: erkKins’ Operation and Maintenance Manual 402F-05, 403F-07, 403F-11 and 403F-15 Industrial EnginesImportant Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skils and tools to perform these functions correctly. Incorrect 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. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings. are not heeded, bodily injury or death could occur to you or to other persons. he hazards are identified by the "Safely Alert Symbol” and followed by a "Signal Word" such as ANGER’, "WARNING" or "CAUTION’. The Safety Alert "WARNING" label is shown below. PEL ‘The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warming explains the hazard and can be either written or pictorially presented Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. ins cannot anticipate every possible circumstance that might involve a potential hazard. The 198 in this publication and on the product are, therefore, not all inclusive. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. Ifa 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 you are authorized to perform this work, and that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use. The information, specifications, and illustrations in this publication are on the basis of information that was, available at the time that the publication was written, The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers or Perkins distributors have the mast current information available. When replacement parts are required for this product Perkins recommends using Perkins re- placement parts. Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or death, In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner's choosing.‘SEBU9064.08, 3 Table of Contents Table of Contents Foreword Safety Section Safety Messages. General Hazard information. Bum Prevention..... Fire Prevention and Explosion Prevention... Crushing Prevention and Cutting Prevention. Before Starting Engine Engine Starting Engine Stopping... Electrical System... Product Information Section General Information ..... Product Identification Information Operation Section Lifting and Storage Features and Controls. Engine Diagnostics Engine Starting Engine Operation ..... Cold Weather Operation Engine Stopping Maintenance Section Refill Capacities. Maintenance Recommendations 10 A 13 13 14 14 14 16 28 30 32 36 43 47 48 65 Maintenance Interval Schedule. 68 Warranty Section Warranty Information. 104 Reference Information Section Reference Materials 105 Index Section Ind 0X. 1064 Foreword ‘SEBU9064.08 Foreword 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. WARNING - This product can A expose you to chemicals including ethylene glycol, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to: www.P65Warnings.ca.gov Do not ingest this chemical. Wash hands after handling to avoid incidental ingestion. WARNING ~ This product can A expose you to chemicals including lead and lead compounds, which are known to the State of California to cause cancer, birth defects, or other reproductive harm. For more information go t www.P65Warnings.ca.gov Wash hands after handling components that may contain lead. 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 the manual with the literature and engine information, 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. Safety This safety section lists basic safety precautions. In addition, this section identifies hazardous, warming situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance, and repair on this product Operation Operating techniques outined in this manuel are basi The operating techniques assist with developing the skills and techniques requlred to porate tne engine more effiienty and economical. Shi and techniques dovolop as the operator gains Knowledge of he engine ard te copobiities othe engine ‘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, Maintenance ‘The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by service hours andior calendar time maintenance intervals. Items in the maintenance schedule are referenced to detailed Instructions that follow, Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine also governs the Maintenance Interval Schedule, Therefore, under severe, dusty, wet, or freezing cold operating conditions, more frequent lubrication, and maintenance than is specified in the Maintenance Interval Schedule may be necessary.‘SEBU9064.08, 5 Foreword 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. Maintenance Intervals Perform maintenance on items at multiples of the original requirement. Each level and/or individual items in each level should be shifled ahead or back depending upon your specific maintenance practices, operation, and application. Perkins recommends that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. Perkins also recommends that a maintenance record be maintained as part of the permanent record of the engine, Your authorized Perkins dealer or your Perkins. distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment. Overhaul Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that interval Major repairs are best left to trained personnel or an authorized Perkins distributor or dealer. Your Perkins dealer or your Perkins distributor offers various 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,6 Safety Section Safety Messages ‘SEBU9064.08 Safety Section Safety Messages There may be several specific waning signs on your engine. The exact location and a description of the waming signs are reviewed in this section. Become familiar with all warning signs. Ensure that all the warning signs are legible. Clean the warning signs or replace the waming 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 nat 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 waming 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. /ARNING LL} inaseaton + son60007 Typical example ‘Warning label (A) is installed in different locations. The location will change according to the physical size of the engine.