Perkins 1204F-E44TA Systems Operation Testing And Adjusting
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Perkins 1204F-E44TA Systems Operation Testing And Adjusting

Industrial engines
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UENR4490-01 (en-us)
February 2017
Systems Operation
Testing and Adjusting
1204F-E44TA and 1204F-E44TTA
Industrial Engines
MT (Engine)
MU (Engine)
MW (Engine)
This document has been printed from SPI2. NOT FOR RESALE

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Summary of Contents for Perkins 1204F-E44TA

  • Page 1 UENR4490-01 (en-us) February 2017 Systems Operation Testing and Adjusting 1204F-E44TA and 1204F-E44TTA Industrial Engines MT (Engine) MU (Engine) MW (Engine) This document has been printed from SPI2. NOT FOR RESALE...
  • Page 2 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.

  • Page 3: Table Of Contents

    UENR4490-01 Table of Contents Table of Contents Cooling System - Check ........110 Cooling System - Inspect ........110 Cooling System - Test........111 Engine Oil Cooler - Inspect ........ 112 Systems Operation Section Water Temperature Regulator - Test ....113 Water Pump - Inspect ........

  • Page 4: Systems Operation Section

    • the fuel injection pump gear Introduction • the water pump gear The camshaft runs at half the rpm of the crankshaft. The 1204F-E44TA and 1204F-E44TTA diesel The fuel injection pump runs at the same rpm as the engines are electronically controlled. The 1204F- crankshaft.
  • Page 5 UENR4490-01 General Information 1204F-E44TTA Engine with Series Turbochargers Illustration 1 g03404422 Typical example (1) Front lifting eye (6) Fuel priming pump (11) Oil sampling valve (2) Crankcase breather (7) In line fuel filter (12) Fuel injection pump (3) Secondary fuel filter (8) Oil level gauge (dipstick) (13) Oil filler (4) Primary fuel filter...
  • Page 6 UENR4490-01 General Information Illustration 2 g03404423 Typical example (14) Air intake (16) Water pump (18) Belt tensioner (15) Coolant outlet (17) Coolant intake (19) Belt This document has been printed from SPI2. NOT FOR RESALE...
  • Page 7 UENR4490-01 General Information Illustration 3 g03404515 Typical example (20) Back pressure valve (25) Starter solenoid (30) Flywheel housing (21) High-pressure turbocharger (26) Starting motor (31) Exhaust gas cooler (NRS) (22) Low-pressure turbocharger (27) Starter relay (32) Rear lifting eye (23) Alternator (28) Oil drain tap (24) Refrigerant compressor (29) Flywheel...
  • Page 8 UENR4490-01 General Information 1204F-E44TA Engine with Single Turbocharger Illustration 4 g03404421 Typical example This document has been printed from SPI2. NOT FOR RESALE...

  • Page 9: Engine Operation

    UENR4490-01 Engine Operation Engine Operation The cast iron cylinder block for the four cylinder engine has four cylinders which are arranged in-line. The cylinder block is made of cast iron. The cylinder block provides support for the full length of the cylinder bores.
  • Page 10 UENR4490-01 Engine Operation Cylinder Head Pistons, Rings, and Connecting rods Illustration 6 g02466936 Typical example (1) Valve keepers (2) Valve spring retainer (3) Valve spring The engine has a cast iron cylinder head (5). The inlet manifold is integral within the cylinder head. There are two inlet valves and two exhaust valves for Illustration 7 g03728612...
  • Page 11 UENR4490-01 Engine Operation The connecting rods (4) are machined from forged A gear at the front of the crankshaft drives the timing steel. The connecting rods have bearing caps (6) that gears. The crankshaft gear turns the idler gear which are fracture split.
  • Page 12 UENR4490-01 Engine Operation The camshaft rotates at half the engine speed. The fuel injection pump rotates at engine speed. Camshaft The engine has a single camshaft. The camshaft is made of cast iron. The camshaft lobes are chill hardened. The camshaft is driven at the front end. As the camshaft turns, the camshaft lobes move the valve system components.

  • Page 13: Air Inlet And Exhaust System (Single Turbocharger)

    UENR4490-01 Engine Operation i05806411 Air Inlet and Exhaust System (Single Turbocharger) Illustration 10 g02469917 Air inlet and exhaust system (1) Aftercooler core (4) Back pressure valve (7) Exhaust cooler (NRS) (2) Air filter (5) Turbocharger (8) Exhaust gas valve (NRS) (3) Clean Emissions Module (CEM) (6) Wastegate actuator (9) Wastegate regulator...
  • Page 14 UENR4490-01 Engine Operation Air is drawn in through the air cleaner into the air inlet of the turbocharger by the turbocharger compressor wheel. The air is compressed to a pressure of about 150 kPa (22 psi) and heated to about 120° C (248°...
  • Page 15 UENR4490-01 Engine Operation Illustration 11 g03706055 Typical example The NOx Reduction System (NRS) operates with the Exhaust gases from the exhaust manifold enter the transfer of the hot exhaust gas from the exhaust inlet of the turbocharger in order to turn the manifold to the exhaust cooler (7).
  • Page 16 UENR4490-01 Engine Operation Turbocharger Illustration 13 g03706081 Typical example Illustration 12 g00302786 (12) Wastegate actuator Typical example of a cross section of a turbocharger (13) Actuating lever (1) Air intake (14) Line (boost pressure) (2) Compressor housing (3) Compressor wheel (4) Bearing (5) Oil inlet port (6) Bearing...
  • Page 17 UENR4490-01 Engine Operation Crankcase Breather When the load on the engine increases, more fuel is injected into the cylinders. The combustion of this The engine crankcase breather is a filtered system. additional fuel produces more exhaust gases. The The crankcase breather system consists of two main additional exhaust gases cause the turbine and the elements, a primary separator in the valve compressor wheels of the turbocharger to turn faster.
  • Page 18 UENR4490-01 Engine Operation Valve System Components The engine lubricating oil enters the lifter (4) through a non-return valve. The engine lubricating oil increases the length of the lifter (4) until all valve lash is removed. If the engine is stationary for a prolonged period the valve springs will cause the lifter (4) to shorten so that when the engine is started engine valve lash is present for the first few seconds.

