Manitou PERKINS ENGINE 854E-E34TA 854F-E34T Lift Truck Repair Manual 647173EN – PDF DOWNLOAD

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Manitou PERKINS ENGINE 854E-E34TA 854F-E34T Lift Truck Repair Manual 647173EN – PDF DOWNLOAD

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Manitou PERKINS ENGINE 854E-E34TA 854F-E34T Lift Truck Repair Manual 647173EN – PDF DOWNLOAD’

Language : English
Pages : 716
Downloadable : Yes
File Type : PDF
Size: 9.99 MB

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Manitou PERKINS ENGINE 854E-E34TA 854F-E34T Lift Truck Repair Manual 647173EN – PDF DOWNLOAD

Specifications Section
Engine Design 4
Fuel Injection Lines 4
Fuel Injection Pump 5
Fuel Injectors 5
Fuel Filter Base (Secondary Fuel Filter Base) 5
Fuel Filter Base (Primary Fuel Filter Base) 6
Fuel Manifold (Rail) 6
Lifter Group 7
Rocker Shaft 7
Valve Mechanism Cover 9
Cylinder Head Valves 10
Cylinder Head 10
Turbocharger 13
Exhaust Gas Valve (NRS) 14
Exhaust Cooler (NRS) 14
Exhaust Manifold 15
Flexible Exhaust Pipe 16
Diesel Particulate Filter (Through Flow Diesel
Particulate Filter (DPF)) 17
Diesel Particulate Filter (Wall Flow Diesel
Particulate Filter (DPF)) 17
Camshaft 17
Camshaft Bearings 18
Engine Oil Filter Base 18
Engine Oil Cooler 19
Engine Oil Pump 19
Engine Oil Pressure 19
Engine Oil Pan (Cast Iron Oil Pan) 19
Engine Oil Pan (Aluminum Oil Pan) 22
Engine Oil Pan (Pressed Steel Oil Pan) 24
Crankcase Breather 25
Water Temperature Regulator and Housing 26
Water Pump 27
Cylinder Block 27
Crankshaft 28
Connecting Rod Bearing Journal 29
Main Bearing Journal 30
Connecting Rod 30
Piston and Rings 31
Piston Cooling Jet 33
Balancer 33
Front Housing and Covers 34
Gear Group (Front) 35
Flywheel 36
Flywheel Housing 37
Crankshaft Pulley 37
Fan Drive 38
Engine Lifting Bracket 38
Alternator 39
Starter Motor 41
Coolant Temperature Sensor 42
Boost Pressure Sensor (If equipped) 42
Oxygen Sensor 43
Inlet Manifold Temperature Sensor (If
equipped) 43
Inlet Manifold Temperature and Pressure Sensor
(If equipped) 44
Temperature Sensor (DPF Inlet) 44
Temperature Sensor (DOC Inlet) 44
Pressure Sensor (NOx Reduction System) 45
Temperature Sensor (NOx Reduction System) 45
Speed/Timing Sensor 46
Electronic Control Module 46
Glow Plugs 47
Index Section
Index 48
Foreword 4
Safety Section
Safety Messages 5
General Hazard Information 6
Burn Prevention 9
Fire Prevention and Explosion Prevention 10
Crushing Prevention and Cutting Prevention 12
Mounting and Dismounting 12
High Pressure Fuel Lines 12
Before Starting Engine 14
Engine Starting 14
Engine Stopping 14
Electrical System 14
Engine Electronics 16
Product Information Section
General Information 17
Product Identification Information 25
Operation Section
Lifting and Storage 30
Features and Controls 32
Engine Diagnostics 49
Engine Starting 53
Engine Operation 56
Cold Weather Operation 60
Engine Stopping 64
Maintenance Section
Refill Capacities 66
Maintenance Recommendations 80
Maintenance Interval Schedule 83
Warranty Section
Warranty Information 112
Reference Information Section
Reference Materials 113
Index Section
Index 114
Systems Operation Section
General Information
Introduction 4
Engine Operation
Basic Engine 7
Air Inlet and Exhaust System 10
Clean Emissions Module 15