‘SEBU9064.08, 7 Safety Section General Hazard Information itaweaion? Typical examples (A) Location of waming label (1) 402F-08, (2) 4036-07 (G)403F-11 General Hazard Information inaseaton3 0704545 ‘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. ware S BH ¥) a 2 & @ ad Wear a hard hat, protective glasses, and other protective equipment, as required, Do not wear loose clothing or jewelry that can snag ‘on controls or on other parts of the engine. Make sure that all protective guards and all covers. are secured in place on the engine.8 Safety Section General Hazard Information ‘SEBU9064.08 Keep the engine free from foreign material. Remove debris, oll, tools, and other items from the deck, from ‘walkways, and from steps. 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. Disconnect the batteries when maintenance is performed or when the electrical system is serviced, Disconnect the battery ground leads. Tape the leads to help prevent sparks. If equipped, allow the diesel exhaust fluid to be purged before disconnecting the battery. 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 Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is, damaged or repair the equipment. For initial start-up of a new engine or for starting an engine that has been serviced, make provisions to stop the engine if an overspeed occurs. The stopping of the engine may be accomplished by shutting off the fuel supply andior the air supply to the engine, Ensure that only the fuel supply line is shut off. Ensure that the fuel return line is open. Start the engine from the operators station (cab). Never short across the starting motor terminals or the batteries. This action could bypass the engine neutral Start system andor he electrical system could be famagi Engine exhaust contains products of combustion which may be harmful to your health. Always start the engine and operate the engine in a ventilated area. If the engine is in an enclosed area, vent the engine ‘exhaust to the outside. Use caution when cover plates are removed. Gradually loosen, but do not remove the last two bolts or nuts that are located at opposite ends of the cover plate or the device. Before removing the last ‘two bolts or nuts, pry the cover loose to relieve any spring pressure or other pressure, Pressure Air and Water Pressurized air and/or water can cause debris andior hot water to be blown out. This action could result in personal injury. ‘The direct application of pressurized air or pressurized water to the body could result in personal injury, 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) Fluid Penetration 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 ifthe pressure is not relieved correctly. Do not remove any hydraulic components or parts ntl pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved oF personal injury may occur. Refer to the OEM information for any procedures that are required to relieve the hydraulic pressure inosvavon 00887600, ‘Always use a board or cardboard when you check for alleak. 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. Containing FI Spillage Care must be taken 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.‘SEBU9064.08, 9 Safety Section General Hazard Information + Only use the tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids. + Only use the tools that are suitable for containing fluids and equipment that is suitable for containing fluids. Obey all local regulations for the disposal of liquids, Static Electricity Hazard when Fueling with Ultra-low Sulfur Diesel Fuel The removal of sulfur and other compounds in ultra- low sulfur diesel fuel (ULSD fuel) decreases the conductivity of ULSD and increases the ability of ULSD to store static charge. Refineries may have treated the fuel with a stalic dissipating additive. Many factors can reduce the effectiveness of the additive over time, Static charges can build up in ULSD fuel while the fuel is flowing through fuel delivery systems, Static electricity discharge when combustible vapors are present could result in a fire of explosion. Ensure that the entire system used to refuel your machine (fuel supply tank, transfer pump, transfer hose, nozzle, and others) is properly grounded and bonded. Consult with your fuel or fuel system supplier to ensure that the delivery system complies with fueling standards for proper grounding and bonding, Avoid static electricity risk when fueling. Ultra- low sulfur diesel fuel (ULSD fuel) poses a greater ion hazard than earlier diesel formul ith a higher sulfur contents. Avoid death or serious injury from fire or explosion, Consult with your fuel or fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices. Waeatone pore Exhaust Use caution. Exhaust fumes can be hazardous to health. If you operate the equipment in an enclosed area, adequate ventilation is necessary. Hexavalent Chromium Perkins equipment and replacement parts comply with applicable regulations and requirements where originally sold, Perkins recommends the use of only genuine Perkins replacement parts. Hexavalent chromium has occasionally been detected on exhaust and heat shield systems on Perkins engines, Although laboratory testing is the only accurate way to know if hexavalent chromium is, in fact, present, the presence of a yellow deposit in areas of high heal (for example, exhaust system componenis or exhaust insulation) may be an indication of the presence of hexavalent chromium. Use caution if you suspect the presence of hexavalent chromium. Avoid skin contact when handling items that you suspect may contain hexavalent chromium, and avoid inhalation of any dust in the suspect area. Inhalation of, or skin contact with, hexavalent chromium dust may be hazardous to your health.10 Safety Section Bum Prevention ‘SEBU9064.08 such yellow deposits are found on the engine, engine component parts, or associated equipment or packages, Perkins recommends following local health and safety regulations and