Operation andMaintenanceManual
1104D-E44T and 1104D-E44TAIndustrial Engines
NP (Engine)NR (Engine)
SEBU9066
March 2014
Страница 1: ...Operation and Maintenance Manual 1104D E44T and 1104D E44TA Industrial Engines NP Engine NR Engine SEBU9066 March 2014...
Страница 2: ...ing 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 canno...
Страница 3: ...Engine Electronics 15 Product Information Section General Information 16 Product Identification Information 22 Operation Section Lifting and Storage 24 Features and Controls 26 Engine Diagnostics 37...
Страница 4: ...ced to detailed instructions that follow Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule The actual operating environment of the...
Страница 5: ...uld loosen the adhesive that secures the warning signs Replace any warning sign that is damaged or missing If a warning sign is attached to a part of the engine that is replaced install a new warning...
Страница 6: ...ntenance and service in structions may cause personal injury or death Illustration 3 g01154858 Typical example Illustration 4 g03450123 The warning label for the Hand High Pressure 2 is a wrap around...
Страница 7: ...ce fluids into glass containers Drain all liquids into a suitable container Obey all local regulations for the disposal of liquids Use all cleaning solutions with care Report all necessary repairs Do...
Страница 8: ...Diesel Fuel The removal of sulfur and other compounds in ultra low sulfur diesel fuel ULSD fuel decreases the conductivity of ULSD and increases the ability of ULSD to store static charge Refineries m...
Страница 9: ...glasses for servicing batteries Wash hands after touching the batteries and connectors Use of gloves is recommended i04823662 Fire Prevention and Explosion Prevention Illustration 9 g00704000 All fue...
Страница 10: ...y or death After the engine has stopped wait for 60 seconds 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 f...
Страница 11: ...rubbing against other parts and excessive heat i02143194 Crushing Prevention and Cutting Prevention Support the component correctly when work beneath the component is performed Unless other maintenan...
Страница 12: ...s Do not step on the high pressure fuel lines Do not deflect the high pressure fuel lines Do not bend or strike the high pressure fuel lines Deformation or damage of the high pressure fuel lines may c...
Страница 13: ...stem 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...
Страница 14: ...to the engine and or shutting off the air supply to the engine i05464430 Electrical System Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit...
Страница 15: ...ot come in contact with the harness connector for the elec tronic unit injectors while the engine is operating Failure to follow this instruction could result in personal injury or death This engine h...
Страница 16: ...ons your engine may appear different from the illustrations Turbocharged Aftercooled Engine Illustration 15 g03453518 Typical example 1 Open Breather System 2 Air Intake 3 Electronic Control Module 4...
Страница 17: ...Illustration 16 g03453526 Typical example 9 Front Lifting Eye 10 Water Pump 11 Coolant Intake 12 Tensioner 13 Belt 14 Coolant Outlet SEBU9066 17 General Information Model View Illustrations...
Страница 18: ...ical example 15 Rear Lifting Eye 16 Alternator 17 Turbocharger 18 Starter Solenoid 19 Starting Motor 20 Oil Drain Plug 21 Flywheel 22 Flywheel Housing 23 Coolant Drain Plug 18 SEBU9066 General Informa...
Страница 19: ...Turbocharge Engine View Illustration 18 g03506649 Typical example SEBU9066 19 General Information Model View Illustrations...
Страница 20: ...of this Perkins engine Engines with prefix NR are turbocharged aftercooled engines 1104D E44TA Engines with prefix NP are turbocharged engines 1104D E44T Engine Specifications Note The front end of t...
Страница 21: ...ne power and the engine speed may be limited The electronic service tool may be used to display the diagnostic codes There are two types of diagnostic codes active and logged Most of the diagnostic co...
Страница 22: ...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 identif...
Страница 23: ...e space Make a copy of this list for a record Keep the information for future reference Record for Reference Engine Model Engine Serial number Engine Low Idle rpm Engine Full Load rpm Primary Fuel Fil...
Страница 24: ...or your Perkins distributor can assist in preparing the engine for extended storage periods Condition for Storage The engine must be stored in a water proof building The building must be kept at a con...
Страница 25: ...inhibitor has been introduced The effect of the vapor phase inhibitor will be lost if the cooling system is open to the atmosphere For maintenance procedures refer to this Operation and Maintenance Ma...
Страница 26: ...d pressure The intake manifold pressure sensor checks the rated pressure in the engine manifold Fuel rail pressure The fuel rail pressure sensor checks for high pressure or low pressure in the fuel ra...
Страница 27: ...e the load 2 Stop the engine 3 Check and maintain the oil level Jacket Water Coolant Temperature Typical temperature range is 83 to 95 C 181 4 to 171 F The maximum allowable temperature at sea level w...