Cooling System 17
Lubrication System 19
Electrical System 19
Cleanliness of Fuel System Components 20
Fuel Injection 21
Electronic Control System 28
Power Sources 41
Glossary of Electronic Control Terms 45
Testing and Adjusting Section
Fuel System
Fuel System – Inspect 50
Air in Fuel – Test 50
Finding Top Center Position for No 1 Piston 52
Fuel Injection Timing – Check 52
Fuel Quality – Test 53
Fuel System – Prime 54
Fuel System Pressure – Test 55
Gear Group (Front) – Time 58
Air Inlet and Exhaust System
Air Inlet and Exhaust System – Inspect 59
Turbocharger – Inspect 59
Exhaust Cooler (NRS) – Test 62
Diesel Particulate Filter – Clean 63
Compression – Test 64
Engine Valve Lash – Inspect 64
Valve Depth – Inspect 65
Valve Guide – Inspect 66
Lubrication System
Engine Oil Pressure – Test 68
Engine Oil Pump – Inspect 68
Excessive Bearing Wear – Inspect 68
Excessive Engine Oil Consumption – Inspect 68
Increased Engine Oil Temperature – Inspect 69
Cooling System
Cooling System – Check 70
Cooling System – Inspect 70
Cooling System – Test 71
Engine Oil Cooler – Inspect 72
Water Temperature Regulator – Test 73
Water Pump – Inspect 73
Basic Engine
Position the Valve Mechanism Before
Maintenance Procedures 74
Piston Ring Groove – Inspect 74
Connecting Rod – Inspect 75
Cylinder Block – Inspect 75
Cylinder Head – Inspect 75
Piston Height – Inspect 76
Flywheel – Inspect 77
Flywheel Housing – Inspect 78
Gear Group – Inspect 79
Crankshaft Pulley – Check 80
Electrical System
Alternator – Test 81
Battery – Test 83
Charging System – Test 83
V-Belt – Test 84
Electric Starting System – Test 85
Index Section
Index 89
Disassembly and Assembly Section
Inspection of Parts 5
Fuel Priming Pump – Remove and Install 10
Flow Control Valve – Remove and Install 11
Fuel Filter Base – Remove and Install 13
Water Separator and Fuel Filter (Primary) –
Remove and Install 17
Fuel Manifold (Rail) – Remove and Install 19
Fuel Injection Lines – Remove 22
Fuel Injection Lines – Install 25
Exhaust Cooler (NRS) – Remove and Install 27
Throttle Valve (Intake Air) – Remove and Install
(Side Facing Inlet Elbow) 29
Throttle Valve (Intake Air) – Remove and Install
(Rear Facing Inlet Elbow) 31
Fuel Injection Pump – Remove 33
Fuel Injection Pump – Install 34
Fuel Injection Pump Gear – Remove 36
Fuel Injection Pump Gear – Install 38
Electronic Unit Injector – Remove 39
Electronic Unit Injector – Install 41
Turbocharger – Remove (Side Mounted
Turbochargers) 43
Turbocharger – Remove (Top Mounted
Turbochargers) 44
Turbocharger – Install (Side Mounted
Turbochargers) 46
Turbocharger – Install (Top Mounted
Turbochargers) 49
Wastegate Solenoid – Remove and Install 51
Exhaust Gas Recirculation Valve – Remove and
Install 53
Flexible Exhaust Pipe – Remove and Install 56
Exhaust Manifold – Remove and Install 60
Diesel Particulate Filter – Remove (Through Flow
Diesel Particulate Filter) 63
Diesel Particulate Filter – Remove (Wall Flow
Diesel Particulate Filter) 64
Diesel Particulate Filter – Install (Through Flow
Diesel Particulate Filter) 66
Diesel Particulate Filter – Install (Wall Flow Diesel
Particulate Filter ) 68
Support and Mounting (CEM) – Remove and
Install (Option 2) 70
Support and Mounting (CEM) – Remove and
Install (Option 1) 71
