Perkins Industrial Engines Operation Manual (EN)

UENR4490-01 (en-us) February 2017 Systems Operation Testing and Adjusting 1204F-E44TA and 1204F-E44TTA Industrial Engines MT (Engine) MU (Engine) MW (Engine)

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Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication. Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others.

You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. 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. Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or death.

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UENR4490-01 3 Table of Contents Table of Contents 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 Systems Operation Section General Information Introduction ..........................................................4 Basic Engine 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 Engine Operation Basic Engine.........................................................9 Air Inlet and Exhaust System (Single Turbocharger) ...................................................13 Air Inlet and Exhaust System (Series Turbochargers)..................................................19 Clean Emissions Module (Diesel Oxidation Catalyst (DOC) and Selective Catalytic Reduction (SCR) System)............................................................24 Clean Emissions Module (Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF) and Selective 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 Electrical System Alternator - Test.................................................122 Battery - Test ....................................................124 Charging System - Test .....................................124 V-Belt - Test ......................................................125 Electric Starting System - Test............................125 Index Section Index................................................................129 Testing and Adjusting Section Fuel System 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 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 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

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General Information 4 UENR4490-01 Systems Operation Section General Information The crankshaft gear turns the idler gear which then turns the following gears: the camshaft gear i05934599 Introduction the accessory drive gear (if equipped) the fuel injection pump gear the water pump gear The 1204F-E44TA and 1204F-E44TTA diesel engines are electronically controlled. The 1204F- E44TA and 1204F-E44TTA engines have an Electronic Control Module (ECM) that receives signals from the fuel injection pump and other sensors in order to control the electronic unit injector. The fuel injection pump supplies fuel to the high- pressure manifold (Rail).

The high-pressure manifold (Rail) distributes fuel to the electronic unit injectors. The camshaft runs at half the rpm of the crankshaft. The fuel injection pump runs at the same rpm as the crankshaft. The fuel injection pump that is installed on the left side of the engine is gear-driven from the timing case. The fuel is transferred to the fuel injection pump by an external electric transfer pump. The electric transfer pump draws fuel across a suction strainer that supplies fuel to the primary fuel filter and the secondary fuel filter. The fuel then travels to the fuel injection pump.

A pressure regulator that is installed in the low-pressure fuel system controls the fuel pressure to the fuel injection pump. The pressure regulator regulates the fuel at an absolute pressure of 150 kPa (22 psi) when the engine is at idle speed. The four cylinders are arranged in-line. The cylinder head assembly has two inlet valves and two exhaust valves for each cylinder. The ports for the exhaust valves are on the right side of the cylinder head. The ports for the inlet valves are on the left side of the cylinder head. Each cylinder valve has a single valve spring. The fuel injection pump increases the fuel to a maximum pressure of 200 MPa (2900 psi).

The fuel injection pump delivers the fuel to the high-pressure manifold (Rail). The fuel injection pump is not serviceable. The engine uses speed sensors and the Electronic Control Module to control the engine speed. Each cylinder has a piston cooling jet that is installed in the cylinder block. The piston cooling jet sprays engine oil onto the inner surface of the piston in order to cool the piston. The pistons have a Quiescent or a Re-entrant combustion chamber in the top of the piston in order to achieve clean exhaust emissions. The piston pin is off-center in order to reduce the noise level. For the specifications of the 1204F engine, refer to the Specifications, “Engine Design”.

The pistons have two compression rings and an oil control ring. The groove for the top ring has a hard metal insert in order to reduce wear of the groove. The skirt has a layer of graphite in order to reduce the risk of seizure when the engine is new. The correct piston height is important in order to ensure that the piston does not contact the cylinder head. The correct piston height also ensures the efficient combustion of fuel which is necessary in order to conform to requirements for emissions. The following model views show a typical 1204F engine. Due to individual applications, your engine may appear different from the illustrations. The crankshaft has five main bearing journals.

End play is controlled by thrust washers which are located on both sides of the number 3 main bearing. The timing case is made of aluminum or cast iron. The timing gears are stamped with timing marks in order to ensure the correct assembly of the gears. When the number 1 piston is at the top center position of the compression stroke, the marked teeth on the idler gear will align with the marks that are on the fuel injection pump gear, the camshaft gear, and the gear on the crankshaft. There are no timing marks on the rear face of the timing case.

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