Perkins Engine 1204E-E44TA, 1204E-E44TTA Service Manual
Operation and
Maintenance
Manual
SEBU8605-01
May 2011
1204E-E44TA and 1204E-E44TTA
Industrial Engines
(Engine)
MK
ML (Engine)
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 premature failures, product damage, personal injury or
death.
SEBU8605-01 3
Table of Contents
Table of Contents
Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 5
General Haz ard Information ................................... 7
Burn Prevention .................................................... 10
Fire Prevention and Explosion Prevention ............. 11
Crushing Prevention and Cutting Prevention ........ 13
Mounting and Dismounting ................................... 13
High Pre ssure Fuel Lines ..................................... 13
Before Starting Engine .......................................... 15
Engine Starting ..................................................... 15
Engine Stopping ................................................... 16
Maintenance In
Warranty Sect
Warranty Information ........................................... 113
terval Schedule ............................ 80
ion
Reference Information Section
Reference Materials ............................................. 117
Index Section
Index .................................................................... 118
Electrical System .................................................. 16
Engine Electronics ................................................ 17
Product Information Section
Model Views ......................................................... 18
Product Identification Information ........................ 27
Operation Section
Lifting and Storage ................................................ 30
Gauges and Indicators .......................................... 34
Features and Controls .......................................... 36
Engine Diagnostics ............................................... 46
Engine Starting ..................................................... 52
Engine Operation .................................................. 55
Engine Stopping ................................................... 57
Cold Weathe r Operation ....................................... 59
Maintenance Section
Refill Capacities .................................................... 63
Maintenance Recommendations .......................... 78
4 SEBU8605-01
Foreword
Foreword
Literature Information
This manual co
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literatu
study and keep it with the literature and engine
information.
English is the primary language for all Perkins
publications. The English used facilitates translation
and consist
Some photographs or illustrations in this manual
show detai
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improveme
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises re
consult with your Perkins dealer or your Perkins
distributor for the latest available information.
Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
g situations. Read and understand the basic
warnin
precautions listed in the safety section before
operating or performing lubrication, maintenance and
on this product.
repair
ntains safety, operation instructions,
re holder or literature storage area. Read,
ency.
ls or attachments that may be different
nt and advancement of product design
garding your engine, or this manual, please
Recommended se
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine a
Schedule. Therefore, under extremely severe,
dusty, wet or freezing cold operating conditions,
more frequen
specified in the Maintenance Interval Schedule may
be necessary.
The maintenance schedule items are organized for
a preventive maintenance management program. If
the prevent
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should min
avoidances resulting from reductions in unscheduled
downtime and failures.
ive maintenance program is followed, a
imize operating costs through cost
rvice should be performed at the
lso governs the Maintenance Interval
t lubrication and maintenance than is
Maintenance Intervals
Perform maintenance on items at multiples of
the original requirement. We recommend that the
maintena
near the engine as a convenient reminder. We also
recommend that a maintenance record be maintained
as part o
Your authorized Perkins dealer or your Perkins
distrib
maintenance schedule to meet the needs of your
operating environment.
nce schedules be reproduced and displayed
f the engine's permanent record.
utor can assist you in adjusting your
Overhaul
Opera
Operating techniques outlined in this manual are
basic
techniques required to operate the engine more
efficiently and economically. Skill and techniques
deve
engine and its capabilities.
The o
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and
discussion of electronic diagnostic information.
tion
. They assist with developing the skills and
lop as the operator gains knowledge of the
peration section is a reference for operators.
stopping the engine. This section also includes a
Maintenance
e maintenance section is a guide to engine care.
Th
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
tervals. Items in the maintenance schedule are
in
referenced to detailed instructions that follow.
Major engine overhaul details are not covered in
the Operation and Maintenance Manual except
e interval and the maintenance items in that
for th
interval. Major repairs should only be carried out by
Perkins authorized personnel. Your Perkins dealer
r Perkins distributor offers a variety of options
or you
regarding overhaul programs. If you experience
a major engine failure, there are also numerous
r failure overhaul options available. Consult with
afte
your Perkins dealer or your Perkins distributor for
information regarding these options.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
th defects, and other reproductive harm. Battery
bir
posts, terminals and related accessories contain lead
and lead compounds. Wash hands after handling.
SEBU8605-01 5
Safety Section
Safety Messages
Safety Section
i04229669
Safety Message s
There may be
engine. The exact location and a description of the
warning signs are reviewed in this section. Please
become fam
Ensure that all of the warning signs are legible. Clean
the warnin
the words cannot be read or if the illustrations are
not visible. Use a cloth, water, and soap to clean
the warni
other harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
warning
coulddropofftheengine.
