Operation and

Maintenance

Manual

402F-05, 403F-07, 403F-11, and 403F-15

Industrial Engines

EG (Engine)

EH (Engine)

EJ (Engine)

EK (Engine)

This document is printed from SPI². Not for RESALE

 

Important Safety Information

Most  accidents    tha t involve  produc  t  op eration,  ma intena nc e and   repair   are  caus  ed  by  failure  to

ob serve  basic   safety   rules  or  precautions  .  An accident    can   often  be  avoided   by  recog nizing  pote ntially

ha za rdous  situations   before   an  accident    oc curs . A person    mus t be  alert   to pote ntial  ha za rds.  This

person   should   also  ha ve  the  ne cessary   training,  skills  and   tools  to perform   the se  func tions properly.

Improper operation, lubrication, maintenance or repair  of this product can be dangerous and

could result in injury  or death.

Do not operate or perform any lubrication, maintenance or repair on this  product, until you have

read and understood the operation, lubrication, maintenance and repair information.

Sa fety precautions     and  warning s  are   provided   in this  ma nua l and   on  the  produc t.  If the se  ha za rd

warning s  are  not  he eded,   bod ily injury  or death   could   oc cur to  you  or to  othe r persons  .

The  ha za rds are   identified   by  the  “Safety  Alert  Symb ol”  and  followed  by  a  “Signa l  Word” suc h  as

“DANGER”, “WARNING”  or “CAUTION”.  The Sa fety  Alert  “WARNING” label  is  shown   below.

The  me aning  of  this safety   alert   symb ol is  as  follows:

Attention! Become Alert! Your Safety is  Involved.

The  me ssage   tha t appears     und er the   warning  explains    the  ha za rd and   can  be   either  written  or

pictorially   presente  d.

Op erations  tha t  ma y caus e  produc  t dama  ge  are  identified   by  “NOTICE” labels   on  the  produc  t and   in

this  pub lication.

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 operating technique that is not specifically recommended by Perkins is used,

you must satisfy yourself that it is safe  for you and for others. You should also ensure that the

product will not be damaged or be  made unsafe by the operation, lubrication, maintenance or

repair procedures that you choose.

The  informa tion, specifications   ,  and  illustrations   in  this  pub lication  are   on the  basis    of informa tion tha t

was  available    at  the  time  tha t the  pub lication   was  written.   The  specifications   , torque  s,  pressure  s,

me asure me nts , adjustme  nts , illustrations ,  and  othe r  items  can  cha  ng e at  any  time.  These  cha ng es  can

affect   the  service   tha t is given   to the  produc  t.  Ob tain the  comp  lete  and  mos t current   informa tion before

you  start any   job. Pe  rkins  dealers   or   Pe rkins  distributors     ha ve  the  mos t current   informa tion  available.

When  replacement  parts  are  required  for  this

product Perkins recommends using Perkins

 replacement  parts.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

This document is printed from SPI². Not for RESALE

 

SEBU9064

3

Table of Contents

Table of Contents

Maintenance Interval Schedule........... ........... 54

Warranty Section

Foreword.............................. ............................. 4

Safety Section

Warranty Information................... ................... 82

Reference Information Section

Reference Materials ........................................ 83

Index Section

Safety Messages....................... ....................... 5

General Hazard Information............... .............. 6

Burn Prevention........................ ........................ 7

Fire Prevention and Explosion Prevention .... ... 8

Crushing Prevention and Cutting Prevention .. . 9

Before Starting Engine ................. .................. 10

Engine Starting........................ ....................... 10

Engine Stopping....................... .......................11

Electrical System...................... .......................11

Product Information Section

Index................................ ............................... 84

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

This document is printed from SPI². Not for RESALE

 

4

SEBU9064

Foreword

Foreword

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 the Maintenance Interval Schedule may

be necessary.

Literature Information

This manual contains safety, operation instructions,

lubrication and maintenance information. This manual

should be stored in or near the engine area in a

literature holder or literature storage area. Read,

study and keep it with the literature and engine

information.

The maintenance schedule items are organized for a

preventive maintenance management program. If the

preventive maintenance program is followed, a

periodic tune-up is not required. The implementation

of a preventive maintenance management program

should minimize operating costs through cost

avoidances resulting from reductions in unscheduled

downtime and failures.

English is the primary language for all Perkins

publications. The English used facilitates translation

and consistency.

Some photographs or illustrations in this manual

show details or attachments that may be different

from your engine. Guards and covers may have been

removed for illustrative purposes. Continuing

improvement and advancement of product design

may have caused changes to your engine which are

not included in this 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.

Maintenance Intervals

Perform maintenance on items at multiples of the

original requirement. We recommend that the

maintenance schedules be reproduced and displayed

near the engine as a convenient reminder. We also

recommend that a maintenance record be maintained

as part of the engine's permanent record.

Safety

Your authorized Perkins dealer or your Perkins

distributor can assist you in adjusting your

maintenance schedule to meet the needs of your

operating environment.

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 performing lubrication, maintenance and

repair on this product.

Overhaul

Major engine overhaul details are not covered in the

Operation and Maintenance Manual except for the

interval and the maintenance items in that interval.

Major repairs should only be carried out by Perkins

authorized personnel. Your Perkins dealer or your

Perkins distributor offers a variety of options

regarding overhaul programs. If you experience a

major engine failure, there are also numerous after

failure overhaul options available. Consult with your

Perkins dealer or your Perkins distributor for

information regarding these options.

Operation

Operating techniques outlined in this manual are

basic. They assist with developing the skills and

techniques required to operate the engine more

efficiently and economically. Skill and techniques

develop as the operator gains knowledge of the

engine and its capabilities.

The operation section is a reference for operators.

Photographs and illustrations guide the operator

through procedures of inspecting, starting, operating

and stopping the engine. This section also includes a

discussion of electronic diagnostic information.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents

are known to the State of California to cause cancer,

birth defects, and other reproductive harm. Battery

posts, terminals and related accessories contain lead

and lead compounds. Wash hands after handling.

Maintenance

The maintenance section is a guide to engine care.

The illustrated, step-by-step instructions are grouped

by service hours and/or calendar time maintenance

intervals. Items in the maintenance schedule are

referenced to detailed instructions that follow.

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SEBU9064

5

Safety Section

Safety Messages

Safety Section

i05333233

Safety Messages

There may be several specific warning signs on your

engine. The exact location and a description of the

warning signs are reviewed in this section. Become

familiar with all warning signs.

Ensure that all of the warning signs are legible. Clean

the warning signs or replace the warning signs if the

words cannot be read or if the illustrations are not

visible. Use a cloth, water, and soap to clean the

warning signs. Do not use solvents, gasoline, or other

harsh chemicals. Solvents, gasoline, or harsh

chemicals could loosen 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  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.

Illustration 1

g01154807

Typical example

Warning label (A) is installed in different locations.

The location will change according to the physical

size of the engine.

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6

SEBU9064

Safety Section

General Hazard Information

Illustration 2

g03378379

Typical examples

(A) Location of warning label

(1) 402F-05

(2) 403F-07

(3) 403F-11

(4) 403F-15

i02328435

General Hazard Information

Illustration 4

g00702020

Wear a hard hat, protective glasses, and other

protective equipment, as required.

Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

Illustration 3

g00104545

Make sure that all protective guards and all covers

are secured in place on the engine.

Attach a “Do Not Operate”  warning tag or a similar

warning tag to the start switch or to the controls

before you service the equipment or before you repair

the equipment.

Keep the engine free from foreign material. Remove

debris, oil, tools, and other items from the deck, from

walkways, and from steps.

This document is printed from SPI². Not for RESALE

 

SEBU9064

7

Safety Section

Burn Prevention

Never put maintenance fluids into glass containers.

Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care.

Report all necessary repairs.

Do not allow unauthorized personnel on the

equipment.

Ensure that the power supply is disconnected before

you work on the bus bar or the glow plugs.

Perform maintenance on the engine with the

equipment in the servicing position. Refer to the OEM

information for the procedure for placing the

equipment in the servicing position.

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 severe injury. If fluid is injected into your skin,

you must get treatment immediately. Seek treatment

from a doctor that is familiar with this type of injury.

Pressure Air and Water

Pressurized air and/or water can cause debris and/or

hot water to be blown out. This could result in

personal injury.

The direct application of pressurized air or

pressurized water to the body could result in personal

injury.

Containing Fluid Spillage

Care must be taken in order to ensure that fluids are

contained during performance of inspection,

maintenance, testing, adjusting and repair of the

engine. Make provision to collect the fluid with a

suitable container before any compartment is opened

or before any component is disassembled.

When pressurized air and/or water is used for

cleaning, wear protective clothing, protective shoes,

and eye protection. Eye protection includes goggles

or a protective face shield.

The maximum air pressure for cleaning purposes

must be below 205 kPa (30 psi). The maximum water

pressure for cleaning purposes must be below

275 kPa (40 psi).

•   Only use the tools that are suitable for collecting

fluids and equipment that is suitable for collecting

fluids.

Fluid Penetration

•   Only use the tools that are suitable for containing

fluids and equipment that is suitable for containing

fluids.

Pressure can be trapped in the hydraulic circuit long

after 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.

Obey all local regulations for the disposal of liquids.

Do not remove any hydraulic components or parts

until pressure has been relieved or personal injury

may occur. Do not disassemble any hydraulic

components or parts until 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.

i02143195

Burn Prevention

Do not touch any part of an operating engine. Allow

the engine to cool before any maintenance is

performed on the engine. Relieve all pressure in the

air system, in the hydraulic system, in the lubrication

system, in the fuel system, or in the cooling system

before any lines, fittings or related items are

disconnected.

Coolant

When the engine is at operating temperature, the

engine coolant is hot. The coolant is also under

pressure. The radiator and all lines to the heaters or

to the engine contain hot coolant.

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8

SEBU9064

Safety Section

Fire Prevention and Explosion Prevention

Any contact with hot coolant or with steam can cause

severe burns. Allow cooling system components to

cool before the cooling system is drained.

A flash fire may result if the covers for the engine

crankcase are removed within fifteen minutes after an

emergency shutdown.

Check the coolant level after the engine has stopped

and the engine has been allowed to cool.

Determine whether the engine 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 could result.

Ensure that the filler cap 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.

If the application involves the presence of

combustible gases, consult your Perkins dealer and/

or your Perkins distributor for additional information

about suitable protection devices.

Cooling system conditioner contains alkali. Alkali can

cause personal injury. Do not allow alkali to contact

the skin, the eyes, or the mouth.

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.

Oils

Hot oil and hot lubricating components can cause

personal injury. Do not allow hot oil to contact the

skin. Also, do not allow hot components to contact the

skin.

Store fuels and lubricants in correctly marked

containers away from unauthorized persons. Store

oily rags and any flammable materials in protective

containers. Do not smoke in areas that are used for

storing flammable materials.

Batteries

Electrolyte is an acid. Electrolyte can cause personal

injury. Do not allow electrolyte to contact the skin or

the eyes. Always wear protective glasses for

servicing batteries. Wash hands after touching the

batteries and connectors. Use of gloves is

recommended.

Do not expose the engine to any flame.

Exhaust shields (if equipped) protect hot exhaust

components from oil or fuel spray in case of a line, a

tube, or a seal failure. Exhaust shields must be

installed correctly.

i02813488

Do not weld on lines or tanks that contain flammable

fluids. Do not flame cut lines or tanks that contain

flammable fluid. Clean any such lines or tanks

thoroughly with a nonflammable solvent prior to

welding or flame cutting.

Fire Prevention and Explosion

Prevention

Wiring must be kept in good condition. All electrical

wires must be correctly routed and securely attached.

Check all electrical wires daily. Repair any wires that

are loose or frayed before you operate the engine.

Clean all electrical connections and tighten all

electrical connections.

Eliminate all wiring that is unattached or unnecessary.

Do not use any wires or cables that are smaller than

the recommended gauge. Do not bypass any fuses

and/or circuit breakers.

Arcing or sparking could cause a fire. Secure

connections, recommended wiring, and correctly

maintained battery cables will help to prevent arcing

or sparking.

Inspect all lines and hoses for wear or for

deterioration. The hoses must be correctly routed.

The lines and hoses must have adequate support

and secure clamps. Tighten all connections to the

recommended torque. Leaks can cause fires.

