Perkins 1204F-E44TA and 1204F-E44TTA Engines Troubleshooting Manual
TABLE OF CONTENTS:
Perkins 1204F-E44TA and 1204F-E44TTA Engines Troubleshooting Manual
Troubleshooting Section
Introduction
General Information 5
Welding Precaution 6
Electronic Service Tools7
Electronic System Overview
System Overview 10
Component Location 12
Diesel Particulate Filter Regeneration 22
Engine Monitoring System 22
Diagnostic Capabilities 23
Electrical Connectors 24
Configuration Parameters
Configuration Parameters 29
Diagnostic Trouble Codes
Diagnostic Trouble Codes32
Event Codes
Event Codes 53
Symptom Troubleshooting
Acceleration Is Poor or Throttle Response Is Poor 65
Alternator Problem (Charging Problem and/or Noisy
Operation) 73
Battery Problem 75
Clean Emissions Module Has High Oxygen Level76
Coolant Contains Oil 77
Coolant Level Is Low 79
Coolant Temperature Is High80
Coolant Temperature Is Low 84
Crankcase Breather Ejects Oil 86
Crankcase Fumes Disposal Tube Has Oil Draining 87
Cylinder Is Noisy 90
DEF Pressure Does Not Respond 93
DEF Pressure Is High 95
DEF Pressure Is Low99
DEF Tank Level Is Low 104
DEF Tank Temperature Is High 107
DEF Tank Temperature Is Low 109
Diesel Oxidation Catalyst Has Incorrect Inlet
Temperature 112
Diesel Oxidation Catalyst Has Low Conversion
Efficiency 115
Diesel Particulate Filter Collects Excessive Soot (If
Equipped) 116
Diesel Particulate Filter Temperature Is Low (If
Equipped) 120
Engine Cranks but Does Not Start 122
Engine Does Not Crank 130
Engine Has Early Wear 132
Engine Has Mechanical Noise (Knock) 134
Engine Misfires, Runs Rough or Is Unstable 137
Engine Overspeeds 143
Engine Shutdown Occurrence 146
Engine Shutdown Occurs Intermittently 147
Engine Stalls at Low RPM 149
Engine Top Speed Is Not Obtained 152
Engine Vibration Is Excessive 159
Exhaust Has Excessive Black Smoke 161
Exhaust Has Excessive White Smoke 165
Exhaust System Contains Coolant 170
Exhaust System Contains Oil 171
Exhaust Temperature Is High 173
Fuel Consumption Is Excessive 176
Fuel Contains Water 180
Fuel Rail Pressure Problem 181
Fuel Temperature Is High 192
Inlet Air Is Restricted 195
Intake Manifold Air Pressure Is High 196
Intake Manifold Air Pressure Is Low 197
Intake Manifold Air Temperature Is High 199
NOx Conversion Is Low 202
NRS Exhaust Gas Temperature Is High 211
NRS Mass Flow Rate Problem 214
Oil Consumption Is Excessive 220
Oil Contains Coolant 223
Oil Contains Fuel 225
Oil Level Is Low 228
Oil Pressure Is Low 229
Power Is Intermittently Low or Power Cutout Is
Intermittent 234
SCR Catalyst Has Incorrect Inlet Temperature 241
SCR Warning System Problem 244
Valve Lash Is Excessive 252
Circuit Tests
Aftertreatment Identification Module – Test 254
CAN Data Link – Test 257
Coolant Level – Test 261
Cooling Fan Control – Test (Hydraulic Driven Fan) 263
Cooling Fan Control – Test (Viscous Clutch Fan) 266
Cooling Fan Speed – Test 268
Data Link – Test 270
Data Link Configuration Status – Test 278
DEF Control Module Power – Test 280
DEF Line Heater – Test 284
DEF Pump – Test 289
DEF Pump Pressure Sensor – Test 292
DEF Pump Sensor Supply – Test 294
DEF Tank Sensor – Test 295
Electrical Power Supply – Test 299
Ether Starting Aid – Test 304
Fuel Transfer Pump – Test 308
Glow Plug Starting Aid – Test 314
Idle Validation – Test 319
Indicator Lamp – Test 326
Injector Data Incorrect – Test 328
Injector Solenoid – Test 330
Mode Selection – Test 337
Motorized Valve – Test 340
NOx Sensor – Test 346
Power Take-Off – Test 349
Relay – Test (Aftertreatment Power Relay) 352
Sensor Calibration Required – Test 355
Sensor (Data Link Type) – Test 359
Sensor Signal (Analog, Active) – Test 364
Sensor Signal (Analog, Passive) – Test 371
Sensor Supply – Test 380
Solenoid Valve – Test (Solenoid Valves that Connect
to the Engine ECM) 385
UENR4469-26 3
Table of Contents
Solenoid Valve – Test (Solenoid Valves that Connect
to the Dosing Control Unit (DCU)) 391
Soot Sensor – Test 397
Speed Control – Test (Analog) 401
Speed Control – Test (PWM) 406
Speed/Timing – Test 413
Switch Circuits – Test (Multiposition Throttle
Switch) 420
Valve Position – Test 423
Water in Fuel – Test 430
Service
Service Tool Features 434
Service Tool Error Identifiers 465
Customer Passwords 478
Factory Passwords 478
ECM Will Not Accept Factory Passwords 479
Electronic Service Tool Does Not Communicate 479
Codes that Inhibit Operation of Aftertreatment
System 484
Test ECM Mode 486
ECM Software – Install 487
ECM – Replace 488
Electrical Connectors – Inspect 489
Injector Code – Calibrate 494
SCR Inducement Emergency Override 495
Index Section
Index 498
DESCRIPTION:
Perkins 1204F-E44TA and 1204F-E44TTA Engines Troubleshooting Manual
General Information:
Important Safety Information:
- Do not perform any procedures in this Troubleshooting Guide until you have read the Operation and Maintenance Manual and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury.
- Also, the following procedures must be observed. Work safely. 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. Safety precautions and warnings are provided in this publication and on the product.
- If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Perkins cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.
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PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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