Perkins 402J-05, 403J-07, 403J-11, 403J-11T, 403J-15, 403J-17, 403J-17T and 404J-22 Industrial Engine. Manual (2020)

M0087369-05

Foreword

Some photographs or illustrations in this manual

show details or attachments that may be different

from your engine. Guards and covers may have been

California Proposition 65 Warning

removed for illustrative purposes. Continuing

improvement and advancement of product design

may have caused changes to your engine which are

Diesel engine exhaust and some of its

not included in this manual. Whenever a question

constituents are known to the State of

arises regarding your engine, or this manual, please

California to cause cancer, birth defects,

consult with your Perkins dealer or your Perkins

distributor for the latest available information.

and other reproductive harm.

WARNING - This product can

Safety

expose you to chemicals

including ethylene glycol, which

This safety section lists basic safety precautions. In

is known to the State of California to

addition, this section identifies hazardous, warning

cause birth defects or other reproductive

situations. Read and understand the basic

precautions listed in the safety section before

harm. For more information go to:

operating or performing lubrication, maintenance,

and repair on this product.

www.P65Warnings.ca.gov

Operation

Do not ingest this chemical. Wash hands

after handling to avoid incidental

Operating techniques outlined in this manual are

ingestion.

basic. The operating techniques assist with

developing the skills and techniques required to

WARNING - This product can

operate the engine more efficiently and economically.

expose you to chemicals

Skill and techniques develop as the operator gains

including lead and lead

knowledge of the engine and the capabilities of the

engine.

compounds, which are known to the

State of California to cause cancer, birth

The operation section is a reference for operators.

defects, or other reproductive harm. For

Photographs and illustrations guide the operator

more information go to:

through procedures of inspecting, starting, operating,

and stopping the engine. This section also includes a

www.P65Warnings.ca.gov

discussion of electronic diagnostic information.

Wash hands after handling components

Maintenance

that may contain lead.

The maintenance section is a guide to engine care.

The illustrated, step-by-step instructions are grouped

Literature Information

by service hours and/or calendar time maintenance

intervals. Items in the maintenance schedule are

This manual contains safety, operation instructions,

referenced to detailed instructions that follow.

lubrication, and maintenance information. This

manual should be stored in or near the engine area in

Recommended service should be performed at the

a literature holder or literature storage area. Read,

appropriate intervals as indicated in the Maintenance

study, and keep the manual with the literature and

Interval Schedule. The actual operating environment

engine information.

of the engine also governs the Maintenance Interval

Schedule. Therefore, under severe, dusty, wet, or

English is the primary language for all Perkins

freezing cold operating conditions, more frequent

publications. The English used facilitates translation

lubrication, and maintenance than is specified in the

and consistency.

Maintenance Interval Schedule may be necessary.

M0087369-05

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 shifted 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.

M0087369-05

Safety Section

Safety Messages

Safety Section

i08164827

Safety Messages

There may be several specific warning signs on your

engine. The exact location and a description of the

warning signs are reviewed in this section. Become

familiar with all warning signs.

Ensure that all the warning signs are legible. Clean

the warning signs or replace the warning signs if the

words cannot be read or if the illustrations are not

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

warning signs. Do not use solvents, gasoline, or

other harsh chemicals. Solvents, gasoline, or harsh

chemicals could loosen the adhesive that secures the

warning signs.

Replace any warning sign that is damaged or

missing. If a warning sign is attached to a part of the

engine that is replaced, install a new warning sign on

the replacement part. Your Perkins dealer or your

distributor can provide new warning signs.

(A) Universal Warning

Do not operate or work on this equipment unless

you have read and understand the instructions

and warnings in the Operation and Maintenance

Manuals. Failure to follow the instructions or

heed the warnings could result in serious injury

or death.

Illustration 1

g01154807

Typical example

Warning label (A) is installed in different locations.

The location will change according to the physical

size of the engine.

M0087369-05

Safety Section

General Hazard Information

Illustration 6

g00702020

Wear a hard hat, protective glasses, gloves, and

other protective equipment, as required.

Do not wear loose clothing or jewelry that can snag

on controls or on other parts of the engine.

Illustration 4

g06367684

Make sure that all protective guards and all covers

Typical example

are secured in place on the engine.

(A) Location of warning label

(6) 404J-22

Keep the engine free from foreign material. Remove

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

i08192616

walkways, and from steps.

Never put maintenance fluids into glass containers.

General Hazard Information

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

Illustration 5

g00104545

Original Equipment Manufacturer (OEM) information

for the procedure for placing the equipment in the

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

servicing position.

warning tag to the start switch or to the controls

before you service the equipment or before you

Do not attempt any repairs that are not understood.

repair the equipment.

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 and/or the air supply to the engine.

Ensure that only the fuel supply line is shut off.

Ensure that the fuel return line is open.

M0087369-05

Safety Section

General Hazard Information

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 and/or the electrical system could be

damaged.

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 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

Illustration 7

g00687600

pressure or other pressure.

Always use a board or cardboard when you check for

Ensure that the correct lifting equipment is used

a leak. Leaking fluid that is under pressure can

when lifting radiators, engines, engine components,

penetrate body tissue. Fluid penetration can cause

or batteries.

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 action could result in

Containing Fluid Spillage

personal injury.

The direct application of pressurized air or

Care must be taken to ensure that fluids are

pressurized water to the body could result in personal

contained during performance of inspection,

injury.

maintenance, testing, adjusting, and repair of the

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

Ensure that any spill that may occur are clear-up

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.

M0087369-05

Safety Section

General Hazard Information

Obey all local regulations for the disposal of liquids.