Illustration 6

g00704000

All fuels, most lubricants, and some coolant mixtures

are flammable.

Flammable fluids that are leaking or spilled onto hot

surfaces or onto electrical components can cause a

fire. Fire may cause personal injury and property

damage.

Oil filters and fuel filters must be correctly installed.

The filter housings must be tightened to the correct

torque.

This document is printed from SPI². Not for RESALE

 

SEBU9064

9

Safety Section

Crushing Prevention and Cutting Prevention

Do not charge a frozen battery. This may cause an

explosion.

The batteries must be kept clean. The covers (if

equipped) must be kept on the cells. Use the

recommended cables, connections, and battery box

covers when the engine is operated.

Fire Extinguisher

Make sure that a fire extinguisher is available. Be

familiar with the operation of the fire extinguisher.

Inspect the fire extinguisher and service the fire

extinguisher regularly. 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 replacement parts.

Illustration 7

g00704059

Use caution when you are refueling an engine. Do not

smoke while you are refueling an engine. Do not

refuel an engine near open flames or sparks. Always

stop the engine before refueling.

Check lines, tubes and hoses carefully. Do not use

your bare hand to check for leaks. Use a board or

cardboard to check for leaks. Tighten all connections

to the recommended torque.

Replace the parts if any of the following conditions

are present:

•   End fittings are damaged or leaking.

•   Outer coverings are chafed or cut.

•   Wires are exposed.

•   Outer coverings are ballooning.

•   Flexible part of the hoses are kinked.

•   Outer covers have embedded armoring.

•   End fittings are displaced.

Make sure that all clamps, guards, and heat shields

are installed correctly. During engine operation, this

will help to prevent vibration, rubbing against other

parts, and excessive heat.

Illustration 8

g00704135

i02143194

Gases from a battery can explode. Keep any open

flames or sparks away from the top of a battery. Do

not smoke in battery charging areas.

Crushing Prevention and

Cutting Prevention

Never check the battery charge by placing a metal

object across the terminal posts. Use a voltmeter or a

hydrometer.

Support the component correctly when work beneath

the component is performed.

Incorrect jumper cable connections can cause an

explosion that can result in injury. Refer to the

Operation Section of this manual for specific

instructions.

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10

SEBU9064

Safety Section

Before Starting Engine

Unless other maintenance instructions are provided,

never attempt adjustments while the engine is

running.

i02157354

Engine Starting

Stay clear of all rotating parts and of all moving parts.

Leave the guards in place until maintenance is

performed. After the maintenance is performed,

reinstall the guards.

Keep objects away from moving fan blades. The fan

blades will throw objects or cut objects.

Do not use aerosol types of starting aids such as

ether. Such use  could result in an explosion and

personal injury.

When objects are struck, wear protective glasses in

order to avoid injury to the eyes.

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 before the engine is started.

Chips or other debris may fly off objects when objects

are struck. Before objects are struck, ensure that no

one will be injured by flying debris.

All protective guards and all protective covers must

be installed if the engine must be started in order to

perform service procedures. To help prevent an

accident that is caused by parts in rotation, work

around the parts carefully.

i02813489

Before Starting Engine

Start the engine from the operator's compartment or

from the engine start switch.

Before the initial start-up of an engine that is new,

serviced or repaired, make provision to shut the

engine off, in order to stop an overspeed. This may

be accomplished by shutting off the air and/or fuel

supply to the engine.

Always start the engine according to the procedure

that is described in the Operation and Maintenance

Manual, “Engine Starting” topic in the Operation

Section. Knowing the correct procedure will help to

prevent major damage to the engine components.

Knowing the procedure will also help to prevent

personal injury.

Overspeed shutdown should occur automatically for

engines that are controlled electronically. If automatic

shutdown does not occur, press the emergency stop

button in order to cut the fuel and/or air to the engine.

To ensure that the jacket water heater (if equipped)

and/or the lube oil heater (if equipped) is working

correctly, check the water temperature gauge and the

oil temperature gauge during the heater operation.

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on,

underneath, or close to the engine. Ensure that the

area is free of personnel.

Engine exhaust contains products of combustion

which can be harmful to your health. Always start the

engine and operate the engine in a well ventilated

area. If the engine is started in an enclosed area, vent

the engine exhaust to the outside.

If equipped, ensure that the lighting system for the

engine is suitable for the conditions. Ensure that all

lights work correctly, if equipped.

All protective guards and all protective covers must

be installed if the engine must be started in order to

perform service procedures. To help prevent an

accident that is caused by parts in rotation, work

around the parts carefully.

Note: The engine is equipped with an automatic

device for cold starting for normal conditions of

operation. If the engine will be operated in very cold

conditions, then an extra cold starting aid may be

required. Normally, the engine will be equipped with

the correct type of starting aid for your region of

operation.

Do not bypass the automatic shutoff circuits. Do not

disable the automatic shutoff circuits. The circuits are

provided in order to help prevent personal injury. The

circuits are also provided in order to help prevent

engine damage.

The 400 Series engines are equipped with a glow

plug starting aid in each individual cylinder that heats

the intake air in order to improve starting.

See the Service Manual for repairs and for

adjustments.

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SEBU9064

11

Safety Section

Engine Stopping

i02234873

Engines that are installed without engine-to-frame

ground straps can be damaged by electrical

discharge.

Engine Stopping

To ensure that the engine and the engine electrical

systems function correctly, an engine-to-frame

ground strap with a direct path to the battery must be

used. This path may be provided by way of a direct

engine ground to the frame.

Stop the engine according to the procedure in the

Operation and Maintenance Manual, “Engine

Stopping (Operation Section)” in order to avoid

overheating of the engine and accelerated wear of

the engine components.

All grounds should be tight and free of corrosion. The

engine alternator must be grounded to the negative

“-” battery terminal with a wire that is adequate to

handle the full charging current of the alternator.

Use the Emergency Stop Button (if equipped) ONLY

in an emergency situation. Do not use the Emergency

Stop Button for normal engine stopping. After an

emergency stop, DO NOTstart the engine until the

problem that caused the emergency stop has been

corrected.

Stop the engine if an overspeed condition occurs

during the initial start-up of a new engine or an engine

that has been overhauled.

To stop an electronically controlled engine, cut the

power to the engine and/or shutting off the air supply

to the engine.

i02176668

Electrical System

Never disconnect any charging unit circuit or battery

circuit cable from 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 produced by some batteries, the

negative  “−” jump start cable should be connected

last from the external power source to the negative

“−”  terminal 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 instructions.

Grounding Practices

Correct grounding for the engine electrical system is

necessary for optimum engine performance and

reliability. Incorrect grounding will result in

uncontrolled electrical circuit paths and in unreliable

electrical circuit paths.

Uncontrolled electrical circuit paths can result in

damage to main bearings, to crankshaft bearing

journal surfaces, and to aluminum components.

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12

SEBU9064

Product Information Section

Model View Illustrations

Product Information

Section

General Information

i05333703

Model View Illustrations

The 403F-15 Engine View

Illustration 9

g03378808

Typical example

(1) Rear lifting eye

(2) Top oil filler cap

(3) Front lifting eye

(4) Water pump

(5) Low mounted oil filler cap

(6) Fuel injection pump

(7) Oil gauge (Dipstick)

(8) Oil drain plug

(9) Oil filter

(10) Electronically controlled actuator

(11) Injector

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SEBU9064

13

General Information

Model View Illustrations

Illustration 10

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

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14

SEBU9064

General Information

Model View Illustrations

Fuel System Components

Illustration 11

g03379882

Typical examples

(1) In-line fuel filter

(3) Primary fuel filter

(5) Secondary fuel filter

(2) Electric fuel pump

(4) Secondary fuel filter (element type)

Note: The electric fuel pump is an option, engines

may have a mechanical fuel lift pump installed.

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SEBU9064

15

General Information

Product Description

Components for Electronic Control

Illustration 12

g03379884

(1) Electronic Control Module (ECM)

(2) Speed sensor

(3) Atmospheric Pressure Sensor

(Barometric Pressure Sensor)

(4) Actuator

Note: Due to individual applications the atmospheric

pressure sensor (3) may appear different from the

illustration.

Engine Specifications

Note: The front end of the engine is opposite the

flywheel end of the engine. The left and the right

sides of the engine are determined from the flywheel

end. The number 1 cylinder is the front cylinder.

i05333638

Product Description

There are four Perkins engines in the 400F 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

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16

SEBU9064

General Information

Product Description

402F-05 Engine

403F-07 Engine

Illustration 13

g01108476

Illustration 14

g00852304

(A) Exhaust valves

(B) Inlet valves

(A) Exhaust valves

(B) Inlet valves

Table 1

Table 2

402F-05 Engine Specifications

403F-07 Engine Specifications

Maximum Operating Speed

(rpm)

Maximum Operating Speed

(rpm)

3600 rpm

3600 rpm

Cylinders and Arrangement

Bore

In-Line 2 cylinder

67 mm (2.64 inch)

72 mm (2.83 inch)

Cylinders and Arrangement

Bore

In-Line 3 cylinder

67 mm (2.64 inch)

72 mm (2.83 inch)

Stroke

Stroke

Displacement

Aspiration

0.507 L (30.939 in

3

)

Displacement

Aspiration

0.762 L (46.500 in

3

)

Naturally Aspirated

Naturally Aspirated

23.5:1

Compression Ratio

Firing Order

23.5:1

1-2

Compression Ratio

Firing Order

1-2-3

Rotation that is viewed from the

flywheel

Rotation that is viewed from the

flywheel

Counterclockwise

Counterclockwise

Valve Lash Setting (Inlet)

Valve Lash Setting (Exhaust)

Injection

0.20 mm (0.008 inch)

0.20 mm (0.008 inch)

Indirect

Valve Lash Setting (Inlet)

Valve Lash Setting (Exhaust)

Injection

0.20 mm (0.008 inch)

0.20 mm (0.008 inch)

Indirect

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SEBU9064

17

General Information

Product Description

403F-11 Engine

403F-15 Engine

Illustration 15

g00852304

Illustration 16

g00852304

(A) Exhaust valves

(B) Inlet valves

(A) Exhaust valves

(B) Inlet valves

Table 3

Table 4

403F-11 Engine Specifications

403F-15 Engine Specifications

Maximum Operating Speed

(rpm)

Maximum Operating Speed

(rpm)

3600 rpm

3000 rpm

Cylinders and Arrangement

Bore

In-Line 3 cylinder

77 mm (3.03 inch)

81 mm (3.19 inch)

Cylinders and Arrangement

Bore

In-Line 3 cylinder

84 mm (3.31 inch)

90 mm (3.54 inch)

Stroke

Stroke

Displacement

Aspiration

1.131 L (69.018 in

3

)

Displacement

Aspiration

1.496 L (91.291 in

3

)

Naturally Aspirated

Naturally Aspirated

22.5:1

Compression Ratio

Firing Order

23:1

Compression Ratio

Firing Order

1-2-3

1-2-3

Rotation that is viewed from the

flywheel

Rotation that is viewed from the

flywheel

Counterclockwise

Counterclockwise

Valve Lash Setting (Inlet)

Valve Lash Setting (Exhaust)

Injection

0.20 mm (0.008 inch)

0.20 mm (0.008 inch)

Indirect

Valve Lash Setting (Inlet)

Valve Lash Setting (Exhaust)

Injection

0.20 mm (0.008 inch)

0.20 mm (0.008 inch)

Indirect

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18

SEBU9064

Product Identification Information

Plate Locations and Film Locations

Product Identification

Information

i05333666

Emissions CertificationFilm

i05333660

Plate Locations and Film

Locations

Perkins  engines are identified by a serial number.

This serial number is shown on a serial number plate.

The plate is mounted above the fuel injection pump

on the right-hand side of the engine block.

A typical example of an engine number is

EK*****N000001X.

E

Engine family

Type of engine

K

*****

The list number of the engine

Country of manufacture

The first digit is a production code.

Engine Serial Number

N

0

00001

X

Illustration 17

g03378752

i05335976

Typical example

Year of Manufacture

Perkins  dealers or Perkins  distributors need all of

these numbers in order to determine the components

that were included with the engine. This information

permits accurate identification of replacement part

numbers.

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 copy of this list for a record. Keep the

information for future reference.