  • Page 19: Air Inlet And Exhaust System (Series Turbochargers)

    UENR4490-01 Engine Operation i05806412 Air Inlet and Exhaust System (Series Turbochargers) Illustration 16 g02467317 Air inlet and exhaust system (1) Aftercooler core (5) Low-pressure turbocharger (9) Exhaust gas valve (NRS) (2) Air filter (6) High-pressure turbocharger (10) Wastegate regulator (3) Clean Emissions Module (CEM) (7) Wastegate actuator (4) Back pressure valve (8) Exhaust cooler (NRS)
  • Page 20 UENR4490-01 Engine Operation Air is drawn in through the air cleaner into the air inlet of the low-pressure turbocharger by the low-pressure turbocharger compressor wheel. The air is compressed to a pressure of about 75 kPa (11 psi) and heated to about 120° C (248° F). From the low- pressure turbocharger, the air passes to the high- pressure turbocharger.
  • Page 21 UENR4490-01 Engine Operation Illustration 17 g02467360 Typical example The NOx Reduction System (NRS) operates with the As the demand for more cooled exhaust gas transfer of the hot exhaust gas from the exhaust increases the electronically controlled valve opens manifold to the exhaust cooler (8). The hot exhaust further.
  • Page 22 UENR4490-01 Engine Operation Turbochargers Illustration 19 g03706099 Typical example Illustration 18 g00302786 (12) Wastegate actuator Typical example of a cross section of a turbocharger (13) Actuating lever (1) Air intake (14) Line (boost pressure) (2) Compressor housing (3) Compressor wheel (4) Bearing (5) Oil inlet port (6) Bearing...
  • Page 23 UENR4490-01 Engine Operation Crankcase Breather When the load on the engine increases, more fuel is injected into the cylinders. The combustion of this The engine crankcase breather is a filtered system. additional fuel produces more exhaust gases. The The crankcase breather system consists of two main additional exhaust gases cause the turbine and the elements, a primary separator in the valve compressor wheels of the turbocharger to turn faster.

  • Page 24: Clean Emissions Module

    UENR4490-01 Engine Operation Valve System Components The engine lubricating oil enters the lifter (4) through a non-return valve. The engine lubricating oil increases the length of the lifter (4) until all valve lash is removed. If the engine is stationary for a prolonged period the valve springs will cause the lifter (4) to shorten so that when the engine is started engine valve lash is present for the first few seconds.
  • Page 25 UENR4490-01 Engine Operation Illustration 22 g03690232 Typical example (1) Exhaust outlet connection (3) Selective Catalytic Reduction (SCR) (4) Diesel Exhaust Fluid (DEF) injector (2) Diesel Oxidation Catalyst (DOC) system (5) Exhaust intake connection The Clean Emissions Module (CEM) for the engine A flexible exhaust pipe connects the engine to the consists of the following components.

  • Page 26: Clean Emissions Module

    UENR4490-01 Engine Operation Exhaust gases and an atomized mist of ammonia and carbon dioxide enter the SCR reaction chamber. Together with the SCR catalyst inside the chamber, the mixture undergoes a chemical reaction that produces nitrogen gas and water vapor. There is an oxidation catalyst after the SCR catalyst.
  • Page 27 UENR4490-01 Engine Operation Illustration 23 g03706448 Typical example (1) Exhaust intake connection (4) Diesel Exhaust Fluid (DEF) injector (6) Selective Catalytic Reduction (SCR) (2) Diesel Oxidation Catalyst (DOC) (5) Exhaust outlet connection system (3) Diesel Particulate Filter (DPF) The Clean Emissions Module (CEM) for the engine The DOC oxidizes the carbon monoxide and the hydrocarbons that are not burnt in the exhaust gas consists of the following components.
  • Page 28 UENR4490-01 Engine Operation A flexible exhaust pipe connects the engine to the Refer to Systems Operation, Testing and Adjusting, Clean Emissions Module (CEM). Refer to “DEF Dosing Control System” for more information Disassembly and Assembly for the correct procedure on the DEF system. to install the flexible exhaust pipe.

