Perkins 1204F-E44TA Diesel Engine Manuals

Perkins 1204F-E44TA Diesel Engine Manuals

Manuals and User Guides for Perkins 1204F-E44TA Diesel Engine. We have 4 Perkins 1204F-E44TA Diesel Engine manuals available for free PDF download: Troubleshooting Manual, Operation And Maintenance Manual, Systems Operation Testing And Adjusting, Supplement Manual

Perkins 1204F-E44TA Troubleshooting Manual

Perkins 1204F-E44TA Troubleshooting Manual (524 pages)

Brand: Perkins | Category: Engine | Size: 4 MB

Table of Contents

Important Safety Information
2
Table of Contents
3
Troubleshooting Section
5
General Information
5
Fault Detection and Reporting
6
Welding Precaution
6
Electronic Service Tools
7
Required Service Tools
7
Electronic System Overview
10
System Overview
10
System Operation
10
Programmable Parameters
11
Component Location
12
Sensor Locations
16
Diesel Particulate Filter Regeneration
22
Engine Monitoring System
22
Diagnostic Capabilities
23
Diagnostic Codes
23
Electrical Connectors
24
Configuration Parameters
29
Diagnostic Trouble Codes
32
Event Codes
53
Troubleshooting
64
Symptom Troubleshooting
65
Acceleration Is Poor or Throttle Response Is Poor
65
Alternator Problem (Charging Problem And/Or Noisy Operation)
73
Recommended Actions
73
Battery Problem
75
Belt Tensioner Noise
76
Clean Emissions Module Has High Oxygen Level
81
Coolant Contains Oil
82
Coolant Level Is Low
84
Coolant Temperature Is High
85
Coolant Temperature Is Low
89
Crankcase Breather Ejects Oil
91
Crankcase Fumes Disposal Tube Has Oil Draining
92
Cylinder Is Noisy
95
DEF Concentration Is Incorrect
98
DEF Pressure Does Not Respond
101
DEF Pressure Is High
103
DEF Pressure Is Low
107
DEF Tank Level Is Low
112
DEF Tank Temperature Is High
115
DEF Tank Temperature Is Low
118
Diesel Oxidation Catalyst Has Incorrect Inlet Temperature
121
Diesel Oxidation Catalyst Has Low Conversion Efficiency
124
Diesel Particulate Filter Collects Excessive Soot (if Equipped)
125
Diesel Particulate Filter Temperature Is Low (if Equipped)
130
Engine Cranks but Does Not Start
132
Recommended Actions
132
Engine Does Not Crank
140
Engine Has Early Wear
142
Engine Has Mechanical Noise (Knock)
144
Engine Misfires, Runs Rough or Is Unstable
147
Engine Overspeeds
153
Engine Shutdown Occurrence
156
Engine Shutdown Occurs Intermittently
157
Engine Stalls at Low RPM
159
Engine Top Speed Is Not Obtained
162
Engine Vibration Is Excessive
169
Exhaust Has Excessive Black Smoke
171
Exhaust Has Excessive White Smoke
175
Exhaust System Contains Coolant
180
Exhaust System Contains Oil
181
Exhaust Temperature Is High
183
Fuel Consumption Is Excessive
186
Fuel Contains Water
190
Fuel Rail Pressure Problem
191
Fuel Temperature Is High
202
Inlet Air Is Restricted
205
Intake Manifold Air Pressure Is High
206
Recommended Actions
206
Intake Manifold Air Pressure Is Low
209
Intake Manifold Air Temperature Is High
211
Nox Conversion Is Low
214
NRS Exhaust Gas Temperature Is High
226
Recommended Actions
227
NRS Mass Flow Rate Problem
228
Oil Consumption Is Excessive
234
Oil Contains Coolant
237
Oil Contains Fuel
240
Oil Level Is Low
242
Oil Pressure Is Low
243
Power Is Intermittently Low or Power Cutout Is Intermittent
248
SCR Catalyst Has Incorrect Inlet Temperature
255
SCR Warning System Problem
258
Valve Lash Is Excessive
266
Recommended Actions
266
Circuit Tests
268
Aftertreatment Identification Module - Test
268
CAN Data Link - Test
271
Coolant Level - Test
276
Cooling Fan Control - Test (Hydraulic Driven Fan)
278
Cooling Fan Control - Test (Viscous Clutch Fan)
281
Cooling Fan Speed - Test
283
Data Link - Test
285
Data Link Configuration Status - Test
293
DEF Control Module Power - Test
296
DEF Line Heater - Test
299
DEF Pump - Test
304
DEF Pump Pressure Sensor - Test
307
DEF Pump Sensor Supply - Test
309
DEF Tank Sensor - Test
311
Electrical Power Supply - Test
314
Ether Starting Aid - Test
319
Fuel Transfer Pump - Test
323
Glow Plug Starting Aid - Test
329
Idle Validation - Test
334
Indicator Lamp - Test
341
Injector Data Incorrect - Test
343
Injector Solenoid - Test
345
Mode Selection - Test
352
Motorized Valve - Test
355
Nox Sensor - Test
361
Power Take-Off - Test
367
Relay - Test (Aftertreatment Power Relay)
370
Sensor Calibration Required - Test
373
Sensor (Data Link Type) - Test
377
Sensor Signal (Analog, Active) - Test
382
Sensor Signal (Analog, Passive) - Test
390
Sensor Supply - Test
399
Solenoid Valve - Test
403
To the Dosing Control Unit (DCU))
403
Solenoid Valve - Test (Solenoid Valves that Connect to the Engine ECM)
409
Soot Sensor - Test
414
Speed Control - Test (Analog)
419
Speed Control - Test (PWM)
424
Speed/Timing - Test
431
Switch Circuits - Test (Multiposition Throttle Switch)
438
Switch Circuits - Test (Air Filter Restriction Switch)
441
Valve Position - Test
443
Water in Fuel - Test
450
Service
454
Service Tool Features
454
Override Parameters
454
Diagnostic Tests
456
Service Procedures
460
Maintenance Indicator
483
Service Tool Error Identifiers
486
Customer Passwords
499
Factory Passwords
499
ECM will Not Accept Factory Passwords
500
Electronic Service Tool Does Not Communicate
500
Codes that Inhibit Operation of Aftertreatment System
505
Test ECM Mode
507
ECM Software - Install
508
ECM Software - Install (Dosing Control Unit (DCU))
509
ECM - Replace
510
Electrical Connectors - Inspect
511
Injector Code - Calibrate
517
SCR Inducement Emergency Override
518
Index
521