Support and Mounting (CEM) – Remove and
Install (Option 3) 73
Inlet Manifold – Remove and Install 74
Inlet and Exhaust Valve Springs – Remove and
Install 77
Inlet and Exhaust Valves – Remove and Install 80
Inlet and Exhaust Valve Guides – Remove and
Install 82
Engine Oil Filter Base – Remove and Install 84
Engine Oil Cooler – Remove 85
Engine Oil Cooler – Install 87
Engine Oil Relief Valve – Remove and Install 88
Engine Oil Pump – Remove 89
Engine Oil Pump – Install 89
Water Pump – Remove 90
Water Pump – Install 91
Water Temperature Regulator – Remove and
Install 92
Engine Lifting Bracket – Remove 94
Engine Lifting Bracket – Install 95
Flywheel – Remove 97
Flywheel – Install 97
Crankshaft Rear Seal – Remove and Install 99
Flywheel Housing – Remove and Install (Non-
Stressed Cylinder Block) 100
Flywheel Housing – Remove and Install
(Stressed Cylinder Block) 104
Power Take-Off Drive – Remove and Install 107
Crankshaft Pulley – Remove and Install 109
Crankshaft Front Seal – Remove and Install 110
Front Cover – Remove and Install 111
Idler Gear – Remove 113
Idler Gear – Install 115
Housing (Front) – Remove 117
Housing (Front) – Install 118
Accessory Drive – Remove and Install 121
Crankcase Breather – Remove 123
Crankcase Breather – Install 123
Valve Mechanism Cover – Remove and
Install 124
Rocker Shaft and Pushrod – Remove 127
Rocker Shaft – Disassemble 128
Rocker Shaft – Assemble 129
Rocker Shaft and Pushrod – Install 129
Cylinder Head – Remove 131
Cylinder Head – Install 132
Lifter Group – Remove and Install 135
Camshaft – Remove and Install 137
Camshaft Gear – Remove and Install 138
Camshaft Bearings – Remove and Install 140
This document is printed from SPI² Not for RESALE
Engine Oil Pan – Remove and Install (Cast Iron
Engine Oil Pan) 141
Engine Oil Pan – Remove and Install (Pressed
Steel Oil Pan) 145
Balancer – Remove 147
Balancer – Install 149
Piston Cooling Jets – Remove and Install 150
Pistons and Connecting Rods – Remove 152
Pistons and Connecting Rods – Disassemble 153
Pistons and Connecting Rods – Assemble 154
Pistons and Connecting Rods – Install 156
Connecting Rod Bearings – Remove (Connecting
rods in position) 157
Connecting Rod Bearings – Install (Connecting
rods in position) 158
Crankshaft Main Bearings – Remove and
Install 160
Crankshaft – Remove 163
Crankshaft – Install 164
Crankshaft Timing Ring – Remove and Install 165
Bearing Clearance – Check 167
Camshaft Position Sensor – Remove and
Install 168
Crankshaft Position Sensor – Remove and
Install 169
Coolant Temperature Sensor – Remove and
Install 170
Engine Oil Pressure Switch – Remove and
Install 171
Fuel Temperature Sensor – Remove and
Install 171
Oxygen Sensor – Remove and Install (Catalytic
Converter) 173
Temperature Sensor (Exhaust) – Remove and
Install 174
Temperature Sensor (DPF) – Remove and
Install 175
Pressure Sensor (DPF) – Remove and Install 176
Pressure Sensor (Exhaust Back Pressure) –
Remove and Install 177
Inlet Manifold Temperature Sensor – Remove
and Install 179
Inlet Manifold Pressure Sensor – Remove and
Install 180
Glow Plugs – Remove and Install 181
Alternator Belt – Remove and Install 183
Idler Pulley – Remove and Install 184
Fan – Remove and Install 185
Fan Drive – Remove and Install 185
Alternator – Remove 187
Alternator – Install 188