Asbestos Information

Perkins equipment and replacement parts that are

Static Electricity Hazard when

shipped from Perkins engine company limited are

Fueling with Ultra-low Sulfur Diesel

asbestos free. Perkins recommends the use of only

genuine Perkins replacement parts. Use the following

Fuel

guidelines when you handle any replacement parts

that contain asbestos or when you handle asbestos

The removal of sulfur and other compounds in ultra-

debris.

low sulfur diesel fuel (ULSD fuel) decreases the

conductivity of ULSD and increases the ability of

Use caution. Avoid inhaling dust that might be

ULSD to store static charge. Refineries may have

generated when you handle components that contain

treated the fuel with a static dissipating additive.

asbestos fibers. Inhaling this dust can be hazardous

Many factors can reduce the effectiveness of the

to your health. The components that may contain

additive over time. Static charges can build up in

asbestos fibers are brake pads, brake bands, lining

ULSD fuel while the fuel is flowing through fuel

material, clutch plates, and some gaskets. The

delivery systems. Static electricity discharge when

asbestos that is used in these components is usually

combustible vapors are present could result in a fire

bound in a resin or sealed in some way. Normal

or explosion. Ensure that the entire system used to

handling is not hazardous unless airborne dust that

refuel your machine (fuel supply tank, transfer pump,

contains asbestos is generated.

transfer hose, nozzle, and others) is properly

grounded and bonded. Consult with your fuel or fuel

If dust that may contain asbestos is present, there

system supplier to ensure that the delivery system

are several guidelines that should be followed:

complies with fueling standards for proper grounding

and bonding.

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

Avoid static electricity risk when fueling. Ultra-

low sulfur diesel fuel (ULSD fuel) poses a greater

• Use a wet method to clean up asbestos materials.

static ignition hazard than earlier diesel formula-

tions with a higher sulfur contents. Avoid death

• A vacuum cleaner that is equipped with a high

or serious injury from fire or explosion. Consult

efficiency particulate air filter (HEPA) can also be

with your fuel or fuel system supplier to ensure

used.

the delivery system is in compliance with fueling

standards for proper grounding and bonding

• Use exhaust ventilation on permanent machining

practices.

jobs.

• Wear an approved respirator if there is no other

Inhalation

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

particles in the air.

Illustration 8

g00702022

Exhaust

Use caution. Exhaust fumes can be hazardous to

health. If you operate the equipment in an enclosed

area, adequate ventilation is necessary.

M0087369-05

Safety Section

Burn Prevention

Dispose of Waste Properly

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 oil 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

Illustration 9

g00706404

cause various skin conditions. Appropriate personal

protective equipment should be used. Refer to

Improperly disposing of waste can threaten the

supplier Material safety Data sheets for detailed

environment. Potentially harmful fluids should be

information.

disposed of in accordance with local regulations.

Always use leakproof containers when you drain

Batteries

fluids. Do not pour waste onto the ground, down a

drain, or into any source of water.

Electrolyte is an acid. Electrolyte can cause personal

injury. Do not allow electrolyte to contact the skin or

i07188265

the eyes. Always wear protective glasses for

servicing batteries. Wash hands after touching the

batteries and connectors. Use of gloves is

Burn Prevention

recommended.

i07188311

Do not touch any part of an operating engine.

Operating engines exhaust gases could burn, do not

Fire Prevention and Explosion

come in contact with hot gases. Allow the engine to

cool before any maintenance is performed on the

Prevention

engine. Relieve all pressure in the air system, in the

hydraulic system, in the lubrication system, in the fuel

system, or in the cooling system before any lines,

fittings, or related items are disconnected.

Coolant

When the engine is at operating temperature, the

engine coolant is hot. The coolant is also under

pressure. The radiator and all lines to the heaters or

to the engine contain hot coolant.

Any contact with hot coolant or with steam can cause

severe burns. Allow cooling system components to

cool 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

Illustration 10

g00704000

filler cap. The filler cap must be cool enough to touch

with a bare hand. Remove the filler cap slowly to

All fuels, most lubricants, and some coolant mixtures

are flammable.

relieve pressure.

M0087369-05

Safety Section

Fire Prevention and Explosion Prevention

Flammable fluids that are leaking or spilled onto hot

Oil filters and fuel filters must be correctly installed.

surfaces or onto electrical components can cause a

The filter housings must be tightened to the correct

fire. Fire may cause personal injury and property

torque.

damage.

A flash fire may result if the covers for the engine

crankcase are removed within 15 minutes after 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 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 11

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

storing flammable materials.

not 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.

Do not weld on lines or tanks that contain flammable

fluids. Do not flame-cut lines or tanks that contain

flammable fluid. Clean any such lines or tanks

thoroughly with a nonflammable solvent prior to

welding or flame cutting.

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

Illustration 12

g00704135

connections, recommended wiring, and correctly

maintained battery cables will help to prevent arcing

Gases from a battery can explode. Keep any open

or sparking.

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

not smoke in battery charging areas.

Inspect all lines and hoses for wear or for

deterioration. The hoses must be correctly routed.

Never check the battery charge by placing a metal

The lines and hoses must have adequate support

object across the terminal posts. Use a voltmeter or a

and secure clamps. Tighten all connections to the

hydrometer.

recommended torque. Leaks can cause fires.

M0087369-05

Safety Section

Crushing Prevention and Cutting Prevention

Incorrect jumper cable connections can cause an

• End fittings are displaced.

explosion that can result in injury. Refer to the

Operation Section of this manual for specific

Make sure that all clamps, guards, and heat shields

instructions.

are installed correctly. During engine operation,

correct installation will help to prevent vibration,

Do not charge a frozen battery. This action may

rubbing against other parts, and excessive heat.

cause an explosion.

i02143194

The batteries must be kept clean. The covers (if

equipped) must be kept on the cells. Use the

recommended cables, connections, and battery box

Crushing Prevention and

covers when the engine is operated.

Cutting Prevention

Fire Extinguisher

Support the component correctly when work beneath

Make sure that a fire extinguisher is available. Be

the component is performed.

familiar with the operation of the fire extinguisher.

Inspect the fire extinguisher and service the fire

Unless other maintenance instructions are provided,

extinguisher regularly. Obey the recommendations

never attempt adjustments while the engine is

on the instruction plate.

running.

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

Ether

Leave the guards in place until maintenance is

performed. After the maintenance is performed,

Ether is flammable and poisonous.

reinstall the guards.

Do not smoke while you are replacing an ether

cylinder or while you are using an ether spray.

Keep objects away from moving fan blades. The fan

blades will throw objects or cut objects.