Record for Reference

Engine Model

Engine Serial Number

ECM Serial Number

Engine Low Idle rpm

Engine Full Load rpm

In-Line Fuel Filter

Primary Fuel Filter

Secondary Fuel Filter Element

Lubrication Oil Filter Element

Auxiliary Oil Filter Element

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SEBU9064

19

Product Identification Information

Reference Information

Total Lubrication System Capacity

Total Cooling System Capacity

Air Cleaner Element

Alternator Belt

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20

SEBU9064

Operation Section

Product Lifting

Operation Section

Lifting and Storage

Lifting eyes are designed and installed for specific

engine arrangements. Alterations to the lifting eyes

and/or the engine make the lifting eyes and the lifting

fixtures obsolete. If alterations are made, ensure that

correct lifting devices are provided. Consult your

Perkins  dealer or your Perkins distributor for

information regarding fixtures for correct engine

lifting.

i05335230

Product 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 a constant temperature.

Engines that are filled with Perkins ELC will have

coolant protection to an ambient temperature of

−36° C (−32.8° F). The engine must not be subjected

to extreme variations in temperature and humidity.

Storage Period

An engine can be stored for up to 6 months provided

all the recommendation are adhered to.

Illustration 18

g03380038

Typical example

Storage Procedure

(1) Rear lifting eye

(2) Front lifting eye

Keep a record of the procedure that has been

completed on the engine.

NOTICE

Never bend the eyebolts and the brackets. Only load

the eyebolts and the brackets under tension. Remem-

ber that the capacity of an eyebolt is less as the angle

between the supporting members and  the object be-

comes less than 90 degrees.

Note: Do not store an engine that has biodiesel in the

fuel system.

1. Ensure that the engine is clean and dry.

a.

b.

If the engine has been operated using

biodiesel, the system must be drained and

new filters installed. The fuel tank will require

flushing.

When it  is necessary to  remove a component at  an

angle, only use a link bracket that is properly 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.

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.

Some removals require lifting the fixtures in order to

obtain correct balance and safety.

2. Drain any water from the primary filter water

separator. Ensure that the fuel tank is full.

To remove the engine ONLY, use the lifting eyes that

are on the engine.

This document is printed from SPI². Not for RESALE

 

SEBU9064

21

Lifting and Storage

Product Storage

3. The engine oil will not need to be drained in order

to store the engine. Provided the correct

specification of engine oil is used the engine can

be stored for up to 6 months. For the correct

specification of engine oil refer to this Operation

and Maintenance Manual, “Fluid

recommendations”.

4. Remove the fan belt from the engine.

Sealed Coolant System

Ensure that the cooling system is filled with Perkins

ELC, or an antifreeze that meets ASTM D6210

specification.

Open Cooling System

Ensure that all cooling drain plugs have 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 must be rotated in order to change the

spring loading on the valve train. Rotate the

crankshaft more than 180 degrees. Visibly check for

damage or corrosion to the engine.

Ensure that the engine is covered completely before

storage. Log the procedure in the record for the

engine.

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22

SEBU9064

Features and Controls

Gauges and Indicators

Features and Controls

2. Inspect the cooling system for leaks.

3. Determine if the engine must be shut down

immediately or if the engine can be cooled by

reducing the load.

i05336041

Gauges and Indicators

Tachometer – This gauge indicates

engine speed (rpm). When the throttle

Your engine may not have the same gauges or all of

the gauges that are described. For more information

about the gauge package, see the OEM information.

controller is moved to the full throttle

position without load, the engine is running at

high idle. The engine is running at the full load

rpm when the throttle controller is at the full

throttle position with maximum rated load.

Gauges provide indications of engine performance.

Ensure that the gauges are in good working order.

Determine the normal operating range by observing

the gauges over a period of time.

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.

Noticeable changes in gauge readings indicate

potential gauge or engine problems. Problems may

also be indicated by gauge readings that change

even if the readings are within specifications.

Determine and correct the cause of any significant

change in the readings. Consult your Perkins dealer

or your Perkins  distributor for assistance.

Ammeter – This gauge indicates the

amount of charge or discharge in the

battery charging circuit. Operation of the

indicator should be to the right side of  “0”  (zero).

NOTICE

If no  oil pressure  is  indicated, STOP  the engine.  If

maximum  coolant temperature  is  exceeded,  STOP

the engine. Engine damage can result.

Fuel Level – This gauge indicates the

fuel level in the fuel tank. The fuel level

gauge operates when the “START/

Engine Oil Pressure – The oil pressure

should be greatest after a cold engine is

started. The typical engine oil pressure

with SAE10W30 is 207 to 413 kPa  (30 to 60 psi) at

rated rpm.

STOP”  switch is in the “ON”  position.

Service Hour Meter – The gauge

indicates operating time of the engine.

Indicators and Lamps

A lower oil pressure is normal at low idle. If the load is

stable and the gauge reading changes, perform the

following procedure:

The following indicator lamps can be installed, for

more information refer to the Original Equipment

Manufacturer (OEM)

1. Remove the load.

•   Shutdown lamp

•   Warning lamp

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

•   Low-pressure oil lamp

Jacket Water Coolant Temperature –

Typical temperature range is 71 to 96°C

(160 to 205°F). The maximum allowable

temperature with the pressurized cooling system

at 90 kPa (13 psi) is 125° C (257° F). Higher

temperatures may occur under certain

conditions. 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.

A multi function lamp is installed on the electric

control module.

i05336105

MonitoringSystem

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.

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SEBU9064

23

Features and Controls

Overspeed

•   Oil pressure sensor

NOTICE

The  Engine Monitoring  System  is not  a  guarantee

against  catastrophic   failures.  Programmed  delays

and derate schedules are designed to minimize false

alarms and provide  time for the operator to  stop the

engine.

•   Coolant temperature sensor

•   Atmospheric pressure sensor (Barometric

pressure sensor)

•   Speed sensor

The following parameters are monitored:

•   Coolant temperature

•   Throttle actuator

•   Oil pressure

•   Engine speed

•   Atmospheric pressure (Barometric pressure)

The coolant temperature, oil pressure, and the engine

speed can trigger an engine shutdown.

•   Atmospheric pressure (Barometric pressure) can

trigger an engine de-rate.

The atmospheric pressure sensor (Barometric

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

(RPM)

3600 Revolutions Per Minute

•   403F-07

•   403F-11

•   403F-15

3600 RPM

3600 RPM

3000 RPM

The overspeed is plus 700 RPM above the given

speed for engines shown.

i05336173

Sensors and Electrical

Components

The following sensors or switches are installed on the

402F-05, 403F-07, 403F-11, and the 403F-15

engines:

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24

SEBU9064

Features and Controls

Sensors and Electrical Components

Illustration 19

g03381125

Typical examples

(1) Oil pressure sensor

(2) Coolant temperature sensor

(3) Atmosphere pressure sensor (Barometric

pressure sensor)

(4) Speed sensor

(5) Throttle actuator

Note: Due ti individual applications the atmosphere

pressure sensor (3) may appear different from the

illustration.

•   Alternator

•   Starting motor

•   Glow plugs

Electrical components install on the 402F-05, 403F-

07, 403F-11, and the 403F-15 engines:

•   Electronic control governor (Location will depend

on the application)

•   Electric fuel pump

This document is printed from SPI². Not for RESALE

 

SEBU9064

25

Features and Controls

Sensors and Electrical Components

Illustration 20

g03381126

Typical examples

(7) Alternator

(9) Glow plugs

(11) Fuel pump

(8) Starting motor

(10) Electronic control model (Controller)

(12) Multi function lamp

When the keyswitch is in the OFF position, the multi

function lamp will not be illuminated. With the

keyswitch in the ON position the multi function lamp

will flash once. The flash will indicate that the system

is powered and ready for operation.

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”.

This document is printed from SPI². Not for RESALE

 

26

SEBU9064

Engine Diagnostics

Self-Diagnostics

Engine Diagnostics

i05339798

Self-Diagnostics

The electronic engines can perform a self-diagnostics

test. When the system detects an active problem, a

diagnostic lamp is activated. This lamp is a multi

function lamp that is located on the electronic control

module. The lamp will flash a code that will give am

indication of the fault. For more information on the

flash codes, refer to this Operation and Maintenance

Manual, “Diagnostic Flash Code Retrieval”.

i05339090

Diagnostic Lamp

The multi function lamp on the electronic control

module can operate as a diagnostic lamp. The

diagnostic function is used to indicate the existence

of an active fault. The active fault is transmitted as a

flash code.

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, the flash code

sequence will continual to be repeated. If a second

flash code has been activated, then the system will

repeat both codes in the given sequence.

Four short flashes will indicate a flash code of 04.

Three long flashes of one second each followed by

one short flash will indicate a flash code of 31.

If there is more than one code to be indicated, the

system will flash the first code then after a delay

interval the next code is flashed.

This document is printed from SPI². Not for RESALE

 

SEBU9064

27

Engine Diagnostics

Diagnostic Flash Code Retrieval

Table 5

Flash Codes with Key ON (Engine not in Operation)

Flash Code

Description

Engine status

Operator Action

13

22

33

Oil pressure switch malfunction.

Disconnection of Oil pressure

switch.

Disconnection of Oil pressure

harness.

Engine will start, but the engine will  Check harness connection. If the

shut down after 180 seconds

fault remains contact your Perkins

dealer or your Perkins  distributor.

Pressure sensor malfunction.

Engine will start, but the engine go Check harness connection. If the

Disconnection of Pressure sensor   to limp home mode.

fault remains contact your Perkins

dealer or your Perkins  distributor.

connector.

Disconnection of Pressure sensor

harness.

Actuator position sensor

malfunction.

Disconnection of Actuator position

sensor connector.

Engine will start, but the engine go Check harness connection. If the

to limp home mode.

fault remains contact your Perkins

dealer or your Perkins  distributor.

Disconnection of Actuator position

sensor harness.

04

Actuator drive malfunction.

Disconnection of Speed sensor

connector.

Engine will not start.

Check harness connection. If the

fault remains contact your Perkins

dealer or your Perkins  distributor.

Disconnection of Speed sensor

harness.

Table 6

Flash Codes During Engine Cranking

Engine status

Engine will not start.

Flash Code

Description

Operator Action

13

Speed sensor malfunction.

Disconnection of Speed sensor

connector.

Check harness connection. If the

fault remains contact your Perkins

dealer or your Perkins  distributor.

Disconnection of Speed sensor

harness.

Table 7

Flash Codes with Engine in Operation

Engine status

Flash Code

Description

Operator Action

31

22

Oil pressure decline.

Weak signal from oil pressure

switch.

Engine will go to limp home mode  Check engine oil.  (1)

but the engine may shut down.

Check harness connection. If the

fault remains contact your Perkins

dealer or your Perkins  distributor.

Short-circuiting.

Pressure sensor malfunction.

Disconnection of Pressure sensor

connector.

The engine will go into limp home   Check harness connection. If the

mode.

fault remains contact your Perkins

dealer or your Perkins  distributor.

Disconnection of Pressure sensor

harness.

33

Actuator position sensor

malfunction.

Disconnection of Actuator position

sensor connector.

The engine will go into limp home   Check harness connection. If the

mode.

fault remains contact your Perkins

dealer or your Perkins  distributor.

Disconnection of Actuator position

sensor harness.

(continued)

This document is printed from SPI². Not for RESALE

 

28

SEBU9064

Engine Diagnostics

Diagnostic Flash Code Retrieval

(Table 7, contd)

04

Actuator drive malfunction.

Disconnection of Speed sensor

connector.

The engine will shut down.

Check harness connection. If the

fault remains contact your Perkins

dealer or your Perkins  distributor.

Disconnection of Speed sensor

harness.

15

Speed sensor malfunction.

Disconnection of Speed sensor

connector.

The engine will go into limp home   Check harness connection. If the

mode.

fault remains contact your Perkins

dealer or your Perkins  distributor.

Disconnection of Speed sensor

harness.

(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 Perkins  dealer or your

Perkins  distributor.

This document is printed from SPI². Not for RESALE

 

SEBU9064

29

Engine Starting

Before Starting Engine

Engine Starting

i05339804

Starting the Engine

i04053911

Before Starting Engine

Perform the required daily maintenance and other

periodic maintenance before the engine is started.

