Manitou PERKINS ENGINE 854F-E34TA Lift Truck Repair Manual 647605EN – PDF DOWNLOAD

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Manitou PERKINS ENGINE 854F-E34TA Lift Truck Repair Manual 647605EN – PDF DOWNLOAD

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Manitou PERKINS ENGINE 854F-E34TA Lift Truck Repair Manual 647605EN – PDF DOWNLOAD

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.

TABLE OF CONTENTS:

Manitou PERKINS ENGINE 854F-E34TA Lift Truck Repair Manual 647605EN – 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 9
Cylinder Head 10
Turbocharger 12
Injector (Diesel Exhaust Fluid) 13
Manifold (Diesel Exhaust Fluid) 14
Diesel Exhaust Fluid Tank 14
Diesel Exhaust Fluid Pump 15
Solenoid Valve (DEF Heater Coolant) 15
Exhaust Gas Valve (NRS) 16
Exhaust Cooler (NRS) 16
Exhaust Manifold 17
Flexible Exhaust Pipe (Turbocharger to Inlet of
Diesel Oxidation Catalyst) 18
Flexible Exhaust Pipe (Selective Catalyst
Reduction (SCR) Mixer Outlet to Inlet of
Selective Catalyst Reduction (SCR)
Canister) 19
Camshaft 19
Camshaft Bearings 20
Engine Oil Filter Base 20
Engine Oil Cooler 20
Engine Oil Pump 21
Engine Oil Pressure 21
Engine Oil Pan (Cast Iron Oil Pan) 21
Engine Oil Pan (Aluminum Oil Pan) 23
Engine Oil Pan (Pressed Steel Oil Pan) 25
Crankcase Breather 26
Water Temperature Regulator and Housing 27
Water Pump 28
Cylinder Block 28
Crankshaft 29
Connecting Rod Bearing Journal 30
Main Bearing Journal 31
Connecting Rod 31
Piston and Rings 32
Piston Cooling Jet 34
Balancer 34
Front Housing and Covers 35
Gear Group (Front) 36
Flywheel 37
Flywheel Housing 38
Crankshaft Pulley 38
Fan Drive 39
Engine Lifting Bracket 39
Alternator 40
Starter Motor 42
Nitrogen Oxide Sensor 43
Coolant Temperature Sensor 43
Ammonia Sensor 44
Inlet Manifold Temperature and Pressure
Sensor 44
Temperature Sensor (DOC Inlet) 45
Temperature Sensor (Exhaust) (Selective
Catalytic Reduction (SCR) Inlet Temperature
Sensor) 45
Temperature Sensor (Exhaust) (Selective
Catalytic Reduction (SCR) Outlet Temperature
Sensor) 45
Pressure Sensor (NOx Reduction System) 46
Temperature Sensor (NOx Reduction System) 46
Speed/Timing Sensor 47
Electronic Control Module 47
Glow Plugs 48
Index Section
Index 49
Foreword 4
Safety Section
Safety Messages 5
General Hazard Information 5
Burn Prevention 9
Fire Prevention and Explosion Prevention 10
Crushing Prevention and Cutting Prevention 12
Mounting and Dismounting 13
High Pressure Fuel Lines 13
Before Starting Engine 14
Engine Starting 15
Engine Stopping 15
Electrical System 15
Engine Electronics 17
Product Information Section
General Information 18
Product Identification Information 24
Operation Section
Lifting and Storage 26
Features and Controls 29
Engine Diagnostics 45
Engine Starting 49
Engine Operation 52
Cold Weather Operation 54
Engine Stopping 58
Maintenance Section
Refill Capacities 60
Maintenance Recommendations 75
Maintenance Interval Schedule 78
Warranty Section
Warranty Information 110
Reference Information Section
Reference Materials 111
Index Section
Index 114
Systems Operation Section
General Information
Introduction 4
Engine Operation
Basic Engine 8
Air Inlet and Exhaust System 11
Clean Emissions Module 16
DEF Dosing Control System 19
Cooling System 25
Lubrication System 27
Electrical System 27
Cleanliness of Fuel System Components 28
Fuel Injection 29
Electronic Control System 36
Power Sources 47
Glossary of Electronic Control Terms 53
Testing and Adjusting Section
Fuel System
Fuel System – Inspect 58
Air in Fuel – Test 58
Finding Top Center Position for No 1 Piston 60
