Perkins 854E-E34TA User manual

This document is printed from SPI². Not for RESALE
Systems Operation
Testing and Adjusting
854E-E34TA and 854F-E34T Industrial
Engines
JR (Engine)
JS (Engine)
JT (Engine)
UENR0623-01
March 2013

This document is printed from SPI². Not for RESALE
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 everypossible circumstance that might involve apotential 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 specificallyrecommended byPerkins 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 startany 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 prema-
ture failures, product damage, personal injury or
death.

This document is printed from SPI². Not for RESALE
Table of Contents
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
UENR0623 3
Table of Contents

This document is printed from SPI². Not for RESALE
Systems Operation Section
General Information
i05241818
Introduction
The following model views show a typical industrial
engine. Due to individual applications, your engine
may appear different from the illustrations.
Illustration 1 g02317613
Typical example
(1) Clean Emissions Module (CEM)
(2) Oil gauge (Dipstick)
(3) Electronic Control Module (ECM)
(4) Air inlet connection from charge cooler
(5) Coolant outlet connection
(6) Air intake from air filter
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General Information

This document is printed from SPI². Not for RESALE
(7) Alternator
(8) Coolant intake connection
(9) Air outlet connection from turbocharger
(10) Turbocharger
(11) Oil drain plug
(12) Starting motor
(13) Flywheel housing
(14) Flywheel
Illustration 2 g03343018
Typical example
(15) Front lifting eye
(16) Oil filler cap
(17) Rear lifting eyes
(18) Secondary fuel filter
(19) Oil filter
(20) Fuel priming pump
(21) Primary fuel filter
(22) Fuel injection pump
(23) Crankcase breather
(24) Water pump
Note: The primary fuel filter (21) may be supplied
loose.
Note: The Electronic Control Module (ECM) (3) will
be mounted to the application.
The 854E-E34TA and 854F-E34T diesel engines are
electronically controlled. The 854E-E34TA and 854F-
E34T engines have an Electronic Control Module
(ECM) that receives signals from the fuel injection
pump and other sensors in order to control the
electronic unit injector. The fuel injection pump
supplies fuel to the fuel manifold (Rail). The fuel
manifold (Rail) distributes fuel to the electronic unit
injectors.
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General Information

This document is printed from SPI². Not for RESALE
The four cylinders are arranged in-line. The cylinder
head assembly has one inlet valve and one exhaust
valve for each cylinder. The port for the exhaust valve
is on the right side of the cylinder head. The port for
the inlet valve is on the top of the cylinder head. Each
cylinder valve has a single valve spring.
Each cylinder has a piston cooling jet that is installed
in the cylinder block. The piston cooling jet sprays
engine oil onto the inner surface of the piston in order
to cool the piston. The pistons have a Quiescent
combustion chamber in the top of the piston in order
to achieve clean exhaust emissions. The piston pin is
off-center in order to reduce the noise level.
The pistons have two compression rings and an oil
control ring. The groove for the top ring has a hard
metal insert in order to reduce wear of the groove.
The skirt has a layer of graphite in order to reduce the
risk of seizure when the engine is new. The correct
piston height is important in order to ensure that the
piston does not contact the cylinder head. The correct
piston height also ensures the efficient combustion of
fuel which is necessary in order to conform to
requirements for emissions.
The crankshaft has five main bearing journals. End
play is controlled by thrust washers which are located
on both sides of the number 3 main bearing.
The timing case is made of cast iron. Some of the
timing gears are stamped with timing marks in order
to ensure the correct assembly of the gears. When
the number 1 piston is at a certain position, the
marked teeth on the camshaft gear will align with the
marks that are on the gear on the crankshaft.
There are no timing marks on the rear face of the
timing case.
The crankshaft gear turns the camshaft gear which
then turns the following gears:
• the idler gear
• the idler gear for the engine oil pump
• the engine oil pump gear
• the accessory drive gear
• the fuel injection pump gear
The camshaft runs at half the rpm of the crankshaft.
The fuel injection pump runs at one and a half times
the speed as the crankshaft.
The fuel injection pump that is installed on the left
side of the engine is gear-driven from the timing case.
The internal fuel transfer pump is driven by the fuel
injection pump. The fuel transfer pump draws low
pressure fuel from the primary fuel filter. The fuel
transfer pump delivers the fuel to the secondary filter.
The fuel then travels to the fuel injection pump.
The fuel injection pump increases the fuel to a
maximum pressure of 160 MPa (23200 psi). The fuel
injection pump delivers the fuel to the fuel manifold
(Rail). The fuel injection pump is not serviceable. The
engine uses speed sensors and the Electronic
Control Module (ECM) to control the engine speed.
For the specifications of the 854E-E34TA and 854F-
E34T engines, refer to the Specifications, “Engine
Design”.
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General Information

