Perkins 1204F engine service & repair manual

Description Perkins 1204F engine service & repair manual

Perkins 1204F-E44TA, 1204F-E44TTA Industrial engines pdf service manual + operation & maintenance manual + testing & adjusting manual + troubleshooting manual

MANUAL CONTENT:
Disassembly and Assembly Section
Fuel Priming Pump - Remove and Install (Electric Fuel Lift Pump (EFLP))
Flow Control Valve - Remove and Install
Fuel Filter Base - Remove and Install (Twin Secondary Fuel Filter)
Fuel Filter Base - Remove and Install (Single Secondary Fuel Filter)
Water Separator and Fuel Filter (Primary) - Remove and Install
Fuel Manifold (Rail) - Remove and Install
Fuel Injection Lines - Remove
Fuel Injection Lines - Install
Exhaust Cooler (NRS) - Remove and Install (Top Mounted Turbocharger)
Exhaust Cooler (NRS) - Remove and Install (Side Mounted Turbocharger)
Exhaust Cooler (NRS) - Remove and Install (Twin Turbochargers)
Inlet Air Control - Remove (NRS Induction Mixer)
Inlet Air Control - Install (NRS Induction Mixer)
Fuel Injection Pump - Remove
Fuel Injection Pump - Install
Fuel Injection Pump Gear - Remove
Fuel Injection Pump Gear - Install
Electronic Unit Injector - Remove
Electronic Unit Injector - Install
Turbocharger - Remove (Second Stage Turbocharger)
Turbocharger - Remove (First Stage Turbocharger)
Turbocharger - Remove (Top Mounted Turbocharger )
Turbocharger - Remove (Side Mounted Turbochargers)
Turbocharger - Install (Side Mounted Turbochargers)
Turbocharger - Install (Second Stage Turbocharger)
Turbocharger - Install (First Stage Turbocharger)
Turbocharger - Install (Top Mounted Turbocharger )
Wastegate Solenoid - Remove and Install
Exhaust Back Pressure Valve - Remove and Install
Clean Emissions Module - Remove and Install
Diesel Exhaust Fluid Lines - Remove and Install
Diesel Exhaust Fluid Pump - Remove and Install
DEF Injector and Mounting - Remove and Install
Diesel Exhaust Fluid Tank - Remove and Install
Manifold (DEF Heater) - Remove and Install
Solenoid Valve (DEF Heater Coolant) - Remove and Install
Flexible Exhaust Pipe - Remove and Install
Exhaust Manifold - Remove and Install (Twin Turbochargers Exhaust manifold)
Exhaust Manifold - Remove and Install (Single Turbocharger Exhaust Manifold)
Exhaust Elbow - Remove and Install
Exhaust Elbow - Remove and Install (Top Mounted and Side Mounted Turbocharger Exhaust Elbow)
Support and Mounting (CEM) - Remove and Install
Inlet and Exhaust Valve Springs - Remove and Install
Inlet and Exhaust Valves - Remove and Install
Engine Oil Filter Base - Remove and Install
Engine Oil Cooler - Remove
Engine Oil Cooler - Install
Engine Oil Pump - Remove
Engine Oil Pump - Install
Water Pump - Remove
Water Pump - Install
Water Temperature Regulator - Remove and Install
Flywheel - Remove
Flywheel - Install
Crankshaft Rear Seal - Remove
Crankshaft Rear Seal - Install
Flywheel Housing - Remove and Install (Wet Back End Housing)
Flywheel Housing - Remove and Install (Standard Housing)
Crankshaft Pulley - Remove and Install
Crankshaft Front Seal - Remove and Install
Crankshaft Front Seal - Remove and Install (Crankshaft Front Seal for Heavy Duty Front Cover)
Front Cover - Remove and Install
Front Cover - Remove and Install (Heavy Duty Front Cover)
Gear Group (Front) - Remove and Install