Inspect the engine compartment. This inspection can

help prevent major repairs at a later date. Refer to the

Operation and Maintenance Manual, “Maintenance

Interval Schedule” for more information.

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.

•   Ensure that the engine has an adequate fuel

supply.

1. Disengage any equipment that is driven by the

engine.

•   Open the fuel supply valve (if equipped).

If the engine has not been started for several weeks,

fuel may have drained from the fuel system. Air may

have entered the filter housing. Also, when fuel filters

have been changed, some air pockets will be trapped

in the engine. In these instances, prime the fuel

system. Refer to the Operation and Maintenance

Manual, “Fuel System - Prime” for more information

on priming the fuel system. Also, check that the fuel

specification is correct and that the fuel condition  is

correct. Refer to the Operation and Maintenance

Manual, “Fuel Recommendations”.

2. Turn the keyswitch to the RUN position. Check that

the multi function lamp on the ECM.

3. If the lamp flashes once only, the engine can be

started normally. If the lamp flashes again, then a

fault has been detected. Refer to this Operation

and Maintenance Manual, “Diagnostic Flash Code

Retrieval” for more information.

4. During cold weather the keyswitch will need to be

in the run position for a time period in order to allow

the glow plug operation. Some systems will have a

wait to start lamp. The wait to start lamp must be

extinguished before starting the engine. Refer to

the original equipment manufacture for information

on how to start an engine in cold weather.

Engine exhaust contains products of combustion

which may be harmful to your health. Always start

and operate  the engine  in a well  ventilated area

and, if in an enclosed area, vent the exhaust to the

outside.

Note: The ambient weather condition will determine

the amount of time the glow plugs will require. If the

engine is warm, heat from the glow plugs will not be

required to start the engine.

•   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.

NOTICE

Do not  engage the  starting motor  when flywheel  is

turning. Do not start the engine under load.

•   Reset all of the shutoffs or alarm components.

•   Ensure that any driven equipment has been

disengaged. Minimize electrical loads or remove

any electrical loads.

If the engine fails  to start within 30 seconds, release

the starter switch or button and wait two minutes to al-

low  the starting  motor to  cool  before attempting  to

start the engine again.

5. Turn the keyswitch in order to operate the starter

motor, and allow the engine to crank. After the

engine has started, allow the keyswitch to return to

the RUN position.

This document is printed from SPI². Not for RESALE

 

30

SEBU9064

Engine Starting

Starting with Jump Start Cables

i05339814

5. Immediately after the engine is started, disconnect

the jump-start cables in reverse order.

Starting with Jump Start

Cables

After jump starting, the alternator may not be able to

fully recharge 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.

i01903609

Improper jump start cable connections can cause

an explosion resulting in personal injury.

After Starting Engine

Prevent sparks  near the  batteries. Sparks  could

cause vapors to explode. Do not allow jump start

cable ends to contact each other or the engine.

Note: In temperatures from 0 to 60°C  (32 to 140°F),

the warm-up time is approximately three minutes. In

temperatures below 0°C (32°F), additional warm-up

time may be required.

NOTICE

Using a battery source with  the same voltage as the

electric starting  motor. Use  ONLY equal  voltage for

jump starting. The use of higher  voltage will damage

the electrical system.

When the engine idles during warm-up, observe the

following conditions:

•   Check for any fluid or for any air leaks at idle rpm

and at one-half full rpm (no load on the engine)

before operating the engine under load. This is not

possible in some applications.

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 start cables.

•   Operate the engine at low idle until all systems

achieve operating temperatures. Check all gauges

during the warm-up period.

Ensure that the main power switch is in the OFF posi-

tion before attaching the jump start cables  to the en-

gine being started.

Note: Gauge readings should be observed and the

data should be recorded frequently while the engine

is operating. Comparing the data over time will help to

determine normal readings for each gauge.

1. Turn the start switch on the stalled engine to the

Comparing data over time will also help detect

abnormal operating developments. Significant

changes in the readings should be investigated.

OFF position. Turn off all the engines accessories.

2. Connect one positive end of the jump-start cable to

the positive cable terminal of the discharged

battery. Connect the other positive end of the jump-

start cable to the positive cable terminal of the

electrical source.

3. Connect one negative end of the jump-start cable

to the negative cable terminal of the electrical

source. Connect the other negative end of the

jump-start cable to the engine block or to the

chassis ground. This procedure helps to prevent

potential sparks from igniting the combustible

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”.

This document is printed from SPI². Not for RESALE

 

SEBU9064

31

Engine Operation

Engine Operation

Engine Operation

•   Be aware of the properties of the different fuels.

Use only the recommended fuels. Refer to the

Operations and Maintenance Manual, “Fuel

Recommendations”for further information.

i05339869

Engine Operation

•   Avoid unnecessary idling.

Shut off the engine rather than idle for long periods of

time.

General Engine Operation

•   Observe the service indicator frequently. Keep the

air cleaner elements clean.

Correct operation and maintenance are key factors in

obtaining the maximum life and economy of the

engine. If the directions in the Operation and

•   Maintain a good electrical system.

Maintenance Manual are followed, costs can be

One faulty battery cell will overwork the alternator.

This fault will consume excess power and excess

fuel.

minimized and engine service life can be maximized.

Check that there are no flash codes active. Refer to

this Operation and Maintenance Manual, “Diagnostic

Flash Code Retrieval” for more information.

•   The belt should be in good condition.

The engine can be operated at the rated rpm after the

engine reaches operating temperature. The engine

will reach normal operating temperature sooner

during a low engine speed (rpm) and during a low-

power demand. This procedure is more effective than

idling the engine at no load. The engine should reach

operating temperature in a few minutes.

•   Ensure that all of the connections of the hoses are

tight. The connections should not leak.

•   Ensure that the driven equipment is in good

working order.

•   Cold engines consume 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.

Gauge readings should be observed and the data

should be recorded frequently while the engine is

operating. Comparing the data over time will help to

determine normal readings for each gauge.

Comparing data over time will also help detect

abnormal operating developments. Significant

changes in the readings should be investigated.

Engine Operation and Altitude

In accordance with emissions regulation of the United

States Environmental Protection Agency the engine

power and emission will be reduced the higher the

altitude that the engine is operated.

i05339949

Fuel ConservationPractices

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 overflow from the fuel tank. Inspect fuel lines for

leaks. Repair the fuel lines, as needed.

This document is printed from SPI². Not for RESALE

 

32

SEBU9064

Cold Weather Operation

Cold Weather Operation

Cold Weather Operation

Hints for Cold Weather Operation

•   If the engine will start, operate the engine until a

minimum operating temperature of 80° C  (176° F)

is achieved. Achieving operating temperature will

help prevent the intake valves and exhaust valves

from sticking.

i05339996

Cold Weather Operation

•   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.

Perkins  Diesel Engines can operate effectively in

cold weather. During cold weather, the starting and

the operation of the diesel engine is dependent on the

following items:

•   The type of fuel that is used

•   The viscosity of the engine oil

•   The operation of the glow plugs

•   Battery condition

•   Install the correct specification of engine lubricant

before the beginning of cold weather. Refer to this

Operation and Maintenance Manual, “Fluid

Recommendations” for the recommended

viscosity of oil.

•   Check all rubber parts (hoses, fan drive belts,)

weekly.

This section will cover the following information:

•   Potential problems that are caused by cold-

weather operation

•   Check all electrical wiring and connections for any

fraying or damaged insulation.

•   Suggest steps which can be taken in order to

minimize starting problems and operating

problems when the ambient air temperature is

between 0° to−40 °C (32° to 40 °F).

•   Keep all batteries fully charged and warm by

ensuring that the engine is allowed to operated at

normal operating temperature.

•   Fill the fuel tank at the end of each shift.

The operation and maintenance of an engine in

freezing temperatures is complex . This complexity is

because of the following conditions:

•   Check the air cleaners and the air intake daily.

Check the air intake more often when you operate

in snow.

•   Weather conditions

•   Engine applications

•   Ensure that the glow plugs are in working order.

Recommendations from your Perkins dealer or your

Perkins  distributor are based on past proven

practices. The information that is contained in this

section provides guidelines for cold-weather

operation.

Personal  injury  or  property damage  can  result

from alcohol or starting fluids.

Alcohol  or starting  fluids  are  highly  flammable

and toxic and if improperly stored could result in

injury or property damage.

Do not use aerosol types of starting aids such as

ether. Such use  could result in an explosion and

personal injury.

•   For jump starting with cables in cold weather, refer

to the Operation and Maintenance Manual,

“Starting with Jump Start Cables.” for instructions.

This document is printed from SPI². Not for RESALE

 

SEBU9064

33

Cold Weather Operation

Cold Weather Operation

Viscosity of the Engine Lubrication

Oil

When the engine is operated below normal operating

temperatures, fuel and oil are not completely 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.

Correct engine oil viscosity is essential. Oil viscosity

affects lubrication properties and wear protection that

the oil provides for the engine. Refer to this Operation

and Maintenance Manual, “Fluid Recommendations”

for the recommended viscosity of oil.

When starting and stopping an engine many times

without being operated in order to warm up

completely, the carbon deposits become thicker. This

starting and stopping can cause the following

problems:

Recommendationsfor the Coolant

Provide cooling system protection for the lowest

expected outside temperature. Refer to this

Operation and Maintenance Manual, “Fluid

Recommendations” for the recommended coolant

mixture.

•   Valves become stuck.

•   Pushrods may become bent.

In cold weather, check the coolant often for the

correct glycol concentration in order to ensure

adequate freeze protection.

•   Other damage to valve train components can

result.

When an engine is started, the engine must be

operated until the coolant temperature is 80° C

(176° F) minimum. Carbon deposits on the valve

stems will be kept at a minimum and the free

operation of the valves and the valve components will

be maintained.

Engine Block Heaters

Engine block heaters (if equipped) heat the engine

jacket water that surrounds the combustion

chambers. This heat provides the following functions:

•   Startability is improved.

•   Warm up time is reduced.

The engine must be thoroughly warmed in order to

keep other engine parts in better condition. The

service life of the engine will be generally extended.

Lubrication will be improved. There will be less acid

and less sludge in the oil. This condition will provide

longer service life for the engine bearings, the piston

rings, and other parts. However, limit unnecessary

idle time to 10 minutes in order to reduce wear and

unnecessary fuel consumption.

An electric block heater can be activated once the

engine is stopped. A block heater can be 110 V dc or

240 V dc. The output can be 750/1000W. Consult

your Perkins dealer or your Perkins distributor for

more information.

Idling the Engine

The Water Temperature Regulator and

Insulated Heater Lines

When idling after the engine is started in cold

weather, increase the engine rpm from 1000 to 1200

rpm. This idling will warm up the engine more quickly.

Maintaining an elevated low idle speed for extended

periods will be easier with the installation of a hand

throttle. The engine should not be “raced” in order to

speed up the warm-up process.

The engine is equipped with a water temperature

regulator. When the engine coolant is below the

correct operating temperature, jacket water circulates

through the engine cylinder block and into the engine

cylinder head. The coolant then returns to the cylinder

block via an internal passage that bypasses the valve

of the coolant temperature regulator. This return

ensures that coolant flows around the engine under

cold operating conditions. The water temperature

regulator begins to open when the engine jacket

water has reached the correct minimum operating

temperature. As the jacket water coolant temperature

rises above the minimum operating temperature, the

water temperature regulator opens further allowing

more coolant through the radiator to dissipate excess

heat.

While the engine is idling, the application of a light

load (parasitic load) will assist in achieving the

minimum operating temperature. The minimum

operating temperature is 80° C (176° F).

Recommendationsfor 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 operation in very

cold temperature conditions, damage to engine valve

mechanisms can result from engine operation for

short intervals. This damage can happen if the engine

is started and the engine is stopped many times

without being operated in order to warm up

completely.

The progressive opening of the water temperature

regulator operates the progressive closing of the

bypass passage between the cylinder block and

head. This action ensures maximum coolant flow to

the radiator in order to achieve maximum heat

dissipation.

This document is printed from SPI². Not for RESALE

 

34

SEBU9064

Cold Weather Operation

Fuel and the Effect from Cold Weather

Note: Do not restrict the air flow. Restriction of the air

flow can damage the fuel system. Perkins

discourages the use of all air flow restriction devices

such as radiator shutters. Restriction of the air flow

can result in the following: high exhaust

Note: Group 2 fuels must have a maximum wear scar

of 650 micrometers (HFRR 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.

temperatures, power loss, excessive fan usage and

reduction in fuel economy.

