Perkins Engine 403f 15t 404f 22 404f 22t Om Sebu8609 01

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SEBU8609-01
January 2013

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.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins 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 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 most current information 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.
SEBU8609 3
Table of Contents

Table of Contents Refill Capacities....................... ....................... 57

Foreword.............................. ............................. 4 Maintenance Recommendations.......... .......... 70

Maintenance Interval Schedule ........... ........... 73

Safety Section

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

Warranty Section

Warranty Information ................... ................... 99

General Hazard Information ............... .............. 5

Burn Prevention........................ ........................ 9 Reference Information Section

Fire Prevention and Explosion Prevention ... .. 10 Reference Materials .................. ................... 103

Crushing Prevention and Cutting Prevention . .11 Index Section

Mounting and Dismounting............... .............. 12 Index............................... .............................. 104

Before Starting Engine ................. .................. 12

Engine Starting ........................ ....................... 12

Engine Stopping ....................... ...................... 13

Electrical System ...................... ...................... 13

Engine Electronics..................... ..................... 14

Product Information Section

General Information.................... .................... 15

Product Identification Information.......... ......... 26

Operation Section

Lifting and Storage..................... ..................... 28

Features and Controls .................. .................. 30

Engine Diagnostics..................... .................... 43

Engine Starting ........................ ....................... 45

Engine Operation...................... ...................... 48

Cold Weather Operation................. ................ 52

Engine Stopping ....................... ...................... 56

Maintenance Section
4 SEBU8609
Foreword

Foreword Recommended service should be performed at the

appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
Literature Information of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty,
This manual contains safety, operation instructions, wet or freezing cold operating conditions, more
lubrication and maintenance information. This manual frequent lubrication and maintenance than is
should be stored in or near the engine area in a specified in the Maintenance Interval Schedule may
literature holder or literature storage area. Read, be necessary.
study and keep it with the literature and engine
information. The maintenance schedule items are organized for a
preventive maintenance management program. If the
English is the primary language for all Perkins preventive maintenance program is followed, a
publications. The English used facilitates translation periodic tune-up is not required. The implementation
and consistency. of a preventive maintenance management program
should minimize operating costs through cost
Some photographs or illustrations in this manual avoidances resulting from reductions in unscheduled
show details or attachments that may be different downtime and failures.
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing Maintenance Intervals
improvement and advancement of product design
may have caused changes to your engine which are Perform maintenance on items at multiples of the
not included in this manual. Whenever a question original requirement. We recommend that the
arises regarding your engine, or this manual, please maintenance schedules be reproduced and displayed
consult with your Perkins dealer or your Perkins near the engine as a convenient reminder. We also
distributor for the latest available information. recommend that a maintenance record be maintained
as part of the engine's permanent record.
Safety Your authorized Perkins dealer or your Perkins
This safety section lists basic safety precautions. In distributor can assist you in adjusting your
addition, this section identifies hazardous, warning maintenance schedule to meet the needs of your
situations. Read and understand the basic operating environment.
precautions listed in the safety section before
operating or performing lubrication, maintenance and Overhaul
repair on this product.
Major engine overhaul details are not covered in the
Operation Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs should only be carried out by Perkins
Operating techniques outlined in this manual are authorized personnel. Your Perkins dealer or your
basic. They assist with developing the skills and Perkins distributor offers a variety of options
techniques required to operate the engine more regarding overhaul programs. If you experience a
efficiently and economically. Skill and techniques major engine failure, there are also numerous after
develop as the operator gains knowledge of the failure overhaul options available. Consult with your
engine and its capabilities.
Perkins dealer or your Perkins distributor for
The operation section is a reference for operators. information regarding these options.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating California Proposition 65 Warning
and stopping the engine. This section also includes a
discussion of electronic diagnostic information. 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
Maintenance posts, terminals and related accessories contain lead
The maintenance section is a guide to engine care. and lead compounds. Wash hands after handling.
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.
SEBU8609 5
Safety Section
Safety Messages

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

General Hazard Information

Illustration 1 g03256898
(1) Universal Warning Illustration 3 g00104545

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.
6 SEBU8609
Safety Section
General Hazard Information

• 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

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.
SEBU8609 7
Safety Section
General Hazard Information

Keep the engine free from foreign material. Remove

debris, oil, 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.
Ensure that the power supply is disconnected before
you work on the bus bar or the glow plugs. Illustration 5 g00687600

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

Inhalation • Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestos
materials.

• A vacuum cleaner that is equipped with a high

efficiency particulate air filter (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.
Illustration 6 g00702022
• Comply with applicable rules and regulations for
Exhaust the work place. In the United States , use
Occupational Safety and Health Administration
Use caution. Exhaust fumes can be hazardous to (OSHA) requirements. These OSHA
health. If you operate the equipment in an enclosed requirements can be found in 29 CFR 1910.1001.
area, adequate ventilation is necessary.
• Obey environmental regulations for the disposal of
Asbestos Information asbestos.

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

Improperly disposing of waste can threaten the

environment. Potentially harmful fluids should be
disposed of according to 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.
SEBU8609 9
Safety Section
Burn Prevention

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

Sulfuric Acid Burn Hazard may cause serious per-

sonal injury or death.
The exhaust gas cooler may contain a small
amount of sulfuric acid. The use of fuel with sulfur
levels greater than 15 ppm may increase the
amount of sulfuric acid formed. The sulfuric acid
may spill from the cooler during service of the en-
gine. The sulfuric acid will burn the eyes, skin and
clothing on contact. Always wear the appropriate
personal protective equipment (PPE) that is noted
on a material safety data sheet (MSDS) for sulfuric
acid. Always follow the directions for first aid that
are noted on a material safety data sheet (MSDS)
for sulfuric acid.
Perkins Engine 403f 15t 404f 22 404f 22t Om Sebu8609 01
Full download:
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SEBU8609
Safety Section
Fire Prevention and Explosion Prevention

i04047444 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
Fire Prevention and Explosion thoroughly with a nonflammable solvent prior to
Prevention welding or flame cutting.
Wiring must be kept in good condition. Ensure that all
electrical wires are 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.
Ensure that the engine is stopped. Inspect all lines
and hoses for wear or for deterioration. The hoses
Illustration 8 g00704000 must be correctly routed. The lines and hoses must
have adequate support and secure clamps.
All fuels, most lubricants, and some coolant mixtures
are flammable. Oil filters and fuel filters must be correctly installed.
The filter housings must be tightened to the correct
Flammable fluids that are leaking or spilled onto hot torque. Refer to the Disassembly and Assembly
surfaces or onto electrical components can cause a manual for more information.
fire. Fire may cause personal injury and property
damage.
After the emergency stop button has been operated,
ensure that you allow 15 minutes, before the engine
covers are removed.
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.
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.
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.
Store fuels and lubricants in correctly marked
containers away from unauthorized persons. Store Illustration 9 g00704059
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for Use caution when you are refueling an engine. Do not
storing flammable materials. smoke while you are refueling an engine. Do not
refuel an engine near open flames or sparks. Always
Do not expose the engine to any flame. stop the engine before refueling.
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.

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