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1104E Series
Perkins 1104E Series Manuals
Manuals and User Guides for Perkins 1104E Series. We have
4
Perkins 1104E Series manuals available for free PDF download: Troubleshooting Manual, Disassembly And Assembly, Operation And Maintenance Manual, Systems Operation Testing And Adjusting
Perkins 1104E Series Troubleshooting Manual (224 pages)
Brand:
Perkins
| Category:
Engine
| Size: 2.06 MB
Table of Contents
Table of Contents
3
Troubleshooting Section
5
Electronic Troubleshooting
5
System Overview
5
Glossary
9
Electronic Service Tools
12
Diagnostic Codes
13
Indicator Lamps
15
Replacing the ECM
18
Self-Diagnostics
19
Sensors and Electrical Connectors
20
Engine Wiring Information
26
Programming Parameters
32
Factory Passwords
32
Flash Programming
32
System Configuration Parameters
34
Troubleshooting Without a Diagnostic Code
35
Alternator Noise (Noisy Operation)
35
Alternator will Not Charge (Charging Problem)
35
Battery
35
Can Not Reach Top Engine RPM
36
Coolant in Engine Oil
38
Coolant Temperature Is too High
39
ECM will Not Accept Factory Passwords
40
ECM will Not Communicate with Other Systems or Display Modules
40
Electronic Service Tool will Not Communicate with ECM
40
Engine Cranks but will Not Start
41
Engine Has Early Wear
43
Engine Misfires, Runs Rough or Is Unstable
43
Engine Oil in Cooling System
46
Engine Speed Does Not Change
46
Engine Stalls at Low RPM
47
Engine Vibration
48
Engine will Not Crank
49
Excessive Black Smoke
50
Excessive Engine Oil Consumption
51
Excessive Valve Lash
52
Excessive White Smoke
53
Intake Air Temperature Is too High
54
Intermittent Engine Shutdown
55
Intermittent Low Power or Power Cutout
56
Low Engine Oil Pressure
58
Low Power/Poor or no Response to Throttle
59
Mechanical Noise (Knock) in Engine
61
Noise Coming from Cylinder
61
Poor Acceleration or Response
62
Troubleshooting with a Diagnostic Code
64
CID 0041 FMI 03 8V Sensor Power Supply, Voltage more than Normal
64
CID 0041 FMI 04 8V Sensor Power Supply, Voltage Less than Normal
64
CID 0091 FMI 02 Throttle Demand Sensor Erratic or Intermittent
64
CID 0091 FMI 03 Throttle Demand Sensor Open Circuit or Shorted High
65
CID 0091 FMI 04 Throttle Demand Sensor Shorted Low
65
CID 0091 FMI 08 Throttle Demand Sensor Abnormal Signal
66
CID 0091 FMI 12 Throttle Demand Sensor out of Calibration
66
CID 0100 FMI 03 Engine Oil Pressure Sensor Open Circuit or Shorted High
66
CID 0100 FMI 04 Engine Oil Pressure Sensor Shorted Low
67
CID 0100 FMI 10 Engine Oil Pressure Sensor, Power Supply Open Circuit
67
CID 0102 FMI 03 Intake Manifold Pressure Sensor, Open Circuit or Shorted High
67
CID 0102 FMI 04 Intake Manifold Pressure Sensor Shorted Low
68
CID 0102 FMI 10 Intake Manifold Pressure Sensor Power Supply Open Circuit
68
CID 0105 FMI 03 Intake Manifold Temperature Sensor Open Circuit or Shorted High
69
CID 0105 FMI 04 Intake Manifold Temperature Sensor Shorted Low
69
CID 0110 FMI 03 Engine Coolant Temperature Sensor Open Circuit or Shorted High
69
CID 0110 FMI 04 Engine Coolant Temperature Sensor Shorted Low
70
CID 0174 FMI 02 Fuel Temperature Sensor Erratic, Intermittent
70
CID 0247 FMI 09 J1939 Datalink, Abnormal Update
71
CID 0253 FMI 02 Incorrect ECM Software
71
CID 0262 FMI 03 5V Sensor Power Supply, Voltage more than Normal
71
CID 0262 FMI 04 5V Sensor Power Supply, Voltage Less than Normal
72
CID 0266 FMI 02 Incorrect Crank-Without-Inject Inputs
72
CID 0320 FMI 02 Speed and Timing Sensor Intermittent Loss of Signal
73
CID 0320 FMI 11 Speed and Timing Sensor Loss of Signal
73
CID 0342 FMI 02 Speed and Timing Sensor
73
Intermittent Signal
73
CID 0774 FMI 02 Throttle Demand Sensor No.2 Erratic or Intermittent
74