When Group 2 diesel fuels are used, the following

components provide a means of minimizing problems

in cold weather:

A cab heater is beneficial in very cold weather. The

feed from the engine and the return lines from the cab

should be insulated in order to reduce heat loss to the

outside air.

•   Glow plugs

Recommendationfor Crankcase Breather

Protection

•   Engine coolant heaters, which may be an Original

Equipment Manufacture (OEM) option

•   Fuel heaters, which may be an OEM option

Crankcase ventilation gases contain a large quantity

of water vapor. This water vapor can freeze in cold

ambient conditions and can plug or damage the

crankcase ventilation system. If the engine is

operated in temperatures below −25° C  (−13° F),

measures must be taken to prevent freezing and

plugging of the breather system. In extreme weather

conditions insulating the breather hose will help to

protect the system.

•   Fuel line insulation, which may be an OEM option

There are three major differences between Group 1

fuels and Group 2 fuels. Group 1 fuels have the

following different characteristics to Group 2 fuels.

•   A lower cloud point

•   A lower pour point

Consult with your Perkins  dealer or your Perkins

distributor for the recommended breather

components for operation from −25° to -40°C

(−13° to -72.°F).

•   A higher energy per unit volume of fuel

Note: Group 3 fuels reduce the life of the engine. The

use of Group 3 fuels is not covered by the Perkins

warranty.

i05340086

Fuel and the Effect from Cold

Weather

Group 3 fuels include Low Temperature Fuels and

Aviation Kerosene Fuels .

Special fuels include Biofuel .

The cloud point is a temperature that allows wax

crystals to form in the fuel. These crystals can cause

the fuel filters to plug.

Note: Only use grades of fuel that are recommended

by Perkins . Refer to this Operation and Maintenance

Manual, “Fluid Recommendations”.

The pour point is the temperature when diesel fuel will

thicken. The diesel fuel becomes more resistant to

flow through fuel lines, fuel filters, and fuel pumps.

The following fuels can be used in this series of

engine.

Be aware of these facts when diesel fuel is

•   Group 1

purchased. Consider the average ambient air

temperature for the engines application. Engines that

are fueled in one climate may not operate well if the

engines are moved t, o another climate. Problems can

result due to changes in temperature.

•   Group 2

•   Group 3

•   Special Fuels

Before troubleshooting for low power or for poor

performance in the winter, check the fuel for waxing.

Perkins  prefer only Group 1 and Group 2 fuels for

use in this series of engines.

Low temperature fuels may be available for engine

operation at temperatures below 0 °C  (32 °F). These

fuels limit the formation of wax in the fuel at low

temperatures.

Group 1 fuels are the preferred group of fuels for

general use by Perkins . Group 1 fuels maximize

engine life and engine performance. Group 1 fuels

are usually less available than Group 2 fuels.

Frequently, Group 1 fuels are not available in colder

climates during the winter.

For more information on cold-weather operation, refer

to the Operation and Maintenance Manual, “Cold

Weather Operation and Fuel Related Components in

Cold Weather”.

This document is printed from SPI². Not for RESALE

 

SEBU9064

35

Cold Weather Operation

Fuel Related Components in Cold Weather

i05200880

Fuel Related Components in

Cold Weather

Fuel Tanks

Condensation can form in partially filled fuel tanks.

Top off the fuel tanks after you operate the engine.

Fuel tanks should contain some provision for draining

water and sediment from the bottom of the tanks.

Some fuel tanks use supply pipes that allow water

and sediment to settle below the end of the fuel

supply pipe.

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.

Drain the water and sediment from any fuel storage

tank at 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 order to remove air bubbles

from the fuel system. Refer to the Operation and

Maintenance Manual in the Maintenance Section for

more information on priming the fuel system.

Fuel Heaters

Fuel heaters help to prevent fuel filters from plugging

in cold weather due to waxing.

For further information on fuel heaters, consult your

Perkins  dealer or distributor.

This document is printed from SPI². Not for RESALE

 

36

SEBU9064

Engine Stopping

Stopping the Engine

Engine Stopping

i03756631

After Stopping Engine

i02334873

Stopping the Engine

Note: Before you check the engine oil, do not operate

the engine for at least 10 minutes in order to allow the

engine oil to return to the oil pan.

NOTICE

•   Check the crankcase oil level. Maintain the oil level

between the “MIN”  mark and the “MAX”  mark on

the engine oil level gauge.

Stopping  the engine  immediately  after it  has  been

working under load, can result in overheating and ac-

celerated wear of the engine components.

•   If necessary, perform minor adjustments. Repair

any leaks and tighten any loose bolts.

Avoid  accelerating  the  engine  prior   to  shutting  it

down.

•   If the engine is equipped with a service hour meter,

note the reading. Perform the maintenance that is

in the Operation and Maintenance Manual,

“Maintenance Interval Schedule”.

Avoiding hot  engine shutdowns will maximize  turbo-

charger shaft and bearing life.

Note: Individual applications will have different

control systems. Ensure that the shutoff procedures

are understood. Use the following general guidelines

in order to stop the engine.

•   Fill the fuel tank in order to help prevent

accumulation of moisture in the fuel. Do not overfill

the fuel tank.

1. Remove the load from the engine. Reduce the

engine speed (rpm) to low idle. Allow the engine to

idle for five minutes in order to cool the engine.

NOTICE

Only  use antifreeze/coolant  mixtures recommended

in the  Refill Capacities and  Recommendations topic

that  is in  this  Operation and  Maintenance  Manual.

Failure to do so can cause engine damage.

2. Stop the engine after the cool down period

according to the shutoff system on the engine and

turn the ignition key switch to the OFF position. If

necessary, refer to the instructions that are

provided by the OEM.

•   Allow the engine to cool. Check the coolant level.

•   If freezing temperatures are expected, check the

coolant for correct antifreeze protection. The

cooling system must be protected against freezing

to the lowest expected outside temperature. Add

the correct coolant/water mixture, if necessary.

i01903586

Emergency Stopping

•   Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in

the instructions from the OEM.

NOTICE

Emergency  shutoff  controls  are  for  EMERGENCY

use ONLY. DO  NOT use emergency shutoff  devices

or controls for normal stopping procedure.

The OEM may have equipped the application with an

emergency stop button. For more information about

the emergency stop button, 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.

This document is printed from SPI². Not for RESALE

 

SEBU9064

37

Maintenance Section

Refill Capacities

Maintenance Section

Refill Capacities

(Table 9, contd)

(1)

These values are the approximate capacities for the crankcase

oil sump which includes the standard factory installed oil filters.

Engines with auxiliary oil filters will require additional oil. Refer

to the OEM specifications for the capacity of the auxiliary oil

filter.

(2)

The Total Lubrication System includes the capacity for the

Crankcase Oil Sump plus the capacity of factory installed oil fil-

ters and other filters added to the lubrication system. Enter the

value for the capacity of the Total Lubrication System in this row.

i05335983

Refill Capacities

403F-11  Engine

LubricationSystem

Table 10

403F-11 Engine

Refill Capacities

The refill capacities for the engine crankcase reflect

the approximate capacity of the crankcase or sump

plus standard oil filters. Auxiliary oil filter systems will

require additional oil. Refer to the OEM specifications

for the capacity of the auxiliary oil filter. Refer to the

Operation and Maintenance Manual, “Maintenance

Section” for more information on Lubricant

Specifications.

Compartment or System

Minimum

Maximum

3.4 L

(3.6 qt)

4.4 L

(4.7 qt)

Crankcase Oil Sump(1)

Total Lubrication System(2)

(1)

These values are the approximate capacities for the crankcase

oil sump which includes the standard factory installed oil filters.

Engines with auxiliary oil filters will require additional oil. Refer

to the OEM specifications for the capacity of the auxiliary oil

filter.

402F-05 Engine

Table 8

(2)

The Total Lubrication System includes the capacity for the

Crankcase Oil Sump plus the capacity of factory installed oil fil-

ters and other filters added to the lubrication system. Enter the

value for the capacity of the Total Lubrication System in this row.

402F-05 Engine

Refill Capacities

Compartment or System

Minimum

Maximum

1.61 L

(1.7 qt)

2.01 L

(2.1 qt)

403F-15 Engines

Crankcase Oil Sump(1)

Table 11

Total Lubrication System(2)

403F-15 Engines

Refill Capacities

(1)

These values are the approximate capacities for the crankcase

oil sump which includes the standard factory installed oil filters.

Engines with auxiliary oil filters will require additional oil. Refer

to the OEM specifications for the capacity of the auxiliary oil

filter.

The Total Lubrication System includes the capacity for the

Crankcase Oil Sump plus the capacity of factory installed oil fil-

ters and other filters added to the lubrication system. Enter the

value for the capacity of the Total Lubrication System in this row.

Compartment or System

Minimum

Maximum

4.5 L

(4.8 qt)

6 L

(6.3 qt)

(2)

Crankcase Oil Sump(1)

Total Lubrication System(2)

(1)

These values are the approximate capacities for the crankcase

oil sump which includes the standard factory installed oil filters.

Engines with auxiliary oil filters will require additional oil. Refer

to the OEM specifications for the capacity of the auxiliary oil

filter.

403F-07 Engine

Table 9

(2)

The Total Lubrication System includes the capacity for the

Crankcase Oil Sump plus the capacity of factory installed oil fil-

ters and other filters added to the lubrication system. Enter the

value for the capacity of the Total Lubrication System in this row.

403F-07 Engine

Refill Capacities

Compartment or System

Minimum

Maximum

Cooling System

2.35 L

(2.5 qt)

3.05 L

(3.2 qt)

Crankcase Oil Sump(1)

To maintain the cooling system, the Total Cooling

System capacity must be known. The approximate

capacity is for the engine cooling system. External

System capacities will vary among applications. Refer

to the OEM specifications for the External System

capacity. This capacity information will be needed in

order to determine the amount of coolant that is

required for the Total Cooling System.

Total Lubrication System(2)

(continued)

This document is printed from SPI². Not for RESALE

 

38

SEBU9064

Refill Capacities

Fluid Recommendations

402F-05 Engine

403F-15 Engines

Table 12

Table 15

402F-05 Engine

Refill Capacities

403F-15 Engines

Refill Capacities

Compartment or System

Liters

Quarts

Compartment or System

Liters

Quarts

Engine Only

1.1

1.2

Engine Only

2.6

2.7

External System Per OEM(1)

Total Cooling System(2)

External System Per OEM(1)

Total Cooling System(2)

(1)

The External System includes 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.

(1)

The External System includes 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.

(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.

(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-07 Engine

i05339080

Fluid Recommendations

Table 13

403F-07 Engine

Refill Capacities

General Coolant Information

Compartment or System

Liters

Quarts

Engine Only

1.2

1.3

NOTICE

Never add coolant  to an overheated engine.  Engine

damage could result. Allow the engine to cool first.

External System Per OEM(1)

Total Cooling System(2)

(1)

The External System includes 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.

NOTICE

If the engine is to be stored in, or shipped to an  area

with below freezing temperatures, the cooling system

must be either protected to the lowest outside temper-

ature or drained completely to prevent damage.

(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-11  Engine

NOTICE

Frequently check the specific gravity of the coolant for

proper freeze protection or for anti-boil protection.

Table 14

403F-11 Engine

Refill Capacities

Clean the cooling system for the following reasons:

•   Contamination of the cooling system

•   Overheating of the engine

Compartment or System

Liters

Quarts

Engine Only

1.9

2.0

External System Per OEM(1)

Total Cooling System(2)

•   Foaming of the coolant

(1)

The External System includes 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.

NOTICE

Never operate  an engine without  water temperature

regulators in the  cooling system. Water  temperature

regulators help to maintain the  engine coolant at the

proper operating temperature.  Cooling system prob-

(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.

lems

can

develop

without

water

temperature

regulators.

This document is printed from SPI². Not for RESALE

 

SEBU9064

39

Refill Capacities

Fluid Recommendations

Many engine failures are related to the cooling

system. The following problems are related to cooling

system failures: Overheating, leakage of the water

pump and plugged radiators or heat exchangers.