Replace
missing.Ifawarningsignisattachedtoapartofthe
engine that is replaced, install a new warning sign on
the rep
provide new warning signs.
lacement part. Your Perkins distributor can
several specific warning signs on your
iliar with all warning signs.
g signs or replace the warning signs if
ng signs. Do not use solvents, gasoline, or
signs. The warning signs that are loosened
any warning sign that is damaged or
The Universal W
positions. The warning labels are located on the rear
right side of the valve mechanism cover and located
on the top for t
arning label (1) is located in two
he NOx reduction system (NRS).
(1) Universal Warning
Do not operate or work on this equipment unless
ave read and understand the instructions
you h
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
the warnings could result in serious injury
heed
or death.
Illustration 1
ypical example
T
g01154807
6 SEBU8605-01
Safety Section
Safety Messages
Illustration 2
ersal Warning
(1) Univ
(2) Han
d (High Pressure)
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu-
ay may cause a fire hazard. Failure to fol-
el spr
low these inspection, maintenance and service instructions may cause personal injury or death.
g02406137
Illustration 3
Typical example
2382677
g0
SEBU8605-01 7
Safety Section
General Hazard Information
Illustration 4
(2) Hand
(High Pressure )
g02406178
The warning label for the Hand (High Pressure)
(2) is a
wrap around label that is installed on the
high-pressure fuel line.
Ether Warning
her warning label will be installed on the air
The et
cleaner or close to the air cleaner. The location will
depend on the application.
Do not use aerosol types of starting aids suc h as
ether. Such use could result in an explosion and
personal injury.
Illustration 5
Typical exa mple
g01154809
i03566024
General Hazard Inf ormation
Illustration 6
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
repaired. Attach the warning tags to the engine and to
each operator control station. When it is appropriate,
disconnect the starting controls.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
g00104545
Tampering with the engine installation or tampering
•
with the OEM supplied wiring can be dangerous.
Personal injury, death and/or engine damage could
result.
Vent the engine exhaust to the outside when the
•
engine is operated in an enclosed area.
8 SEBU8605-01
Safety Section
General Hazard Information
If the engine is
•
secondary brake or the parking brake systems
unless the vehicle is blocked or unless the vehicle
is restrained
Wear a hard hat, protective glasses, and other
•
protective e
When work is performed around an engine that is
•
operating,
to help prevent damage to hearing.
Do not wear l
•
on controls or on other parts of the engine.
Ensure tha
•
securedinplaceontheengine.
Never put m
•
Glass containers can break.
Use all cl
•
Report all necessary repairs.
•
Unless other instructions are provided, perform the
maintenance under the following conditions:
not running, do not release the
.
quipment, as required.
wear protective devices for ears in order
oose clothing or jewelry that can snag
t all protective guards and all covers are
aintenance fluids into glass containers.
eaning solutions with care.
For initial sta
•
engine that has been serviced, make provisions to
stop the engine if an overspeed occurs. This may
be accomplish
and/or the air supply to the engine.
Start the eng
•
Never short across the starting motor terminals or
the batteries. This could bypass the engine neutral
start syste
damaged.
Engine exha
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If th
engine exhaust to the outside.
Cautiousl
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
Filler caps
•
Grease fit
•
Pressure taps
•
rt-up of a new engine or for starting an
ed by shutting off the fuel supply
ine from the operator's station (cab).
m and/or the electrical system could be
ust contains products of combustion
e engine is in an enclosed area, vent the
y remove the following parts. To help
tings
The engine is stopped. Ensure that the engine can
•
not be started.
Theprotectivelocksorthecontrolsareinthe
•
applied position.
Engage the secondary brakes or parking brakes.
•
the vehicle or restrain the vehicle before
Block
•
maintenance or repairs are performed.
nnect the batteries when maintenance
Disco
•
is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
the leads in order to help prevent sparks.
Ta p e
Disconnect the connector for the unit injector that
•
cated on the valve cover base. This will help
is lo
prevent personal injury from the high voltage to the
unit injectors. Do not come in contact with the unit
ector terminals while the engine is operating.
inj
Do not attempt any repairs or any adjustments to
•
engine while the engine is operating.
the
Do not attempt any repairs that are not understood.
•
e the proper tools. Replace any equipment that
Us
is damaged or repair the equipment.
Breathers
•
Drain pl
•
Use caution when cover plates are removed.
Gradua
bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing the
last t
relieve any spring pressure or other pressure.
Illustration 7
Wear a hard hat, protective glasses, and other
•
protective equipment, as required.
ugs
lly loosen, but do not remove the last two
wo bolts or nuts, pry the cover loose in order to
g00702020
When work is performed around an engine that is
•
operating, wear protective devices for ears in order
to help prevent damage to hearing.
SEBU8605-01 9
Safety Section
General Hazard Information
Do not wear loos
•
on controls or on other parts of the engine.
Ensure that al
•
securedinplaceontheengine.
Never put mai
•
Glass containers can break.
Use all clea
•
Report all necessary repairs.
•
Unless other instructions are provided, perform
the maintenance under the following conditions:
The engine is stopped. Ensure that the engine
•
cannot be started.