CID 0774 FMI 03 Throttle Demand Sensor No.2 Open Circuit or Shorted High
74
CID 0774 FMI 04 Throttle Demand Sensor No.2 Shorted Low
75
CID 0774 FMI 08 Throttle Demand Sensor
75
Abnormal Signal
75
CID 0774 FMI 12 Throttle Demand Sensor No.2 out of Calibration
75
CID 1627 FMI 03 Fuel Injection Pump Relay DID Not Turn off
76
CID 1684 FMI 00 Fuel Injection Pump, Fuel Temperature more than Normal
76
CID 1684 FMI 03 Fuel Injection Pump, Fuelling Fault
77
CID 1684 FMI 04 Fuel Injection Pump, Supply Voltage Fault
77
CID 1684 FMI 02 Fuel Injection Pump, Software Failure
77
CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse Width
78
CID 1684 FMI 07 Fuel Injection Pump, Mechanical Fault
78
CID 1684 FMI 08 Fuel Injection Pump, Crankshaft Reference Fault
79
CID 1684 FMI 09 Fuel Injection Pump, CAN Fault
80
CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff Signal Error
80
CID 1684 FMI 11 Fuel Injection Pump, Internal Sensor Fault
81
CID 1684 FMI 12 Fuel Injection Pump, Device Failure
81
CID 1684 FMI 14 Fuel Injection Pump, no Communications
82
CID 1743 FMI 02 Engine Speed Mode Selection Switch State, Invalid State
83
CID 1894 FMI 02 Set Speed Control Disengage Switch State, Invalid State
83
CID 1895 FMI 02 Set Speed Control Speed Toggle Switch, Invalid State
83
Troubleshooting with an Event Code
85
Event Codes
85
E015 High Engine Coolant Temperature Derate
85
E016 High Engine Coolant Temperature Shutdown
85
E017 High Engine Coolant Temperature Warning
85
E025 High Intake Air Temperature Derate
86
E027 High Intake Air Temperature Warning
86
E040 Low Engine Oil Pressure Shutdown
86
E054 High Fuel Temperature Derate
87
E056 High Fuel Temperature Warning
88
E100 Low Engine Oil Pressure Warning
89
E190 Engine Overspeed Warning
90
E442 Engine Failed to Stop with a No-Fuel Command
90
E883 Engine Failed to Stop When Fuel Solenoid Disengaged
91
Diagnostic Functional Tests
92
Volt Engine Pressure Sensor Supply Circuit - Test
92
Air Inlet Heater Circuit - Test
99
Analog Throttle Position Sensor Circuit - Test
104
CAN Data Link Circuit - Test
113
Data Link Circuit - Test
118
Digital Throttle Position Sensor Circuit - Test
126
Electrical Connectors - Inspect
135
Electrical Power Supply Circuit - Test
146
Engine Oil Level Switch Circuit - Test
152
Engine Pressure Sensor Open or Short Circuit - Test
157
Engine Speed/Timing Sensor Circuit - Test
164
Engine Temperature Sensor Open or Short Circuit - Test
171
Fuel Injection Pump Circuit - Test
178
Indicator Lamp Circuit - Test
195
Mode Selection Circuit - Test
198
Set Speed Circuit - Test
204
Throttle Switch Circuit - Test
212
Index
221
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Perkins 1104E Series Disassembly And Assembly (136 pages)
Brand:
Perkins
| Category:
Engine
| Size: 6.75 MB
Table of Contents
Important Safety Information
2
Table of Contents
3
Disassembly and Assembly Section
4
Fuel Priming Pump - Remove and Install
4
Fuel Filter Base - Remove and Install
6
Fuel Injection Lines - Remove
9
Fuel Injection Lines - Install
9
Fuel Injector Cover - Remove and Install (if Equipped)
10
Fuel Injection Pump - Remove (Delphi DP210)
11
Fuel Injection Pump - Remove (Delphi STP)
13
Fuel Injection Pump - Remove (Delphi DPG)
14
Fuel Injection Pump - Remove (Bosch EPVE for the 1104 Engines Only)
16
Fuel Injection Pump - Remove (Delphi DPA)
17
Fuel Injection Pump - Install (Delphi DP210)
19
Fuel Injection Pump - Install (Delphi STP)
20
Fuel Injection Pump - Install (Delphi DPG)
22
Fuel Injection Pump - Install (Bosch EPVE for the 1104 Engines Only)
24
Fuel Injection Pump - Install (Delphi DPA)
26
Fuel Injector - Remove
27
Fuel Injector - Install
28
Turbocharger - Remove
29
Turbocharger - Install
30
Exhaust Manifold - Remove and Install
31
Exhaust Elbow - Remove and Install (if Equipped)