Do not store ether cylinders in living areas or in the

When objects are struck, wear protective glasses in

engine compartment. Do not store ether cylinders in

order to avoid injury to the eyes.

direct sunlight or in temperatures above 49° C

(120° F). Keep ether cylinders away from open

Chips or other debris may fly off objects when objects

flames or sparks.

are struck. Before objects are struck, ensure that no

one will be injured by flying debris.

Lines, Tubes, and Hoses

i05875651

Do not bend high-pressure lines. Do not strike high-

pressure lines. Do not install any lines that are bent

Mounting and Dismounting

or damaged. Do not clip any other items to the high-

pressure lines.

Repair any lines that are loose or damaged. Leaks

Do not climb on the engine. The engine has not been

can cause fires. Consult your Perkins dealer or your

designed with mounting or dismounting locations.

Perkins distributor for repair or for replacement parts.

Refer to the OEM for the location of foot and hand

Check lines, tubes, and hoses carefully. Do not use

holds for your specific application.

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

cardboard to check for leaks. Tighten all connections

i05874054

to the recommended torque.

Before Starting Engine

Replace the parts if any of the following conditions

are present:

• End fittings are damaged or leaking.

NOTICE

• Outer coverings are chafed or cut.

For initial start-up of a new or rebuilt engine, and for

start-up of an engine that has been serviced, make

• Wires are exposed.

provision to shut the engine off should an overspeed

occur. This may be accomplished by shutting off the

• Outer coverings are ballooning.

air and/or fuel supply to the engine.

• Flexible parts of the hoses are kinked.

• Outer covers have embedded armoring.

M0087369-05

Safety Section

Engine Starting

Always start the engine according to the procedure

that is described in the Operation and Maintenance

Manual, “Engine Starting” topic in the Operation

Engine exhaust contains products of combustion

Section. Knowing the correct procedure will help to

which may be harmful to your health. Always

prevent major damage to the engine components.

start and operate the engine in a well ventilated

Knowing the procedure will also help to prevent

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

personal injury.

to the outside.

To ensure that the jacket water heater (if equipped)

Inspect the engine for potential hazards.

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

correctly, check the water temperature gauge and the

Do not start the engine or move any of the controls if

oil temperature gauge during the heater operation.

there is a “DO NOT OPERATE” warning tag or similar

warning tag attached to the start switch or to the

Engine exhaust contains products of combustion

controls.

which can be harmful to your health. Always start the

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

engine and operate the engine in a well ventilated

underneath, or close to the engine. Ensure that the

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

area is free of personnel.

vent the engine exhaust to the outside.

If equipped, ensure that the lighting system for the

Note: The engine is equipped with an automatic

engine is suitable for the conditions. Ensure that all

device for cold starting for normal conditions of

lights work properly, if equipped.

operation. If the engine will be operated in very cold

conditions, then an extra cold starting aid may be

All protective guards and all protective covers must

required. Normally, the engine will be equipped with

be installed if the engine must be started in order to

the correct type of starting aid for your region of

perform service procedures. To help prevent an

operation.

accident that is caused by parts in rotation, work

around the parts carefully.

The 400 Series engines are equipped with a glow

plug starting aid in each individual cylinder that heats

Do not bypass the automatic shutoff circuits. Do not

the intake air in order to improve starting.

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

i02234873

engine damage.

Engine Stopping

See the Service Manual for repairs and for

adjustments.

Stop the engine according to the procedure in the

i02157354

Operation and Maintenance Manual, “Engine

Stopping (Operation Section)” in order to avoid

Engine Starting

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.

Do not use aerosol types of starting aids such as

After an emergency stop, DO NOT start the engine

ether. Such use could result in an explosion and

until the problem that caused the emergency stop

personal injury.

has been corrected.

Stop the engine if an overspeed condition occurs

If a warning tag is attached to the engine start switch

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

or to the controls, DO NOT start the engine or move

engine that has been overhauled.

the controls. Consult with the person that attached

the warning tag before the engine is started.

To stop an electronically controlled engine, cut the

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

All protective guards and all protective covers must

to the engine.

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.

M0087369-05

Safety Section

Electrical System

i02176668

Electrical System

Never disconnect any charging unit circuit or battery

circuit cable from the battery when the charging unit

is operating. A spark can cause the combustible

gases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible

gases that are produced by some batteries, the

negative “-” jump start cable should be connected

last from the external power source to the negative

“-” terminal of the starting motor. If the starting motor

is not equipped with a negative “-” terminal, connect

the jump start cable to the engine block.

Check the electrical wires daily for wires that are

loose or frayed. Tighten all loose electrical wires

before the engine is started. Repair all frayed

electrical wires before the engine is started. See the

Operation and Maintenance Manual for specific

starting instructions.

Grounding Practices

Correct grounding for the engine electrical system is

necessary for optimum engine performance and

reliability. Incorrect grounding will result in

uncontrolled electrical circuit paths and in unreliable

electrical circuit paths.

Uncontrolled electrical circuit paths can result in

damage to main bearings, to crankshaft bearing

journal surfaces, and to aluminum components.

Engines that are installed without engine-to-frame

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 alternator must be grounded to the negative

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

handle the full charging current of the alternator.

M0087369-05

Product Information Section

Product Description

(3) Primary fuel filter

(4) Secondary fuel filter (element type)

(5) Secondary fuel filter

Note: The electric fuel pump is an option, engines

(Table 1, contd)

may have a mechanical fuel lift pump installed.

Cylinders and Arrangement

In-Line 2 cylinder

Bore

67 mm (2.64 inch)

i08164720

Stroke

72 mm (2.83 inch)

Product Description

Displacement

0.507 L (30.939 in³)

Aspiration

Naturally Aspirated

The information within this section is for Perkins

engines 402J-05, 403J-07, 403J-11, 403J-11T, 403J-

Compression Ratio

23.5:1

15, 403J-17, 403J-17T and the 404J-22 engines.

Firing Order

1-2

These engines have the following characteristics:

Rotation that is viewed from the

Counterclockwise

flywheel

• In-Line 2 cylinder (402J-05)

Valve Lash Setting (Inlet)

0.20 mm (0.008 inch)

• In-Line 3 cylinder (403J-07, 403J-11, 403J-11T,

403J-15, 403J-17 and the 403J-17T)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection

Indirect

• In-Line 4 cylinder (404J-22)

• 2 Valves in each cylinder

403J-07 Engine

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.