Disconnect the batteries when maintenance
•
is performed or when the electrical system is
serviced
Tape the leads in order to help prevent sparks.
Do not att
•
Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
. Disconnect the battery ground leads.
empt any repairs that are not understood.
e clothing or jewelry that can snag
l protective guards and all covers are
ntenance fluids into glass containers.
ning solutions with care.
Illustration 8
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
g00687600
Containing Fluid Spillage
Pressurized Air and Water
Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
person
When pressurized air and/or pressurized water is
used f
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
wate
275kPa(40psi).
al injury.
or cleaning, wear protective clothing, protective
r pressure for cleaning purposes must be below
Fluid Penetration
sure can be trapped in the hydraulic circuit long
Pres
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
ape rapidly if the pressure is not relieved correctly.
esc
Do not remove any hydraulic components or parts
il pressure has been relieved or personal injury
unt
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
personal injury may occur. Refer to the OEM
or
information for any procedures that are required to
relieve the hydraulic pressure.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjustingand repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
Asbestos Information
Illustration 9
g00702022
10 SEBU8605-01
Safety Section
Burn Prevention
Perkins replac
Perkins are asbestos free. Perkins recommends
the use of only genuine Perkins replacement parts.
Use the follow
replacement parts that contain asbestos or when you
handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fib
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, c
asbestos that is used in these components is usually
boundinaresinorsealedinsomeway.Normal
handling i
contains asbestos is generated.
If dust tha
are several guidelines that should be followed:
Never use
•
Avoid brushing materials that contain asbestos.
•
Avoid grinding materials that contain asbestos.
•
ement parts that are shipped from
ing guidelines when you handle any
ers. Inhaling this dust can be hazardous
lutch plates, and some gaskets. The
s not hazardous unless airborne dust that
t may contain asbestos is present, there
compressed air for cleaning.
Dispose of Waste Properly
Illustration 10
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
dispose
Always use leakproof containers when you drain
fluids. D
drain, or into any source of water.
d of according to local regulations.
o not pour waste onto the ground, down a
g0070640
4
Use a wet
•
materials.
A vacuum
•
efficiency particulate air filter (HEPA) can also be
used.
Use exhaust ventilation on permanent machining
•
jobs.
Wear an approved respirator if there is no other
•
way to control the dust.
Comply with applicable rules and regulations
•
for the work place. In the United States, use
Occu
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
Obey environmental regulations for the disposal
•
of asbestos.
Stay away from areas that might have asbestos
•
particles in the air.
method in order to clean up asbestos
cleaner that is equipped with a high
pational Safety and Health Administration
i04224009
Burn Prevention
Do not touch any part of an operating engine
system. The engine, the exhaust, and the engine
aftertreatment system surface temperatures can
reach temperatures of approximately 600° C
(1112 ° F) under normal operating conditions.
Allow the engine system to cool before any
maintenance is performed.
Relieve all pressure in the following systems,
hydraulic system, lubrication system, fuel system,
and the coolant system before the related items are
disconnected.
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may c ause personal injury or death.
After the engine has stopped, you must wait for 10
minutes in order to allow the fuel pressure to be
purged from the high-pressure fuel lines before any
service or repair is performed on the engine fuel lines.
SEBU8605-01 11
Safety Section
Fire Prevention and Explosion Prevention
Allow the press
the hydraulic system, in the lubrication system, or
in the cooling system before any lines, fittings, or
related items
Induction Sys
Sulfuric Acid Burn Hazard may cause serious personal injury or death.
The exhaust gas cooler may contain a small
amount of sulfuric acid. The use of fuel with sulfur levels
amount of sulfuric acid formed. The sulfuric acid
may spill from the cooler during service of the
engine. Th
and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that
is noted o
for sulfuric acid. Always follow the directions for
first aid that are noted on a material safety data
sheet (M
ure to be purged in the air system, in
are disconnected.
tem
greater than 15 ppm may increase the
e sulfuric acid will burn the eyes, skin
n a material safety data sheet (MSDS)
SDS) for sulfuric acid.
Batteries
Electrolyte i
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing
batteries. Wa
and connectors. Use of gloves is recommended.
s an acid. Electrolyte can cause personal
sh hands after touching the batteries
i03652933
Fire Prevention and Explosion
Prevention
Coolant
When the engine is at operating temperature, the
engine
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool b
Check that the coolant level after the engine has
stop
Ensure that the filler cap is cool before removing the
fille
withabarehand.Removethefiller cap slowly in
order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the
Oil
Hot oil and hot lubricating components can cause
pe
skin. Also, do not allow hot components to contact
the skin.
coolant is hot. The coolant is also under
efore the cooling system is drained.
ped and the engine has been allowed to cool.
rcap.Thefiller cap must be cool enough to touch
skin, the eyes, or the mouth.
s
rsonal injury. Do not allow hot oil to contact the
Illustration 11
All fuels, most lubricants, and some coolant mixtures
are flammable.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.