Electric Starting Motor – Remove and Install 190
Index Section
Index 192
Troubleshooting Section
Introduction
General Information 5
Welding Precaution 6
Electronic Service Tools 6
Electronic System Overview
System Overview 9
Component Location 10
Diesel Particulate Filter Regeneration 19
Engine Monitoring System 19
Diagnostic Capabilities 19
Electrical Connectors 20
Configuration Parameters
Configuration Parameters 22
Diagnostic Trouble Codes
Diagnostic Trouble Codes 23
Symptom Troubleshooting
Acceleration Is Poor or Throttle Response Is
Poor 31
Alternator Problem (Charging Problem and/or
Noisy Operation) 34
Battery Problem 36
Coolant Contains Oil 37
Coolant Level Is Low 38
Coolant Temperature Is High 38
Crankcase Breather Ejects Oil 42
Cylinder Is Noisy 45
Diesel Particulate Filter Active Regeneration
Occurrence Is Excessive 46
Diesel Particulate Filter Active Regeneration
Was Interrupted 48
Diesel Particulate Filter Collects Excessive
Soot 49
Diesel Particulate Filter Has Differential Pressure
Problem 51
Diesel Particulate Filter Temperature Is Low 54
Engine Cranks but Does Not Start 55
Engine Does Not Crank 60
Engine Has Early Wear 62
Engine Has Mechanical Noise (Knock) 64
Engine Misfires, Runs Rough or Is Unstable 67
Engine Overspeeds 70
Engine Shutdown Occurs Intermittently 70
Engine Stalls at Low RPM 72
Engine Top Speed Is Not Obtained 74
Engine Vibration Is Excessive 77
Exhaust Has Excessive Black Smoke 79
Exhaust Has Excessive White Smoke 82
Exhaust System Contains Coolant 85
Exhaust System Contains Oil 86
Fuel Consumption Is Excessive 88
Fuel Contains Water 91
Fuel Rail Pressure Problem 92
Fuel Temperature Is High 98
Inlet Air Is Restricted 99
Intake Manifold Air Pressure Is High 100
Intake Manifold Air Pressure Is Low 101
Intake Manifold Air Temperature Is High 103
NRS Mass Flow Rate Problem 104
Oil Consumption Is Excessive 107
Oil Contains Coolant 109
Oil Contains Fuel 111
Oil Pressure Is Low 114
Power Is Intermittently Low or Power Cutout Is
Intermittent 117
Valve Lash Is Excessive 119
Circuit Tests
Data Link – Test 121
ECM Memory – Test 124
Electrical Power Supply – Test 127
Glow Plug Starting Aid – Test 131
Idle Validation – Test 137
Indicator Lamp – Test 144
Injector Data Incorrect – Test 147
Injector Solenoid – Test 150
Mode Selection – Test 155
Motorized Valve – Test 158
Oxygen Level – Test 163
Power Take-Off – Test 169
Relay – Test (Start Relay) 174
Relay – Test (ECM Main Relay) 179
Sensor Signal (Analog, Active) – Test 183
Sensor Signal (Analog, Passive) – Test 190
Sensor Supply – Test 195
Solenoid Valve – Test 199
Speed Control – Test 205
Speed/Timing – Test 210
Switch Circuits – Test (Throttle Switch) 218
Switch Circuits – Test (Engine Oil Pressure
Switch) 221
Switch Circuits – Test (Air Filter Restriction
Switch) 225
Valve Position – Test 229
UENR0612 3
Table of Contents
Water in Fuel – Test 234
Service
Service Tool Features 238
Electronic Service Tool Does Not
Communicate 239
ECM Software – Install 241
ECM – Replace 242
Electrical Connectors – Inspect 243
Injector Code – Calibrate 246
Index Section
Index 248

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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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