  • Page 29: Def Dosing Control System

    UENR4490-01 Engine Operation i06885263 DEF Dosing Control System This document has been printed from SPI2. NOT FOR RESALE...
  • Page 30 UENR4490-01 Engine Operation Illustration 24 g03690311 This document has been printed from SPI2. NOT FOR RESALE...
  • Page 31 UENR4490-01 Engine Operation Typical example (1) Exhaust inlet from back pressure valve (7) Diesel Exhaust Fluid (DEF) supply line (13) Suction connector (2) Selective Catalytic Reduction (SCR) (8) Diesel Exhaust Fluid (DEF) pump and (14) Backflow connector system dosing control unit (15) Coolant return connector (3) Exhaust out (9) Coolant supply from engine line...
  • Page 32 UENR4490-01 Engine Operation Once the engine has stopped, the DEF pump will DEF does degrade over time at elevated continue flowing in cooling mode to keep the DEF temperatures. Due to freezing risk, the tank, pump, injector cool. Then the DEF pump will proceed to a and lines must be heated and designed to contain purge mode.
  • Page 33 UENR4490-01 Engine Operation Coolant Diverter Valve The coolant supplied by the engine will flow through the tubes when the coolant diverter valve opens. Coolant runs along the pickup tube to the bottom of the tank and then spirals around the level sensor. The heat from the coolant will thaw any frozen DEF in the tank or header.
  • Page 34 UENR4490-01 Engine Operation DEF Injector Illustration 29 g03403971 Typical example Illustration 28 g03708843 (1) Sensing unit Typical example (2) Cable (black for engine out, gray for CEM out) (1) Electrical connector (3) Sensor electronic control unit (2) DEF outlet connection (4) Electrical connector (3) DEF inlet connection The NOx sensor contains a sensing element, a...

  • Page 35: Cooling System

    UENR4490-01 Engine Operation Even though the system has been purged of DEF • Water pump there are small quantities of DEF that can be left • Cylinder block behind. The DEF supply line, suction, and the back flow line are heated to thaw any remaining DEF in the •...
  • Page 36 UENR4490-01 Engine Operation Coolant Flow Illustration 30 g02332698 Typical example (1) Radiator (3) Bypass for the water temperature (6) Cylinder block (2) Water temperature regulator and regulator (7) Engine oil cooler housing (4) Exhaust gas cooler (NRS) (8) Water pump (5) Cylinder head The coolant flows from the bottom of the radiator (1) Some coolant flows through a cavity in the front of...

  • Page 37: Lubrication System

    UENR4490-01 Engine Operation The coolant then flows into the housing of the water Engines have piston cooling jets that are supplied temperature regulator (2). If the water temperature with oil from the oil gallery. The piston cooling jets regulator (2) is closed, the coolant goes directly spray lubricating oil on the underside of the pistons in through a bypass (3) to the inlet side of the water order to cool the pistons.
  • Page 38 UENR4490-01 Engine Operation Starting Motor The starting motor turns the engine via a gear on the engine flywheel. The starting motor speed must be high enough in order to initiate a sustained operation of the fuel ignition in the cylinders. The starting motor consists of the main armature and a solenoid.

  • Page 39: Cleanliness Of Fuel System Components

    The sealing plugs must not be reused. Dispose of the sealing plugs immediately after use. Contact your nearest Perkins distributor in order to obtain the correct sealing plugs. This document has been printed from SPI2. NOT FOR RESALE...

  • Page 40: Fuel Injection

    UENR4490-01 Engine Operation For more information, refer to Operation and Maintenance Manual, “Fluid Recommendations”. i05916409 Fuel Injection Introduction This document has been printed from SPI2. NOT FOR RESALE...
  • Page 41 UENR4490-01 Engine Operation Illustration 33 g03723525 This document has been printed from SPI2. NOT FOR RESALE...
  • Page 42 UENR4490-01 Engine Operation Typical example (1) In-line fuel filter (5) Secondary fuel filter (9) Pressure relief valve (2) Electric transfer pump (6) Fuel Injection Pump (10) Electronic unit injector (3) Primary fuel filter (7) Inlet pressure regulator (11) Fuel cooler (optional) (4) ECM that is fuel cooled.
  • Page 43 UENR4490-01 Engine Operation High Pressure Fuel System Illustration 34 g02450116 Typical example (1) Fuel injection pump (4) Fuel pressure sensor (8) Fuel transfer pump (2) Fuel temperature sensor (5) Electronic unit injector (3) Suction control valve for the fuel injection (6) Fuel manifold (rail) pump (7) Pressure relief valve...
  • Page 44 UENR4490-01 Engine Operation Secondary Fuel Filter • The fuel injection pump is replaced. • The ECM is replaced. For the correct procedure to prime the fuel system, refer to Systems Operation, Testing and Adjusting, “Fuel System - Prime”. Primary Filter/Water Separator Illustration 36 g03723527 Typical example...
  • Page 45 UENR4490-01 Engine Operation The fuel pump assembly consists of a low-pressure transfer pump and a high-pressure fuel injection pump. The pump assembly is driven from a gear in the front timing case at engine speed. The fuel injection pump (1) has two plungers that are driven by a camshaft.
  • Page 46 UENR4490-01 Engine Operation Control Illustration 38 g02450148 Typical example of the electrical control system for the fuel system (1) Electronic Control Module (ECM) (3) Wastegate regulator (5) Inlet manifold pressure sensor (2) Throttle position sensor (4) Fuel rail pressure sensor (6) Atmospheric pressure sensor This document has been printed from SPI2.
  • Page 47 UENR4490-01 Engine Operation (7) Coolant temperature sensor (11) Fuel injection pump (14) Electronic unit injectors (8) Inlet manifold air temperature sensor (12) Suction control valve for the fuel (9) Secondary speed/timing sensor injection pump (10) Primary speed/timing sensor (13) Fuel temperature sensor The ECM determines the quantity, timing, and Note: If a replacement electronic unit injector is pressure of the fuel in order to be injected into the...