Fuel Injection Timing – Check 60
Fuel Quality – Test 61
Fuel System – Prime 62
Fuel System Pressure – Test 63
Gear Group (Front) – Time 66
Air Inlet and Exhaust System
Air Inlet and Exhaust System – Inspect 67
Turbocharger – Inspect 67
Exhaust Cooler (NRS) – Test 70
Compression – Test 71
Engine Valve Lash – Inspect 71
Valve Depth – Inspect 73
Valve Guide – Inspect 73
Diesel Exhaust Fluid Quality – Test 74
Aftertreatment SCR System Dosing – Test 75
Diesel Exhaust Fluid Tank – Flush 75
Lubrication System
Engine Oil Pressure – Test 78
Engine Oil Pump – Inspect 78
Excessive Bearing Wear – Inspect 78
Excessive Engine Oil Consumption – Inspect 78
Increased Engine Oil Temperature – Inspect 79
Cooling System
Cooling System – Check 80
Cooling System – Inspect 80
Cooling System – Test 81
Engine Oil Cooler – Inspect 82
Water Temperature Regulator – Test 83
Water Pump – Inspect 83
Basic Engine
Position the Valve Mechanism Before
Maintenance Procedures 84
Piston Ring Groove – Inspect 84
Connecting Rod – Inspect 85
Cylinder Block – Inspect 85
Cylinder Head – Inspect 85
Piston Height – Inspect 86
Flywheel – Inspect 87
Flywheel Housing – Inspect 88
Gear Group – Inspect 89
Crankshaft Pulley – Check 90
Electrical System
Alternator – Test 91
Battery – Test 93
Charging System – Test 93
V-Belt – Test 94
Electric Starting System – Test 95
Index Section
Index 99
Disassembly and Assembly Section
Fuel Priming Pump – Remove and Install 5
Flow Control Valve – Remove and Install 6
Fuel Filter Base – Remove and Install 8
Water Separator and Fuel Filter (Primary) –
Remove and Install 12
Fuel Manifold (Rail) – Remove and Install 14
Fuel Injection Lines – Remove 17
Fuel Injection Lines – Install 20
Exhaust Cooler (NRS) – Remove and Install 22
Throttle Valve (Intake Air) – Remove and Install
(Rear Facing Inlet Elbow) 24
Throttle Valve (Intake Air) – Remove and Install
(Side Facing Inlet Elbow) 26
Fuel Injection Pump – Remove 28
Fuel Injection Pump – Install 29
Fuel Injection Pump Gear – Remove 31
Fuel Injection Pump Gear – Install 32
Electronic Unit Injector – Remove 33
Electronic Unit Injector – Install 35
Turbocharger – Remove (Top Mounted
Turbocharger) 37
Turbocharger – Remove (Side Mounted
Turbochargers) 40
Turbocharger – Install (Top Mounted
Turbocharger) 42
Turbocharger – Install (Side Mounted
Turbocharger) 45
Wastegate Solenoid – Remove and Install 47
Exhaust Gas Recirculation Valve – Remove and
Install 49
Selective Catalytic Reduction (SCR) Canister –
Remove and Install 53
Clean Emissions Module – Remove and Install
(Top Mounted Diesel Oxidation Catalyst
(DOC)) 55
Clean Emissions Module – Remove and Install
(Flywheel Mounted Diesel Oxidation Catalyst
(DOC)) 56
Diesel Exhaust Fluid Lines – Remove and
Install 58
Diesel Exhaust Fluid Pump – Remove and
Install 63
DEF Injector and Mounting – Remove and
Install 65
Diesel Exhaust Fluid Tank – Remove and
Install 68
Manifold (DEF Heater) – Remove and Install 70
Solenoid Valve (DEF Heater Coolant) – Remove
and Install 74
Flexible Exhaust Pipe – Remove and Install
(Flexible Exhaust Pipe from the Turbocharger
and the Diesel Oxidation Catalyst (DOC)) 75
Flexible Exhaust Pipe – Remove and Install
(Flexible Exhaust Pipe Between DOC and the
SCR) 76
Exhaust Manifold – Remove and Install (Side
Mounted Turbocharger Exhaust Manifold) 80
Exhaust Manifold – Remove and Install (Top
Mounted Turbocharger Exhaust Manifold) 83
Support and Mounting (CEM) – Remove and
Install (Flywheel Housing Mounted CEM) 87
Support and Mounting (CEM) – Remove and
Install (Top Mounted DOC) 88
Inlet Manifold – Remove and Install 91
