failures are related to the cooling system The following problems are related to cooling...
Страница 59: ...lycol Use ethylene glycol in conditions that require additional protection against boiling or freezing Table 13 Propylene Glycol Concentration Freeze Protection 50 Percent 29 C 20 F To check the conce...
Страница 60: ...you must maintain the recommended concentration of ELC Lowering the proportion of antifreeze lowers the proportion of additive This action will lower the ability of the coolant to protect the system f...
Страница 61: ...into a suitable container Dispose of the coolant according to local regulations Flush the system with clean water Fill the system with the Perkins ELC Drain a portion of the cooling system into a suit...
Страница 62: ...in Table 17 Table 18 Example Of The Equation For Adding The SCA To The Heavy Duty Coolant For Maintenance Total Volume of the Cooling System V Multiplication Factor Amount of SCA that is Required X 1...
Страница 63: ...stem is designed in order to collect this particulate matter There is a very small percentage of particulate matter that is left behind as the soot is burnt This matter will eventually block the filte...
Страница 64: ...conform to the following guidelines See the appropriate Lubricant Viscosities Refer to the illustration 40 in order to find the correct oil viscosity grade for your engine At the specified interval s...
Страница 65: ...ons The fuel information within this OMM is for use with the following engine models 403F 15T 404F 22 404F 22T and 404F 22TA Diesel Fuel Requirements Perkins is not in a position to continuously evalu...
Страница 66: ...n 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 n...
Страница 67: ...l 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 wi...
Страница 68: ...gulations 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 AS...
Страница 69: ...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 addit...
Страница 70: ...n 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 weldin...
Страница 71: ...intenance 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 Perk...
Страница 72: ...sary 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 in...
Страница 73: ...00 Service Hours Alternator and Fan Belts Replace 75 Belts Inspect Replace 77 Crankcase Breather Canister Replace 83 Engine Valve Lash Check 89 Turbocharger Inspect 96 Every 2000 Service Hours Alterna...
Страница 74: ...too loose vibration causes unnecessary wear on the belt and pulleys Loose belts may slip enough to cause overheating To accurately check the belt tension a suitable gauge should be used Illustration 4...
Страница 75: ...n Remove all electrical loads 2 Turn off any battery chargers Disconnect any battery chargers 3 The NEGATIVE cable connects the NEGATIVE battery terminal to the NEGATIVE terminal on the starting motor...
Страница 76: ...t switch to the OFF position Turn the ignition switch if equipped to the OFF position and remove the key and all electrical loads 2 Disconnect the negative battery terminal Ensure that the cable canno...
Страница 77: ...y Change NOTICE Care must be taken to ensure that fluids are con tained during performance of inspection mainte nance testing adjusting and repair of the product Be prepared to collect the fluid with...
Страница 78: ...is 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 mi...
Страница 79: ...e prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Dispose of all fluids according to Local regulations and mandat...
Страница 80: ...minute to avoid air locks Cooling system air locks may result in engine damage 2 Fill the cooling system with ELC Refer to the Operation and Maintenance Manual Fluid Recommendations topic Maintenance...
Страница 81: ...tall the filler cap and inspect the cooling system for leaks Note The coolant will expand as the coolant heats up during normal engine operation The additional volume will be forced into the coolant r...
Страница 82: ...and Install for the replacement procedure of the water temperature regulator or consult your Perkins dealer or your Perkins distributor Note If only the water temperature regulators are replaced drai...
Страница 83: ...cap i05199993 Crankcase Breather Canister Replace Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Ensure that the engine is stop...
Страница 84: ...late Filter or Catalytic Converter Muffler Failure to do so could result in personal injury The muffler catalytic converter muffler and diesel particulate filter will become extremely hot during engin...
Страница 85: ...on of cables into the rear of the connectors Avoid electrical components such as the alternator the starter and the ECM Protect the fuel injection pump from fluids in order to wash the engine Aftertre...
Страница 86: ...ine Air Precleaner Check Clean Illustration 55 g01453058 Typical engine air precleaner 1 Wing nut 2 Cover 3 Body Remove wing nut 1 and cover 2 Check for an accumulation of dirt and debris in body 3 Cl...
Страница 87: ...ontaining 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 d...
Страница 88: ...n 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 debr...
Страница 89: ...elp 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 t...
Страница 90: ...onents 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 Operatio...
Страница 91: ...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...
Страница 92: ...nected fuel system component NOTICE Care must be taken to ensure that fluids are con tained during performance of inspection mainte nance testing adjusting and repair of the product Be prepared to co...
Страница 93: ...fuel tank in order to drain the water and the sediment Close the drain valve Check the fuel daily Allow five minutes after the fuel tank has been filled before draining water and sediment from the fu...
Страница 94: ...ctions to the recommended torque Do not clip any other item to the high pressure lines Check for the following conditions End fittings that are damaged or leaking Outer covering that is chafed or cut...
Страница 95: ...ects of the operating environment Inspect the radiator for these items Damaged fins corrosion dirt grease insects leaves oil and other debris Clean the radiator if necessary Personal injury can result...
Страница 96: ...system Therefore by products from oil and from combustion can collect in the turbocharger compressor housing Over time this buildup can contribute to loss of engine power increased black smoke and ov...
Страница 97: ...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 engine is a fire hazard R...
Страница 98: ...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 followin...
Страница 99: ...the Perkins Engine Company limited suggested retail price for all warranted parts replaced and labor charges based on Perkins Engine Company limited recommended time allowance for the warranty repair...
Страница 100: ...to the initial owner and to the subsequent owner of the 400F diesel engines that such an engine is 1 Designed built and equipped so that the engine conforms at the time of sale with all applicable reg...
Страница 101: ...ns Engines Company Limited deems improper Attachments accessory items or parts not sold nor approved by Perkins Engines Company Limited Improper engine maintenance repair or abuse Use of improper fuel...
Страница 102: ...r the following items ENGINE AFTERTREATMENT SYSTEM The Engine Aftertreatment Systems are sensitive to the type of fuel and lubricants that is used Also the engine aftertreatment systems are sensitive...
Страница 103: ...ne 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...
Страница 104: ...n 79 Fill 80 Flush 80 Coolant Level Check 80 Engines With a Coolant Recovery Tank 80 Engines Without a Coolant Recovery Tank 81 Coolant Temperature Regulator Replace 82 Cooling System Supplemental Coo...
Страница 105: ...s 50 Fuel Filter In Line Replace 90 Fuel Injector Test Change 91 Identification of a suspect Fuel Injector 91 Fuel Related Components in Cold Weather 55 Fuel Filters 55 Fuel Heaters 55 Fuel Tanks 55 F...
Страница 106: ...ndition for Storage 28 R Radiator Clean 95 Radiator Pressure Cap Clean Replace 96 Reference Information 27 Record for Reference 27 Reference Information Section 103 Reference Materials 103 Refill Capa...
Страница 107: ...aintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Inf...
Страница 108: ...2013Perkins Engines Company Limited All Rights Reserved...