After the emergency stop button is operated ensure
that you allow 15 minutes, before the engine covers
are removed.
Determinewhethertheenginewillbeoperatedinan
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
If the application involves the presence of combustible
gases, consult your Perkins dealer and/or your
Perkins distributor for additional information about
suitable protection devices.
Remove all flammable combustible materials or
conductive materials such as fuel, oil, and debris from
the engine. Do not allow any flammable combustible
materials or conductive materials to accumulate on
the engine.
g00704000
12 SEBU8605-01
Safety Section
Fire Prevention and Explosion Prevention
Store fuels and
lubricants in correctly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. D
o not smoke in areas that are used for
storing flammable materials.
Do not expose
theenginetoanyflame.
Exhaust shields (if equipped) protect hot exhaust
components
from oil or fuel spray in case of a line,
a tube, or a seal failure. Exhaust shields must be
installed correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fl
uid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. All electrical
wires must be correctly routed and securely attached.
Check all
electrical wires daily. Repair any wires
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all elect
rical connections.
Eliminate all wiring that is unattached or unnecessary.
Do not us
e any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.
Illustration 12
g00704059
Use caution when you are refueling an engine. Do
not smoke while you are refueling an engine. Do not
refuel an engine near open flames or sparks. Always
stop the engine before refueling.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and correctly
ined battery cables will help to prevent arcing
mainta
or sparking.
Contact with high pressure fuel may cause fluid
tration and burn hazards. High pressure fu-
pene
el spray may cause a fire hazard. Failure to follow these inspection, maintenance and service in-
ctions may cause personal injury or death.
stru
After the engine has stopped, you must wait for 10
utes in order to allow the fuel pressure to be
min
purged from the high pressure fuel lines before any
service or repair is performed on the engine fuel lines.
Ensure that the engine is stopped. Inspect all lines
and hoses for wear or for deterioration. The hoses
st be correctly routed. The lines and hoses must
mu
have adequate support and secure clamps.
l filters and fuel filters must be correctly installed.
Oi
The filter housings must be tightened to the correct
torque. Refer to the Disassembly and Assembly
anual for more information.
m
Illustration 13
g00704135
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
ahydrometer.
SEBU8605-01 13
Safety Section
Crushing Prevention and Cutting Prevention
Incorrect jump
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions
Do not charge a frozen battery. This may cause an
explosion.
The batteries must be kept clean. The covers
(if equippe
recommended cables, connections, and battery box
covers when the engine is operated.
er cable connections can cause
.
d) must be kept on the cells. Use the
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect th
extinguisher regularly. Obey the recommendations
on the instruction plate.
e fire extinguisher and service the fire
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are
damaged
Leaks can cause fires. Consult your Perkins dealer
or your P
Replace the parts if any of the following conditions
are pre
.
erkins distributor for replacement parts.
sent:
i02143194
Crushing Prevention and
Cutting Preve
Support the component correctly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Lea
is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will
ve the guards in place until maintenance
be injured by flying debris.
ntion
i04016709
Mounting and Dismounting
High pressure fuel line or lines are removed.
•
End fittings are damaged or leaking.
•
coverings are chafed or cut.
Outer
•
Wires are exposed.
•
Outer coverings are ballooning.
•
ible part of the hoses are kinked.
Flex
•
Outer covers have embedded armoring.
•
End fittings are displaced.
•
e sure that all clamps, guards, and heat shields
Mak
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
ts, and excessive heat.
par
Do not climb on the engine or the engine
aftertreatment. The engine and aftertreatment have
not been designed with mounting or dismounting
locations.
Refer to the OEM for the location of foot and hand
holds for your specific application.
i03814031
h Pressure Fu el Lines
Hig
Contact with high pressure fuel may cause fluid
enetration and burn hazards. High pressure fu-
p
el spray may cause a fire hazard. Failure to follow these inspection, maintenance and service in-
tructions may c ause personal injury or death.
s
14 SEBU8605-01
Safety Section
High Pressure Fuel Lines
Illustration 14
(1) High
(2) High
(3) Hig
-pressure line
-pressure line
h-pressure line
-pressure line
(4) High
-pressure fuel manifold (rail)
(5) High
h-pressure line
(6) Hig
The high-pressure fuel lines are the fuel lines that
are bet
ween the high-pressure fuel pump and the
high-pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These
ines are different from fuel lines on other fuel
fuel l
systems.
These
•
•
•
differences are because of the following items:
The high-pressure fuel lines are constantly charged
high pressure.
with
The internal pressures of the high-pressure fuel
s are higher than other types of fuel system.
line
The high-pressure fuel lines are formed to shape
then strengthened by a special process.
and
Do not step on the high-pressure fuel lines. Do not
ect the high-pressure fuel lines. Do not bend or
defl
strike the high-pressure fuel lines. Deformation or
damage of the high-pressure fuel lines may cause a
int of weakness and potential failure.
po
Do not check the high-pressure fuel lines with the
gine or the starting motor in operation. After the
en
engine has stopped wait 10 minutes in order to allow
the fuel pressure to be purged from the high-pressure
uel lines. before any service or repair is performed.
f
g02067853
transfer line that is high pressure
(7) Fuel
Do not loosen the high-pressure fuel lines in order
to remo
ve air from the fuel system. This procedure
is not required.
lly inspect the high-pressure fuel lines before
Visua
the engine is started. This inspection should be each
day.
