Perkins 1204F-E44TA and 1204F-E44TTA Industrial Engine System Operation Testing and Adjusting Manual
TABLE OF CONTENTS:
Perkins 1204F-E44TA and 1204F-E44TTA Industrial Engine System Operation Testing and Adjusting Manual
Systems Operation Section
General Information
Introduction 4
Engine Operation
Basic Engine9
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
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 – Inspect97
Valve Guide – Inspect98
Diesel Exhaust Fluid Quality – Test99
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
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
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
Alternator – Test 122
Battery – Test 124
Charging System – Test 124
V-Belt – Test 125
Electric Starting System – Test 125
Index Section
Index 129
DESCRIPTION:
Perkins 1204F-E44TA and 1204F-E44TTA Industrial Engine System Operation Testing and Adjusting Manual
INTRODUCTION:
The 1204F-E44TA and 1204F-E44TTA diesel engines are electronically controlled. The 1204FE44TA 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 highpressure manifold (Rail). The high-pressure manifold (Rail) distributes fuel to the electronic unit injectors. 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. 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. 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 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.
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]