402J-05 Engine

Illustration 28

g00852304

(A) Exhaust valves

(B) Inlet valves

Table 2

403J-07 Engine Specifications

Maximum Operating Speed

3600 rpm

(rpm)

Illustration 27

g01108476

Cylinders and Arrangement

In-Line 3 cylinder

(A) Exhaust valves

(B) Inlet valves

Bore

67 mm (2.64 inch)

Table 1

Stroke

72 mm (2.83 inch)

402J-05 Engine Specifications

Displacement

0.762 L (46.500 in³)

Maximum Operating Speed

Aspiration

Naturally Aspirated

3600 rpm

(rpm)

(continued)

M0087369-05

Product Information Section

Product Description

(Table 2, contd)

403J-11T Engine

Compression Ratio

23.5:1

Firing Order

1-2-3

Rotation that is viewed from the

Counterclockwise

flywheel

Valve Lash Setting (Inlet)

0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection

Indirect

403J-11 Engine

Illustration 30

g00852304

(A) Exhaust valves

(B) Inlet valves

Table 4

403J-11T Engine Specifications

Maximum Operating Speed

2800 rpm

(rpm)

Cylinders and Arrangement

In-Line 3 cylinder

Bore

77 mm (3.03 inch)

Stroke

81 mm (3.19 inch)

Illustration 29

g00852304

(A) Exhaust valves

Displacement

1.131 L (69.018 in³)

(B) Inlet valves

Aspiration

Turbocharged

Table 3

Compression Ratio

22.1:1

403J-11 Engine Specifications

Firing Order

1-2-3

Maximum Operating Speed

3600 rpm

Rotation that is viewed from the

(rpm)

Counterclockwise

flywheel

Cylinders and Arrangement

In-Line 3 cylinder

Valve Lash Setting (Inlet)

0.20 mm (0.008 inch)

Bore

77 mm (3.03 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Stroke

81 mm (3.19 inch)

Injection

Indirect

Displacement

1.131 L (69.018 in³)

Aspiration

Naturally Aspirated

Compression Ratio

23:1

Firing Order

1-2-3

Rotation that is viewed from the

Counterclockwise

flywheel

Valve Lash Setting (Inlet)

0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection

Indirect

M0087369-05

Product Information Section

Product Description

403J-15 Engine

403J-17 Engine

Illustration 31

g00852304

Illustration 32

g00852304

(A) Exhaust valves

(B) Inlet valves

Table 5

Table 6

403J-15 Engine Specifications

403J-17 Engine Specifications

Maximum Operating Speed

2800 rpm

(rpm)

Cylinders and Arrangement

In-Line 3 cylinder

Cylinders and Arrangement

In-Line 3 cylinder

Bore

84 mm (3.31 inch)

Bore

84 mm (3.31 inch)

Stroke

90 mm (3.54 inch)

Stroke

100 mm (3.94 inch)

Displacement

1.496 L (91.291 in³)

Displacement

1.663 L (101.5 in³)

Aspiration

Naturally Aspirated

Aspiration

Naturally Aspirated

Compression Ratio

22.5:1

Compression Ratio

23:1

Firing Order

1-2-3

Firing Order

1-2-3

Rotation that is viewed from the

Counterclockwise

flywheel

Valve Lash Setting (Inlet)

0.20 mm (0.008 inch)

Valve Lash Setting (Inlet)

0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection

Indirect

Injection

Indirect

M0087369-05

Product Information Section

Product Description

403J-17T Engine

404J-22 Engine

Illustration 33

g00852304

Illustration 34

g00296424

(A) Exhaust valves

(B) Inlet valves

Table 7

Table 8

403J-17T Engine Specifications

404J-22 Engine Specifications

Maximum Operating Speed

3000 rpm

(rpm)

Cylinders and Arrangement

In-Line 3 cylinder

Cylinders and Arrangement

In-Line four cylinder

Bore

84 mm (3.31 inch)

Bore

84.0 mm (3.31 inch)

Stroke

100 mm (3.94 inch)

Stroke

100.0 mm (3.94 inch)

Displacement

1.663 L (101.5 in³)

Displacement

2.216 L (135.229 in³)

Aspiration

Turbocharged

Aspiration

NA⁽¹⁾

Compression Ratio

23:1

Compression Ratio

23.3:1

Firing Order

1-2-3

Firing Order

1-3-4-2

Rotation that is viewed from the

Counterclockwise

flywheel

Valve Lash Setting (Inlet)

0.20 mm (0.008 inch)

Valve Lash Setting (Inlet)

0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

0.20 mm (0.008 inch)

Injection

Indirect

Injection

Indirect

⁽¹⁾ Naturally Aspirated

M0087369-05

Product Information Section

Product Identification Information

i07785792

Product Identification

Information

Emissions Certification Film

i07191707

Plate Locations and Film

Locations

Perkins engines are identified by a serial number.

This serial number is shown on a serial number plate.

The plate is mounted above the fuel injection pump

on the right-hand side of the engine block.

A typical example of an engine number is

IF*****N000001X.

Engine family

Type of engine

*****

The list number of the engine

Country of manufacture

The first digit is a production code.

00001

Engine Serial Number

Illustration 35

g06435423

Typical example

Year of Manufacture

Perkins dealers or Perkins distributors need all these

numbers to determine the components that were

included with the engine. This information permits

accurate identification of replacement part numbers.

Illustration 36

g02157153

Typical example

Illustration 36 is a representation of the label that will

be installed next to the fuel filler cap on the fuel tank

of the application.

M0087369-05

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

i08137513

Product Lifting

Illustration 38

g03380038

Typical example

(1) Rear lifting eye

(2) Front lifting eye

NOTICE

Always inspect lifting eyebolts 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 lifting beam to lift the engine. All

supporting members (chains and cables) should be

parallel to each other. The chains and cables should

Illustration 37

g01097527

be perpendicular to the top of the object that is being

Perpendicular engine lifting

lifted.

Some removals require lifting the fixtures to obtain

correct balance and safety.

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

lifting.