If you inspect the engine in operation, always use
the proper inspection procedure in order to avoid
d penetration hazard. Refer to Operation and
a flui
Maintenance Manual, “General hazard Information”.
ect the high-pressure fuel lines for damage,
Insp
•
deformation, a nick, a cut, a crease, or a dent.
ot operate the engine with a fuel leak. If there
Do n
•
is a leak, do not tighten the connection in order
to stop the leak. The connection must only be
htened to the recommended torque. Refer to
tig
Disassembly and Assembly, “Fuel injection lines Remove and Fuel injection lines - Install”.
If the high-pressure fuel lines are torqued correctly,
•
and the high-pressure fuel lines are leaking the
gh-pressure fuel lines must be replaced.
hi
SEBU8605-01 15
Safety Section
Before Starting Engine
Ensure that all
•
are in place. Do not operate the engine with clips
that are damaged, missing, or loose.
Do not attach any other item to the high-pressure
•
fuel lines.
Loosened high-pressure fuel lines must be
•
replaced. Also removed high-pressure fuel lines
must be repl
Assembly manual, “ Fuel Injection Lines - Install”.
clips on the high-pressure fuel lines
aced. Refer to Disassembly and
i02813489
Before Starting Engine
Before the initial start-up of an engine that is new,
serviced or repaired, make provision to shut the
engine off, in order to stop an overspeed. This may
be accomplished by shutting off the air and/or fuel
supply to the engine.
Overspeed shutdown should occur automatically for
engines that are controlled electronically. If automatic
shutdown does not occur, press the emergency stop
button in order to cut the fuel and/or air to the engine.
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights work correctly, if equipped.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.
See the Service Manual for repairs and for
adjustments.
i03996487
Engine Starting
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal in
If a warning tag is attached to the engine start switch,
or to the co
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perfor
accident that is caused by parts in rotation, work
around the parts carefully.
Start the engine from the operators compartment or
from the engine start switch.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual
Section. Knowing that the correct procedure will help
to prevent major damage to the engine components.
Knowin
personal injury.
To ens
and/or the lube oil heater (if equipped) is working
correctly, check the water temperature gauge. Also,
check
operation.
ne exhaust contains products of combustion
Engi
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
. If the engine is started in an enclosed area,
area
vent the engine exhaust to the outside.
e: The engine is equipped with a device for cold
Not
starting. If the engine will be operated in very cold
conditions, then an extra cold starting aid may be
uired. Normally, the engine will be equipped with
req
the correct type of starting aid for your region of
operation.
These engines are equipped with a glow plug starting
aid in each individual cylinder that heats the intake air
order to improve starting. Some Perkins engines
in
may have a cold starting system that is controlled by
the ECM that allows a controlled flow of ether into
he engine. The ECM will disconnect the glow plugs
t
before the ether is introduced. This system would
be installed at the factory.
jury.
ntrols DO NOT start the engine or move
m service procedures. To help prevent an
, “Engine Starting” topic in the Operation
g that the procedure will also help to prevent
ure that the jacket water heater (if equipped)
the oil temperature gauge during the heater
16 SEBU8605-01
Safety Section
Engine Stopping
i02234873
Engine Stopping
Stop the engin
the Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating
the engine components.
Use the Emer
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency
problem that caused the emergency stop has been
corrected.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an engine
that has b
To stop an electronically controlled engine, cut the
power to t
to the engine.
e according to the procedure in
of the engine and accelerated wear of
gency Stop Button (if equipped) ONLY
stop, DO NOT start the engine until the
een overhauled.
he engine and/or shutting off the air supply
i04231629
Grounding Practices
Illustration 15
Typical exa mple
(1) Ground to the battery
(2) Primary position for grounding
(3) Ground to the starting motor
(4) Ground to the engine block
g02407417
Electrical System
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” cable should be connected last from
the external power source to the primary position for
grounding.
Check the electrical wires daily for wires that
are loose or frayed. Tighten all loose electrical
connections before the engine is started. Repair all
frayed electrical wires before the engine is started.
See the Operation and Maintenance Manual for
specific starting instructions.
Illustration 16
Typical exa mple
(5) Ground to the battery
(6) Ground to the cylinder block
g02407418
Correct grounding for the engine electrical system
is necessary for optimum engine performance
and reliability. Incorrect grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
SEBU8605-01 17
Safety Section
Engine Electronics
Uncontrolled e
damage to the crankshaft bearing journal surfaces
and to aluminum components.
Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
discharge.