•   Corrosion

•   Formation of mineral deposits

•   Rust

These failures can be avoided with correct cooling

system maintenance. Cooling system maintenance is

as important as maintenance of the fuel system and

the lubrication system. Quality of the coolant is as

important as the quality of the fuel and the lubricating

oil.

•   Scale

•   Foaming of the coolant

Many additives are depleted during engine operation.

These additives must be replaced periodically.

Coolant is normally composed of three elements:

Water, additives and glycol.

Additives must be added at the correct concentration.

Over concentration of additives can cause the

inhibitors to drop out-of-solution. The deposits can

enable the following problems to occur:

Water

Water is used in the cooling system in order to

transfer heat.

•   Formation of gel compounds

•   Reduction of heat transfer

Distilled water or deionized water is

recommended for use in engine cooling systems.

•   Leakage of the water pump seal

•   Plugging of radiators, coolers, and small passages

DO NOT use the following types of water in cooling

systems: Hard water, softened water that has been

conditioned with salt and sea water.

Glycol

If distilled water or deionized water is not available,

use water with the properties that are listed in Table

16 .

Glycol in the coolant helps to provide protection

against the following conditions:

Table 16

•   Boiling

Acceptable Water

Property

Maximum Limit

40 mg/L

•   Freezing

Chloride (Cl)

•   Cavitation of the water pump

Sulfate (SO4)

Total Hardness

Total Solids

Acidity

100 mg/L

For optimum performance, Perkins  recommends a

1:1 mixture of a water/glycol solution.

170 mg/L

Note: Use a mixture that will provide protection

against the lowest ambient temperature.

340 mg/L

pH of 5.5 to 9.0

Note: 100 percent pure glycol will freeze at a

temperature of −23 °C (−9 °F).

For a water analysis, consult one of the following

sources:

Most conventional antifreezes use ethylene glycol.

Propylene glycol may also be used. In a 1:1 mixture

with water, ethylene and propylene glycol provide

similar protection against freezing and boiling. Refer

to Table 17 and refer to table 18 .

•   Local water utility company

•   Agricultural agent

•   Independent laboratory

Table 17

Ethylene Glycol

Additives

Concentration

50 Percent

Freeze Protection

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:

−36 °C (−33 °F)

60 Percent

−51 °C (−60 °F)

This document is printed from SPI². Not for RESALE

 

40

SEBU9064

Refill Capacities

Fluid Recommendations

Table 19

NOTICE

Do not use propylene glycol in concentrations that ex-

ceed 50 percent glycol  because of the reduced heat

transfer capability of  propylene glycol. Use  ethylene

glycol in  conditions that require additional protection

against boiling or freezing.

Coolant Service Life

Service Life  (1)

Coolant Type

6,000 Service Hours or Three

Years

Perkins  ELC

Commercial Heavy-Duty Anti-

freeze that meets ASTM

D6210

Table 18

3000 Service Hours or Two Years

Propylene Glycol

A Perkins approved SCA

inhibitor

3000 Service Hours or Two Years

Concentration

Freeze Protection

50 Percent

−29 °C (−20 °F)

(1)

Use the interval that occurs first. The cooling system must also

be flushed out at this time.

To check the concentration of glycol in the coolant,

measure the specific gravity of the coolant.

ELC

Perkins  provides ELC for use in the following

applications:

Coolant Recommendations

•   ELC

•   SCA

•   ASTM

Extended Life Coolant

Supplement Coolant Additive

American Society for Testing and

•   Heavy-duty spark ignited gas engines

•   Heavy-duty diesel engines

•   Automotive applications

Materials

The anti-corrosion package for ELC is different from

the anti-corrosion package for other coolants. ELC is

an ethylene glycol base coolant. However, ELC

contains organic corrosion inhibitors and antifoam

agents with low amounts of nitrite. Perkins ELC has

been formulated with the correct amount of these

additives in order to provide superior corrosion

protection for all metals in engine cooling systems.

The following two coolants are used in Perkins

diesel engines:

Preferred – Perkins  ELC

Acceptable – A commercial heavy-duty antifreeze

that meets ASTM D6210 specifications

ELC is available in a premixed cooling solution with

distilled water. ELC is a 1:1 mixture. The Premixed

ELC provides freeze protection to −36 °C  (−33 °F).

The Premixed ELC is recommended for the initial fill

of the cooling system. The Premixed ELC is also

recommended for topping off the cooling system.

NOTICE

The  400F  industrial  engines  must  be operated

with a 1:1 mixture of water and glycol.

Containers of several sizes are available. Consult

your Perkins  distributor for the part numbers.

NOTICE

Do not use a commercial coolant/antifreeze that only

meets the  ASTM  D3306 specification.  This type  of

coolant/antifreeze   is   made   for   light   automotive

applications.

ELC Cooling System Maintenance

Correct additions to the Extended Life

Coolant

Perkins  recommends a 1:1 mixture of water and

glycol. This mixture 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.

NOTICE

Use only  Perkins products for pre-mixed  or concen-

trated coolants.

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. Distilled water or

deionized water is preferred. Water which has the

recommended properties may be used

Mixing Extended Life Coolant with other products re-

duces the Extended Life  Coolant service life. Failure

to  follow the  recommendations  can reduce  cooling

system components life unless appropriate corrective

action is performed.

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In order to maintain the correct balance between the

antifreeze and the additives, you must maintain the

recommended concentration of ELC. Lowering the

proportion of antifreeze lowers the proportion of

additive. This action will lower the ability of the

coolant to protect the system from pitting, from

cavitation, from erosion, and from deposits.

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. Drain the cleaner into a suitable container. Flush

the cooling system with clean water.

NOTICE

Do not use a conventional coolant to top-off a cooling

system that is filled with Extended Life Coolant (ELC).

6. Fill the cooling system with clean water and

operate the engine until the engine is warmed to

49° to 66°C (120° to 150°F).

Do not  use  standard supplemental  coolant additive

(SCA).

When using Perkins ELC, do not use standard SCA's

or SCA filters.

NOTICE

Incorrect or incomplete flushing of the cooling system

can  result  in  damage  to  copper  and  other  metal

components.

ELC Cooling System Cleaning

To avoid damage to the cooling system, make sure to

completely flush the cooling system with  clear water.

Continue to flush the system until all  the signs of the

cleaning agent are gone.

Note: If the cooling system is already using ELC,

cleaning agents are not required to be used at the

specified coolant change interval. Cleaning agents

are only required if the system has been

contaminated by the addition of some other type of

coolant or by cooling system damage.

7. Drain the cooling system into a suitable container

and flush the cooling system with clean water.

Clean water is the only cleaning agent that is required

when ELC is drained from the cooling system.

Note: The cooling system cleaner must be thoroughly

flushed from the cooling system. Cooling system

cleaner that is left in the system will contaminate the

coolant. The cleaner may also corrode the cooling

system.

8. Repeat Steps 6 and repeat steps 7 until the system

is completely clean.

Before the cooling system is filled, the heater control

(if equipped) must be set to the HOT position. Refer

to the OEM in order to set the heater control. After the

cooling system is drained and the cooling system is

refilled, operate the engine until the coolant level

reaches the normal operating temperature and until

the coolant level stabilizes. As needed, add the

coolant mixture in order to fill the system to the

specified level.

9. Fill the cooling system with the Perkins Premixed

ELC.

Changing to Perkins  ELC

ELC Cooling System Contamination

To change from heavy-duty antifreeze to the Perkins

ELC, perform the following steps:

NOTICE

Mixing ELC with other products reduces the effective-

ness of  the ELC and  shortens the  ELC service life.

Use only  Perkins Products  for premixed or  concen-

trate coolants.  Failure to follow  these recommenda-

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

containers before opening any compartment or disas-

sembling any component containing fluids.

tions

component life.

can   result   in    shortened   cooling   system

ELC cooling systems can withstand contamination to

a maximum of 10 percent of conventional heavy-duty

antifreeze or SCA. If the contamination exceeds 10

percent of the total system capacity, perform ONE of

the following procedures:

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.

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•   Drain the cooling system into a suitable container.

Dispose of the coolant according to local

regulations. Flush the system with clean water. Fill

the system with the Perkins  ELC.

Table 20

Equation For Adding The SCATo The Heavy-Duty Coolant At

The Initial Fill

V × 0.045 = X

•   Drain a portion of the cooling system into a

suitable container according to local regulations.

Then, fill the cooling system with premixed ELC.

This procedure should lower the contamination to

less than 10 percent.

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Table 21 is an example for using the equation that is

in Table 20 .

•   Maintain the system as a conventional Heavy-Duty

Coolant. Treat the system with an SCA. Change

the coolant at the interval that is recommended for

the conventional Heavy-Duty Coolant.

Table 21

Example Of The Equation For Adding The SCATo The Heavy-

Duty Coolant At The Initial Fill

Total Volume of the

Cooling System (V)

Multiplication

Factor

Amount of SCA

that is Required (X)

Commercial Heavy-Duty Antifreeze and

SCA

15 L (4 US gal)

× 0.045

0.7 L (24 oz)

NOTICE

Commercial   Heavy-Duty  Coolant   which   contains

as  part of  the  corrosion protection  system

Adding The SCA to The Heavy-Duty

Coolant For Maintenance

Amine

must not be used.

Heavy-duty antifreeze of all types REQUIRE periodic

additions of an SCA.

NOTICE

Test the antifreeze periodically for the concentration

of SCA. For the interval, refer to the Operation and

Maintenance Manual, “Maintenance Interval

Schedule” (Maintenance Section). Test the

concentration of SCA.

Never operate  an engine without  water temperature

regulators in the  cooling system. Water  temperature

regulators help to maintain the  engine coolant at the

correct operating temperature. Cooling  system prob-

lems

regulators.

can

develop

without

water

temperature

Additions of SCA are based on the results of the test.

The size of the cooling system determines the

amount of SCA that is needed.

Check the antifreeze (glycol concentration) in order to

ensure adequate protection against boiling or

freezing. Perkins recommends the use of a

refractometer for checking the glycol concentration. A

hydrometer should not be used.

Use the equation that is in Table 22  to determine the

amount of Perkins  SCA that is required, if

necessary:

Table 22

Equation For Adding The SCATo The Heavy-Duty Coolant For

Maintenance

Perkins  engine cooling systems should be tested at

500 hour intervals for the concentration of SCA.

V × 0.014 = X

Additions of SCA are based on the results of the test.

An SCA that is liquid may be needed at 500 hour

intervals.

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Adding the SCA to Heavy-Duty Coolant at

the Initial Fill

Table 23 is an example for using the equation that is

in Table 22 .

Table 23

Commercial heavy-duty antifreeze that meets ASTM

D4985 specifications MAY require an addition of SCA

at the initial fill. Read the label or the instructions that

are provided by the OEM of the product.

Example Of The Equation For Adding The SCATo The Heavy-

Duty Coolant For Maintenance

Total Volume of the

Cooling System (V)

Multiplication

Factor

Amount of SCA

that is Required (X)

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.

15 L (4 US gal)

× 0.014

0.2 L (7 oz)

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Cleaning the System of Heavy-Duty

Antifreeze

Perkins  cooling system cleaners are designed to

clean the cooling system of harmful scale and

corrosion. Perkins  cooling system cleaners dissolve

mineral scale, corrosion products, light oil

contamination, and sludge.

•   Clean the cooling system after used coolant is

drained or before the cooling system is filled with

new coolant.

•   Clean the cooling system whenever the coolant is

contaminated or whenever the coolant is foaming.

Illustration 21

g03383033

Typical API symbol

i05341026

Fluid Recommendations

Terminology

Certain abbreviations follow the nomenclature of SAE

J754. Some classifications follow SAE J183

General Lubricant Information

abbreviations, and some classifications follow the

EMA Recommended Guideline on Diesel Engine Oil.

In addition to Perkins  definitions, there are other

definitions that will be of assistance in purchasing

lubricants. Recommended oil viscosities can be

found in this publication, “Fluid Recommendations/

Engine Oil” topic (Maintenance Section).

Because of government regulations regarding the

certification of exhaust emissions from the engine, the

lubricant recommendations must be followed.

•   API

American Petroleum Institute

Society Of Automotive Engineers Inc.

Association des Constructers

•   SAE

Engine Oil

•   ACEA

Commercial Oils

European Automobiles .