guidelines, utilizing good hygiene, and adhering to safe work practices ‘when handling the equipment or parts. Perkins also recommends the following: + Wear appropriate Personal Protective Equipment (PPE) + Wash your hands and face with soap and water prior to eating, drinking, or smoking, and also uring rest room breaks, to prevent ingestion of any yellow powder + Never use compressed air for cleaning areas suspected of containing hexavalent chromium + Avoid brushing, grinding, or cutting materials suspected of containing hexavalent chromium + Obey environmental regulations for the disposal of all materials that may contain or have come into contact with hexavalent chromium + Stay away from areas that might have hexavalent chromium particles in the ai. Asbestos Information Perkins equipment and replacement parts that are, shipped from Perkins engine company limited are asbestos free. Perkins recommends the use of only genuine Perkins replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you hancle asbestos Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers. inhaling this dust can be hazardous to your health, The components that may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is usually ound in a resin or sealed in some way. Normal gis not hazardous unless airborne dust that 8 asbestos is generated. I dust that may contain asbestos is present, there are several guidelines that should be followed: + Never use compressed air for cleaning, + Avoid brushing materials that contain asbestos. + Avoid grinding materials that contain asbestos. + Use a wet method to clean up asbestos materials. + Ayacuum cleaner that is equipped with a high cofficiency particulate air fiter (HEPA) can also be used. + Use exhaust ventilation on permanent machining jobs. + Wear an approved respirator if there is no other way to control the dust. + Comply with applicable rules and regulations for the work place. In the United States, use ‘Occupational Safety and Health Administration (OSHA) requirements. These OSHA requirements can be found in "29 CFR 1910.1001" + Obey environmental regulations for the disposal of asbestos. + Stay away from areas that might have asbestos pearlicles in the air. Dispose of Waste Properly inoseaion7 00706404 Improperty disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of in accordance with local regulations. ‘Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water. Burn Prevention Do not touch any part of an operating engine. Operating engines exhaust gases could bum, do not come in contact with hot gases. 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, fitfings, or related items are disconnected.‘SEBU9064.08, 1" Safety Section Fire Prevention and Explosion Prevention 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. Any contact with hot coolant or with steam can cause severe bums, Allow cooling system components to oo! before the cooling system is drained, Check that the coolant level after the engine has stopped and the engine has been allowed to cool. 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 to relieve pressure. Cooling system conditioner contains alkali, Alkali can cause personal injury, Do not allow alkali to contact the skin, the eyes, or the mouth. Oils ‘Skin may be irritated following repeated or prolonged exposure to mineral and synthetic base oils. Refer to your suppliers Material Safety Data Sheets for detailed information. Hot oll and lubricating components can cause personal injury. Do not allow hot oil to contact the skin. Appropriate personal protective equipment should be used Diesel Fuel Diesel may be irritating to the eyes, respiratory system, and skin, Prolonged exposure to diesel may cause various skin conditions. Appropriate personal protective equipment should be used, Refer to Supplier Material safety Data sheets for detailed information. 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, lorvaeass Fire Prevention and Explosion Prevention ery ‘pareaees Allfuels, most lubricants, and some coolant mixtures are flammable.12 Safety Section Fire Prevention and Explosion Prevention ‘SEBU9064.08 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. A flash fire may result if the covers for the engine crankcase are removed within 15 minutes afler an emergency shutdown. 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 resull I the application involves the presence of combustible gases, consult your Perkins dealer an or your Perkins distributor for additional information about suitable protection devices. Remove all flammable combustible materials or conductive materials such as fuel, ol, and debris. from the engine, Do not allow any flammable combustible materials or conductive materials to accumulate on the engine. Store fuels and lubricants in correctly marked containers away from unauthorized persons. Store oily rags and any flammable materials in protective containers. Do not smoke in areas that are used for Storing flammable matenals, Do not expose the engine to any flame. Exhaust shields (if equipped) protect hot exhaust components from oll or fuel spray in case of a line, a tube, or a seal failure. Exhaust shields must be installed correctly, Do not weld on lines or tanks that contain flammable fluids. Do not flame-cut lines or tanks that contain flammable fluid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding o flame cutting. Wiring must be kept in good condition. Ensure that all electrical wires are correctly installed and securely attached, Check all electrical wires daily, Repair any ‘wires that are loose or frayed before you operate the engine. Clean all electrical 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 ines 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. ll fiters and fuel fters must be correctly installed The filter housings must be tightened to the correct s 60 \ 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. Q® ineawaten 10 HOTS Gases from a battery can explode. Keep any open flames or sparks away from the top of a battery. Do not smoke in batlery charging areas. Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer.‘SEBU9064.08 13 Safety Section Crushing Prevention and Cutting Prevention Incorrect jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for specific. instructions. Do not charge a frozen battery, This action 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 regulary. Obey tne recommendations on the instruction plate. Ether Ether is flammable and poisonous. Do not smoke while you are replacing an ether cylinder or while you are using an ether spray. Do not store ether cylinders in living areas or in the engine compartment. Do not store ether cylinders in direct sunlight or in temperatures above 49° C (120° F). Keep ether cylinders away from open flames or sparks, 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 thal are loose or damaged. Leaks can cause fires. Consult your Perkins dealer or your Perkins distributor for repair or for replacement parts. 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 fitings are damaged or leaking + Outer coverings are chafed or cut + Wires are exposed. + Outer coverings are ballooning, + Flexible parts of the hoses are kinked + Outer covers have embedded armoring + End fitings are displaced. Make sure that all clamps, guards, and heat shields are installed correctly, During engine operation, correct installation will help to prevent vibration, rubbing against other parts, and excessive heal, lo2yaai04 Crushing Prevention and Cutting Prevention ‘Support the component correctly when work beneath the component is performed, Unies other maintenance instructions are provided, never attempt adjustments while the engine is running, 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, When objects are struck, wear protective glasses in order to avoid injury to the eyes. 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. Before Starting Engine NOTICE, For intial start-up of a new or rebuilt engine, and for start-up of an engine that has been serviced, make Provision to shut the engine off should an overspeed ‘occur. This may be accomplished by shutting off the air andior fuel supply to the engine, 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, ifin an enclosed area, vent the exhaust to the outside. Inspect the engine for potential hazards, 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 fo the controls.14 Safety Section Engine Starting ‘SEBU9064.08 Before starting the engine, ensure that no one is on, underneath, or close to the engine, Ensure that the area is free of personnel I equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work properly, if equipped. All protective guards and all protective covers must be 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 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. See the Service Manual for repairs and for adjustments. Engine Starting Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury. Ifa warning tag is attached to the engine start switch or to the contrals, DO NOTsstart the engine or move the controls. Consult with the person that attached the warning tag before the engine is started. 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. Start the engine from the operator's compartment or from the engine start switch, Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, “Engine Starling’ 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. 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 oll temperature gauge during the heater operation. 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. Note: The engine is equipped with an automatic. device for cold starting for normal conditions of operation. Ifthe 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, 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, Engine Stopping 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. Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. Alter an emergency stop, DO NOT start the engine uni he problem that caused the emergency stop fas 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 andlor shutting off the air supply to the engine, voar7e8es 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. Ifthe starting motor is not equipped with a negative "-" terminal, connect the jump start cable to the engine block.‘SEBU9064.08, 15 Safety Section Electrical System 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 reliably, 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. Engines that are installed without engine-to-rame ground straps can be damaged by electrical discharge. 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, All grounds should be tight and free of corrosion. The engine altemator must be grounded to the negative “."battery terminal with a wire that is adequate to handle the full charging current ofthe alternator.16 ‘SEBU9064.08 Product Information Section General Information Product Information Section General Information Model View Illustrations 403F-15 Engine View inaseaton 71 05972808 Typical example (1) Rear iting eye (5) Low mounted a lr ap (9) otter (2) Top ot filer cap (6) Fuelinjecton pump (10) Electronically contoled actuator or (2) Frontiting eye (7) Oil gauge (Dipstick) sop solenoid (a) Water pam (6) Oilerain plug (itingetor‘SEBU9064.08 17 Product Information Section Model View tlustrations inaweaton 2 p39T8877 (12) Aine (15) Solenoid for starter (18) Fan bet (13) Coolant outlet (18) Starting motor (18) Coolant intake connection (14) Exraustmanifols (17) Atornator18 ‘SEBU9064.08 Product Information Section Model View lustrations 403F-11 Engine View inuswaten rer Typical example (1) ol flor cap (6) Ollovel gauge (dipstick) (8) Secondary tue itor {2} Front engine lting eyo (ouster (10) Valve mechanism cover breather (3) Coolant ara tap, (7) Stop sotenoia (11) Aileaner assembly (@) Ot rain plug (6) Fuel wansfer pump‘SEBU9064-08 19 Product Information Section Model View ltustrations 9) L @ gla al] © © ° a a © « A‘ \ | 3 ®) \ coe © — 8) intaton1@ onsseneet ‘Typical example (12) Exhaust maniolé wth combined (14) Stating motor (17) Coolant temperature sensor silencer (15) Atemator (18) Coolant temperature regulator housing (13) Rear engine iting eye (18) Fan bel. (19) Oilpressure stem20 ‘SEBU9064.08 Product Information Section Model View Illustrations 403F-07 Engine View With Factory Radiator Typical example (1) Air leaner assembly (3) Elyuhec with cooting ns (5) Radiator assemaly {2)Rear engine ling eye (@)Exnaustmantold ane mule assembly (6) Radiator cap,‘SEBU9064-08 24 Product Information Section Model View ttustrations Typical example (7) Front engine iting eye (9) Secondary ue ter (8) Radiator coolant drain valve (10) Aircleaner assembly valve22 ‘SEBU9064.08 Product Information Section Model View Illustrations 402F-05 Engine View inaseaten 7 osszT Typical example (1) Front engine iting eye (4) Ethos! (7)Rear engine iting eyo (2) dipstick (6) Secondary fuel ter (3) o1'ter (6) Fusl valve‘SEBU9064.08, 23 Product Information Section Model View tlustrations inaweaton 18 ps2 Typical example (2) ot ter cap (10) 04 drain pug (12) Engine crankcase breather (9) Staring motor (11) Atemator Fuel System Components 1 2 3 inaweaten 8 905570862 Typical examples (1) Indie uel tor (2) Electric fuel pump24 ‘SEBU9064.08 Product Information Section Model View llustrations (2) Primary fuel er (4) Secondary fuel er (element ype) (6) Secondary fue ter Note: The electric fuel pump is an option, engines may have a mechanical fuel lft pump installed,‘SEBU9064-08 25 Product Information Section Model View tlustrations (6) Fuel fter fora 1000-hour service (7) Mecharieal uel ft pump Components for Electronic Control iMasvaien 1 0557 (1) Electronic Control Module (ECM) (@) Atmosphere Pressure Sensor (@) Actuator (2) Speed sensor (Garometnc Pressure Sensor)26 Product Information Section Product Description ‘SEBU9064.08 Note: Due to individual applications the atmospheric pressure sensor (3) may appear different from the ilustration, Product Description ‘There are four Perkins engines inthe 400F series that are below 19Kw power band, These engines are, 4402F-06, 403F-07, 403F-11, and the 403F-15. These engines have the fllowng Gnaractenstos + InLine 2 cylinder (402F-05) + In-Line 3 cylinder (403F-07, 403F-11, and the 403F-15) + Naturally aspirated + Fuel limiter only on certain electronically governed fuel systems + 2Valves in each cylinder The constant speed engine mode! 403F-11 with a prefix ET can be configured to operate with an extended service period, The engine with extender service periods requires the correct oil fiter, fue! filer, and the correct cil gauge (dipstick). 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. 402F-05 Engine Zh SN AN le) UF Y a 8 ite 22 sor08e76 (a) Exhaust valves {5} it valves ‘Tablet {402-05 Engine Specifications Maximum Operating Speed 3600 rpm com ia [Gyindere and Arrangement rein 2 eyinder bore 67 mm (264 inch) Stroke Tamm (283 inch) Displacement 0.507 (30.939 1) [Aspiration Naturally Aspirated [Compression Rava 2353 Feng Order 12 Rotation hati viewed rom the tyre ave Lash Seting (net) counterclockwise (0.20 mm (0.008 inch) Valve Lash Seting Exhaust) (0.20 mm (0.008 neh) Iiecion Ineieet 403F-07 Engine ° 9 & inaseaton 73, (A) Exhaust vatves (8) inietvaives. 0085208 “Toble2 “409F-07 Engine Specifications Maximum Operaing Spoed 3600 rpm com) i [Cyindore and Arangement IreLine 3 eyinder Bore 7 mm (264 neh) sroke 72mm (283 inch) isoiacement 0.762 (48.500 FF) (continued)‘SEBU9064.08, 403F-15 Engine 27 Product information Section Product Description (Table 2, con) [Aspiration Naturally Aspirated [Compression Ratio 2384 Fring Order 128 Rotation tale viewed rom the yw counterclockwise valve Lash Seting (et) (0.20 mm (0.008 inch) valve Lash Setting Exhaust) (0.20 mm (0.008 neh) injection Indirect 403F-11 Engine (A) Exhaust valves (8) niet vaives. Tobles 00857308 “403-11 Engine Specifications Maximom Operating Speed com 3600 rpm [Gyincore and Arangement In-Line 3 eyingor Bore 77 mm (3.08 neh) stroke ‘Btmm (8.18 inch) Displacement THOT (68.078 in) [Aspiration Naturally Aspirated [Compression Ratio 2a ring Order 123 Rotation that is viewed Fam the yuo! counterclockwise [valve Lash Seting (net) (0.20 mm (0.008 inch) valve Lash Sating Exhaust) (0.20 mm (0.008 inch) Injection Indit . & (a) Exhaust valves (B) niet valves ‘Table “403-15 Engine Specifications Maximum Operating Speed com) 3000 rpm [Gyinders and Arangement IreLine 3 eyinder Bore 4mm (8.34 ch) SivoKe ‘90mm (3.54 inch) [Displacement 1496 (91291 ie) [Aspiration Naturally Aspirated [Compression Ratio 25:1 Firing Order 128) Rotation hati viewed tom the syne! counterclockwise Valve Lash Seting (net) (0.20 mm (0.008 inch) Valve Lash Setting Exhaust) (0.20 mm (0.008 inch) Indirect28 Product Information Section Product Identification Information ‘SEBU9064.08 Product Identification Information 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. Atypical example of an engine number is EK**"**N000001X. E Engine family k Type of engine se The list umber ofthe engine N Country of manufacture ° The first digit is a production code. 00001 Engine Serial Number x 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 humbers. ication Film EMISSION CONTROL INFORMATION Perkins: [3132s" Sasa —| aes a DATE OF MANUFACTURE: #5 “THIS ENGINE CONFORMS TO 2012 US. EPA [AND CALIFORNIA REGULATIONS FOR LARGE NON-ROAD STATIONARY COMPRESSION-IGNITION ENGINES ULTRA LOW SULFUR FUEL ONLY EC TYPE: APPROVAL No: _asnnaaH3 arte incseaton 26 wae Typical example | ucrracow sutrun Fuet on. | LOW SULFUR FUEL ONLY Typical example llustration 27 is a representation of the label that will be installed next to the fuel filler cap on the fuel tank of the application,‘SEBU9064.08, 29 Product Information Section Reference Information 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 Fiter Element ‘Auxiliary Ol Filter Element Total Lubrication System Capacity Total Cooling System Capacity Air