M0087369-05

Operation Section

Product Storage

i05335259

Sealed Coolant System

Product Storage

Ensure that the cooling system is filled with Perkins

ELC, or an antifreeze that meets “ASTM D6210”

specification.

Perkins are not responsible for damage which may

Open Cooling System

occur when an engine is in storage after a period in

service.

Ensure that all cooling drain plugs have been

opened. Allow the coolant to drain. Install the drain

Your Perkins dealer or your Perkins distributor can

plugs. Place a vapor phase inhibitor into the system.

assist in preparing the engine for extended storage

The coolant system must be sealed once the vapor

periods.

phase inhibitor has been introduced. The effect of the

vapor phase inhibitor will be lost if the cooling system

Condition for Storage

is open to the atmosphere.

For maintenance procedures ref to this Operation

The engine must be stored in a water proof building.

and Maintenance Manual.

The building must be kept at a constant temperature.

Engines that are filled with Perkins ELC will have

coolant protection to an ambient temperature of

Monthly Checks

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

to extreme variations in temperature and humidity.

The crankshaft must be rotated in order to change

the spring loading on the valve train. Rotate the

Storage Period

crankshaft more than 180 degrees. Visibly check for

damage or corrosion to the engine.

An engine can be stored for up to 6 months provided

Ensure that the engine is covered completely before

all the recommendation are adhered to.

storage. Log the procedure in the record for the

engine.

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

filters 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 filter water

separator. Ensure that the fuel tank is full.

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.

M0087369-05

Operation Section

Features and Controls

3. Determine if the engine must be shut down

Features and Controls

immediately or if the engine can be cooled by

reducing the load.

i07191743

Tachometer - This gauge indicates

Gauges and Indicators

engine speed (rpm). When the throttle

controller is moved to the full throttle

position without load, the engine is running at

Your engine may not have the same gauges or all the

high idle. The engine is running at the full load

gauges that are described. For more information

rpm when the throttle controller is at the full

about the gauge package, see the OEM information.

throttle position with maximum rated load.

Gauges provide indications of engine performance.

Ensure that the gauges are in good working order.

NOTICE

To help prevent engine damage, never exceed the

Determine the normal operating range by observing

high idle rpm. Overspeeding can result in serious

the gauges over a period of time.

damage to the engine. The engine can be operated

Noticeable changes in gauge readings indicate

at high idle without damage, but should never be al-

potential gauge or engine problems. Problems may

lowed to exceed high idle rpm.

also be indicated by gauge readings that change

even if the readings are within specifications.

Determine and correct the cause of any significant

Ammeter - This gauge indicates the

change in the readings. Consult your Perkins dealer

amount of charge or discharge in the

or your Perkins distributor for assistance.

battery charging circuit. Operation of

the indicator should be to the right side of “0”

NOTICE

(zero).

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

maximum coolant temperature is exceeded, STOP

Fuel Level - This gauge indicates the

the engine. Engine damage can result.

fuel level in the fuel tank. The fuel level

gauge operates when the “START/STOP”

switch is in the “ON” position.

Engine Oil Pressure - The oil pressure

should be greatest after a cold engine is

Service Hour Meter - The gauge

started. The typical engine oil pressure

indicates operating time of the engine.

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

rated rpm.

Indicators and Lamps

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

stable and the gauge reading changes, perform the

The following indicator lamps can be installed, for

following procedure:

more information refer to the Original Equipment

Manufacturer (OEM)

1. Remove the load.

• Warning lamp

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

• Low-pressure oil lamp

Jacket Water Coolant Temperature -

i08164725

Typical temperature range is 71 to 96°C

(160 to 205°F). The maximum allowable

Overspeed

temperature with the pressurized cooling system

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

temperatures may occur under certain

•

402J-05

3600 Revolution Per Minute

conditions. The water temperature reading may

(RPM)

vary according to load. The reading should never

exceed the boiling point for the pressurized

•

403J-07

3600 RPM

system that is being used.

•

403J-11

3600 RPM

If the engine is operating above the normal range

and steam becomes apparent, perform the following

•

403J-11T

2800 RPM

procedure:

•

403J-15

2800 RPM

1. Reduce the load and the engine rpm.

2. Inspect the cooling system for leaks.

•

403J-17

2800 RPM

M0087369-05

Operation Section

Engine Starting

i08193087

Engine Starting

Starting the Engine

i04053911

Before Starting Engine

Perform the required daily maintenance and other

Do not use aerosol types of starting aids such as

periodic maintenance before the engine is started.

ether. Such use could result in an explosion and

Inspect the engine compartment. This inspection can

personal injury.

help prevent major repairs at a later date. Refer to

the Operation and Maintenance Manual,

Refer to the OEM manual for your type of controls.

“Maintenance Interval Schedule” for more

Use the following procedure to start the engine.

information.

1. Move the throttle lever to the low idle position

• Ensure that the engine has an adequate fuel

before you start the engine.

supply.

NOTICE

• Open the fuel supply valve (if equipped).

Do not operate the glow plugs for more than 60 sec-

onds at one time. Damage to the glow plugs could

If the engine has not been started for several weeks,

occur.

fuel may have drained from the fuel system. Air may

have entered the filter housing. Also, when fuel filters

have been changed, some air pockets will be trapped

in the engine. In these instances, prime the fuel

system. Refer to the Operation and Maintenance

Manual, “Fuel System - Prime” for more information

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

specification is correct and that the fuel condition is

correct. Refer to the Operation and Maintenance

Manual, “Fuel Recommendations”.

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.

• Do not start the engine or move any of the controls

if there is a “DO NOT OPERATE” warning tag or

similar warning tag attached to the start switch or

to the controls.

Illustration 40

g06581786

• Reset all of the shutoffs or alarm components.

2. Turn the engine start switch to the HEAT position.

• Ensure that any driven equipment has been

Hold the engine start switch in the HEAT position

disengaged. Minimize electrical loads or remove

any electrical loads.

for time shown in illustration 40 . This action will

activate the glow plugs and aid in the starting of

the engine.

NOTICE

Do not crank the engine for more than 30 seconds.

Allow the electric starting motor to cool for two mi-

nutes before cranking the engine again.