•   ECF

Engine Crankcase Fluid

NOTICE

Perkins require the use of the following specifica-

tion of  engine oil. Failure  to use the  appropriate

specification of  engine oil  will reduce the  life of

your engine.

Licensing

The Engine Oil Licensing and Certification System

by the American Petroleum Institute (API)  and the

Association des Constructers European

Automobilesand (ACRA) is recognized by Perkins .

For detailed 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.

Table 24

Classifications for the 400F IndustrialEngines

Oil Specification

CJ-4

ACEA E9

ECF-3

API CJ-4 and ACEA E9 oil categories have the

following chemical limits:

•   0.1 percent maximum sulfated ash

•   0.12 percent maximum phosphorous

•   0. 4 percent maximum sulfur

The chemical limits were developed in order to

maintain the expected life of the engine.

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Fluid Recommendations

Maintenance intervals for engines that use

biodiesel – The oil change interval can be adversely

affected by the use of biodiesel. Use oil analysis in

order to monitor the condition of the engine oil. Use

oil analysis also in order to determine the oil change

interval that is optimum.

Aftermarket Oil Additives

Perkins  does not recommend the use of aftermarket

additives in oil. 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.

Note: These engine oils are not approved by

Perkins  and these engine oils must not be used:

CC, CD, CD-2, CF-4, CG-4, CH-4 and CI-4.

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 the performance of the finished oil.

The aftermarket additive could fail to mix with the

finished oil. This failure could produce sludge in the

crankcase. Perkins  discourages the use of

Lubricant Viscosity Recommendations

The correct SAE viscosity grade of oil is determined

by the minimum ambient temperature during cold

engine start-up, and the maximum ambient

temperature during engine operation.

Refer to illustration 22 (minimum temperature) in

order to determine the required oil viscosity for

starting a cold engine.

aftermarket additives in finished oils.

To achieve the best performance from a Perkins

engine, conform to the following guidelines:

Refer to illustration 22 (maximum temperature) in

order to select the oil viscosity for engine operation at

the highest ambient temperature that is anticipated.

•   See the appropriate “Lubricant Viscosities”. Refer

to the illustration 22 in order to find the correct oil

viscosity grade for your engine.

Generally, use the highest oil viscosity that is

available to meet the requirement for the temperature

at start-up.

•   At the specified interval, service 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 engines may be equipped with an oil sampling

valve. If oil analysis is required, the oil sampling valve

is used to obtain samples of the engine oil. The oil

analysis will complement the preventive maintenance

program.

The oil analysis is a diagnostic tool that is used to

determine oil performance and component wear

rates. Contamination can be identified and measured

by using oil analysis. The oil analysis includes the

following tests:

Illustration 22

g02932046

Lubricant Viscosities

Supplemental heat is recommended for cold soaked

starts below the minimum ambient temperature.

Supplemental heat may be required for cold soaked

starts that are above the minimum temperature that is

stated, depending on the parasitic load and other

factors. Cold soaked starts occur when the engine

has not been operated for a period of time. This

interval will allow the oil to become more viscous due

to cooler ambient temperatures.

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•   The Wear Rate Analysis monitors the wear of the

engines metals. The amount of wear metal and

type of wear metal that is in the oil is analyzed. The

increase in the rate of engine wear metal in the oil

is as important as the quantity of engine wear

metal in the oil.

NOTICE

These recommendations are subject to  change with-

out notice. Contact your  local Perkins  distributor  for

the most up-to-date recommendations.

The fuel information within this OMM is for use with

the following engine models: 402F-05, 403F-07,

403F-11, and 403F-15

•   Tests are conducted in order to detect

contamination of the oil by water, glycol, or fuel.

•   The Oil Condition Analysis determines the loss of

the oils lubricating properties. An infrared analysis

is used to compare the properties of new oil to the

properties of the used oil sample. This analysis

allows technicians to determine the amount of

deterioration of the oil during use. This analysis

also allows technicians to verify the performance

of the oil according to the specification during the

entire oil change interval.

Diesel Fuel Requirements

Perkins  is not in a position to continuously evaluate

and monitor all worldwide distillate diesel fuel

specifications that are published by governments and

technological societies.

The Perkins table for Specification for Distillate

Diesel Fuel provides a known reliable baseline in

order to judge the expected performance of distillate

diesel fuels that are derived from conventional

sources.

i05341022

Satisfactory engine performance is dependent on the

use of a good quality fuel. The use of a good quality

fuel will give the following results: long engine life and

acceptable exhaust emissions levels . The fuel must

meet the minimum requirements that are stated in the

table 25 .

Fluid Recommendations

•   Glossary

•   ISO International Standards Organization

•   ASTMAmerican Society for Testing and Materials

NOTICE

The footnotes are of the  key part Perkins  Specifica-

tion for Distillate Diesel  Fuel Table. Read ALL of  the

footnotes.

•   HFRRHigh Frequency Reciprocating Rig for

Lubricity  testing of diesel fuels

•   FAMEFatty Acid Methyl Esters

•   CFRCo-ordinating Fuel Research

•   ULSDUltra Low Sulfur Diesel

•   RMERape Methyl Ester

•   SMESoy Methyl Ester

•   EPA Environmental Protection Agency of the

United States

•   PPM Parts Per Million

General Information

NOTICE

Every attempt is made to provide accurate, up-to-date

information. By use  of this document y, ou agree  that

Perkins Engines Company Limited is not responsible

for errors or omissions.

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SEBU9064

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Table 25

Perkins Specification for DistillateDiesel Fuel(1)

Property

UNITS

Requirements

ASTMTest

ISOTest

Aromatics

Ash

%Volume

%Weight

35% maximum

D1319

D482

ISO3837

ISO6245

0.01% maximum

Carbon Residue on 10%

Bottoms

%Weight

0.35% maximum

D524

ISO4262

Cetane Number  (2)

Cloud Point

-

40 minimum

D613/D6890

ISO5165

ISO3015

°C

The cloud point must not ex-  D2500

ceed the lowest expected

ambient temperature.

Copper Strip Corrosion

-

No. 3 maximum

D130

ISO2160

Density at 15 °C (59 °F)(3)   Kg / M

3

801 minimum and 876

maximum

No equivalent test

ISO 3675ISO 12185

ISO3405

Distillation

°C

10% at 282 °C (539.6 °F)

maximum

D86

90% at 360 °C (680 °F)

maximum

Flash Point

°C

-

legal limit

D93

ISO2719

Thermal Stability

Minimum of 80% reflectance D6468

after aging for 180 minutes

at 150 °C (302 °F)

No equivalent test

Pour Point

°C

6 °C (42.8 °F) minimum be-  D97

low ambient temperature

ISO3016

Sulfur  (1)

%mass

0.0015

D5453/D26222

ISO 20846ISO 20884

ISO3405

Kinematic Viscosity  (4)

2

“MM” “/S (cSt)”

The viscosity of the fuel that D445

is delivered to the fuel injec-

tion pump. “1.4 minimum/

4.5 maximum”

Water and sediment

Water

% weight

% weight

% weight

mg/100mL

0.1% maximum

0.1% maximum

0.05% maximum

D1796

D1744

D473

ISO3734

No equivalent test

ISO3735

Sediment

Gums and Resins  (5)

10 mg per 100 mL

maximum

D381

ISO6246

Lubricity corrected wear

mm

0.52 maximum

D6079

ISO12156-1

scar diameter at 60 °C

(140 °F).  (6)

(1)

This specification 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)

(3)

A fuel with a higher cetane number is recommended in order to operate at a higher altitude or in cold weather.

“Via standards tables, the equivalent API  gravity for the minimum density of 801 kg / m  (kilograms per cubic meter) is 45 and for the maximum

3

density of 876 kg / m is 30”.

3

(4)

The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. Fuel should also meet the minimum viscosity

requirementand the fuel should meet the maximum viscosity requirements at 40 °C  (104 °F) of either the ASTM D445 test method or the ISO

3104 test method. If a fuel with a low viscosity is used, cooling of the fuel may be required to maintain “1.4 cSt”or greater viscosity at the fuel in-

jection pump. Fuels with a high viscosity might require fuel heaters in order to lower the viscosity to “1.4 cSt” at the fuel injection pump.

Follow the test conditions and procedures for gasoline (motor).

The lubricity of a fuel is a concern with ultra low sulfur fuel. To determine the lubricity of the fuel, use the ISO 12156-1 or ASTM D6079 High

Frequency Reciprocating Rig (HFRR) test. If the lubricity of a fuel does not meet the minimum requirements, consult your fuel supplier. Do not

treat the fuel without consulting the fuel supplier. Some additives are not compatible. These additives can cause problems in the fuel system.

(5)

(6)

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Engines that are manufactured by Perkins  are

certified with the fuel that is prescribed by the United

States Environmental Protection Agency. Engines

that are manufactured by Perkins are certified with

the fuel that is prescribed by the European

Certification. Perkins does not certify diesel engines

on any other fuel.

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, poor  combustion,  deposits in  the  fuel

injectors, reduced service life of  the fuel system, de-

posits in the combustion chamber and reduced  serv-

ice life of the engine.

The Perkins 400F diesel engines must be operated

using Ultra Low Sulfur Diesel. The sulphur content of

this fuel must be lower than 15 PPM. This fuel

complies with the emissions regulations that are

prescribed by the Environmental Protection Agency

of the United States

The fuels that are listed in the table 26  are

acceptable to use on all 400F engines.

Table 26

Acceptable Fuel Specification for the 400F Engines(1)

Fuel Specification

EN590

Comments

European Automotive Diesel 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

JIS K2204

“North American Middle Distillate general purpose Diesel fuel with less

than 15 PPM sulfur level”

“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 MUST have less than

10 PPM sulfur level”

(1)

All the fuels must comply with the specification in the table for the Perkins Specification DistillateDiesel Fuel .

Diesel Fuel Characteristics

Cetane numbers in excess of 45 are normally

expected from current diesel fuel. However, a cetane

number of 40 may be experienced in some territories.

The United States of America is one of the territories

that can have a low cetane value. A minimum cetane

value of 40 is required during average starting

conditions. A fuel with higher cetane number is

recommended for operations at high altitudes or in

cold-weather operations.

Cetane Number

Fuel that has a high cetane number will give a shorter

ignition delay. A high cetane number will produce a

better ignition quality. Cetane numbers are derived for

fuels against proportions of cetane and

heptamethylnonane  in the standard CFR engine.

Refer to ISO 5165 for the test method.

Fuel with a low cetane number can be the root cause

of problems during a cold start.

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Viscosity

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 inch). The

fuel lubricity test must be performed on an HFRR,

operated at 60 °C (140 °F). Refer to ISO 12156-1.

Viscosity is the property of a liquid of offering

resistance to shear or flow. Viscosity decreases with

increasing temperature. This decrease in viscosity

follows a logarithmic relationship for normal fossil

fuel. The common reference is to kinematic viscosity.

kinematic viscosity is the quotient of the dynamic

viscosity that is divided by the density. The

determination of kinematic viscosity is normally by

readings from gravity flow viscometers at standard

temperatures. Refer to ISO 3104 for the test method.

Lubricity

Lubricity is the capability of the fuel to prevent pump

wear. The fluids lubricity describes the ability of the

fluid to reduce the friction between surfaces that are

under load. This ability reduces the damage that is

caused by friction. Fuel injection systems rely on the

lubricating properties of the fuel. Until fuel sulfur limits

were mandated, the fuels lubricity was generally

believed  to be a function of fuel viscosity.

The viscosity of the fuel is significant because fuel

serves as a lubricant for the fuel system components.

Fuel must have sufficient viscosity in order 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 fuel injection pump, damage to the fuel injection

pump can occur. This damage can be excessive

scuffing and seizure. Low viscosity may lead to

difficult hot restarting, stalling, and loss of

The lubricity has particular significance to the current

low viscosity fuel , low sulfur fuel, and low aromatic

fossil  fuel. These fuels are made in order to meet

stringent exhaust emissions. A test method for

measuring the lubricity of diesel fuels has been

developed and the test is based on the HFRR method

that is operated at 60°C (140°F). Refer to ISO 12156

part 1 and CEC document F06-A-96 for the test

method.

performance. High viscosity may result in seizure of

the pump.