Inlet and Exhaust Valve Springs – Remove and
Install 94
Inlet and Exhaust Valves – Remove and Install 96
Inlet and Exhaust Valve Guides – Remove and
Install 99
Engine Oil Filter Base – Remove and Install 100
Engine Oil Cooler – Remove 102
Engine Oil Cooler – Install 103
Engine Oil Relief Valve – Remove and Install 104
Engine Oil Pump – Remove 105
Engine Oil Pump – Install 106
Water Pump – Remove 107
Water Pump – Install 108
Water Temperature Regulator – Remove and
Install 109
Engine Lifting Bracket – Remove 110
Engine Lifting Bracket – Install 111
Flywheel – Remove 112
Flywheel – Install 113
Crankshaft Rear Seal – Remove and Install 114
Flywheel Housing – Remove and Install
(Stressed Cylinder Block) 116
Flywheel Housing – Remove and Install (Non-
Stressed Cylinder Block) 118
Power Take-Off Drive – Remove and Install 121
Crankshaft Pulley – Remove and Install 123
Crankshaft Front Seal – Remove and Install 124
Front Cover – Remove and Install 126
Idler Gear – Remove 128
Idler Gear – Install 130
Housing (Front) – Remove 132
Housing (Front) – Install 133
Accessory Drive – Remove and Install 136
UENR4503 3
Table of Contents
Crankcase Breather – Remove 138
Crankcase Breather – Install 139
Valve Mechanism Cover – Remove and
Install 140
Rocker Shaft and Pushrod – Remove 144
Rocker Shaft – Disassemble 146
Rocker Shaft – Assemble 146
Rocker Shaft and Pushrod – Install 147
Cylinder Head – Remove 149
Cylinder Head – Install 151
Lifter Group – Remove and Install 153
Camshaft – Remove and Install 155
Camshaft Gear – Remove and Install 156
Camshaft Bearings – Remove and Install 158
Engine Oil Pan – Remove and Install (Pressed
Steel Oil Pan) 159
Engine Oil Pan – Remove and Install (Cast Iron
Engine Oil Pan) 161
Balancer – Remove 165
Balancer – Install 166
Piston Cooling Jets – Remove and Install 168
Pistons and Connecting Rods – Remove 169
Pistons and Connecting Rods – Disassemble 171
Pistons and Connecting Rods – Assemble 172
Pistons and Connecting Rods – Install 173
Connecting Rod Bearings – Remove (Connecting
rods in position) 175
Connecting Rod Bearings – Install (Connecting
rods in position) 176
Crankshaft Main Bearings – Remove and
Install 177
Crankshaft – Remove 180
Crankshaft – Install 181
Crankshaft Timing Ring – Remove and Install 183
Bearing Clearance – Check 184
Nitrogen Oxide Sensor – Remove and Install
(Nitrogen Oxide Sensor on Engine) 185
Camshaft Position Sensor – Remove and
Install 188
Crankshaft Position Sensor – Remove and
Install 189
Coolant Temperature Sensor – Remove and
Install 190
Engine Oil Pressure Switch – Remove and
Install 191
Fuel Temperature Sensor – Remove and
Install 192
Temperature Sensor (Exhaust) – Remove and
Install (Temperature Sensor Exhaust before
SCR) 193
Temperature Sensor (Exhaust) – Remove and
Install (Temperature Sensor Exhaust After
SCR) 194
Temperature Sensor (Exhaust) – Remove and
Install (Exhaust Manifold Temperature Sensor
for NRS) 195
Temperature Sensor (Exhaust) – Remove and
Install 196
Pressure Sensor (Exhaust Back Pressure) –
Remove and Install 197
Inlet Manifold Temperature Sensor – Remove
and Install 199
Inlet Manifold Pressure Sensor – Remove and
Install 200
Glow Plugs – Remove and Install 201
Alternator Belt – Remove and Install 202
Idler Pulley – Remove and Install 204
Fan – Remove and Install 204
Fan Drive – Remove and Install 205
Alternator – Remove 207
Alternator – Install 208
Electric Starting Motor – Remove and Install 210
Index Section
Index 212
Troubleshooting Section
Introduction
General Information 5
Welding Precaution 6
Electronic Service Tools 7