  • Page 48: Electronic Control System

    UENR4490-01 Engine Operation Fuel Manifold The electronic control system has the following components: • ECM • Pressure sensor • Temperature sensors • Crankshaft speed/timing sensor • Camshaft speed/timing sensor • The suction control valve for the fuel injection pump • Wastegate solenoid •...
  • Page 49 UENR4490-01 Engine Operation Engines with Series Turbochargers Illustration 41 g03694010 A typical example of a block diagram for the engine with series turbochargers (1) Air cleaner (11) Wastegate regulator (21) Atmospheric pressure sensor (2) Air inlet temperature sensor (12) NRS differential pressure sensor (22) ECM (3) Low-pressure turbocharger (13) Engine...
  • Page 50 UENR4490-01 Engine Operation Engines with a Single Turbocharger Illustration 42 g03694003 A typical example of a block diagram for the engine with a single turbocharger (1) Air cleaner (11) NRS differential pressure sensor (21) ECM (2) Air inlet temperature sensor (12) Engine (22) Fuel transfer pump (3) Exhaust gas cooler (NRS)
  • Page 51 UENR4490-01 Engine Operation Aftertreatment System with a DOC, DPF, and DEF system Illustration 43 g03694431 Block diagram for the aftertreatment system with a DOC, DPF, and DEF system (31) Diesel Exhaust Fluid (DEF) level sensor (40) Diesel Oxidation Catalyst (DOC) inlet (47) Diesel Particulate Filter (DPF) (32) DEF temperature sensor temperature sensor...
  • Page 52 UENR4490-01 Engine Operation Aftertreatment System with a DOC, and DEF system Illustration 44 g03694448 Block diagram for the aftertreatment system with a DOC and DEF system (31) Diesel Exhaust Fluid (DEF) level sensor (40) Inlet NOx sensor (47) DEF injector (32) DEF temperature sensor (41) Diesel Oxidation Catalyst (DOC) inlet (48) Selective Catalytic Reduction (SCR)
  • Page 53 UENR4490-01 Engine Operation Illustration 45 g03706468 Typical example (1) Coolant temperature sensor (5) Electronic Control Module (ECM) (9) Engine oil pressure sensor (2) Fuel pressure sensor (6) Atmospheric pressure sensor (10) Fuel temperature sensor (3) Inlet manifold temperature sensor (7) Electric fuel transfer pump (11) Suction control valve for the fuel (4) Boost pressure sensor (8) Crankshaft speed/timing sensor...
  • Page 54 UENR4490-01 Engine Operation Illustration 46 g03706470 Typical example (12) Wastegate regulator (14) Exhaust gas valve for the NOx (16) Differential Pressure Sensor for the (13) Inlet pressure sensor for the NOx Reduction System (NRS) NOx Reduction System (NRS) Reduction System (NRS) (15) Temperature Sensor for the NOx Reduction System (NRS) This document has been printed from SPI2.
  • Page 55 UENR4490-01 Engine Operation Illustration 47 g03706472 Typical example (17) Oil level switch (if equipped) (19) Water in fuel switch (21) Exhaust back pressure valve (18) Inlet Air Temperature Sensor (20) Camshaft speed/timing sensor This document has been printed from SPI2. NOT FOR RESALE...
  • Page 56 UENR4490-01 Engine Operation Illustration 48 g03706475 Typical example (1) Coolant temperature sensor (3) Inlet manifold temperature sensor (5) Electronic Control Module (ECM) (2) Fuel pressure sensor (4) Boost pressure sensor Illustration 49 g03706478 Typical example (6) Atmospheric pressure sensor (9) Engine oil pressure sensor (11) Suction control valve for the fuel (7) Electric fuel transfer pump (10) Fuel temperature sensor...
  • Page 57 UENR4490-01 Engine Operation Illustration 50 g03706479 Typical example (12) Wastegate regulator (14) Exhaust gas valve for the NOx (16) Differential Pressure Sensor for the (13) Inlet pressure sensor for the NOx Reduction System (NRS) NOx Reduction System (NRS) Reduction System (NRS) (15) Temperature Sensor for the NOx Reduction System (NRS) Illustration 51...
  • Page 58 UENR4490-01 Engine Operation Illustration 52 g03706552 Typical example (18) Inlet Air Temperature Sensor (20) Camshaft speed/timing sensor (19) Water in fuel switch (21) Exhaust back pressure valve This document has been printed from SPI2. NOT FOR RESALE...
  • Page 59 UENR4490-01 Engine Operation Sensor Locations for the Clean Emissions Module This document has been printed from SPI2. NOT FOR RESALE...
  • Page 60 UENR4490-01 Engine Operation DOC and SCR Illustration 53 g03421173 Typical example (1) SCR Temperature Sensor (3) DEF Injector (2) Identification Module (4) DOC Temperature Sensor This document has been printed from SPI2. NOT FOR RESALE...
  • Page 61 UENR4490-01 Engine Operation DOC, DPF, and SCR Illustration 54 g03421178 Typical example (1) SCR Temperature Sensor (4) DPF Temperature Sensor (7) NOx Sensor location (2) DOC Temperature Sensor (5) Soot Sensor Connection (3) Soot Sensor Connection (6) DEF Injector Note: The location of the soot sensor module will depend on the application.
  • Page 62 UENR4490-01 Engine Operation The ECM has an excellent record of reliability. Any problems in the system are most likely to be the connectors and the wiring harness. The ECM should be the last item in troubleshooting the engine. The programmable software contains all the fuel setting information.
  • Page 63 When the ECM increases the FRC only to Perkins distributors. Since factory passwords Limit, the ECM allows more fuel into the cylinder. contain alphabetic characters, only an electronic...
  • Page 64 UENR4490-01 Engine Operation Speed/Timing Sensors The secondary speed/timing sensor is located on the right-hand side of the cylinder block toward the rear of the engine. The secondary speed/timing sensor generates a signal that is related to the camshaft position. The secondary speed/timing sensor detects the movement of the teeth on the timing ring (2) for the camshaft.
  • Page 65 UENR4490-01 Engine Operation Illustration 58 g03710917 Schematic for speed/timing sensor When the engine is cranking, the ECM uses the signal from the speed/timing sensor on the camshaft. When the engine is running the ECM uses the signal from the speed/timing sensor on the crankshaft. This speed/timing sensor is the primary source of the engine position.
  • Page 66 UENR4490-01 Engine Operation Pressure Sensors Illustration 59 g03710923 Schematic for the pressure sensors The boost pressure sensor and the engine oil pressure sensor are active sensors. The boost pressure sensor provides the ECM with a measurement of inlet manifold pressure in order to control the air/fuel ratio.
  • Page 67 UENR4490-01 Engine Operation Temperature Sensors Illustration 60 g03710926 Schematic for the engine temperature sensors Illustration 61 g03711261 Schematic for the temperature sensors for the Clean Emissions Module (CEM) with a DOC/SCR only This document has been printed from SPI2. NOT FOR RESALE...
  • Page 68 UENR4490-01 Engine Operation Illustration 62 g03711262 Schematic for the temperature sensors for the Clean Emissions Module (CEM) with a DOC/DPF/SCR The air inlet temperature sensor and the coolant temperature sensor are passive sensors. Each sensor provides a temperature input to the ECM. The ECM controls following operations: •...