To ensure that the engine and the engine electrical
systems fun
ground strap with a direct path to the battery must be
used. This path may be provided by way of a direct
engine grou
The connections for the grounds should be tight and
free of cor
grounded to the negative “-” battery terminal with
a wire that is adequate to handle the full charging
current of
The power supply connections and the ground
connecti
be from the isolator to the battery.
lectrical circuit paths can result in
ction correctly, an engine-to-frame
nd to the frame.
rosion. The engine alternator must be
the alternator.
ons for the engine electronics should always
i03642610
Engine Electronics
Derate
•
Shutdown
•
The following monitored engine operating conditions
have the ability to limit engine speed and/or the
engine power
Engine Coolant Temperature
•
Engine Oil Pressure
•
Engine Spee
•
Intake Manifold Air Temperature
•
Engine Intake Throttle Valve Fault
•
Wastegate
•
Supply Voltage to Sensors
•
Fuel Pressure in Manifold (Rail)
•
NOx Reduc
•
Engine Aftertreatment System
•
:
d
Regulator
tion System
Tampe
or the OEM wiring installation can be dangerous
and could result in personal injury o r death and/or
engin
Electrical Shock Hazard. The electronic unit injectors use DC voltage. The ECM s ends this voltage
to the electronic unit injectors. Do not come in
contact with the harness connector for the electronic unit injectors while the engine is operating.
Failure to follow this instruction could result in
personal injury or death.
This engine has a comprehensive, programmable
Engine Monitoring System. The Electronic Control
Module (ECM) has the ability to monitor the engine
operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
initiate an immediate action.
ring with the electronic system installation
e damage.
The Engine Monitoring package can vary for different
engine models and different engine applications.
However
monitoring control will be similar for all engines.
Note: M
modules that are available for Perkins Engines will
work in unison with the Engine Monitoring System.
Toget
monitoring function for the specific engine application.
Refer to Troubleshooting for more information on the
Engin
, the monitoring system and the engine
any of the engine control systems and display
her, the two controls will provide the engine
eMonitoringSystem.
The following actions are available for engine
monitoring control:
Warning
•
18 SEBU8605-01
Product Information Section
Model Views
Product Information
Section
Model Views
i04231649
Model View Illustrations
The following model views show typical features
of the engine and the aftertreatment system.
Due to individual applications, your engine, or
your aftertreatment may appear different from the
illustrations.
1204E-E44TTA
Illustration 17
(1) Front lifting eye
(2) Crankcase breather
(3) N Ox Reduction system (NRS)
(4) Primary fuel filter
(5) Secondary fuel filter
(6) Electronic control module (ECM)
(7) Fuel priming pump
(8) Oil gauge (dipstick)
(9) Fuel strainer
(10) Oil filter
g02409511
(11) Oil sampling valve
(12) Oil filler
(13) High-pressure fuel pump
SEBU8605-01 19
Product Information Section
Model Views
Illustration 18
(14) Rear lifting eye
(15) High-pressure turbocharger
(16) Low-pressure turbocharger
(17) Back pressure valve
(18) Starting motor
(19) Oil drain plug
(20) Exhaust outlet
(21) Flywheel housing
g02409512
(22) Flywheel
(23) NRS cooler
20 SEBU8605-01
Product Information Section
Model Views
Illustration 19
(24) Belt
(25) Air intake
(26) Coolant outlet connection
(27) Thermostat housing
(28) Water pum p
(29) Coolant inlet connection
g02409862
(30) Crankshaft pulley
(31) Belt tensioner
(32) Alternator
SEBU8605-01 21
Product Information Section
Model Views
1204E-E44TA
Illustration 20
(1) Front lifting eye
(2) Crankcase breather
(3) NOx reduction system (NRS)
(4) Secondary fuel filter
(5) Primary f u el filter
(6) Fuel priming pump
(7) Fuel strainer
(8) Electronic control module (ECM)
g02407436
(9) Oil fi lter
(10) Oil sampling valve
(11) High-pressure fuel pump
22 SEBU8605-01
Product Information Section
Model Views
Illustration 21
(12) Rear lifting eye
(13) Oil gauge (dipstick)
(14) Turbocharger
(15) Starting motor
(16) Oil drain valve
(17) Oil drain plug
(18) Back pressure valve
(19) Flywheel housing
g02407536
(20) Flywheel
(21) Exhaust outlet
(22) NRS cooler
SEBU8605-01 23
Product Information Section
Model Views
Illustration 22
(23) Oil filler
(24) Air intake
(25) Outlet connection for coolant
(26) Thermostat housing
(27) Water pum p
(28) Coolant intake connector
(29) Rear lifting eye
(30) Belt tensioner
g02407537
(31) Alternator
(32) Belt
24 SEBU8605-01
Product Information Section
Model Views
Engine Aftertreatment System
Illustration 23
Typical example
xible exhaust pipe
(1) Fle
et connection
(2) Inl
Engin
e Description
an emissions module
(3) Cle
nting cradle
(4) Mou
i04340692
Perkins has designed two versions of the 1204E
industrial engine.