Perkins  recommends kinematic viscosities of 1.4 and

4.5 mm2/sec that is delivered to the fuel injection

pump. If a fuel with a low viscosity is used, cooling 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 in order to

lower the viscosity to 4.5 cSt at the fuel injection

pump.

Lubricity wear scar diameter of 0.52 mm

(0.0205 inch) MUST NOT be exceeded. The fuel

lubricity test must be performed on an HFRR,

operated at 60 °C (140 °F). Refer to ISO 12156-1.

Distillation

Density

Distillation is an indication of the mixture of different

hydrocarbons in the fuel. A high ratio of light weight

hydrocarbons can affect the characteristics of

combustion.

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 influence determines

from a heat output given injected volume of fuel. This

parameter is quoted in the following kg/m at 15 °C

(59 °F).

Recommendation for Biodiesel and Using

B20

Perkins  recommends a value of density of 841 kg/m

in order to obtain the correct power output. Lighter

fuels are acceptable but these fuels will not produce

the rated power.

Biodiesel is a fuel that can be defined as mono-alkyl

esters of fatty acids . Biodiesel is a fuel that can be

made from various feedstock. The most commonly

available biodiesel in Europe is Rape Methyl Ester

(REM) . This biodiesel is derived from rapeseed oil .

Soy Methyl Ester (SME) is the most common

biodiesel in the United States. This biodiesel is

derived from soybean oil . Soybean oil or rapeseed

oil  are the primary feedstocks. These fuels are

together known as Fatty Acid Methyl Esters (FAME) .

Sulfur

The level of sulfur is governed by emissions

legislations . Regional regulation, national

regulations, or international regulations 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.

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Raw pressed vegetable oils are NOTacceptable for

use as a fuel in any concentration in compression

engines . Without esterification, these oils solidify in

the crankcase and the fuel tank. These fuels may not

be compatible with many of the elastomers that are

used in engines that are manufactured today. In

original forms, these oils are not suitable for use as a

fuel in compression engines . Alternate base stocks

for biodiesel may include animal tallow, waste

cooking oils , or various other feedstocks. In order to

use any of the products that are listed as fuel, the oil

must be esterified .

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 fuel filters. Perkins

recommend that after the initial usage of B20

biodiesel blended fuel the fuel filters must be replaced

at 50 hours.

Glycerides  present in biodiesel fuel will also cause

fuel filters to become blocked more quickly. Therefore

the regular service interval should be reduced to 250

hours.

Fuel made of 100 percent FAME is generally referred

to as B100 biodiesel or neat biodiesel.

Biodiesel can be blended with distillate diesel fuel.

The blends can be used as fuel. The most commonly

available biodiesel blends are B5, which is 5 percent

biodiesel and 95 percent distillate diesel fuel. B20,

which is 20 percent biodiesel and 80 percent distillate

diesel fuel.

When biodiesel fuel is used, crank case oil may be

influenced. This influence is due to the chemical

composition and characteristics of biodiesel fuel,

such as density and volatility, and to chemical

contaminants that can be present in this fuel, such as

alkali and alkaline metals (sodium, potassium,

calcium, and magnesium).

Note: The percentages given are volume-based.

•   Crankcase oil fuel dilution can be higher when

biodiesel or biodiesel blends are used. This

increased level of fuel dilution when using

biodiesel or biodiesel blends is related to the

typically lower volatility of biodiesel. The long-term

effect of biodiesel concentration in crankcase oil is

currently unknown.

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 not certify engines on any other

fuel. The user of the engine has the responsibility of

using the correct fuel that is recommended by the

manufacturer and allowed by the EPA and other

appropriate regulatory agencies.

•   Perkins  recommend the use of oil analysis in

order to check the quality of the engine oil if

biodiesel fuel is used. Ensure that the level of

biodiesel in the fuel is noted when the oil sample is

taken.

Performance Related Issues

SpecificationRequirements

Due to the lower energy content than the standard

distillate fuel B20 will cause a power loss in order of 2

to 4 percent. In addition, over time the power may

deteriorate further due to deposits in the fuel injectors.

The neat biodiesel must conform to the latest

EN14214 or ASTM D6751 (in the USA). The

biodiesel can only be blended in mixture of up to 20%

by volume in acceptable mineral diesel fuel meeting

latest edition of EN590 or ASTM D975 S15

designation.

Biodiesel and biodiesel blends are known to cause an

increase in fuel system deposits, most significant of

which are deposits within the fuel injector. These

deposits can cause a loss in power due to restricted

or modified fuel injection or cause other functional

issues associated with these deposits.

In United States Biodiesel blends of B6 to B20 must

meet the requirements listed in the latest edition of

ASTM D7467 (B6 to B20) and must be of an API

gravity of 30-45.

Note: Perkins  T400012 Fuel Cleaner is most

effective in cleaning and preventing the formation of

deposits. Perkins  Diesel Fuel Conditioner helps to

limit deposit issues by improving the stability of

biodiesel and biodiesel blends. For more information

refer to “Perkins  Diesel Fuel System Cleaner”.

In North America biodiesel and biodiesel blends must

be purchased from the BQ-9000 accredited

producers and BQ-9000 certified distributors.

In other areas of the world, the use of biodiesel that is

BQ-9000 accredited and certified, or that is

accredited and certified by a comparable biodiesel

quality body to meet similar biodiesel quality

standards is required.

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50

SEBU9064

Refill Capacities

Fluid Recommendations

General Requirements

Aftermarket Fuel Additives

Biodiesel has poor oxidation stability, which can result

in long-term problems in the storage of biodiesel.

Biodiesel fuel should be used within 6 months of

manufacture. Equipment should not be stored with

the B20 biodiesel blends in the fuel system for longer

than 3 months.

Supplemental diesel fuel additives are not generally

recommended . This recommendation is due to

potential damage to the fuel system or the engine.

Your fuel supplier or the fuel manufacturer will add the

appropriate supplemental diesel fuel additives.

Perkins  recognizes the fact that additives may be

required in some special circumstances. 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.

Due to poor oxidation stability and other potential

issues, it is strongly recommended that engines with

limited operational time either not use B20 biodiesel

blends or, while accepting some risk, limit biodiesel

blend to a maximum of B5. Examples of applications

that should limit the use of biodiesel are the following:

Standby Generator sets and certain emergency

vehicles.

Note: For the best results, your fuel supplier should

treat the fuel when additives are required. The treated

fuel must meet the requirements that are stated in

table 25 .

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.

Perkins  Diesel Fuel System Cleaner

Perkins  T400012 Fuel Cleaner is the only fuel

cleaner that is recommended by Perkins .

Microbial contamination and growth can cause

corrosion in the fuel system and premature plugging

of the fuel filter. Consult your supplier of fuel for

assistance in selecting appropriate anti-microbial

additive.

If biodiesel or biodiesel blends of fuel are to be used,

Perkins  require the use of Perkins  fuel cleaner. The

use of the fuel is in order to remove deposits within

the fuel system that is created with the use of

biodiesel. For more information on the use of

biodiesel and biodiesel blends refer to

Water accelerates microbial contamination and

growth. When biodiesel is compared to distillate fuels,

water is naturally more likely to exist in the biodiesel.

It is therefore essential to check frequently and if

necessary, drain the water separator.

“Recommendation for Biodiesel and Using B20”.

Perkins  fuel cleaner will remove deposits that can

form in the fuel system with the use of biodiesel and

biodiesel blends. These deposits can create a loss of

power and engine performance.

Materials such as brass, bronze, copper, lead, tin,

and zinc accelerate the oxidation process of the

biodiesel fuel. The oxidation process can cause

deposits formation therefore these materials must not

be used for fuel tanks and fuel lines.

Once the fuel cleaner has been added to the fuel, the

deposits within the fuel system are removed after 30

hours of engine operation. For maximum results,

continue to use the fuel cleaner for up to 80 hours.

Perkins  fuel cleaner can be used on an on-going

basis with no adverse impact on engine or fuel

system durability.

Fuel for Cold Weather Operation

The European standard EN590 contains climate

dependant requirements and a range of options. The

options can be applied differently in each country.

There are five classes that are given to arctic climates

and severe winter climates . 0, 1, 2, 3 and 4.

Details instruction on the rate of which the fuel

cleaner must be use are on the container.

Note: Perkins  fuel cleaner is compatible with

existing and U.S. EPATier 4 nonroad certified diesel

engine emission control catalysts and particulate

filters. Perkins  fuel system cleaner contains less

than 15 ppm of sulfur and is acceptable for use with

ULSD fuel.

Fuel that complies with EN590 CLASS 4 can be used

at temperatures as low as −44 °C (−47.2 °F). Refer

to EN590 for a detailed discretion of the 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).

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SEBU9064

51

Maintenance Recommendations

System Pressure Release

Maintenance

Recommendations

Components for the driven equipment should also be

considered. When possible, remove the component

that requires welding. When welding on an engine

that is equipped with an ECM and removal of the

component is not possible, the following procedure

must be followed. This procedure minimizes the risk

to the electronic components.

i04056177

System Pressure Release

1. Stop the engine. Remove the electrical power from

the ECM.

Coolant System

2. Ensure that the fuel supply to the engine is turned

off.

3. Disconnect the negative battery cable from the

battery. If a battery disconnect switch is installed,

open the switch.

Pressurized system: Hot  coolant can cause seri-

ous burn. To open cap, stop engine, wait until ra-

diator is cool.  Then loosen cap  slowly to relieve

the pressure.

4. Disconnect all electronic components from the

wiring harnesses. Include the following

components:

Ensure that the power supply is isolated before any

service or repair is performed.

•   Electronic components for the driven equipment

To relieve the pressure from the coolant system, turn

off the engine. Allow the cooling system pressure cap

to cool. Remove the cooling system pressure cap

slowly in order to relieve pressure.

•   ECM

•   Sensors

•   Relays

Fuel System

To relieve the pressure from the fuel system, turn off

the engine.

NOTICE

Do not use electrical components (ECM or ECM sen-

sors)  or electronic  component grounding  points  for

grounding the welder.

Engine Oil

To relieve pressure from the lubricating system, turn

off the engine.

i05341018

Welding on Engines with

Electronic Controls

Correct welding procedures are necessary in order to

avoid damage to the following components:

•   Electronic Control Module (ECM) on the engine

•   Clean Emissions Module (CEM)

•   Sensors

•   Associated components

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52

SEBU9064

Maintenance Recommendations

Severe Service Application

i04150276

Severe Service Application

Severe service is the application of an engine that

exceeds the current published standards for that

engine. Perkins  maintains standards for the

following engine parameters:

•   Performance such as power range, speed range,

and fuel consumption

•   Fuel quality

•   Operational Altitude

•   Maintenance intervals

•   Oil selection and maintenance

•   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.

Illustration 23

g01075639

Use the example above. The current flow from the

welder to the ground clamp of the welder will not

damage any associated components.

Severe service operation can accelerate component

wear. Engines that operate under severe conditions

may need more frequent maintenance intervals in

order to ensure maximum reliability and retention of

full service life.

(1) Engine

(2) Welding electrode

(3) Keyswitch in the OFF position

(4) Battery disconnect switch in the open position

(5) Disconnected battery cables

(6) Battery

(7) Electrical/Electronic 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

Due to individual applications, it is not possible to

identify all of the factors which can contribute to

severe service operation. Consult your Perkins

dealer or your Perkins  distributor for the unique

maintenance that is necessary for the engine.

The operating environment, incorrect operating

procedures, and incorrect maintenance procedures

can be factors which contribute to a severe service

application.

5. When possible, connect the ground clamp for the

welding equipment directly to the engine

component that will be welded. Place the clamp as

close as possible to the weld. Close positioning

reduces the risk of welding current damage to the

engine bearings, to the electrical components, and

to other components.

EnvironmentalFactors

Ambient temperatures – The engine may be

exposed to extended operation in cold environments

or hot environments. Valve components can be

damaged by carbon buildup if the engine is frequently

started and stopped in cold temperatures. Hot intake

air reduces engine performance.

6. Protect the wiring harnesses from welding debris

and/or from welding spatter.

7. Use standard welding procedures to weld the

materials together.

Quality of the air – The engine may be exposed to

extended operation in an environment that is dirty or

dusty, unless the equipment is cleaned regularly.

Mud, dirt, and dust can encase components.

Maintenance can be difficult. The buildup can contain

corrosive chemicals.

This document is printed from SPI². Not for RESALE