Electronic System Overview
System Overview 10
Component Location 11
Engine Monitoring System 17
Diagnostic Capabilities 18
Electrical Connectors 19
Configuration Parameters
Configuration Parameters 20
Diagnostic Trouble Codes
Diagnostic Trouble Codes 21
Symptom Troubleshooting
Acceleration Is Poor or Throttle Response Is Poor 31
Alternator Problem (Charging Problem and/or Noisy
Operation) 35
Battery Problem 37
Coolant Contains Oil 38
Coolant Level Is Low 39
Coolant Temperature Is High 39
Coolant Temperature Is Low 43
Crankcase Breather Ejects Oil 45
Cylinder Is Noisy 47
DEF Concentration Is Incorrect 48
DEF Does Not Purge 50
DEF Module Does Not Respond 51
DEF Pressure Does Not Respond 53
DEF Pressure Is High 58
DEF Pressure Is Low 60
DEF Tank Level Is Low 63
DEF Tank Temperature Is High 65
DEF Tank Temperature Is Low 68
Desulfation Is Frequent 71
Engine Cranks but Does Not Start 74
Engine Does Not Crank 79
Engine Has Early Wear 81
Engine Has Mechanical Noise (Knock) 83
Engine Misfires, Runs Rough or Is Unstable 86
Engine Overspeeds 89
Engine Shutdown Occurs Intermittently 90
Engine Stalls at Low RPM 91
Engine Top Speed Is Not Obtained 93
Engine Vibration Is Excessive 96
Exhaust Has Excessive Black Smoke 98
Exhaust Has Excessive White Smoke 101
Exhaust System Contains Coolant 104
Exhaust System Contains DEF Deposits 105
Exhaust System Contains Oil 108
Fuel Consumption Is Excessive 109
Fuel Contains Water 113
Fuel Rail Pressure Problem 114
Fuel Temperature Is High 121
Inlet Air Is Restricted 121
Intake Manifold Air Pressure Is High 122
Intake Manifold Air Pressure Is Low 124
Intake Manifold Air Temperature Is High 126
NOx Conversion Is Low 128
NRS Mass Flow Rate Problem 131
Oil Consumption Is Excessive 132
Oil Contains Coolant 135
Oil Contains Fuel 137
Oil Pressure Is Low 139
Power Is Intermittently Low or Power Cutout Is
Intermittent 142
SCR Catalyst Has Incorrect Inlet Temperature 145
SCR Warning System Problem 146
Valve Lash Is Excessive 159
Circuit Tests
CAN Data Link – Test 161
DEF Injector – Test 165
DEF Line Heater – Test 169
DEF Pump – Test 176
DEF Pump Pressure Sensor – Test 181
DEF Return Valve – Test 184
DEF Tank Sensor – Test 188
ECM Memory – Test 193
Electrical Power Supply – Test 195
Glow Plug Starting Aid – Test 199
Idle Validation – Test 205
Indicator Lamp – Test 212
Injector Data Incorrect – Test 216
Injector Solenoid – Test 219
Mode Selection – Test 225
Motorized Valve – Test 229
NOx Sensor – Test 236
Power Take-Off – Test 240
Relay – Test (Start Relay) 245
Relay – Test (ECM Main Relay) 251
Relay – Test (SCR Relay) 256
Sensor (Data Link Type) – Test (Ammonia
Sensor) 262
Sensor Signal (Analog, Active) – Test (Exhaust Gas
Pressure Sensor) 266
Sensor Signal (Analog, Active) – Test 272
Sensor Signal (Analog, Passive) – Test 279
Sensor Supply – Test 286
Solenoid Valve – Test (Coolant Diverter Valve) 290
Solenoid Valve – Test 292
Speed Control – Test 299
Speed/Timing – Test 305
Switch Circuits – Test (Engine Oil Pressure
Switch) 313
Switch Circuits – Test (Throttle Switch) 318
Switch Circuits – Test (Air Filter Restriction
Switch) 323
Valve Position – Test 329
Water in Fuel – Test 335
Service
Service Tool Features 339
Electronic Service Tool Does Not Communicate 341
ECM Software – Install 343
ECM – Replace 344
Electrical Connectors – Inspect 345
Injector Code – Calibrate 348
Index Section
Index 350

Customer Support: [email protected]

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• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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