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Perkins 1204F-E44TA Operation And Maintenance Manual

Perkins 1204F-E44TA Operation And Maintenance Manual (146 pages)

Industrial Engines

Brand: Perkins | Category: Engine | Size: 2 MB

Table of Contents

Table of Contents

3
- Foreword
  4
- Safety Section
  
  6
  - Safety Messages
    6
  - General Hazard Information
    9
  - Burn Prevention
    13
  - Fire Prevention and Explosion Prevention
    15
  - Crushing Prevention and Cutting Prevention
    17
  - Mounting and Dismounting
    17
  - High Pressure Fuel Lines
    17
  - Before Starting Engine
    19
  - Engine Starting
    19
  - Engine Stopping
    19
  - Electrical System
    20
  - Engine Electronics
    21
- Product Information Section
  
  22
  - General Information
    22
  - Product Identification Information
    32
- Operation Section
  
  35
  - Lifting and Storage
    35
  - Features and Controls
    42
  - Engine Diagnostics
    63
  - Engine Starting
    69
  - Engine Operation
    73
    
    When Required
    73
  - Cold Weather Operation
    75
  - Engine Stopping
    80
- Maintenance Section
  
  82
  - Refill Capacities
    82
  - Maintenance Recommendations
    100
Maintenance Interval Schedule Every 1000 Service Hours

103
- Maintenance Interval Schedule
  103
- Aftercooler Core - Clean/Test
  104
- Alternator and Fan Belts - Replace
  104
- Battery - Replace
  104
- Battery or Battery Cable - Disconnect
  105
- Belt - Inspect
  106
- Belt Tensioner - Check
  106
- Coolant (DEAC) - Change
  107
- Coolant (ELC) - Change
  109
- Coolant Extender (ELC) - Add
  110
- Coolant Level - Check
  110
- DEF Filler Screen - Clean
  111
- DEF Manifold Filters - Replace
  112
- Diesel Exhaust Fluid - Fill
  112
- Diesel Exhaust Fluid Filter - Clean/Replace
  113
- Diesel Exhaust Fluid Tank - Flush
  114
- Driven Equipment - Check
  114
- Engine - Clean
  115
- Engine Air Precleaner - Check/Clean
  117
- Replace
  117
- Engine Mounts - ins Pect
  119
- Engine Oil Level - Check
  119
- Engine Oil and Filter - Change
  120
- Engine Oil Sample - Obtain
  120
- Fan Clearance - Check
  123
- Fuel System - Prime
  125
- Fuel System Primary Filter (Water Separator)
  126
- Fuel System Primary Filter/Water Separator
  128
- Fuel System Secondary Filter - Replace
  128
- Fuel Tank Water and Sediment - Drain
  130
- Hoses and Clamps - Inspect/Replace
  130
- Radiator - Clean
  131
- Turbocharger - Inspect
  132
- Walk-Around ins Pection
  134
- Water Pump - Inspect
  136
- Warranty Section
  
  137
  - Warranty Information
    137
- Reference Information Section
  
  138
  - Reference Materials
    138
- Indexsection
  
  141
  - Index
    141

Perkins 1204F-E44TA Systems Operation Testing And Adjusting

Perkins 1204F-E44TA Systems Operation Testing And Adjusting (132 pages)