  • Page 69: Power Sources

    UENR4490-01 Engine Operation Position Sensors Illustration 63 g03710929 A typical example of a schematic of the position sensors i06927825 Power Sources Introduction The engine supplies power to the ECM. The ECM powers the following components: • All sensors on the engine and the clean emissions module •...
  • Page 70 UENR4490-01 Engine Operation ECM Power Supply Illustration 64 g03813883 The power supply to the ECM and the system is The display screen on the electronic service tool can drawn from the 24 V or the 12 V battery. The power be used to check the voltage supply.
  • Page 71 UENR4490-01 Engine Operation Power Supply for the Pressure Sensors Illustration 65 g03710923 Schematic for the pressure sensors The ECM supplies 5 VDC volts through the ECM connector to each sensor. The power supply is protected against short circuits. A short in a sensor or a wiring harness will not damage the ECM.
  • Page 72 UENR4490-01 Engine Operation Power Supply for the Glow plugs Illustration 66 g03815124 Typical example This document has been printed from SPI2. NOT FOR RESALE...
  • Page 73 UENR4490-01 Engine Operation Power Supply for the Diesel Exhaust Fluid (DEF) Dosing Control System Illustration 67 g06166003 Typical example of a schematic diagram of the DEF dosing control system This document has been printed from SPI2. NOT FOR RESALE...

  • Page 74: Glossary Of Electronic Control Terms

    UENR4490-01 Engine Operation Cold Mode – Cold mode is a mode for cold starting i05934639 and for cold engine operation. This mode is used for Glossary of Electronic Control engine protection, reduced smoke emissions, and faster warm-up time. Terms Communication Adapter Tool – The communication adapter provides a communication link between the ECM and the Electronic Service Tool.
  • Page 75 UENR4490-01 Engine Operation Engine Speed/Timing Sensor – An engine speed/ Diesel Particulate Filter – The Diesel Particulate timing sensor is a hall effect switch that provides a Filter filters particulates from the exhaust gases. The digital signal to the ECM. The ECM interprets this hot exhaust gases burn off the particulates.
  • Page 76 UENR4490-01 Engine Operation Dosing Control Unit (DCU) – The DCU controls the the parameter identifier (PID) in the descriptions of injection of Diesel Exhaust Fluid (DEF) into the the fault code. The descriptions of the FMIs are in the exhaust gas stream. following list.
  • Page 77 UENR4490-01 Engine Operation manifold (rail). Hertz (Hz) – Hertz is the measure of frequency in cycles per second. Fuel Manifold (Rail) – This item is sometimes referred to as the High Pressure Fuel Rail. The fuel High Pressure Fuel Rail Pump – See “Fuel rail supplies fuel to the electronic unit injectors.
  • Page 78 UENR4490-01 Engine Operation exists, the signal or the supply voltage can no longer reach the intended destination. Oxides of Nitrogen (NOx) – NOx is a component of the exhaust gases that are produced by the combustion process. NOx is reduced by the NRS system and is further reduced by the SCR component of the aftertreatment system.
  • Page 79 UENR4490-01 Engine Operation an undesirable point. An example of a short circuit is a wire which rubs against a vehicle frame and this Total Tattletale – The total tattletale is the total rubbing eventually wears off the wire insulation. number of changes to all the parameters that are Electrical contact with the frame is made and a short stored in the ECM.

  • Page 80: Testing And Adjusting Section

    UENR4490-01 Fuel System Testing And Adjusting 5. Cut the old filter open with a suitable filter cutter. Inspect the filter for excess contamination. Section Determine the source of the contamination. Make the necessary repairs. Fuel System i04103212 Air in Fuel - Test i04081693 Table 1 Fuel System - Inspect...
  • Page 81 UENR4490-01 Fuel System 6. Stop the engine. Refer to Operation and Maintenance Manual, “Stopping the Engine” for the correct procedure. Illustration 69 g02305093 Typical example 7. If necessary, remove the low-pressure fuel line from the retaining clips. Remove the low-pressure fuel line from the inlet connection (1) of the secondary fuel filter base.