Gear Group (Front) - Remove and Install (Heavy Duty Gear Group (Front))
Idler Gear - Remove
Idler Gear - Install
Housing (Front) - Remove
Housing (Front) - Remove (Heavy Duty Housing (Front))
Housing (Front) - Install
Housing (Front) - Install (Heavy Duty Housing (Front))
Accessory Drive - Remove and Install (Accessory Drive SAE "B")
Accessory Drive - Remove and Install (Accessory Drive SAE "A")
Crankcase Breather - Remove
Crankcase Breather - Install
Valve Mechanism Cover - Remove and Install
Rocker Shaft and Pushrod - Remove
Rocker Shaft - Disassemble
Rocker Shaft - Assemble
Rocker Shaft and Pushrod - Install
Cylinder Head - Remove
Cylinder Head - Install
Lifter Group - Remove and Install (Hydraulic Lifter Group)
Camshaft - Remove and Install
Camshaft Gear - Remove and Install
Camshaft Bearings - Remove and Install
Engine Oil Pan - Remove and Install (Aluminum and Pressed Steel Oil Pans)
Engine Oil Pan - Remove and Install (Cast Iron Oil Pan)
Balancer - Remove
Balancer - Install
Piston Cooling Jets - Remove and Install
Pistons and Connecting Rods - Remove
Pistons and Connecting Rods - Disassemble
Pistons and Connecting Rods - Assemble
Pistons and Connecting Rods - Install
Connecting Rod Bearings - Remove (Connecting Rods in Position)
Connecting Rod Bearings - Install (Connecting Rods in Position)
Crankshaft Main Bearings - Remove and Install (Crankshaft in Position)
Crankshaft - Remove
Crankshaft - Install
Crankshaft Timing Ring - Remove and Install
Crankshaft Gear - Remove and Install
Crankshaft Gear (Balancer Drive) - Remove and Install
Bearing Clearance - Check
Refrigerant Compressor - Remove and Install
Nitrogen Oxide Sensor - Remove and Install (Nitrogen Oxide Sensor on Engine)
Nitrogen Oxide Sensor - Remove and Install (Nitrogen Oxide Sensor Positioned in Original Equipment Manufacture (OEM) Exhaust Tube Assembly)
Atmospheric Pressure Sensor - Remove and Install
Camshaft Position Sensor - Remove and Install
Crankshaft Position Sensor - Remove and Install
Coolant Temperature Sensor - Remove and Install
Engine Oil Pressure Sensor - Remove and Install
Fuel Temperature Sensor - Remove and Install
Ammonia Sensor - Remove and Install (Ammonia Sensor if Equipped)
Soot Antenna - Remove and Install
Temperature Sensor (Exhaust) - Remove and Install (Selective Catalytic Reduction (SCR) Temperature Sensor)
Temperature Sensor (DPF) - Remove and Install
Temperature Sensor (Catalyst Inlet) - Remove and Install
Temperature Sensor (Cooled Exhaust Gas) - Remove and Install
Pressure Sensor (Cooled Exhaust Gas) - Remove and Install (Differential Pressure Sensor and Inlet Pressure Sensor)
Boost Pressure Sensor - Remove and Install
Inlet Manifold Temperature Sensor - Remove and Install
Glow Plugs - Remove and Install
Alternator Belt - Remove and Install
Idler Pulley - Remove and Install (Grooved Idler Pulley)
Idler Pulley - Remove and Install (Flat Idler Pulley)
Belt Tensioner - Remove and Install
Fan - Remove and Install
Fan Drive - Remove and Install
Electronic Control Module - Remove
Electronic Control Module - Install
Alternator - Remove
Alternator - Install
Electric Starting Motor - Remove and Install
Air Compressor - Remove and Install (Single Cylinder Air Compressor)
Air Compressor - Remove and Install (Twin Cylinder Air Compressor)
Index