Cleaner Element ‘Alternator Belt30 ‘SEBU9064.08 Operation Section Lifting and Storage Operation Section Lifting and Storage Product Li inn 28 5056 Typical example (1)Rear iting eye (2)Frentiting eye NOTICE, ‘Always inspect lifting eyebolis and all other lifting equipment for damage before performing any lifting, Never bend the eyebolts and the brackets. Never perform product lifting if components are damaged, Only load the eyebolts and the brackets under ten- sion, Remember that the capacity of an eyebolt is less’as the angle between the supporting members and the object becomes less than 90 degrees, Use a hoist to remove heavy components. Use an. adjustable iting beam to lift the engine. All supporting members (chains and cables) should be — parallel to each other. The chains and cables should Imaseaion 28 010978527 be perpendicular to the top of the object that is being Perpendicular engine lifting lined. ‘Some removals require lifting the fixtures to obtain correct balance and safely. To remove the engine ONLY, use the lifting eyes that are on the engine, 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 liking.‘SEBU9064.08 at Operation Section Product Storage Product Storage Perkins are not responsible for damage which may occur when an engine is in storage afer a period in service, Your Perkins dealer or your Perkins distributer 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 ata constant temperature. Engines that are filed 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. Storage Procedure Keep a record of the procedure that has been completed on the engine. Note: Do not store an engine that has biodiesel in the fuel system, 1 Ensure that the engine is clean and dry. a. If the engine has been operated using biodiesel, the system must be drained and new fiters installed. The fuel tank will require flushing, b. Fill the fuel system with an ultra low sulfur fuel For more information on acceptable fuels refer to this Operation and Maintenance Manual, “Fluid recommendations", Operate the engine for 15 minutes in order to remove all biodiesel from the system. 2. Drain any water from the primary fiter water separator. Ensure that the fuel tank is ful 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 filed 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.32 Operation Section Features and Controls ‘SEBU9064.08 Features and Controls Gauges and Indicators 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. 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 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, NOTICE If no oil pressure is indicated, STOP the engine. If maximum coolant temperature is exceeded, STOP the engine. Engine damage can result. Engine Oil Pressure - The oil pressure (De) should be greatest after a cold engine is Started. The typical engine oil pressure with SAETOWS rated rpm. 207 to 413 kPa (30 to 60 psi at A lower oil pressure is normal at low idl. Ifthe load is stable and the gauge reading changes, perform the following procedure: 4. Remove the load. 2, Reduce engine speed to low idle. 3. Check and maintain the oil level. 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 use: Ifthe engine is operating above the normal range and steam becomes apparent, perform the following procedure: 4. Reduce the load and the engine rpm. 2. Inspect the cooling system for leaks. 3. Determine if the engine must be shut down immediately or ifthe engine can be cooled by reducing the load, (7g Tachometer - This gauge indicates (G) eraine speed (rm) when the trot = controller is moved to the full throttle position without load, the engine fe runing at high ale The engine is running atthe fll oad rpm when the throtle controle eat the fll throttle postion with maximum rated load. NOTICE To help prevent engine damage, never exceed the high idle rpm. Overspeeding can result in serious damage to the engine. The engine can be operated at high idle without damage, but should never be al- lowed to exceed high idle rpm. Ammster— Ths gauge indeates the 4) amount of charge orsischarge inthe battory charging eeu Operation of the indicator should be to the right side of (zero). Fuel Lovel—This gauge inlcats the cy fuel level in the fuel tank. The fuel level gauge operates when the “STARTISTOP™ switch is inthe “ON" postion. C Service Hour Meter - The gauge indicates operating time of the engine. © Indicators and Lamps ‘The following indicator amps can be installed, for more information refer tothe Original Equipment Manufacturer (OEM) + Shuldown lamp + Waring lamp + Low-prossure oil amp ‘Ammulti function lamp is installed on the electric control module. Monitoring System 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.‘SEBU9064.08, 33 Operation Section ‘Overspeed The following parameters are monitored: + Coolant temperature + 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, Overspeed + 402F-05 3600 Revolutions Per Minute (RPM) + 403F-07 3600 RPM + 403F-11 3600 RPM + 403F-15__________3000 RPM The overspeed is plus 700 RPM above the given speed for engines shown. Sensors and Electrical Components The following sensors or switches are installed on the 402F-05, 403F-07, 403F-11, and the 403F-15 engines: + Oil pressure switch + Coolant temperature sensor + Atmospheric pressure sensor (Barometric pressure sensor) + Speed sensor + Throttle actuator34 Operation Section ‘Sensors and Electrical Components SEBU9064.08 inaweaten 30 Typical examples (1) 0 pressure sensor (2) Coolant temperate Note: Due to individual applications the atmosphere pressure sensor (3) may appear different from the illustration Electrical components install on the 402F-05, 403F- 07, 403F-11, and the 403F-15 engines: + Alternator + Starting motor + Glow plugs + Electronic control governor (Location will depend ‘on the application) (@) Atmosphere pressure sensor ontor (aromotnc prossure sonsor) aosNaTT2s (4) Speed sensor (5) Thre actuator or stop solenoid + Electric fuel pump‘SEBU9064.08 36 Operation Section ‘Sensors and Electrical Components imaseaion 31 Typical examples (7)Atemstor (9) Glow pigs (11) Fuel pump (@) Staring motor (10) Electronic contal medel(Contalle) (12) Mutuncton 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". 