33
Inlet and Exhaust Valve Springs - Remove and Install
34
Inlet and Exhaust Valves - Remove and Install
36
Inlet and Exhaust Valve Guides - Remove and Install
39
Inlet and Exhaust Valve Seat Inserts - Remove and Install
41
Engine Oil Filter Base - Remove and Install
43
Oil Filter
45
Engine Oil Cooler - Remove
47
Engine Oil Cooler - Install
48
Engine Oil Relief Valve - Remove and Install (Engine Oil Pump)
50
Engine Oil Relief Valve - Remove and Install (Balancer Unit for the 1104 Engines Only)
51
Engine Oil Pump - Remove (Engines Without a Balancer)
52
Engine Oil Pump - Install (Engines Without a Balancer)
53
Water Pump - Remove
54
Water Pump - Disassemble
54
Water Pump - Assemble
56
Water Pump - Install
57
Water Temperature Regulator - Remove and Install
58
Flywheel - Remove
61
Flywheel - Install
61
Crankshaft Rear Seal - Remove
62
Crankshaft Rear Seal - Install
63
Crankshaft Wear Sleeve (Rear) - Remove
65
Flywheel Housing - Remove and Install
66
Crankshaft Wear Sleeve (Rear) - Install
66
Crankshaft Pulley - Remove and Install
68
Crankshaft Front Seal - Remove
71
Crankshaft Front Seal - Install
72
Crankshaft Wear Sleeve (Front) - Remove
73
Crankshaft Wear Sleeve (Front) - Install
73
Front Cover - Remove and Install
74
Gear Group (Front) - Remove
75
Gear Group (Front) - Install
77
Idler Gear - Remove and Install
78
Housing (Front) - Remove
83
Housing (Front) - Install
84
Accessory Drive - Remove and Install
86
Crankcase Breather - Remove and Install
88
Valve Mechanism Cover - Remove and Install
90
Rocker Shaft and Pushrod - Remove
92
Rocker Shaft - Disassemble
93
Rocker Shaft - Assemble
94
Rocker Shaft and Pushrod - Install
95
Cylinder Head - Remove
96
Cylinder Head - Install
97
Lifter Group - Remove and Install
100
Camshaft - Remove and Install
101
Camshaft Gear - Remove and Install
102
Camshaft Bearings - Remove and Install
103
Engine Oil Pan - Remove and Install
104
Balancer - Remove (some 1104 Engines Only)
106
Balancer - Install (some 1104 Engines Only)
107
Piston Cooling Jets - Remove and Install
109
Pistons and Connecting Rods - Remove
109
Pistons and Connecting Rods - Disassemble
110
Pistons and Connecting Rods - Assemble
111
Pistons and Connecting Rods - Install
113
Connecting Rod Bearings - Remove
114
Connecting Rod Bearings - Install
114
Crankshaft Main Bearings - Remove
115
Crankshaft Main Bearings - Install (Crankshaft in Position)
117
Crankshaft - Remove
119
Crankshaft - Install
121
Crankshaft Gear - Remove and Install
124
Bearing Clearance - Check
125
Glow Plugs - Remove and Install (if Equipped)
126
V-Belts - Remove and Install
128
Fan - Remove and Install
128
Fan Drive - Remove and Install
129
Alternator - Remove
130
Alternator - Install
130
Electric Starting Motor - Remove and Install
131
Vacuum Pump - Remove and Install (some 1104 Engines Only)
132
Hydraulic Pump (Steering) - Remove
132
Hydraulic Pump (Steering) - Install
132
Index
133
Perkins 1104E Series Operation And Maintenance Manual (86 pages)
Brand:
Perkins
| Category:
Engine
| Size: 1.27 MB
Table of Contents
Table of Contents
3
Foreword
4
Safety Section
5
Safety Messages
5
General Hazard Information
5
Burn Prevention
7
Fire Prevention and Explosion Prevention
7
Engine Starting
9
Before Starting Engine
9
Crushing Prevention and Cutting Prevention
9
Engine Stopping
10
Electrical System
10
Engine Electronics
11
Product Information Section
12
General Information
12
Model Views
13
Product Identification Information
17
Operation Section
19
Lifting and Storage
19
Gauges and Indicators
22
Features and Controls
23
Engine Diagnostics
27
Engine Starting
29
Engine Operation
33
Engine Stopping
34
Cold Weather Operation
35
Maintenance Section
39
Refill Capacities
39
Maintenance Interval Schedule