This document is printed from SPI². Not for RESALE
Engine Operation
i04169549
Basic Engine
Introduction
The eight major mechanical components of the basic
engine are the following parts:
• Cylinder block
• Cylinder head
• Pistons
• Connecting rods
• Crankshaft
• Timing gear case and gears
• Camshaft
Cylinder Block
Illustration 3 g02859296
Typical example
The cast iron cylinder block for the engine has four
cylinders which are arranged in-line. The cylinder
block is made of cast iron. The cylinder block
provides support for the full length of the cylinder
bores. The cylinder bores are machined into the
block.
The cylinders are honed to a specially controlled
finish in order to ensure long life and low oil
consumption.
The cylinder block has five main bearings which
support the crankshaft. Thrust washers are installed
on both sides of number 3 main bearing in order to
control the end play of the crankshaft. The thrust
washers can only be installed one way.
Passages supply the lubrication for the crankshaft
bearings. These passages are machined into the
cylinder block.
Cooling passages are cast into the cylinder block in
order to allow the circulation of coolant.
The cylinder block has a bush that is installed for the
front camshaft journal. The other camshaft journals
run directly in the cylinder block.
The engine has a cooling jet that is installed in the
cylinder block for each cylinder. The piston cooling jet
sprays lubricating oil onto the inner surface of the
piston in order to cool the piston.
A Multi-Layered Steel (MLS) cylinder head gasket is
used between the engine block and the cylinder head
in order to seal combustion gases, water, and oil.
Cylinder Head
Illustration 4 g02859418
Typical example
(1) Valve keepers
(2) Valve spring retainer
(3) Valve spring
The engine has a cast iron cylinder head (4). There is
one inlet valve and one exhaust valve for each
cylinder.
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Engine Operation

This document is printed from SPI². Not for RESALE
The port for the inlet valve is on the top of the cylinder
head. The port for the exhaust valve is on the right
side of the cylinder head. The valve stems move in
valve guides that are pressed into the cylinder head.
There is a renewable oil seal that fits over the top of
the valve guide. The valve seats and the valve guides
are replaceable.
Pistons, Rings, and Connecting
rods
Illustration 5 g02859336
Typical example
The pistons (3) have a Quiescent combustion
chamber in the top of the piston in order to provide an
efficient mix of fuel and air. The piston pin (9) is off-
center in order to reduce the noise level. The position
pin (9) is retained in the correct position by two
circlips (8).
The pistons (3) have two compression rings (1) and
an oil control ring (2). The groove for the top ring has
a hard metal insert in order to reduce wear of the
groove. The piston skirt has a coating of graphite in
order to reduce the risk of seizure when the engine is
new.
The correct piston height is important in order to
ensure that the piston does not contact the cylinder
head. The correct piston height also ensures the
efficient combustion of fuel which is necessary in
order to conform to requirements for emissions.
The connecting rods (4) are machined from forged
steel. The connecting rods have bearing caps (6) that
are fracture split . The bearing caps (6) on fracture
split connecting rods (4) are retained with bolts (7).
Connecting rods with bearing caps that are fracture
split have the following characteristics:
• The splitting produces an accurately matched
surface on each side of the fracture for improved
strength.
• The correct connecting rod must be installed with
the correct bearing cap. Each connecting rod and
bearing cap have a unique serial number. When a
connecting rod is assembled the serial numbers
for the connecting rod and bearing cap must
match.
Crankshaft
Illustration 6 g02841976
Typical example
(1) Crankshaft gear
(2) Crankshaft
(3) Crankshaft thrust washers
The crankshaft can be a spheroidal graphite iron
casting.
The crankshaft has five main journals. Thrust
washers are installed on both sides of number 3 main
bearing in order to control the end play of the
crankshaft.
The crankshaft changes the linear energy of the
pistons and connecting rods into rotary torque in
order to power external equipment.
A gear at the front of the crankshaft drives the timing
gears. The crankshaft gear turns the idler gear which
then turns the following gears:
• Camshaft gear
• Fuel injection pump and fuel transfer pump
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Engine Operation

This document is printed from SPI². Not for RESALE
Lip type seals are used on both the front of the
crankshaft and the rear of the crankshaft.
A timing ring is installed to the crankshaft. The timing
ring is used by the ECM in order to measure the
engine speed and the engine position.
A timing ring for the balancer can be installed to the
crankshaft. The timing ring for the balancer drives the
balancer.
Gears and Timing Gear Case
Illustration 7 g02859276
Typical example
The crankshaft oil seal is mounted in the cover of the
timing case. The timing case is made of cast iron. The
timing case cover is made from aluminum.
The timing gears are made of steel.
The crankshaft gear (5) drives the camshaft gear (4)
and an idler gear (6) for the engine oil pump. The idler
gear (6) for the engine oil pump drives the oil pump
gear (7). The camshaft gear (4) drives the idler gear
(2) and the accessory drive gear (3). The idler gear
(2) drives the fuel injection pump gear (1).
The camshaft gear rotates at half the engine speed.
The fuel injection pump gear rotates at one and a half
times engine speed.
Camshaft
The engine has a single camshaft. The camshaft is
made of cast iron. The camshaft lobes are chill
hardened.
The camshaft is driven at the front end. As the
camshaft turns, the camshaft lobes move the valve
system components. The valve system components
move the cylinder valves.
The camshaft gear must be timed to the crankshaft
gear. The relationship between the lobes and the
camshaft gear causes the valves in each cylinder to
open at the correct time. The relationship between
the lobes and the camshaft gear also causes the
valves in each cylinder to close at the correct time.
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Engine Operation

This document is printed from SPI². Not for RESALE
i04174031
Air Inlet and Exhaust System
Illustration 8 g02720982
Air inlet and exhaust system
(1) Aftercooler core
(2) Air filter
(3) Diesel particulate filter
(4) Turbocharger
(5) Wastegate actuator
(6) Boost pressure chamber
(7) Exhaust gas valve (NRS)
(8) Wastegate regulator
(9) Exhaust cooler (NRS)
(10) Inlet manifold
(11) Throttle valve
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Engine Operation