M0087369-05

Operation Section

Starting with Jump Start Cables

3. When the glow plug indicator light is illuminated,

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

turn the engine start switch to the START position

the positive cable terminal of the discharged

and crank the engine.

battery. Connect the other positive end of the

jump-start cable to the positive cable terminal of

4. When the engine starts, release the engine start

the electrical source.

switch.

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

5. Allow the engine to idle. Refer to the Operation

to the negative cable terminal of the electrical

and Maintenance Manual, “After Starting Engine”

source. Connect the other negative end of the

for more information.

jump-start cable to the engine block or to the

Note: If the glow plug indicator light flashes rapidly

chassis ground. This procedure helps to prevent

for 2 to 3 seconds or fails to illuminate, a malfunction

potential sparks from igniting the combustible

exists in the cold start system. Do not use ether or

gases that are produced by some batteries.

other starting fluids to start the engine.

Note: The engine electronic control module must be

6. If the engine does not start, release the engine

powered before the starting motor is operated or

start switch and allow the electric starting motor to

damage can occur.

cool. Then, repeat steps 2 through step 5.

4. Start the engine in the normal operating

7. Turn the engine start switch to the OFF position to

procedure. Refer to this Operation and

stop the engine.

Maintenance Manual, “Starting the Engine”.

5. Immediately after the engine is started, disconnect

i05339814

the jump-start cables in reverse order.

Starting with Jump Start

After jump starting, the alternator may not be able to

fully recharge batteries that are severely discharged.

Cables

The batteries must be replaced or charged to the

proper voltage with a battery charger after the engine

is stopped.

i06791278

Improper jump start cable connections can cause

an explosion resulting in personal injury.

After Starting Engine

Prevent sparks near the batteries. Sparks could

cause vapors to explode. Do not allow jump start

cable ends to contact each other or the engine.

Note: In temperatures from 0°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.

NOTICE

Using a battery source with the same voltage as the

When the engine idles during warm-up, observe the

electric starting motor. Use ONLY equal voltage for

following conditions:

jump starting. The use of higher voltage will damage

the electrical system.

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

Do not reverse the battery cables. The alternator can

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

be damaged. Attach ground cable last and remove

before operating the engine under load. This

first.

action may not be possible in some applications.

Turn all electrical accessories OFF before attaching

• Operate the engine at low idle until all systems

the jump start cables.

achieve operating temperatures. Check all gauges

during the warm-up period.

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

tion before attaching the jump start cables to the en-

Constant speed engines should be allowed to

gine being started.

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

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

speed with no load for 2 minutes.

OFF position. Turn off all the engines accessories.

M0087369-05

Operation Section

Engine Operation

Table 9

Engine Operation

Engine

CO₂ Value

i08246271

402J-05

1011.99 g/kWh

403J-07

1011.99 g/kWh

Engine Operation

403J-11

910.01 g/kWh

403J-11T

940.15 g/kWh

General Engine Operation

403J-15

940.14 g/kWh

Correct operation and maintenance are key factors in

403J-17 variable speed

940.14 g/kWh

obtaining the maximum life and economy of the

engine

engine. If the directions in the Operation and

Maintenance Manual are followed, costs can be

403J-17 constant speed

780.1 g/kWh

minimized and engine service life can be maximized.

engine

403J-17T

1072.31 g/kWh

The engine can be operated at the rated rpm after

the engine reaches operating temperature. The

404J-22 variable speed

940.14 g/kWh

engine will reach normal operating temperature

engine

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

low-power demand. This procedure is more effective

404J-22 constant speed

780.1 g/kWh

than idling the engine at no load. The engine should

engine

reach operating temperature in a few minutes.

Gauge readings should be observed and the data

i05339949

should be recorded frequently while the engine is

operating. Comparing the data over time will help to

Fuel Conservation Practices

determine normal readings for each gauge.

Comparing data over time will also help detect

abnormal operating developments. Significant

The efficiency of the engine can affect the fuel

changes in the readings should be investigated.

economy. Perkins design and technology in

manufacturing provides maximum fuel efficiency in

NOTICE

all applications. Follow the recommended procedures

The engine and emissions control system shall be

in order to attain optimum performance for the life of

operated, used, and maintained in accordance with

the engine.

the instructions provided. Failure to follow the instruc-

tions could result in emissions performance that does

• Avoid spilling fuel.

not meet the requirements applicable to the category

of the engine. No deliberate tampering with, or mis-

Fuel expands when the fuel is warmed up. The fuel

use of the engine emissions control system should

may overflow from the fuel tank. Inspect fuel lines for

take place. Prompt action is critical to rectify any in-

leaks. Repair the fuel lines, as needed.

correct operation, use, or maintenance of the emis-

sions control system.

• Be aware of the properties of the different fuels.

Use only the recommended fuels. Refer to the

Operations and Maintenance Manual, “Fuel

Carbon Dioxide (CO₂) Emissions

Recommendations”for further information.

Statement

• Avoid unnecessary idling.

Emissions regulations require that the value of the

Shut off the engine rather than idle for long periods of

CO2 emissions be reported to the end user. For the

time.

engines listed in table 9 , g/kWh was determined to

be the CO2 value during the EU type approval

• Observe the service indicator frequently. Keep the

process. This value was recorded in EU type

air cleaner elements clean.

approval certificate. This CO2 measurement results

from testing over a fixed test cycle, under laboratory

• Maintain a good electrical system.

conditions, with a parent engine representative of the

engine family. These values shall not imply or

One faulty battery cell will overwork the alternator.

express any guarantee of the performance of a

This fault will consume excess power and excess

particular engine.

fuel.

• The belt should be in good condition.

M0087369-05

Operation Section

Cold Weather Operation

• Install the correct specification of engine lubricant

Cold Weather Operation

before the beginning of cold weather. Refer to this

Operation and Maintenance Manual, “Fluid

i07192374

Recommendations” for the recommended

viscosity of oil.

Cold Weather Operation

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

weekly.

Perkins Diesel Engines can operate effectively in

• Check all electrical wiring and connections for any

cold weather. During cold weather, the starting and

fraying or damaged insulation.

the operation of the diesel engine depends on the

following items:

• Keep all batteries fully charged and warm by

ensuring that the engine is allowed to operate at

• The type of fuel that is used

normal operating temperature.

