Perkins Engine 403f 15t 404f 22 404f 22t Om Sebu8609 01
Perkins Engine 403f 15t 404f 22 404f 22t Om Sebu8609 01
Perkins Engine 403f 15t 404f 22 404f 22t Om Sebu8609 01
Operation and
Maintenance
Manual
403F-15T, 404F-22 and 404F-22T
Industrial Engines
EL (Engine)
EN (Engine)
EP (Engine)
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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, skills and tools to perform these functions 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.
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.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
Fire Prevention and Explosion Prevention ... .. 10 Reference Materials .................. ................... 103
Operation Section
Maintenance Section
4 SEBU8609
Foreword
Safety Section
i05139549 Do not operate or work on this equipment unless
you have read and understand the instructions
Safety Messages and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or heed
the warnings could result in serious injury or
death.
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. The warning signs that are loosened
could drop off the engine.
Replace any warning sign that is damaged or
missing. If a warning sign is attached to a part of the
engine that is replaced, install a new warning sign on
the replacement part. Your Perkins dealer or your Illustration 2 g01154807
distributor can provide new warning signs. Typical example
(1) Universal Warning The location of the universal warning label is located
on the right side of the valve mechanism cover.
i05139571
Illustration 1 g03256898
(1) Universal Warning Illustration 3 g00104545
• Tampering with the engine installation or tampering • The engine is stopped. Ensure that the engine
with the OEM supplied wiring can be dangerous. cannot be started.
Personal injury, death and/or engine damage
could result. • The protective locks or the controls are in the
applied position.
• Vent the engine exhaust to the outside when the
engine is operated in an enclosed area. • Engage the secondary brakes or parking brakes.
• If the engine is not running, do not release the • Block the vehicle or restrain the vehicle before
secondary brake or the parking brake systems maintenance or repairs are performed.
unless the vehicle is blocked or unless the vehicle
is restrained. • Disconnect the batteries when maintenance is
performed or when the electrical system is
• Wear a hard hat, protective glasses, and other serviced. Disconnect the battery ground leads.
protective equipment, as required. Tape the leads in order to help prevent sparks.
• When work is performed around an engine that is • Do not attempt any repairs or any adjustments to
operating, wear protective devices for ears in order the engine while the engine is operating.
to help prevent damage to hearing.
• Do not attempt any repairs that are not
• Do not wear loose clothing or jewelry that can snag understood. Use the proper tools. Replace any
on controls or on other parts of the engine. equipment that is damaged or repair the
equipment.
• Ensure that all protective guards and all covers are
secured in place on the engine. • For initial start-up of a new engine or for starting an
engine that has been serviced, make provisions to
• Never put maintenance fluids into glass stop the engine if an overspeed occurs. The
containers. Glass containers can break. stopping of the engine may be accomplished by
shutting off the fuel supply and/or the air supply to
• Use all cleaning solutions with care. the engine. Ensure that only the fuel supply line is
shut off. Ensure that the fuel return line is open.
• Report all necessary repairs.
• Start the engine from the operators station (cab).
Unless other instructions are provided, perform the Never short across the starting motor terminals or
maintenance under the following conditions:
the batteries. This action could bypass the engine
neutral start system and/or the electrical system
could be damaged.
Illustration 4 g00702020
Perform maintenance on the engine with the Always use a board or cardboard when you check for
equipment in the servicing position. Refer to the OEM a leak. Leaking fluid that is under pressure can
information for the procedure for placing the penetrate body tissue. Fluid penetration can cause
equipment in the servicing position. serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
Pressure Air and Water you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Pressurized air and/or water can cause debris and/or
hot water to be blown out. This could result in Containing Fluid Spillage
personal injury.
The direct application of pressurized air or Care must be taken in order to ensure that fluids are
contained during performance of inspection,
pressurized water to the body could result in personal maintenance, testing, adjusting, and repair of the
injury. engine. Make provision to collect the fluid with a
When pressurized air and/or water is used for suitable container before any compartment is opened
cleaning, wear protective clothing, protective shoes, or before any component is disassembled.
and eye protection. Eye protection includes goggles
or a protective face shield. • Only use the tools that are suitable for collecting
fluids and equipment that is suitable for collecting
The maximum air pressure for cleaning purposes fluids.
must be below 205 kPa (30 psi). The maximum water
pressure for cleaning purposes must be below • Only use the tools that are suitable for containing
275 kPa (40 psi). fluids and equipment that is suitable for containing
fluids.
Fluid Penetration Obey all local regulations for the disposal of liquids.
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.
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.
8 SEBU8609
Safety Section
General Hazard Information
Perkins equipment and replacement parts that are • Stay away from areas that might have asbestos
shipped from Perkins are asbestos free. Perkins particles in the air.
recommends the use of only genuine Perkins
replacement parts. Use the following guidelines when Dispose of Waste Properly
you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
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
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
If dust that may contain asbestos is present, there are
several guidelines that should be followed:
Illustration 7 g00706404
i05200861 Coolant
Burn Prevention 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.
Do not touch any part of an operating engine system.
The engine, the exhaust, and the engine Any contact with hot coolant or with steam can cause
aftertreatment system can reach temperatures as severe burns. Allow cooling system components to
high as 650 °C (1202 °F) under normal operating cool before the cooling system is drained.
conditions.
Check that the coolant level after the engine has
At idle engine speed and/or zero vehicle speed, an stopped and the engine has been allowed to cool.
operator can request a manual regeneration. Under
this condition, the exhaust gas temperature can reach Ensure that the filler cap is cool before removing the
650 °C (1202 °F). Otherwise automatic regeneration filler cap. The filler cap must be cool enough to touch
can produce exhaust gas temperatures as high as with a bare hand. Remove the filler cap slowly in
650 °C (1202 °F). order to relieve pressure.
Allow the engine system to cool before any Cooling system conditioner contains alkali. Alkali can
maintenance is performed. Relieve all pressure in the cause personal injury. Do not allow alkali to contact
following systems, hydraulic system, lubrication the skin, the eyes, or the mouth.
system, fuel system, and the cooling system before
related items are disconnected. 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
Contact with high pressure fuel may cause fluid skin.
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow Batteries
these inspection, maintenance and service in-
structions may cause personal injury or death. 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
After the engine has stopped, allow if active the servicing batteries. Wash hands after touching the
regeneration active lamp to be extinguished before batteries and connectors. Use of gloves is
any service or repair is performed. recommended.
Induction System
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