Operation & Maintenance
Foreword
Safety Section
Safety Messages
General Hazard Information
Burn Prevention
Fire Prevention and Explosion Prevention
Crushing Prevention and Cutting Prevention
Mounting and Dismounting
High Pressure Fuel Lines
Before Starting Engine
Engine Starting
Engine Stopping
Electrical System
Engine Electronics
Product Information Section
General Information
Product Identification Information
Operation Section
Lifting and Storage
Features and Controls
Engine Diagnostics
Engine Starting
Engine Operation
Cold Weather Operation
Engine Stopping
Maintenance Section
Refill Capacities
Maintenance Recommendations
Maintenance Interval Schedule
Warranty Section Warranty Information
Reference Information Section Reference Materials
Index Section

Systems Operation Section
General Information Introduction
Engine Operation Basic Engine
Air Inlet and Exhaust System (Single Turbocharger)
Air Inlet and Exhaust System (Series Turbochargers)
Clean Emissions Module (Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF) and Selective Catalytic Reduction (SCR) System)
Clean Emissions Module (Diesel Oxidation Catalyst (DOC) and Selective Catalytic Reduction (SCR) System)
DEF Dosing Control System
Cooling System
Lubrication System
Electrical System
Cleanliness of Fuel System Components
Fuel Injection
Electronic Control System
Power Sources
Glossary of Electronic Control Terms

Testing and Adjusting Section
Fuel System Fuel System - Inspect
Air in Fuel - Test
Finding Top Center Position for No. 1 Piston
Fuel Injection Timing - Check
Fuel Quality - Test
Fuel System - Prime
Gear Group (Front) - Time
Air Inlet and Exhaust System Air Inlet and Exhaust System - Inspect
Turbocharger - Inspect (Series Turbochargers)
Turbocharger - Inspect (Single Turbocharger)
Exhaust Cooler (NRS) - Test
Compression - Test
Engine Valve Lash - Inspect
Valve Depth - Inspect
Valve Guide - Inspect
Diesel Exhaust Fluid Quality - Test
Aftertreatment SCR System Dosing - Test
Diesel Exhaust Fluid Tank - Flush
Lubrication System Engine Oil Pressure - Test
Engine Oil Pump - Inspect
Excessive Bearing Wear - Inspect
Excessive Engine Oil Consumption - Inspect
Increased Engine Oil Temperature - Inspect
Cooling System
Cooling System - Check
Cooling System - Inspect
Cooling System - Test
Engine Oil Cooler - Inspect
Water Temperature Regulator - Test
Water Pump - Inspect
Basic Engine Position the Valve Mechanism Before Maintenance Procedures
Piston Ring Groove - Inspect
Connecting Rod - Inspect
Cylinder Block - Inspect
Cylinder Head - Inspect
Piston Height - Inspect
Flywheel - Inspect
Flywheel Housing - Inspect
Gear Group - Inspect
Crankshaft Pulley - Check
Electrical System Alternator - Test
124 Battery - Test
Charging System - Test
V-Belt - Test
Electric Starting System - Test
Index Section

