M0064276 (en-us)

December 2015

Systems Operation
Testing and Adjusting
4008-30 Industrial Engine
SD8 (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 prema-
ture failures, product damage, personal injury or
death.
M0064276 3
Table of Contents

Table of Contents Flywheel - Inspect ...............................................33

Flywheel Housing - Inspect ..................................34
Crankshaft Thrust - Measure................................35
Systems Operation Section Vibration Damper ................................................36
Gear Group (Front)..............................................37
Fuel System
Fuel System Operation ..........................................4 Electrical System
Fuel Injector Mechanism........................................4 Battery ...............................................................38
Charging System ................................................38
Electric Starting System.......................................38
Air Inlet and Exhaust System
Air Inlet and Exhaust System .................................5
Valve Mechanism ..................................................5 Index Section
Lubrication System Index..................................................................40
Lubrication System ...............................................7

Cooling System
Cooling System ....................................................9

Basic Engine
Cylinder Block, Liners and Heads .........................10
Pistons, Rings and Connecting Rods ...................10
Crankshaft ......................................................... 11
Camshaft ........................................................... 11

Electrical System
Electrical System ................................................12

Testing and Adjusting Section

Electronic Control System

Engine Governing - Adjust ...................................16

Fuel System
General Information (Fuel System) (Diesel)...........17
Fuel System Inspection .......................................17
Checking Engine Cylinders ..................................17

Air Inlet and Exhaust System

Valve Lash - Adjust..............................................18
Turbocharger ......................................................20

Lubrication System
General Information (Lubrication System) .............23
Engine Oil Pressure - Test ...................................23
Excessive Bearing Wear - Inspect ........................24
Excessive Engine Oil Consumption - Inspect.........25
Increased Engine Oil Temperature - Inspect ..........25
Engine Oil Pressure is Low ..................................25
Engine Oil Pressure is High .................................26

Cooling System
General Information (Cooling System) ..................28
Visual Inspection.................................................29
Water Temperature Regulator - Test .....................29

Basic Engine
Connecting Rod Bearings ....................................31
Main Bearings.....................................................31
Cylinder Block.....................................................31
Cylinder Head .....................................................31
4 M0064276
Fuel System

Systems Operation Section A speed sensor measures engine speed. A digital

governor regulates the input of the fuel to the engine
so that the actual engine speed matches the desired
engine speed. Engine speed is maintained by the
Fuel System governor by a speed sensor. The speed sensor is
mounted next to the flywheel gear. The governor
actuator that is controlled by the digital governor for
the required load is connected to the linkage of the
fuel injectors. The fuel is injected into the cylinder at
precisely the correct moment for the most efficient
i06512690
combustion.
Fuel System Operation i06551615

Fuel Injector Mechanism

The fuel supply circuit is a conventional design for
engines that use fuel injectors. The fuel supply circuit
uses a fuel transfer pump to deliver fuel from the fuel
tank to the fuel injectors. The transfer pump is a fixed The fuel injector mechanism provides the downward
displacement gear pump. The fuel transfer pump is force that is required to pressurize the fuel in the fuel
installed to the back of the oil pump. injection pump. The mechanically operated fuel
injector allows fuel to be injected into the combustion
A fuel priming pump is on the fuel transfer pump to fill chamber.
the system. The system must be primed after the
Force is transmitted from the fuel injector lobe on the
filter changes. The system must be primed after
camshaft through the lifter to the pushrod. The force
draining the fuel supply and return manifolds, when
from the pushrod is transmitted through the rocker
the fuel injectors are replaced.
assembly and to the top of the fuel injection pump.
The fuel flows continuously from the fuel supply The adjusting nut allows setting of the injector timing.
manifold through the fuel injectors. The fuel flows
when either the supply or the fill port in the injector is
not closed by the injector body assembly plunger.
The fuel that is not injected into the cylinder is
returned to the tank through the fuel return manifold.
A pressure regulating valve is installed at the end of
the fuel return manifold. The pressure regulating
valve controls the entire fuel system pressure. This
ensures that the fuel injectors are correctly filled with
fuel.
The mechanically actuated fuel injector system
provides total control of injection timing. The injection
timing is varied to optimize the performance of the
engine.
M0064276 5
Air Inlet and Exhaust System