1204E-E44TA (MK)
•
4E-E44TTA (ML)
120
•
The 1204E-E44TA (MK) engine is equipped with a
gle turbocharger.
sin
The 1204E-E44TTA (ML) engine is equipped with
ries turbochargers. An engine that is equipped
se
with series turbochargers have a low-pressure
turbocharger and a high-pressure turbocharger.
g02483
let connec tion
(5) Out
Turbocharged charge cooled
•
Engine Specifications
The front end of the engine is opposite the flywheel
end of the engine. The left and the right sides of the
ne are determined from the flywheel end. The
engi
number 1 cylinder is the front cylinder.
616
The Perkins 1204E industrial engines have the
following characteristics.
In-line four cylinder
•
our stroke cycle
F
•
SEBU8605-01 25
Product Information Section
Model Views
Electronic Engine Features
Illustration 24
(A) Exhaust valves
(B) Inlet valves
Table 1
1204E-E44TA and 1204E-E44TTA Engine
Operating Range (rpm) 800 to 2200
Number of Cylinders 4 In-Line
Bore
Stroke 127 mm (4.99 inch)
Power
Aspiration
Compression Ratio
Displacement
Firing Order 1-3-4-2
Rotation (flywheel end) Counterclockwise
(1)
The operating rpm is dependent on the engine rating, the
application, and the configuration of the throttle.
Specifications
105 mm (
(80.46 to 147.51 hp)
(140.805 to 173.65 hp)
MK Single Turbocharged
charge cooled
ML Series Turbocharged
charge cooled
4.4 L (268.504 cubic inch)
4.13 inch)
MK
60 to 110 kW
ML
105 to129.5 kW
16.5:1
g01187485
(1)
Theengineope
rating conditions are monitored.
The Electronic Control Module (ECM) controls the
response of the engine to these conditions and to
the demands of
the operator. These conditions and
operator demands determine the precise control of
fuel injection by the ECM. The electronic engine
control syst
Engine monitoring
•
Engine speed governing
•
Control of t
•
Cold start strategy
•
Automatic air/fuel ratio control
•
Torque ri
•
Injection timing control
•
System diagnostics
•
Aftertr
•
em provides the following features:
he injection pressure
se shaping
eatment low temperature regeneration
For more information on electronic engine features,
refer to
the Operation and Maintenance Manual,
“Features and Controls” topic (Operation Section).
Engine Diagn ostics
The eng
that the engine systems are functioning correctly. The
operator will be alerted to the condition by a “Stop or
Warni
horsepower and the vehicle speed may be limited.
Theelectronicservicetoolmaybeusedtodisplay
the di
There are three types of diagnostic codes: active,
logg
Most of the diagnostic codes are logged and stored
in th
the Operation and Maintenance Manual, “Engine
Diagnostics” topic (Operation Section).
The ECM provides an electronic governor that
controls the injector output in order to maintain the
des
ine has built-in diagnostics in order to ensure
ng” lamp. Under certain conditions, the engine
agnostic codes.
ed, and event.
e ECM. For additional information, refer to
ired engine rpm.
gine Cooling and Lubrication
En
The cooling system and lubrication system consists
the following components:
of
Gear-driven centrifugal water pump
•
26 SEBU8605-01
Product Information Section
Model Views
Water temperat
•
engine coolant temperature
Gear-driven r
•
Oil cooler
•
The engine lubricating oil is supplied by a rotor type
oil pump. The engine lubricating oil is cooled and the
engine lubr
can provide unrestricted flow of lubrication oil to
the engine if the oil filter element should become
plugged.
Engine efficiency, efficiency of emission controls, and
engine per
operation and maintenance recommendations.
Engine performance and efficiency also depend on
the use of r
coolants. Refer to this Operation and Maintenance
Manual, “Maintenance Interval Schedule” for more
informat
formance depend on adherence to proper
ion on maintenance items.
Aftertre
The aftertreatment system is approved for use by
Perkins
approved Perkins aftertreatment system must be
used on a Perkins engine.
. In order to be emission-compliant only the
ure regulator which regulates the
otor type oil pump
icating oil is filtered. The bypass valve
ecommended fuels, lubrication oils, and
atment System
Expected engin
average power that is demanded. The average power
that is demanded is based on fuel consumption of the
engine over a p
at full throttle and/or operating at reduced throttle
settings result in a lower average power demand.
Reduced hour
operating time before an engine overhaul is required.
e life is generally predicted by the
eriod. Reduced hours of operation
s of operation will increase the length of
Aftermarket Products and Perkins
Engines
Perkins does not warrant the quality or performance
of non-Perk
When auxiliary devices, accessories, or consumables
(filters, a
manufacturers are used on Perkins products, the
Perkins warranty is not affected simply because of
such use.