  • Page 82: Finding Top Center Position For No. 1 Piston

    UENR4490-01 Fuel System Illustration 70 g02352952 8. Connect Tooling (A) to the low-pressure fuel line 12. Prime the fuel system. Refer to Operation and and the secondary fuel filter base. Connect the Maintenance Manual, “Fuel System - Prime” for open end of the tube to the inlet connection (1) of the correct procedure.

  • Page 83: Fuel Injection Timing - Check

    UENR4490-01 Fuel System 3. Install Tooling (B) through the hole (X) in the camshaft gear (1) into the front housing. Use Tooling (B) in order to lock the camshaft in the correct position. i04319681 Fuel Injection Timing - Check Table 3 Required Tools Part Description Tool...

  • Page 84: Fuel Quality - Test

    UENR4490-01 Fuel System Note: The number one piston may be on the compression stroke or the exhaust stroke. 4. Install Tooling (B) into Hole (X) in the cylinder block. Use Tooling (B) in order to locate the crankshaft in the correct position. Note: Do not use excessive force to install Tooling (B).

  • Page 85: Fuel System - Prime

    UENR4490-01 Fuel System 3. If fuel quality is still suspected as a possible cause 1. Ensure that the fuel system is in working order. to problems regarding engine performance, Check that the fuel supply valve (if equipped) is in disconnect the fuel inlet line. Temporarily operate the “ON”...

  • Page 86: Gear Group (Front) - Time

    UENR4490-01 Fuel System i03578027 Gear Group (Front) - Time Illustration 75 g01907773 Typical example (1) Camshaft gear (2) Idler gear (3) Fuel Injection Pump gear 1. Install the camshaft gear (1) onto the camshaft. Refer to Disassembly and Assembly, “Camshaft Gear - Remove and Install”...

  • Page 87: Air Inlet And Exhaust System

    UENR4490-01 Air Inlet and Exhaust System Air Inlet and Exhaust Inspection of the Crankcase Breather System i03965393 Air Inlet and Exhaust System - Inspect A general visual inspection should be made to the air inlet and exhaust system. Make sure that there are no signs of leaks in the system.

  • Page 88: Turbocharger - Inspect (Series Turbochargers)

    UENR4490-01 Air Inlet and Exhaust System 2. If there is sludge or debris in the canister, remove the canister. Refer to Disassembly and Assembly, “Crankcase Breather - Remove and Install”. Clean the inside of the canister. Check that the gas inlet, the outlet connections, and the connections for the oil drain are clear.
  • Page 89 UENR4490-01 Air Inlet and Exhaust System Inspection of the Compressor and NOTICE the Compressor Housing Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are con- tained during performance of inspection, mainte- nance, testing, adjusting and repair of the product.
  • Page 90 UENR4490-01 Air Inlet and Exhaust System b. Inspect the engine air cleaner element. Replace 3. Turn the rotating assembly by hand. While you turn a dirty engine air cleaner element with a clean the assembly, push the assembly sideways. The engine air cleaner element.

  • Page 91: Turbocharger - Inspect (Single Turbocharger)

    UENR4490-01 Air Inlet and Exhaust System The following levels of boost pressure indicate a Note: The wastegate actuator is installed to the high- potential problem with the wastegate actuator or pressure turbocharger. wastegate regulator: 1. Disconnect the pipe for the boost sensor (1) at the •...
  • Page 92 UENR4490-01 Air Inlet and Exhaust System 1. Inspect the compressor wheel for damage from a NOTICE foreign object. If there is damage, determine the Care must be taken to ensure that fluids are con- tained during performance of inspection, mainte- source of the foreign object.
  • Page 93 UENR4490-01 Air Inlet and Exhaust System position. This motion is visible from the exposed e. If steps 4.a through 4.d did not reveal the source spring and lever mechanism. of the oil leakage, turbocharger (3) has internal damage. Replace the turbocharger. f.

  • Page 94: Exhaust Cooler (Nrs) - Test

    UENR4490-01 Air Inlet and Exhaust System Illustration 81 g03706092 Illustration 82 g02424917 Typical example Typical example 1. Disconnect the pipe for the boost sensor (3) at the 1. Follow steps 1.a to 1.i in order to test the coolant wastegate actuator (1). Connect an air supply to side of the exhaust gas cooler (NRS).

  • Page 95: Compression - Test

    UENR4490-01 Air Inlet and Exhaust System cooling system or the engine. Refer the service A compression test should not be the only method which is used to determine the condition of an manual in order to check for leakage. If the engine.

  • Page 96: Engine Valve Lash - Inspect

    UENR4490-01 Air Inlet and Exhaust System 6. Install the fuse for the glow plugs. • Bent pushrods • Broken socket on the upper end of a pushrod i04319692 • Loose adjustment screw for the valve lash Engine Valve Lash - Inspect •...

  • Page 97: Valve Depth - Inspect

    UENR4490-01 Air Inlet and Exhaust System 3. Install Tooling (B) into the hole (X) in the cylinder 8. If there is an engine valve lash at any position the block. Use Tooling (B) in order to locate the engine valve lash may be caused by a normal crankshaft in the correct position.