Troubleshooting Section
Introduction
General Information
Welding Precaution
Electronic Service Tools
Electronic System Overview
System Overview
Component Location
Diesel Particulate Filter Regeneration
Engine Monitoring System
Diagnostic Capabilities
Electrical Connectors
Configuration Parameters
Diagnostic Trouble Codes
Event Codes
Symptom Troubleshooting Acceleration Is Poor or Throttle Response Is Poor
Alternator Problem (Charging Problem and/or Noisy Operation)
Battery Problem
Belt Tensioner Noise
Clean Emissions Module Has High Oxygen Level
Coolant Contains Oil
Coolant Level Is Low
Coolant Temperature Is High
Coolant Temperature Is Low
Crankcase Breather Ejects Oil
Crankcase Fumes Disposal Tube Has Oil Draining
Cylinder Is Noisy
DEF Concentration Is Incorrect
DEF Pressure Does Not Respond
DEF Pressure Is High
DEF Pressure Is Low
DEF Tank Level Is Low
DEF Tank Temperature Is High
DEF Tank Temperature Is Low
Diesel Oxidation Catalyst Has Incorrect Inlet Temperature
Diesel Oxidation Catalyst Has Low Conversion Efficiency
Diesel Particulate Filter Collects Excessive Soot (If Equipped)
Diesel Particulate Filter Temperature Is Low (If Equipped)
Engine Cranks but Does Not Start
Engine Does Not Crank
Engine Has Early Wear
Engine Has Mechanical Noise (Knock)
Engine Misfires, Runs Rough or Is Unstable
Engine Overspeeds
Engine Shutdown Occurrence
Engine Shutdown Occurs Intermittently
Engine Stalls at Low RPM
Engine Top Speed Is Not Obtained
Engine Vibration Is Excessive
Exhaust Has Excessive Black Smoke
Exhaust Has Excessive White Smoke
Exhaust System Contains Coolant
Exhaust System Contains Oil
Exhaust Temperature Is High
Fuel Consumption Is Excessive
Fuel Contains Water
Fuel Rail Pressure Problem
Fuel Temperature Is High
Inlet Air Is Restricted
Intake Manifold Air Pressure Is High
Intake Manifold Air Pressure Is Low
Intake Manifold Air Temperature Is High
NOx Conversion Is Low
NRS Exhaust Gas Temperature Is High
NRS Mass Flow Rate Problem
Oil Consumption Is Excessive
Oil Contains Coolant
Oil Contains Fuel
Oil Level Is Low
Oil Pressure Is Low
Power Is Intermittently Low or Power Cutout Is Intermittent
SCR Catalyst Has Incorrect Inlet Temperature
SCR Warning System Problem
Valve Lash Is Excessive
Circuit Tests
Aftertreatment Identification Module - Test
CAN Data Link - Test
Coolant Level - Test
Cooling Fan Control - Test (Hydraulic Driven Fan)
Cooling Fan Control - Test (Viscous Clutch Fan)
Cooling Fan Speed - Test
Data Link - Test
Data Link Configuration Status - Test
DEF Control Module Power - Test
DEF Line Heater - Test
DEF Pump - Test
DEF Pump Pressure Sensor - Test
DEF Pump Sensor Supply - Test
DEF Tank Sensor - Test
Electrical Power Supply - Test
Ether Starting Aid - Test
Fuel Transfer Pump - Test
Glow Plug Starting Aid - Test
Idle Validation - Test
Indicator Lamp - Test
Injector Data Incorrect - Test
Injector Solenoid - Test
Mode Selection - Test
Motorized Valve - Test
NOx Sensor - Test
Power Take-Off - Test
Relay - Test (Aftertreatment Power Relay)
Sensor Calibration Required - Test
Sensor (Data Link Type) - Test
Sensor Signal (Analog, Active) - Test
Sensor Signal (Analog, Passive) - Test
Sensor Supply - Test
Solenoid Valve - Test (Solenoid Valves that Connect to the Dosing Control Unit (DCU))
Solenoid Valve - Test (Solenoid Valves that Connect to the Engine ECM)
Soot Sensor - Test
Speed Control - Test (Analog)
Speed Control - Test (PWM)
Speed/Timing - Test
Switch Circuits - Test (Multiposition Throttle Switch)
Switch Circuits - Test (Air Filter Restriction Switch)
Valve Position - Test
Water in Fuel - Test
Service Tool FeaturesService Tool Error Identifiers
Customer Passwords
Factory Passwords
ECM Will Not Accept Factory Passwords
Electronic Service Tool Does Not Communicate
Codes that Inhibit Operation of Aftertreatment System
Test ECM Mode
ECM Software - Install
ECM Software - Install (Dosing Control Unit (DCU))
ECM - Replace
Electrical Connectors - Inspect
Injector Code - Calibrate
SCR Inducement Emergency Override
Index Section