Страница 28: ...lluminated the reason for illumination should be investigated immediately The glow plug warning lamp will flash in order to show that the engine is been held at low speed This function will be perform...
Страница 29: ...stic fault has been detected The engine is shutdown or shut down is imminent i05546770 Monitoring System If the Shutdown mode has been selected and the warning indicator activates engine shutdown may...
Страница 30: ...ngine can be restarted after a shutdown for use in an emergency A shutdown of the engine may occur in as little as 20 seconds The engine can be restarted after a shutdown for use in an emergency Howev...
Страница 31: ...ld Pressure Sensor 3 Bus Bar for Glow Plugs 4 Connector for Injectors 1 and Injector 2 5 Connector for Injectors 3 and Injector 4 6 Inlet Manifold Temperature Sensor 7 Fuel Rail Pressure Sensor 8 Diag...
Страница 32: ...example 9 Electronic Control Module 10 Primary Speed Timing sensor 11 Oil Pressure Sensor 12 Secondary Speed Timing sensor 13 Solenoid for the high pressure fuel pump 32 SEBU9066 Features and Controls...
Страница 33: ...ation 27 g03470356 Typical example 14 Alternator 15 Starting Motor and solenoid 16 Water in Fuel Switch 17 Electric Fuel Pump Priming Pump SEBU9066 33 Features and Controls Sensors and Electrical Comp...
Страница 34: ...ture Sensor 2 Inlet Manifold Pressure Sensor 3 Bus Bar for Glow Plugs 4 Connector for Injectors 1 and Injector 2 5 Connector for Injectors 3 and Injector 4 6 Inlet Manifold Temperature Sensor 34 SEBU9...
Страница 35: ...re Sensor 8 Diagnostic Connector 9 Electronic Control Module 10 Primary Speed Timing sensor 11 Oil Pressure Sensor 12 Secondary Speed Timing sensor 13 Solenoid for the high pressure fuel pump SEBU9066...
Страница 36: ...ation 30 g03474458 Typical example 14 Alternator 15 Starting Motor and solenoid 16 Water in Fuel Switch 17 Electric Fuel Pump Priming Pump 36 SEBU9066 Features and Controls Sensors and Electrical Comp...
Страница 37: ...c Service Tools for more information i05537601 Diagnostic Flash Code Retrieval Diagnostic Lamp Use the DIAGNOSTIC lamp or an electronic service tool to determine the diagnostic flash code Use the foll...
Страница 38: ...g Calibration Fault X X 144 Engine Operation Mode Se lector Switch Fault X X 151 Air Inlet Pressure Sensor X X 154 Throttle Position Sensor Fault X X 155 Secondary Throttle Position sensor Fault X X 1...
Страница 39: ...ogged in the memory of the ECM The codes that have been logged by the ECM can be identified by the electronic service tool The active codes that have been logged will be cleared when the fault has bee...
Страница 40: ...d for future reference For more information on diagnostic codes refer to the Troubleshooting Guide for this engine i05495474 Configuration Parameters The engine electronic control module ECM has two t...
Страница 41: ...able 5 Customer Specified Parameters Specified Parameters Record ECM Identification Parameters ECM Serial Number Software Group Part Number Software Group Release Date Software Group Description Selec...
Страница 42: ...ol Engine Fan Type Configuration Pulley Ratio Temperature Error Increasing Hysteresis Temperature Error Decreasing Hysteresis Current Ramp Rate Fan Speed Proportional Gain Percentage Fan Speed Integra...
Страница 43: ...tus User Defined Switch Installation Status Auxiliary Temperature Sensor Installation Status Auxiliary Pressure Sensor Installation Status Engine Charge Air Cooler 1 Outlet Temperature Sensor Installa...
Страница 44: ...i05570730 Cold Weather Starting Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury Startability will be improved at temperatures below 1...
Страница 45: ...electric starting motor and crank the engine Note The operating period of the warning light for the glow plugs will change due to the temperature of the engine NOTICE Do not engage the starting motor...
Страница 46: ...h are considered unusable are still rechargeable Refer to Operation and Maintenance Manual Battery Replace and Testing and Adjusting Manual Battery Test i05495593 After Starting Engine After starting...
Страница 47: ...ed procedures in order to attain optimum performance for the life of the engine Avoid spilling fuel Fuel expands when the fuel is warmed up The fuel may overflow from the fuel tank Inspect fuel lines...
Страница 48: ...sticking The cooling system and the lubrication system for the engine do not lose heat immediately upon shutdown This means that an engine can be shut down for a period and the engine can still have...
Страница 49: ...low idle for 3 minutes before used at operational speed If the low idle option is not available then operate the engine at operational speed with no load for 2 minutes Recommendations for Coolant War...