  • Page 98: Valve Guide - Inspect

    UENR4490-01 Air Inlet and Exhaust System 1. Ensure that the face of the valves are clean. Ensure that the bottom face of the cylinder head is clean. Ensure that the cylinder head is not distorted. Refer to Systems Operation, Testing and Adjusting, “Cylinder Head - Inspect”...

  • Page 99: Diesel Exhaust Fluid Quality - Test

    UENR4490-01 Air Inlet and Exhaust System The original valve guides are bored into the cylinder head. When new valve guides(1) are installed, new valves and new valve seat inserts must be installed. The cylinder head must be rebored in order to install the new valve guide.

  • Page 100: Aftertreatment Scr System Dosing - Test

    UENR4490-01 Air Inlet and Exhaust System Note: Dispose of the DEF removed as per local regulations and mandates. i06887136 Aftertreatment SCR System Dosing - Test Required Tooling Table 9 Required Tools Part Description Tool Part Number T402192 Container Test Kit (DEF) T401199 Test Procedure 1.
  • Page 101 UENR4490-01 Air Inlet and Exhaust System Illustration 94 g03370860 Typical example 5. Click “Diagnostics” in the main menu, then click “Diagnostic Tests” . This document has been printed from SPI2. NOT FOR RESALE...
  • Page 102 UENR4490-01 Air Inlet and Exhaust System Illustration 95 g03370869 Typical example 6. Proceed by clicking “DEF Dosing System Accuracy Test” . This document has been printed from SPI2. NOT FOR RESALE...
  • Page 103 UENR4490-01 Air Inlet and Exhaust System Illustration 96 g03370974 Typical example Note: This test should run for 5 minutes. If the test only runs for 1 minute, repeat the test a further four times. 8. After the test has completed, check the measuring container to inspect the amount of DEF in the container.

  • Page 104: Diesel Exhaust Fluid Tank - Flush

    UENR4490-01 Air Inlet and Exhaust System 10. Use the electronic service tool to perform the “Aftertreatment System Functional Test” . i05934698 Diesel Exhaust Fluid Tank - Flush Required Tools Table 10 Required Tools Part Description Tool Part Number Plugs Flushing Procedure 1.
  • Page 105 UENR4490-01 Air Inlet and Exhaust System 8. Reinstall the manifold (DEF heater) into the DEF tank. Refer to Disassembly and Assembly, “Manifold (DEF Heater) - Remove and Install” for the correct procedure. Illustration 100 g03710738 Typical example (8) DEF pump (9) DEF filter cap 9.
  • Page 106 UENR4490-01 Air Inlet and Exhaust System 15. Perform the “Aftertreatment System Functional Test” in the electronic service tool. This test will verify that the DEF system is working correctly following the flush and filter replacement. This document has been printed from SPI2. NOT FOR RESALE...

  • Page 107: Lubrication System

    UENR4490-01 Lubrication System Lubrication System Perform the following procedures in order to inspect the oil pump. Refer to Specifications, “Engine Oil Pump” for clearances and torques. i03994210 Engine Oil Pressure - Test Low Oil Pressure The following conditions will cause low oil pressure. •...

  • Page 108: Excessive Bearing Wear - Inspect

    UENR4490-01 Lubrication System Refer to Specifications for more information regarding component wear limits. i02414692 Excessive Engine Oil Consumption - Inspect Engine Oil Leaks on the Outside of the Engine Check for leakage at the seals at each end of the crankshaft.

  • Page 109: Increased Engine Oil Temperature - Inspect

    UENR4490-01 Lubrication System Excessive consumption of engine oil can also result if engine oil with the wrong viscosity is used. Engine oil with a thin viscosity can be caused by fuel leakage into the crankcase or by increased engine temperature. i03577881 Increased Engine Oil Temperature - Inspect...

  • Page 110: Cooling System

    UENR4490-01 Cooling System Cooling System a. Perform the “Testing The Water Temperature Regulator ” procedures. b. Clean the radiator and other components with hot water or steam at low pressure. Detergent in the water may also be used. Compressed air i05355811 may be used to remove materials from the Cooling System - Check...

  • Page 111: Cooling System - Test

    UENR4490-01 Cooling System 4. Inspect the drive belt for the fan. The coolant level must be to the correct level in order to check the coolant system. The engine must be 5. Inspect the blades of the fan for damage. cold and the engine must not be running.

  • Page 112: Engine Oil Cooler - Inspect

    UENR4490-01 Cooling System 2. Carefully inspect the filler cap. Look for any 6. Check all connections and hoses of the cooling damage to the seals and to the sealing surface. system for leaks. Inspect the following components for any foreign The radiator and the cooling system do not have substances: leakage if all of the following conditions exist:...

  • Page 113: Water Temperature Regulator - Test

    UENR4490-01 Cooling System 1. Place a container under the oil cooler in order to 1. Remove the water temperature regulator from the collect any engine oil or coolant that drains from engine. Refer to Disassembly and Assembly the oil cooler. Manual, “Water Temperature Regulator - Remove and Install”.

  • Page 114: Basic Engine

    UENR4490-01 Basic Engine Basic Engine i04319693 Position the Valve Mechanism Before Maintenance Procedures NOTICE Ensure that this procedure is carried out before the rocker shaft is removed. Table 11 Required Tools Part Description Tool Part Number Illustration 107 g02333215 Typical example Crankshaft Turning Tool 21825576 One electronic unit injector is not shown for clarity.