0838112636 Operation Section Engine Diagnostics ‘SEBU9064.08 Engine Diagnostics 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 mult 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 fn the flash codes, refer to this Operation and Maintonance Manval, “Diagnostic Flash Code etrieval’. lorose401 Diagnostic Lamp The multi-function lamp that is installed remotely or on the engine controller can operate as a diagnostic, lamp. The diagnostic function is used to indicate the oxistence 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’. Diagnostic Flash Code Retrieval The multifunction 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. Ifa 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 lash the first code then after a delay interval the next code is flashed.‘SEBU9064.08 a7 Operation Section Diagnostic Flash Code Retrieval ‘abies Flash Codes with Key ON (Engine notin Operation) Flash Code Description Engine tats Operator Action (ON pressure switch mattnetion. — [Engine willsant, batthe engine [Check harness connection the Disconnection af Oilpressure [wil shut cow after 180 saconds_ taut remains contact your Perkins switch dealer or your Perkins distributor Disconnection of Oil pressure hamess lea Preseure sensor malfuncion. [Engine wil start buthe engine go | Check harness connection the bisconnection of Pressure sensor {to imp hame mode, aut remains contact your Perkins connector dealer o° your Perkins distributor Disconnection of Pressure sensor ames, ss [Actuator positon sensor Engine wl stan, but the engine go [Check harness connection the mattuncton to imp home mode, aut remains contact your Perkins Disconnection of Actuator positon dealer o° your Perkins distributor Disconnection of Actuator postion sensor harness, oe actvatorarive mattuncion Engine wil not sta. [check harness connection. the Disconnection of Speed sensor taut remains contact your Perkins connector, dealer or your Perkins dstbutor. Disconnection of Speed sensor hamess Table 6 Flash Godes During Engine Granking Flash Code Description Engine status Operator Action a Speed sensor matfuncion Engine witnot star. [check harness connection the Disconnection of Speed sensor aut romains contact your Perkins connector dealer 0° your Perkins distributor Disconnection of Speed sansor ames ‘Table 7 Flash Codes with Engine in Operation Flash Code Description Engine tats Operator Action sr oi pressure dectne Engine wil got imp horse mode [Check engine ol Weak signal from ol pressure |butthe engine may shutdown. | check hamess connection. the switch aut romans contact your Parkins Shore-cirutng dealer or your Perkins distributor lee Pressure sensor mattuncion. [The engine wil gointo imp home | Check harness connection. the Disconnection of Pressure sensor |mode, taut remains contact your Perkins connector. dealer or your Perkins distributor Disconnection of Pressure sensor ames, ss Actuator positon sensor Tie engine wil go into imp home [Check harness connection Ihe mattunction mode aut romans contact your Perkins Disconnection of Actuator poston dealer o° your Perkins distributor Disconnection of Actuator poston sensor harness, (continued)38 Operation Section Diagnostic Flash Code Retrieval ‘SEBU9064.08 (Table 7, cont) oe [actuator dive maltnetion Disconnection of Speed sensor connector. Disconnection of Speed sensor ames rhe engine wil shut down. [check harness connection. the taut remain contact your Perkins dealer o° your Perkins distributor Speed sensor maltuncion. Disconnection af Speed sensor Disconnection of Speed sonsor hamess Fhe engine wil go into imp home mode [check harness connection the taut rains contact your Perkins dealer or your Perkins dstroutor 157 Checking engine ols pat ofthe daly engine check. Operating an engine wila low love of ngne olan damage your engine. For more information on diagnostic messages and diagnostic tools contact your Perkins dealer or your Perkins distributor.‘SEBU9064.08 39 Operation Section Engine Starting Engine Starting 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, + Ensure that the engine has an adequate fuel supply. + Open the fuel supply valve (if equipped). Ifthe engine has not been started for several weeks, fuel may have drained from the fuel system, Air may have entered the fiter housing. Also, when fuel fiters have been changed, some air packets 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 Manuai, “Fuel Recommendations”. 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. + Donot start the engine or move any of the controls if there is a "DO NOT OPERATE" waming tag or similar warning tag attached to the start switch or to the controls. + Resetall of the shutoffs or alarm components. + Ensure that any driven equipment has been disengaged. Minimize electrical loads or remove any electrical loads, Starting the Engine Do not use aerosol types of starting aids such as ‘ether. Such use could result in an explosion and personal injury. Note: Do not adjust the engine speed control during start-up. The electronic control module (ECM) will control the engine speed during start-up. 4. Disengage any equipment that is driven by the engine. 2. Turn the keyswitch to the RUN position. Check the ‘multi-function lamp on the ECM. 3. f the lamp flashes once only, the engine can be started normally. Ifthe 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 heat position for a time period to allow the {glow plug operation. Some systems will have a wait to start lamp. 5. 