Страница 50: ...and plugging of the breather system An open breather system will operate more effectively in temperatures below 25 C 13 F In extreme weather conditions insulating the breather hose will help to protec...
Страница 51: ...led between the fuel tank and the engine fuel inlet After you change the fuel filter always prime the fuel system in order to remove air bubbles from the fuel system Refer to the Operation and Mainten...
Страница 52: ...use emergency shutoff devices or controls for normal stopping procedure Ensure that any components for the external system that support the engine operation are secured after the engine is stopped Eme...
Страница 53: ...l tank in order to help prevent accumulation of moisture in the fuel Do not overfill the fuel tank NOTICE Only use antifreeze coolant mixtures recommended in this Operation and Maintenance Manual Refi...
Страница 54: ...amage NOTICE Frequently check the specific gravity of the coolant for proper freeze protection or for anti boil protection Clean the cooling system for the following reasons Contamination of the cooli...
Страница 55: ...Perkins recommends a 1 1 mixture of a water glycol solution Note Use a mixture that will provide protection against the lowest ambient temperature Note 100 percent pure glycol will freeze at a tempera...
Страница 56: ...correct amount of these additives in order to provide superior corrosion protection for all metals in engine cooling systems ELC is available in a premixed cooling solution with distilled water ELC is...
Страница 57: ...e system until all the signs of the cleaning agent are gone 7 Drain the cooling system into a suitable container and flush the cooling system with clean water Note The cooling system cleaner must be t...
Страница 58: ...ty antifreeze of all types REQUIRE periodic additions of an SCA Test the antifreeze periodically for the concentration of SCA For the interval refer to the Operation and Maintenance Manual Maintenance...
Страница 59: ...of your engine Table 16 Minimum Oil Specification for 1104D E44T and 1104D E44TA Industrial Engines Minimum Oil specification API CH 4 ECF 1 Engines Operating on B20 Biodiesel Refer to this Manual Fl...
Страница 60: ...propriate Lubricant Viscosities Refer to the illustration 33 in order to find the correct oil viscosity grade for your engine At the specified interval service the engine Use new oil and install a new...
Страница 61: ...t up to date recommendations Diesel Fuel Requirements Perkins is not in a position to continuously evaluate and monitor all worldwide distillate diesel fuel specifications that are published by govern...
Страница 62: ...ional regulations or international regulations can require a fuel with a specific sulfur limit Consult all applicable regu lations before selecting a fuel for a given engine application Perkins fuel s...
Страница 63: ...the fuel is significant because fuel serves as a lubricant for the fuel system components Fuel must have sufficient viscosity in order to lubricate the fuel system in both extremely cold temperatures...
Страница 64: ...is Rape Methyl Ester RME This biodiesel is derived from rapeseed oil Soy Methyl Ester SME is the most common biodiesel in the United States This biodiesel is derived from soybean oil Soybean oil or ra...
Страница 65: ...ncrease in fuel system deposits most significant of which are deposits within the fuel injector These deposits can cause a loss in power due to restricted or modified fuel injection or cause other fun...
Страница 66: ...e only fuel cleaner that is recommended by Perkins If biodiesel or biodiesel blends of fuel are to be used Perkins require the use of Perkins fuel cleaner The use of the fuel is in order to remove dep...
Страница 67: ...to the weld This will help reduce the pos sibility of damage Note Perform the welding in areas that are free from explosive hazards 1 Stop the engine Turn the switched power to the OFF position 2 Ensu...
Страница 68: ...m reliability and retention of full service life Due to individual applications it is not possible to identify all of the factors which can contribute to severe service operation Consult your Perkins...
Страница 69: ...or 1 Year Battery Electrolyte Level Check 71 Cooling System Supplemental Coolant Additive SCA Test Add 78 Engine Air Cleaner Element Dual Element Canister Type Clean Replace 79 Engine Air Cleaner Elem...
Страница 70: ...the engine and accelerate the engine to high idle rpm This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for...
Страница 71: ...battery terminal 10 Turn the battery disconnect switch to the ON position i02724529 Battery Electrolyte Level Check When the engine is not run for long periods of time or when the engine is run for s...
Страница 72: ...a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause...
Страница 73: ...oner Refer to Disassembly and Assembly Alternator Belt Remove and Install for the correct procedure i05539567 Coolant Commercial Heavy Duty Change NOTICE Care must be taken to ensure that fluids are c...
Страница 74: ...and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain cock or remove the drain plug on the engin...
Страница 75: ...uct 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 m...
Страница 76: ...gine at low idle until the temperature reaches 49 to 66 C 120 to 150 F 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remov...
Страница 77: ...rder for Perkins ELC to achieve 12000 hours an extender must be added at 6000 hours For a suitable extender contact your Perkins dealer or Perkins distributor i05525293 Coolant Level Check Pressurized...