52
Every 2000 Service Hours Aftercooler Core - Inspect
53
Every 4000 Service Hours Aftercooler Core - Clean/Test
53
Alternator - Inspect
54
Alternator and Fan Belts - Inspect/Adjust/Replace
54
Battery - Replace
55
Every 500 Service Hours or 1 Year Battery Electrolyte Level - Check
55
Battery or Battery Cable - Disconnect
56
Every 3000 Service Hours or 2 Years Cooling System Coolant (Commercial Heavy-Duty) - Change
56
Every 12 000 Service Hours or 6 Years Cooling System Coolant (ELC) - Change
58
Cooling System Coolant Level - Check
59
Every 6000 Service Hours or 3 Years Cooling System Coolant Extender (ELC) - Add
59
Cooling System Supplemental Coolant Additive (SCA) - Test/Add
60
Crankcase Breather (Canister) - Replace
61
Driven Equipment - Check
62
Engine - Clean
62
Engine Air Cleaner Element (Dual Element) - Clean/Replace
63
Engine Air Cleaner Element (Single Element)
63
Engine Air Cleaner Element (Single Element) - Inspect/Replace
65
Engine Air Cleaner Service Indicator - Inspect
65
Inspect/Replace
65
Engine Mounts - Inspect
66
Engine Oil Level - Check
66
Engine Oil Sample - Obtain
66
Engine Oil and Filter - Change
67
Engine Protective Devices - Check
69
Every 1000 Service Hours Engine Valve Lash - Inspect/Adjust
69
Every 3000 Service Hours Fuel Injector - Test/Change
70
Fuel Injector - Test/Change
70
Fuel System - Prime
71
Fuel System Primary Filter/Water Separator - Drain
72
Fuel System Primary Filter (Water Separator) Element - Replace
73
Fuel System Secondary Filter - Replace
73
Every 50 Service Hours or Weekly Fuel Tank Water and Sediment - Drain
75
Hoses and Clamps - Inspect/Replace
76
Radiator - Clean
77
Severe Service Application - Check
78
Starting Motor - Inspect
78
Turbocharger - Inspect
79
Walk-Around Inspection
79
Water Pump - Inspect
80
Warranty Information
81
Warranty Section
81
Index
82
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Perkins 1104E Series Systems Operation Testing And Adjusting (64 pages)
Brand:
Perkins
| Category:
Engine
| Size: 2.88 MB
Table of Contents
Table of Contents
3
Systems Operation Section General Information Introduction
4
Engine Operation
6
Basic Engine
6
Air Inlet and Exhaust System
7
Cooling System
10
Lubrication System
11
Electrical System
12
Fuel Injection
14
Electronic Control System
22
Power Sources
25
Glossary of Electronic Control Terms
29
Testing and Adjusting Section
32
Fuel System
32
Fuel System - Inspect
32
Air in Fuel - Test
32
Finding Top Center Position for No. 1 Piston
33
Fuel Injection Timing - Adjust
34
Fuel Injection Timing - Check
35
Fuel Quality - Test
35
Fuel System - Prime
36
Fuel System Pressure - Test
36
Air Inlet and Exhaust System - Inspect
38
Air Inlet and Exhaust System
38
Wastegate - Test
38
Compression - Test
39
Engine Valve Lash - Inspect/Adjust
39
Valve Depth - Inspect
41
Valve Guide - Inspect
41
Lubrication System
43
Engine Oil Pressure - Test
43
Engine Oil Pump - Inspect
43
Excessive Bearing Wear - Inspect
44
Excessive Engine Oil Consumption - Inspect
44
Increased Engine Oil Temperature - Inspect
45
Cooling System
46
Cooling System - Check (Overheating)
46
Cooling System - Inspect
47
Cooling System - Test
47
Engine Oil Cooler - Inspect
49
Water Temperature Regulator - Test
49
Basic Engine
50
Piston Ring Groove - Inspect
50
Connecting Rod - Inspect
50
Connecting Rod Bearings - Inspect
51
Main Bearings - Inspect
51
Cylinder Block - Inspect
51
Cylinder Head - Inspect
52
Piston Height - Inspect
52
Flywheel - Inspect
53
Flywheel Housing - Inspect
54
Gear Group - Inspect
55
Electrical System
56
Alternator - Test
56
Battery - Test
56
V-Belt - Test
57
Charging System - Test
57
Electric Starting System - Test
58
Glow Plugs - Test
60
Index
61
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