Industrial Engines

Brand: Perkins | Category: Engine | Size: 1 MB

Table of Contents

Table of Contents
3
Systems Operation Section
4
General Information
4
Introduction
4
Engine Operation
9
Basic Engine
9
Air Inlet and Exhaust System (Single Turbocharger)
13
Air Inlet and Exhaust System (Series Turbochargers)
19
Clean Emissions Module
24
System)
24
Clean Emissions Module
26
(DOC), Diesel Particulate Filter (DPF) and Selective
26
Catalytic Reduction (SCR) System)
26
DEF Dosing Control System
29
Cooling System
35
Lubrication System
37
Electrical System
37
Cleanliness of Fuel System Components
39
Fuel Injection
40
Electronic Control System
48
Power Sources
69
Glossary of Electronic Control Terms
74
Testing and Adjusting Section
80
Fuel System
80
Fuel System - Inspect
80
Air in Fuel - Test
80
Finding Top Center Position for No. 1 Piston
82
Fuel Injection Timing - Check
83
Fuel Quality - Test
84
Fuel System - Prime
85
Gear Group (Front) - Time
86
Air Inlet and Exhaust System
87
Air Inlet and Exhaust System - Inspect
87
Turbocharger - Inspect (Series Turbochargers)
88
Turbocharger - Inspect (Single Turbocharger)
91
Exhaust Cooler (NRS) - Test
94
Compression - Test
95
Engine Valve Lash - Inspect
96
Valve Depth - Inspect
97
Valve Guide - Inspect
98
Diesel Exhaust Fluid Quality - Test
99
Aftertreatment SCR System Dosing - Test
100
Diesel Exhaust Fluid Tank - Flush
104
Lubrication System
107
Engine Oil Pressure - Test
107
Engine Oil Pump - Inspect
107
Excessive Bearing Wear - Inspect
108
Excessive Engine Oil Consumption - Inspect
108
Increased Engine Oil Temperature - Inspect
109
Cooling System
110
Cooling System - Check
110
Cooling System - Inspect
110
Cooling System - Test
111
Engine Oil Cooler - Inspect
112
Water Temperature Regulator - Test
113
Water Pump - Inspect
113
Basic Engine
114
Position the Valve Mechanism before Maintenance Procedures
114
Piston Ring Groove - Inspect
114
Connecting Rod - Inspect
115
Cylinder Block - Inspect
116
Cylinder Head - Inspect
116
Piston Height - Inspect
117
Flywheel - Inspect
118
Flywheel Housing - Inspect
119
Gear Group - Inspect
120
Crankshaft Pulley - Check
121
Electrical System
122
Alternator - Test
122
Battery - Test
124
Charging System - Test
124
V-Belt - Test
125
Electric Starting System - Test
125
Index
129

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Perkins 1204F-E44TA Supplement Manual

Perkins 1204F-E44TA Supplement Manual (41 pages)

DEF SYSTEM

Brand: Perkins | Category: Engine | Size: 2 MB

Table of Contents

Table of Contents
3
1 Introduction

5
- Safety Requirements
  5
- Terminology
  6
2 Mandatory Installation Requirements

7
- General Requirements
  7
- Cleanliness
  7
- Prohibited Materials
  7
- Def Specification
  7
- Def Tank
  8
  - General
    8
  - Positioning
    8
  - DEF Tank Mounting
    9
  - DEF Filler Neck Extensions/Remote Fill
    9
- Tank Header
  9
- PEU (with Integrated DCU)
  10
- Def Component Relative Positions
  11
  - DEF Tank to PEU
    11
  - PEU to DEF Injector
    12
- Def Coolant Valve
  13
- Def Tank Coolant Supply Lines
  14
- Def Lines
  15
3 Scr System Fundamentals

16
- Platform Technologies
  16
- Diesel Exhaust Fluid (Def)
  16
  - General DEF Information
    16
  - Standards
    16
  - DEF Quality
    16
  - DEF Storage
    16
- Regulations
  17
4 Scr System

18
- At/ Scr System Schematic
  18
- Components
  20
  - DEF Tank
    20
  - DEF Filler Cap
    21
  - DEF Tank Header
    21
  - Coolant Lines and Valve
    22
  - DEF Pump
    23
  - DEF Control Unit (DCU)
    23
  - DEF Lines
    24
  - DEF Injector
    25
- Operational Parameters
  26
  - DEF Component Temperature Requirements
    26
  - DEF Component Vibration Requirements
    27
5 Scr System Design Considerations

28
- Def Line and Coolant Schematic
  28
- Customer Connections
  28
  - Coolant Connections
    29
  - DEF Connection Detail
    31
- Materials
  33
  - Rubber Components (Seals, Etc.)
    33
  - Metallic Components
    33
- Def Tanks
  34
  - DEF Tank Sizing
    34
  - DEF Tank Mounting and Installation
    35
  - DEF Tank Straps
    35
  - Bulk Fuel and DEF Tanks
    37
- Def Component Mounting and Isolation
  38
  - PEU/DCU Mounting Requirements
    38
  - DEF Component Relative Positioning
    39
- Def Tank Service Considerations
  39
  - DEF Tank Filling
    39
  - Overfill Protection
    39
  - Remote Fill
    40
  - DEF Tank Draining
    40
- Production and Manufacturing
  40
6 Record of Amendment

41
- Changes from Issue 1 to Issue 2
  41
- Changes from Issue 2 to Issue 3
  41

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