Страница 78: ...ld also result in radiator tube blockage overheating and or accelerated water pump seal wear Never use both liquid supplemental coolant additive and the spin on element if equipped at the same time Th...
Страница 79: ...ng benefits Easy detection of fluid leaks Maximum heat transfer characteristics Ease of maintenance Note Caution must be used in order to prevent electrical components from being damaged by excessive...
Страница 80: ...t for the turbocharger 1 Remove the cover Remove the primary air cleaner element 2 The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleane...
Страница 81: ...ecting the Primary Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry dusty environment Clean...
Страница 82: ...element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage...
Страница 83: ...tant instruments Check for ease of resetting The service indicator should reset in less than three pushes Check the movement of the yellow core when the engine is accelerated to the engine rated speed...
Страница 84: ...eterioration should be replaced Refer to the OEM information for the recommended torques i05300117 Engine Oil Level Check Hot oil and hot components can cause personal injury Do not allow hot oil or h...
Страница 85: ...ination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean The sample can be checked for the following the quality of the oil the existence of any cool...
Страница 86: ...ubricating system Only use oil filters recom mended by Perkins 1 Remove the oil filter with a suitable tool Note The following actions can be carried out as part of the preventive maintenance program...
Страница 87: ...h the correct amount of new engine lubricating oil Refer to this Operation and Maintenance Manual Refill Capacities for more information on refill capacities NOTICE If equipped with an auxiliary oil f...
Страница 88: ...to cool before meas uring adjusting valve lash clearance Ensure that the engine is stopped before measuring the valve lash To obtain an accurate measurement allow the valves to cool before this mainte...
Страница 89: ...anual General Hazard Information and High Pressure Fuel Lines before adjustments and repairs are performed Note Refer to Testing and Adjusting Manual Cleanliness of Fuel System Components for detailed...
Страница 90: ...dle will help ensure that the air has been removed from the fuel system 6 If the engine will not start repeat steps 2 to step 5 After the engine has stopped you must wait for 10 minutes in order to al...
Страница 91: ...or Cold Weather Starting for more information 8 If the engine will not start repeat step 6 to step 7 Ensure that the keyswitch is in the OFF position during fuel system prime After the engine has sto...
Страница 92: ...n into the container Remove the tube Illustration 64 g03352754 Typical example 4 Disconnect the electrical connector 8 and by hand remove connecting bowl 7 Remove the old O ring seal 6 Clean connectin...
Страница 93: ...nsure that the filter is dry before engine operation 6 If necessary prime the fuel system refer to this Operation and Maintenance Manual Fuel System Prime i05269459 Fuel System Secondary Filter Replac...
Страница 94: ...n into the container and remove the tube 4 Remove the filter bowl 2 from filter body 1 Rotate the filter bowl counterclockwise in order to remove the assembly Illustration 67 g03353105 Typical example...
Страница 95: ...nate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the...
Страница 96: ...ical method of replacing coolant hoses Refer to the OEM information for further information on the coolant system and the hoses for the coolant system Pressurized System Hot coolant can cause seri ous...
Страница 97: ...Manual Electric Starting System Test for more information on the checking procedure and for specifications or consult your Perkins dealer or your Perkins distributor for assistance i04144491 Turbocha...
Страница 98: ...nd correct the leak If leaking is suspected check the flu id levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Acc...
Страница 99: ...engine overheating problems that could result in the following conditions Cracks in the cylinder head A piston seizure Other potential damage to the engine Illustration 69 g03364302 A Weep hole B Vent...
Страница 100: ...ndards that are prescribed by the law at the time of manufacture and this engine may be covered by an Emissions Warranty Consult your authorized Perkins dealer or your authorized Perkins distributor i...
Страница 101: ...ne performance 4 Highly trained technicians carry out all repairs 5 Transferable coverage should you sell your machine Flexible coverage provides the right level of protection for your Perkins Engine...
Страница 102: ...Cooling System Supplemental Coolant Additive SCA Test Add 78 Add the SCA If Necessary 78 Test for SCA Concentration 78 Crushing Prevention and Cutting Prevention 11 D Diagnostic Flash Code Retrieval...
Страница 103: ...r 50 Fuel Filters 51 Fuel Heaters 51 Fuel Tanks 50 Fuel System Prime 89 Electric Prime 90 Hand Fuel Priming Pump 90 Fuel System Primary Filter Water Separator Element Replace 92 Fuel System Primary Fi...
Страница 104: ...ct Lifting 24 Product Storage 24 Condition for Storage 24 R Radiator Clean 96 Reference Information 23 Record for Reference 23 Reference Information Section 101 Reference Materials 101 Refill Capaciti...
Страница 105: ...aintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Inf...
Страница 106: ...2014 Perkins Engines Compony All Rights Reserved...
