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Perkins 404F-22 Service Manual

Perkins 404F-22
108 pages
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Operation and
Maintenance
Manual
403F-15T, 404F-22 and 404F-22T
Industrial Engines
EL (Engine)
EN (Engine)
EP (Engine)
SEBU8609-01
January 2013

Table of Contents

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Perkins 404F-22 Specifications

General IconGeneral
BrandPerkins
Model404F-22
CategoryEngine
LanguageEnglish

Summary

Operation and Maintenance Manual

Engine Identification

Identifies the engine models covered in the manual.

Important Safety Information

Safety Messages

Explains warning symbols, signal words, and their meanings.

Foreword

Literature Information

Describes the manual's purpose and content.

Safety

Introduces the safety precautions section.

Operation

Introduces the operation procedures section.

Maintenance

Introduces the maintenance procedures section.

Safety Section

Safety Messages

Details warning signs and their locations on the engine.

General Hazard Information

Identifies hazards and warning signals.

Safety Section

General Hazard Information

Lists general safety precautions and procedures.

Safety Section

General Hazard Information

Covers pressure air/water safety and fluid penetration hazards.

Safety Section

General Hazard Information

Discusses inhalation hazards and asbestos safety.

Dispose of Waste Properly

Provides guidelines for proper waste disposal.

Safety Section

Burn Prevention

Details hazards from hot engine parts and systems.

Coolant

Discusses hazards associated with hot coolant.

Safety Section

Fire Prevention and Explosion Prevention

Covers risks from flammable fluids and electrical issues.

Safety Section

Crushing Prevention and Cutting Prevention

Details hazards from moving parts and objects.

Safety Section

Before Starting Engine

Covers pre-start maintenance and safety checks.

Engine Starting

Outlines safety precautions during engine start.

Safety Section

Engine Stopping

Details safe engine stopping procedures.

Electrical System

Safety precautions for electrical systems.

Safety Section

Engine Electronics

Safety precautions for electronic systems.

Product Information Section

Model View Illustrations (Engines and Aftertreatment)

Shows typical engine features and components.

Product Information Section

Model View Illustrations (Engines and Aftertreatment)

Shows typical engine features and components.

Product Information Section

Model View Illustrations (Engines and Aftertreatment)

Shows typical engine features with labels.

Product Information Section

Model View Illustrations (Engines and Aftertreatment)

Shows typical engine features with labels.

Product Information Section

Model View Illustrations (Engines and Aftertreatment)

Shows typical engine features with labels.

Product Information Section

Aftertreatment System

Illustrates the aftertreatment system components.

Product Information Section

Off Engine Parts

Illustrates the ECM and in-line fuel filter.

Product Information Section

Product Description

Describes the 400F engine's features.

Product Information Section

Product Description

Provides engine specifications for 403F-15T and 404F-22.

Product Information Section

Product Description

Details engine specs, electronic features, diagnostics.

Product Information Section

Product Description

Discusses aftermarket products and aftertreatment system.

Product Identification Information

Plate Locations and Film Locations

Shows serial number plate and emissions label location.

Product Identification Information

Reference Information

Information needed for ordering parts.

Operation Section

Lifting and Storage

Covers lifting procedures and product storage.

Operation Section

Lifting and Storage

Discusses storage procedures and monthly checks.

Features and Controls

Alarms and Shutoffs

Explains engine alarms and shutdown conditions.

Features and Controls

Gauges and Indicators

Describes various gauges and indicator lamps.

Features and Controls

Monitoring System

Explains engine monitoring modes (Warning, Derate, Shutdown).

Features and Controls

Monitoring System (Engine Warning Indicators)

Details warning indicators and operator actions.

Sensors and Electrical Components (Engine and Aftertreatment)

Lists key sensors and electrical components.

Engine Diagnostics

Self-Diagnostics

Explains the engine's self-diagnostic capabilities.

Engine Operation with Active Diagnostic Codes

How to operate with active diagnostic codes.

Engine Diagnostics

Configuration Parameters

How parameters affect engine performance and emissions.

Engine Starting

Before Starting Engine

Covers pre-start maintenance and checks.

Cold Weather Starting

Procedure for starting the engine in cold weather.

Engine Starting

Starting the Engine

Step-by-step procedure for starting the engine.

Starting with Jump Start Cables

Safety and procedure for jump-starting.

Engine Starting

After Starting Engine

Post-start checks and observations.

Engine Operation

Engine Operation

General principles for engine life and economy.

Diesel Particulate Filter Regeneration

Explains the DPF regeneration process.

Engine Operation

Diesel Particulate Filter Regeneration

Details regeneration indicators, switches, and modes.

Engine Operation

Fuel Conservation Practices

Tips for efficient fuel usage.