• The viscosity of the engine oil

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

• The operation of the glow plugs

• Check the air cleaners and the air intake daily.

• Battery condition

Check the air intake more often when you operate

in snow.

This section will cover the following information:

• Ensure that the glow plugs are in working order.

• Potential problems that are caused by cold-

weather operation

• Suggest steps which can be taken to minimize

Personal injury or property damage can result

starting problems and operating problems when

from alcohol or starting fluids.

the ambient air temperature is between

0° to-40 °C (32° to 40 °F).

Alcohol or starting fluids are highly flammable

and toxic and if improperly stored could result in

The operation and maintenance of an engine in

injury or property damage.

freezing temperatures is complex . This complexity is

because of the following conditions:

• Weather conditions

• Engine applications

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and

Recommendations from your Perkins dealer or your

personal injury.

Perkins distributor are based on past proven

practices. The information that is contained in this

section provides guidelines for cold-weather

• For jump starting with cables in cold weather, refer

operation.

to the Operation and Maintenance Manual,

“Starting with Jump-Start Cables.” for instructions.

Hints for Cold-Weather Operation

Viscosity of the Engine Lubrication

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

Oil

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

is achieved. Achieving operating temperature will

Correct engine oil viscosity is essential. Oil viscosity

help prevent the intake valves and exhaust valves

affects lubrication properties and wear protection that

from sticking.

the oil provides for the engine. Refer to this Operation

and Maintenance Manual, “Fluid Recommendations”

• The cooling system and the lubrication system for

for the recommended viscosity of oil.

the engine do not lose heat immediately upon

shutdown. The engine can be shut down for a

Recommendations for the Coolant

period and the engine can still have the ability to

start readily.

Provide cooling system protection for the lowest

expected outside temperature. Refer to this

Operation and Maintenance Manual, “Fluid

Recommendations” for the recommended coolant

mixture.

M0087369-05

Operation Section

Cold Weather Operation

In cold weather, check the coolant often for the

• Other damage to valve train components can

correct glycol concentration to ensure adequate

result.

freeze protection.

When an engine is started, the engine must be

operated until the coolant temperature is 80° C

Engine Block Heaters

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

stems will be kept at a minimum and the free

Engine block heaters (if equipped) heat the engine

operation of the valves and the valve components will

jacket water that surrounds the combustion

be maintained.

chambers. This heat provides the following functions:

The engine must be thoroughly warmed to keep

• Startability is improved.

other engine parts in better condition. The service life

of the engine will be extended. Lubrication will be

• Warm up time is reduced.

improved. There will be less acid and less sludge in

the oil. This condition will provide longer service life

An electric block heater can be activated once the

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

for the engine bearings, the piston rings, and other

parts. However, limit unnecessary idle time to 10

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

minutes to reduce wear and unnecessary fuel

your Perkins dealer or your Perkins distributor for

consumption.

more information.

The Water Temperature Regulator and

Idling the Engine

Insulated Heater Lines

When idling after the engine is started in cold

The engine is equipped with a water temperature

weather, increase the engine rpm from 1000 to 1200

regulator. When the engine coolant is below the

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

correct operating temperature, jacket water circulates

Maintaining an elevated low idle speed for extended

through the engine cylinder block and into the engine

periods will be easier with the installation of a hand

cylinder head. The coolant then returns to the

throttle. The engine should not be “raced” to speed

cylinder block via an internal passage that bypasses

up the warm-up process.

the valve of the coolant temperature regulator. This

While the engine is idling, the application of a light

return ensures that coolant flows around the engine

under cold operating conditions. The water

load (parasitic load) will help in achieving the

minimum operating temperature. The minimum

temperature regulator begins to open when the

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

engine jacket water has reached the correct

minimum operating temperature. As the jacket water

coolant temperature rises above the minimum

Recommendations for Coolant

operating temperature, the water temperature

Warm Up

regulator opens further allowing more coolant

through the radiator to dissipate excess heat.

Warm up an engine that has cooled below normal

The progressive opening of the water temperature

operating temperatures due to inactivity. This warm

regulator operates the progressive closing of the

-up should be performed before the engine is

bypass passage between the cylinder block and

returned to full operation. During operation in very

head. This action ensures maximum coolant flow to

cold temperature conditions, damage to engine valve

the radiator to achieve maximum heat dissipation.

mechanisms can result from engine operation for

short intervals. This damage can happen if the

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

engine is started and the engine is stopped many

flow can damage the fuel system. Perkins

times without being operated to warm up completely.

discourages the use of all air flow restriction devices

such as radiator shutters. Restriction of the air flow

When the engine is operated below normal operating

can result in the following: high exhaust

temperatures, fuel and oil are not burned completely

in the combustion chamber. This fuel and oil causes

temperatures, power loss, excessive fan usage, and

soft carbon deposits to form on the valve stems.

reduction in fuel economy.

Generally, the deposits do not cause problems and

the deposits are burned off during operation at

normal engine operating temperatures.

When starting and stopping an engine many times

without being operated to warm up completely, the

carbon deposits become thicker. This starting and

stopping can cause the following problems:

• Valves become stuck.

• Pushrods may become bent.

M0087369-05

Operation Section

Fuel and the Effect from Cold Weather

A cab heater is beneficial in very cold weather. The

• A higher energy per unit volume of fuel

feed from the engine and the return lines from the

cab should be insulated to reduce heat loss to the

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

outside air.

use of Group 3 fuels is not covered by the Perkins

warranty.

i05340086

Group 3 fuels include Low Temperature Fuels and

Aviation Kerosene Fuels.

Fuel and the Effect from Cold

Special fuels include Biofuel.

Weather

The cloud point is a temperature that allows wax

crystals to form in the fuel. These crystals can cause

Note: Only use grades of fuel that are recommended

the fuel filters to plug.

by Perkins. Refer to this Operation and Maintenance

The pour point is the temperature when diesel fuel

Manual, “Fluid Recommendations”.

will thicken. The diesel fuel becomes more resistant

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

The following fuels can be used in this series of

engine.