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.40 Operation Section Starting with Jump Start Cables ‘SEBU9064.08 Note: The ambient weather condition will determine the amount of time the glow plugs will require. Ifthe engine is warm, heat fram the glow plugs will not be required to start the engine, 6. Turn the engine start switch to the HEAT position, Hold the engine start switch in the HEAT position for time shown in illustration 32 NOTICE Do not engage the starling motor when flywheel is turning, Do not start the engine under load, I the engine fails to start within 30 seconds, release the starter switch or button and wait two minutes to allow the starting motor to cool before attempting to start the engine again. 7. Tur the keyswitch 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, Starting with Jump Start Cables Improper jump start cable connections can cause an explosion resulting in personal injury. Prevent sparks near the batteries. Sparks could cause vapors to explode, Do not ailow jump start cable ends to contact each other or the engine. 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. Do not reverse the battery cables. The altemator can be damaged. Attach ground cabie last and remove first Turn all electrical accessories OFF before attaching the jump start cables. Ensure that the main power switch is in the OFF posi- tion before attaching the jump start cables fo the en- gine being started. 4. Turn the start switch on the stalled engine to the 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’. 5. Immediately after the engine is started, disconnect the jump-start cables in reverse order. After jump starting, the alternator may not be able to 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. After Starting Engine Note: In temperatures from 0°C to 60°C (32°F to 140°F), the warm-up time is approximately 3 minutes. In temperatures below 0°C (32°F), extra ‘warm-up time may be required. When the engine idles during warm-up, observe the following conditions: + Check for any fluid or for any alr leaks at idle rpm and at one-half full rpm (no load on the engine) before operating the engine under load. This action may not be possible in some applications. + Operate the engine at low idle until all systems. achieve operating temperatures. Check all gauges during the warm-up period, Constant speed engines should be allowed to operate at low idle for 3 minutes before used at operational speed. If the low idle option is not available, then operate the engine at operational speed with no load for 2 minutes.‘SEBU9064.08, a4 Operation Section After Starting Engine 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. Comparing data over time will also help detect abnormal operating developments. Significant changes in the readings should be investigated.42 Operation Section Engine Operation ‘SEBU9064.08 Engine Operation Engine Operation General Engine Operation Correct operation and maintenance are key factors in obtaining the maximum life and economy of the engine. ithe directions in the Operation and Maintenance Manual are followed, costs can be. 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 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, 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 Fuel Conservation Practices The efficiency of the engine can affect the fuel economy. Perkins design and technology in manufacturing provides maximum fuel efficiency in all applications. Follow the recommended procedures In order to attain optimum performance for the life of the engine, + Avoid spilling fuel Fuel expands when the fuel is warmed up, The fuel may overflow from the fuel tank, Inspect fuel lines for leaks. Repair the fuel ines, as needed + 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, + Avoid unnecessary idling Shut off the engine rather than idle for long periods of time. + Observe the service indicator frequently. Keep the air cleaner elements clean. + Maintain a good electrical system, One faulty battery cell will overwork the alternator. This fault will consume excess power and excess. fuel + The belt should be in good condition, + 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.‘SEBU9064.08 43 Operation Section Cold Weather Operation Cold Weather Operation Cold Weather Operation 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 thats used + The viscosity ofthe engine oll + The operation of the glow plugs + Battery condition This section will cover the folowing information: + Potential problems that are caused by cold weather operation + 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). The operation and maintenance of an engine in {freezing temperatures is complex . This complexity is because of the following conditions: + Weather conditions + Engine applications 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. Hints for Cold Weather Operation + Ifthe 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, + The cooling system and the lubrication system for the engine do not lose heat immediately upon shutdown, This means that an engine can be shut, down for a period and the engine can still have the ability to start readily. Install the correct specification of engine lubricant before the beginning of cold weather. Refer to this Operation and Maintenance Manual, “Fluid Recommendations’ for the recommended viscosity of oil Check all rubber parts (hoses, fan drive belts,) weekly. Check all electrical wiring and connections for any fraying or damaged insulation. 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 Check the air cleaners and the air intake daily. Check the air intake more often when you operate + Ensure that the glow plugs are in working order. 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. Viscosity of the Engine Lubrication oil Correct engine ol viscosity is essential. Oil viscosity affects hiorcation properies and wear protection that the oll provides forthe engine, Refer to this Operat and Maintenance Manual, “Fluid Recommendations for the recommended viscosity of oll. Recommendations for the Coolant Provide cooling system protection for the lowest expected outside temperature. Refer to this, Operation and Maintenance Manual, "Fluid Recommendations forthe recommended coolant mixture,