However, failures that result from the installation
or use of o
accessories, or consumables are NOT Perkins
defects. Therefore, the defects are NOT covered
under th
ins fluids and filters.
dditives, catalysts,) which are made by other
ther manufacturers devices,
e Perkins warranty.
Clean Emission Mo dule (CEM)
The CEM
single unit, the Diesel Oxidation Catalyst DOC and
the Diesel Particulate Filter DPF. The function of the
CEM is
the required emissions regulation for the country of
operation.
Theengineexhaustisconnectedbyaflexible pipe to
the CEM. The exhaust gases pass through the DOC
in or
and hydrocarbons. The exhaust gases then enter the
DPF where any particulate matter soot and ash will
be tr
The CEM uses a passive regeneration process to
ure that normal operation of the engine removes
ens
the soot. The soot is removed at an equal rate of
which the soot is captured. The ash remains in the
DPF
En
Engine efficiency and maximum utilization of engine
rformance depend on the adherence to proper
pe
operation and maintenance recommendations. In
addition, use recommended fuels, coolants, and
bricants. Use the Operation and Maintenance
lu
Manual as a guide for required engine maintenance.
comprises of two main components in a
to ensure that the engine exhaust meets
der to remove contaminants, carbon monoxide,
apped.
and must be removed at an engine overhaul.
gine Service Life
SEBU8605-01 27
Product Information Section
Product Identification Information
Product Identification
Information
i03865704
Plate Locations and Film
Locations
(Engine Aftertreatment System
)
Illustration 25
Typical example
The module arrangement exhaust plate is installed
on the mounting plate (1). The location of the
arrangement plate mounting plate can alter
depending on the application.
Illustration 26
Module Arrangement Exhaust Plate
g02109493
g02109488
Record the information that is on the plate. This
information identifies the engine aftertreatment
system. This information will be required by your
Perkins distributor. The information is essential in
order to be emissions complaint.
28 SEBU8605-01
Product Information Section
Product Identification Information
Plate Locations and Film
Locations
(Engine)
i03827189
Serial Number Plate (1)
Theengineserialnumberplateislocatedonthe
left side of the cylinder block to the rear of the front
engine mounting.
ation 28
Illustr
Serial number plate
g02101733
i038672
Reference Num bers
76
Illustration 27
g02077373
Perkins engines are identified by an engine serial
number.
An example of an engine number is
ML*****U000001U.
*****
____________________The list number for the engine
_____________________________________The type of engine
ML
____________________________ Built in the United Kingdom
U
000001
U
___________________________ Engine Serial Number
_____________________________________Year of Manufacture
Perkins dealers or Perkins distributors need all of
these numbers in order to determine the components
that were included with the engine. This information
permits accurate identification of replacement part
numbers.
The numbers for fuel setting information for electronic
engines are stored within the flash file. These
numbers can be read by using the electronic service
tool.
ation for the following items may be needed to
Inform
order parts. Locate the information for your engine.
Record the information in the appropriate space.
Make a
copy of this list for a record. Keep the
information for future reference.
Record for Reference
ne Model
Engi
Engine Serial number _____________________________________
Engine Low Idle rpm ______________________________________
ine Full Load rpm
Eng
Primary Fuel Filter _________________________________________
Water Separator Element ________________________________
condary Fuel Filter Element
Se
Lubrication Oil Filter Element ___________________________
Auxiliary Oil Filter Element _______________________________
otal Lubrication System Capacity
T
_______________________________________________
_____________________________________
__________________________
_____________________
Total Cooling System Capacity _______ __________________
Air Cleaner Element _______________________________________
SEBU8605-01 29
Product Information Section
Product Identification Information
Drive Belt ____
________________________________________________
Engine Aftertreatment System
Part Number ________________________________________________
______________________________________________
Serial Numbe
Emissions C
An emission label is installed on the front gear cover.
Note: Asec
the engine. If necessary, the second emission label
will be installed on the application by the original
equipment
r
i04274850
ertification Film
ondemissionlabelwillbesuppliedwith
manufacturer.
Illustration 29
Typical example
g02443596
30 SEBU8605-01
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage
Product Lifting
(Engine)
i04332972
Some removals r
obtain correct balance and safety.
To re mov e th e e
are on the engine.
Lifting eyes
engine arrangements. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obs
that correct lifting devices are provided. Consult
your Perkins dealer or your Perkins distributor for
informatio
lifting.
n regarding fixtures for correct engine
equire lifting the fixtures in order to
ngine ONLY, use the lifting eyes that
are designed and installed for specific
olete. If alterations are made, ensure
Illustration 30
NOTICE
er bend the eyebolts and the brackets. Only load
Nev
the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle
ween the supporting members and the object be-
bet
comes less than 90 degrees.
en it is necessary to remove a component at an
Wh
angle, only use a link bracket that is properly rated for
the weight.
Use a hoist to remove heavy components. Use
an adjustable lifting beam to lift the engine. All
upporting members (chains and cables) should be
s
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
g01097527
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