Be aware of these facts when diesel fuel is

purchased. Consider the average ambient air

• Group 1

temperature for the engines application. Engines that

are fueled in one climate may not operate well if the

• Group 2

engines are moved to another climate. Problems can

result due to changes in temperature.

• Group 3

Before troubleshooting for low power or for poor

• Special Fuels

performance in the winter, check the fuel for waxing.

Perkins prefer only Group 1 and Group 2 fuels for

Low temperature fuels may be available for engine

use in this series of engines.

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

fuels limit the formation of wax in the fuel at low

Group 1 fuels are the preferred group of fuels for

temperatures.

general use by Perkins. Group 1 fuels maximize

engine life and engine performance. Group 1 fuels

For more information on cold-weather operation,

are usually less available than Group 2 fuels.

refer to the Operation and Maintenance Manual,

Frequently, Group 1 fuels are not available in colder

“Cold Weather Operation and Fuel Related

climates during the winter.

Components in Cold Weather”.

Note: Group 2 fuels must have a maximum wear

scar of 650 micrometers (HFRR to ISO 12156-1).

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Group 2 fuels are considered acceptable for issues of

Fuel Related Components in

warranty. This group of fuels may reduce the life of

the engine, the engines maximum power, and the

Cold Weather

engines fuel efficiency.

When Group 2 diesel fuels are used, the following

components provide a means of minimizing problems

Fuel Tanks

in cold weather:

Condensation can form in partially filled fuel tanks.

• Glow plugs

Top off the fuel tanks after you operate the engine.

• Engine coolant heaters, which may be an Original

Fuel tanks should contain some provision for draining

Equipment Manufacture (OEM) option

water and sediment from the bottom of the tanks.

Some fuel tanks use supply pipes that allow water

• Fuel heaters, which may be an OEM option

and sediment to settle below the end of the fuel

supply pipe.

• Fuel line insulation, which may be an OEM option

Some fuel tanks use supply lines that take fuel

There are three major differences between Group 1

directly from the bottom of the tank. If the engine is

fuels and Group 2 fuels. Group 1 fuels have the

equipped with this system, regular maintenance of

following different characteristics to Group 2 fuels.

the fuel system filter is important.

• A lower cloud point

• Alowerpourpoint

M0087369-05

Operation Section

Engine Stopping

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Engine Stopping

After Stopping Engine

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Stopping the Engine

Note: Before you check the engine oil, do not

operate the engine for at least 10 minutes in order to

allow the engine oil to return to the oil pan.

NOTICE

• Check the crankcase oil level. Maintain the oil

Stopping the engine immediately after it has been

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

working under load, can result in overheating and ac-

on the engine oil level gauge.

celerated wear of the engine components.

Avoid accelerating the engine prior to shutting it

• If necessary, perform minor adjustments. Repair

down.

any leaks and tighten any loose bolts.

Avoiding hot engine shutdowns will maximize turbo-

• If the engine is equipped with a service hour

charger shaft and bearing life.

meter, note the reading. Perform the maintenance

that is in the Operation and Maintenance Manual,

“Maintenance Interval Schedule”.

Note: Individual applications will have different

control systems. Ensure that the shutoff procedures

• Fill the fuel tank in order to help prevent

are understood. Use the following general guidelines

accumulation of moisture in the fuel. Do not overfill

to stop the engine.

the fuel tank.

1. Remove the load from the engine. Reduce the

NOTICE

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

Only use antifreeze/coolant mixtures recommended

idle for 5 minutes to cool the engine.

in the Refill Capacities and Recommendations topic

that is in this Operation and Maintenance Manual.

2. Stop the engine after the cool down period

Failure to do so can cause engine damage.

according to the shutoff system on the engine.

Turn the ignition key switch to the OFF position. If

necessary, refer to the instructions that are

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

provided by the OEM.

• If freezing temperatures are expected, check the

coolant for correct antifreeze protection. The

NOTICE

cooling system must be protected against freezing

Before any service or repairs are performed, ensure

that the power supply to the engine is disconnected.

to the lowest expected outside temperature. Add

the correct coolant/water mixture, if necessary.

• Perform all required periodic maintenance on all

i07764840

driven equipment. This maintenance is outlined in

the instructions from the OEM.

Emergency Stopping

NOTICE

Emergency shutoff controls are for EMERGENCY

use ONLY. DO NOT use emergency shutoff devices

or controls for normal stopping procedure.

The Original Equipment Manufacturer (OEM) may

have equipped the application with an emergency

stop button. For more information about the

emergency stop button, refer to the OEM information.

Ensure that any components for the external system

that support the engine operation are secured after

the engine is stopped.

M0087369-05

Maintenance Section

Refill Capacities

(Table 11, contd)

Maintenance Section

⁽²⁾ The Total Lubrication System includes the capacity for the

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

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

value for the capacity of the Total Lubrication System in this

Refill Capacities

row.

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403J-11 Engine

Refill Capacities

Table 12

403J-11 Engine

Refill Capacities

Lubrication System

Compartment or System

Minimum

Maximum

The refill capacities for the engine crankcase reflect

3.4 L

4.4 L

Crankcase Oil Sump⁽¹⁾

the approximate capacity of the crankcase or sump

(3.6 qt)

(4.7 qt)

plus standard oil filters. Auxiliary oil filter systems will

Total Lubrication System⁽²⁾

require more oil. Refer to the OEM specifications for

the capacity of the auxiliary oil filter. Refer to the

⁽¹⁾ These values are the approximate capacities for the crankcase

Operation and Maintenance Manual, “Maintenance

oil sump which includes the standard factory installed oil filters.

Engines with auxiliary oil filters will require more oil. Refer to

Section” for more information on Lubricant

the OEM specifications for the capacity of the auxiliary oil filter.

Specifications.

The Total Lubrication System includes the capacity for the

(2)

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

402J-05 Engine

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

value for the capacity of the Total Lubrication System in this

Table 10

row.

402J-05 Engine

403J-11T

Refill Capacities

Compartment or System

Minimum

Maximum

Table 13

403J-11T Engine

1.61 L

2.01 L

Crankcase Oil Sump⁽¹⁾

Refill Capacities

(1.7 qt)

(2.1 qt)