Cold Weather Operation

Cold Weather Operation

General advice for operating in cold weather.

Hints for Cold Weather Operation

Specific tips for cold weather operation.

Cold Weather Operation

Viscosity of the Engine Lubrication Oil

Importance of oil viscosity in cold weather.

Recommendations for the Coolant

Coolant recommendations for warm-up and freeze protection.

Cold Weather Operation

Fuel and the Effect from Cold Weather

How fuel quality and type affect cold weather performance.

Cold Weather Operation

Fuel Related Components in Cold Weather

Discusses fuel system components in cold weather.

Engine Stopping

Stopping the Engine

Normal engine stopping procedure.

Emergency Stopping

Use of emergency stop controls.

Maintenance Section

Refill Capacities

Lubrication and cooling system capacities.

Maintenance Section

Refill Capacities

Cooling system capacities and fluid recommendations.

Maintenance Section

Fluid Recommendations

Discusses glycol types and coolant recommendations.

Maintenance Section

Fluid Recommendations

Covers ELC coolant and system cleaning.

Maintenance Section

Fluid Recommendations

Details engine oil specifications and viscosity.

Refill Capacities

Fluid Recommendations

Covers diesel fuel requirements.

Maintenance Recommendations

System Pressure Release

Procedure for releasing pressure in systems.

Maintenance Recommendations

Severe Service Application

Defines severe service and its impact on maintenance.

Maintenance Interval Schedule

Maintenance Recommendations

Alternator and Fan Belts - Inspect/Adjust

Procedure for inspecting and adjusting belts.

Maintenance Recommendations

Battery - Replace

Procedure for replacing a battery.

Maintenance Recommendations

Battery or Battery Cable - Disconnect

Procedure for disconnecting battery cables.

Maintenance Recommendations

Coolant (Commercial Heavy-Duty) - Change

Procedure for changing commercial heavy-duty coolant.

Maintenance Recommendations

Coolant (ELC) - Change

Procedure for changing ELC coolant.

Maintenance Recommendations

Coolant Level - Check

Checking the engine coolant level.

Maintenance Recommendations

Coolant Level - Check

Checking the engine coolant level.

Maintenance Recommendations

Coolant Temperature Regulator - Replace

Procedure for replacing the water temperature regulator.

Maintenance Recommendations

Crankcase Breather (Canister) - Replace

Procedure for replacing the crankcase breather canister.

Maintenance Recommendations

Diesel Particulate Filter - Clean

Procedure for cleaning the Diesel Particulate Filter (DPF).

Maintenance Recommendations

Engine - Clean

Procedure for cleaning the engine.

Engine Air Cleaner Element - Replace

Procedure for replacing the air cleaner element.

Maintenance Recommendations

Engine Oil Level - Check

Procedure for checking the engine oil level.

Maintenance Recommendations

Engine Oil and Filter - Change

Procedure for changing engine oil and filter.

Maintenance Recommendations

Engine Valve Lash - Check

Procedure for checking engine valve lash.

Maintenance Recommendations

Fan Clearance - Check

Procedure for checking fan clearance.

Fuel Filter (In-Line) - Replace

Procedure for replacing the in-line fuel filter.

Maintenance Recommendations

Fuel Injector - Test/Change

Procedure for testing and changing fuel injectors.

Maintenance Recommendations

Fuel System - Prime

Procedure for priming the fuel system.

Fuel System Secondary Filter - Replace

Procedure for replacing the secondary fuel filter.

Maintenance Recommendations

Fuel Tank Water and Sediment - Drain

Draining water and sediment from the fuel tank.

Glow Plugs (ARD Combustion) - Replace

Procedure for replacing glow plugs.

Maintenance Recommendations

Hoses and Clamps - Inspect/Replace

Procedure for inspecting and replacing hoses and clamps.

Maintenance Recommendations

Radiator - Clean

Procedure for cleaning the radiator.

Maintenance Recommendations

Radiator Pressure Cap - Clean/Replace

Procedure for cleaning and replacing the radiator pressure cap.

Turbocharger - Inspect

Procedure for inspecting the turbocharger.

Maintenance Recommendations

Walk-Around Inspection

Performing a walk-around inspection for leaks and loose connections.

Maintenance Recommendations

Water Pump - Inspect

Procedure for inspecting the water pump.

Warranty Section

Federal Emission Control Warranty

Details the federal emissions warranty.

Warranty Section

California Emission Control Warranty Statement

Details the California emissions warranty.

Warranty Section

Emissions Warranty Information

Explains aftertreatment system function and maintenance.

Reference Information Section

Engine Protection Plans (Extended Service Contract)

Information on extended service contracts.

Product and Dealer Information

Product Information

Fields for engine and equipment details.

Dealer Information

Fields for dealer contact details.

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