  • Page 115: Connecting Rod - Inspect

    UENR4490-01 Basic Engine Inspect the Clearance of the Piston Inspect the Piston Ring End Gap Ring 1. Remove the piston rings and clean the grooves and the piston rings. Illustration 109 g00782363 (1) Piston ring (2) Cylinder ring ridge (3) Feeler gauge 1.

  • Page 116: Cylinder Block - Inspect

    UENR4490-01 Basic Engine If the piston pin bearing requires replacement but the 3. Check the front camshaft bearing for wear. Refer original connecting rod is not replaced, the following to Specifications, “Camshaft Bearings” for the procedures must be performed: correct specification of the camshaft bearing. If a new bearing is needed, use a suitable adapter to 1.

  • Page 117: Piston Height - Inspect

    UENR4490-01 Basic Engine Note: The dimension of the valve seats to the flame face must be corrected after resurfacing the cylinder head. Refer to Specifications, “Cylinder Head” for the correct dimensions for the valve seats. i04156372 Piston Height - Inspect Table 13 Required Tools Part...

  • Page 118: Flywheel - Inspect

    UENR4490-01 Basic Engine 3. Position Tooling (B) and Tooling (A) in order to measure the piston height above the cylinder block. The piston height should be measured at positions (X) or (Y). Slowly rotate the crankshaft in order to determine when the piston is at the highest position.

  • Page 119: Flywheel Housing - Inspect

    UENR4490-01 Basic Engine Concentricity of the Flywheel 4. Calculate the difference between the lowest measurement and the highest measurement of the Housing four locations. This difference must not be greater than 0.03 mm (0.001 inch) for every 25 mm Note: This check must be made with the flywheel and the starter removed and the bolts for the flywheel (1.0 inch) of the radius of the flywheel.

  • Page 120: Gear Group - Inspect

    UENR4490-01 Basic Engine i03578981 Gear Group - Inspect Illustration 116 g01199467 Typical example 1. Install Tooling (A). See illustration 116 . 2. Set the pointer of the dial indicator to 0 mm (0 inch). Illustration 117 g01907773 (1) Camshaft gear 3.

  • Page 121: Crankshaft Pulley - Check

    UENR4490-01 Basic Engine 5. Measure the end play on idler gear (2). Refer to 6. Slowly rotate the crankshaft in order to measure Disassembly and Assembly, “Idler Gear - Install” the runout of the circumference of the crankshaft for the correct procedure. Refer to Specifications, pulley.

  • Page 122: Electrical System

    UENR4490-01 Electrical System Electrical System c. The value of the voltage is less than the voltage in step 1.b. Go to step 6. Note: Severely discharged batteries can cause low system voltage. This can occur even while the engine is running above idle, and the alternator is i03635721 working properly.
  • Page 123 UENR4490-01 Electrical System d. Turn the disconnect switch to the ON position. Note: The standard acceptable draw is 0.05 amperes. A current value above this figure usually Connect an ammeter across the disconnect indicates a problem. However, some large switch terminals. Connect the red lead to the machines with multiple control modules have a terminal on the frame side.

  • Page 124: Battery - Test

    UENR4490-01 Electrical System e. The current is below 0.015 amperes. The alternator is operating correctly. There is an electrical load on the machine. Go to step 8. Never disconnect any charging unit circuit or bat- tery circuit cable from the battery when the charg- f.

  • Page 125: V-Belt - Test

    UENR4490-01 Electrical System Alternator output should be 28 ± 1 V on a 24 V • More than one section of the poly v-belt is system and 14 ± 0.5 V on a 12 V system. No displaced in one rib of a maximum length of adjustment can be made in order to change the rate 50.8 mm (2 inch).
  • Page 126 UENR4490-01 Electrical System • Loose connections • Corroded connections • Faulty switch contacts Diagnosis Procedures The procedures for diagnosing the starting motor are intended to help the technician determine if a starting motor needs to be replaced or repaired. The procedures are not intended to cover all possible problems and conditions.
  • Page 127 UENR4490-01 Electrical System Diagnosis Procedure for 12 V 4 kW and the starting motor cable that goes to the starting motor are within specifications. Go to Starting Motor step 6. If the starting motor does not crank or cranks slow, c.
  • Page 128 UENR4490-01 Electrical System • Ensure that any lead wires are not shorted. a. Measure the voltage drops in the cranking circuits with the multimeter. Compare the results 2. Measure the voltage of the battery. with the voltage drops which are allowed in table 18 .

  • Page 129: Index

    UENR4490-01 Index Section Index Crankshaft Pulley - Check........121 Cylinder Block - Inspect ........116 Aftertreatment SCR System Dosing - Test... 100 Cylinder Head - Inspect ........116 Required Tooling..........100 Resurfacing the Cylinder Head ....... 117 Test Procedure ..........100 Air in Fuel - Test ..........80 Air Inlet and Exhaust System .......87 Air Inlet and Exhaust System - Inspect ....87...
  • Page 130 Glossary of Electronic Control Terms ....74 Important Safety Information ........2 Increased Engine Oil Temperature - Inspect ..109 Introduction ............4 1204F-E44TA Engine with Single Turbocharger ...8 1204F-E44TTA Engine with Series Turbochargers ..........5 Lubrication System........37, 107 Piston Height - Inspect........117 Piston Ring Groove - Inspect......
  • Page 131 This document has been printed from SPI2. NOT FOR RESALE...
  • Page 132 ©2017 Perkins Engines Company Limited All Rights Reserved April 2017 This document has been printed from SPI2. NOT FOR RESALE...

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