Air Inlet and Exhaust Clean inlet air from the air cleaners is pulled through
air inlet (4) into the turbocharger compressor by
System compressor wheel (5). The rotation of the
compressor wheel compresses the air. The rotation
of the turbocharger compressor wheel then forces
the air through a tube to aftercooler (2). The
aftercooler lowers the temperature of the
i06515116
compressed air before the air enters the inlet
chamber in each cylinder head. Air flow from the inlet
chamber into the cylinder heads is controlled by the
Air Inlet and Exhaust System inlet valves.
There are two inlet valves and two exhaust valves for
each cylinder. Refer to Systems Operation, “Valve
The components of the air inlet and exhaust system Mechanism”. The inlet valves open when the piston
control the quality and the amount of air that is moves down on the inlet stroke. The cooled,
available for combustion. There are two separate compressed air is forced into the cylinder from the
turbochargers that are installed on the rear of the inlet chamber.
engine.
The inlet valves close and the piston starts to move
The hot charge air from the turbochargers is directed up on the compression stroke. When the piston is
by large air pipes to the aftercooler. The cooling of near the top of the compression stroke, fuel is
the charge air is achieved by inserting this additional injected into the cylinder. The fuel mixes with the air
radiator in front of the normal radiator that cools and combustion starts. The force of the combustion
water. The single radiator fan pushes air through pushes the piston downward on the power stroke.
each matrix in series. The air passes through the When the piston moves upward again, the piston is
matrix for charge air. After the air passes through the on the exhaust stroke. The exhaust valves open and
radiator for charge air, the air is directed through the exhaust gases are pushed through the exhaust
pipes that have a large bore to the air intake port into exhaust manifold (1). After the piston makes
manifolds. the exhaust stroke, the exhaust valves close and the
cycle starts again.
The camshaft controls the movement of the valve
system components and injectors. Exhaust gases from exhaust manifold (1) go into the
turbine side of the turbocharger. The exhaust gases
cause turbine wheel (6) to turn. The turbine wheel is
connected to the shaft that drives the turbocharger
compressor wheel (5). The exhaust gases exit
through exhaust outlet (7).

i02856821

Valve Mechanism

The valve system components control the flow of the

inlet air and the exhaust gases into the cylinders and
out of the cylinders during engine operation.
Illustration 1 g01188937 The crankshaft gear drives the camshaft gears
Air Inlet And Exhaust System through idlers. The camshaft must be timed to the
(1) Exhaust manifold crankshaft in order to get the correct relation between
(2) Aftercooler the piston and the valve movement.
(3) Engine cylinder
(4) Air inlet The camshaft has three lobes for each cylinder. Two
(5) Turbocharger compressor wheel lobes operate the valves and one operates the fuel
(6) Turbocharger turbine wheel injector.
(7) Exhaust outlet
As the camshaft turns, the lobes on the camshaft
cause lifters to move up and down. This movement
causes pushrods to move rocker arms. The
movement of the rocker arms cause bridge pieces to
move downward. The bridge pieces open two valves
simultaneously. The valves can be either inlet valves
or exhaust valves. There are two inlet valves and two
exhaust valves for each cylinder.
6 M0064276
Air Inlet and Exhaust System

Valve springs cause the valves to close when the

lifters move downward.
M0064276 7
Lubrication System

Lubrication System

i06512672

Lubrication System

Lubrication System Components

Illustration 2 g01372216
Typical example of the lubrication system components
(A) Oil pressure circuit (2) Engine oil pump (7) Engine oil pan
(B) Oil circuit for piston cooling (3) Engine oil relief valve (8) Oil supply line for turbocharger
(C) Oil pressure relief (4) Strainer (9) Oil return line for turbocharger
(D) Oil return to sump (5) Oil cooler
(1) Oil supply line for rocker shafts (6) Oil filters
8 M0064276
Lubrication System

Engine Oil Flow Through the

Engine Oil Filter and Engine Oil
Cooler
When the engine is at normal operating temperature,
the engine oil pump (2) pumps engine oil from the
engine oil pan (7) through the strainer (4). The engine
oil is pumped to the engine oil cooler (5). The engine
oil flows through the engine oil filters (6) to the oil
gallery in the cylinder block and to the supply line (1)
for the rocker shafts. Engine oil from the turbocharger
goes back through the return line (9) to the engine oil
pan (7).
The three engine oil filters are full flow oil filters.

Engine Oil Flow in the Engine

The engine oil pump has a pressure relief valve that
is designed to open if the engine oil pressure
becomes excessive. This prevents high-pressure
engine oil from damaging the O-ring seals for the
engine oil cooler and for the engine oil filter. The
remainder of the engine oil is pumped normally to the
engine oil gallery in the cylinder block.
The engine oil gallery is the source of pressurized
engine oil for the engine and for the attachments.
The flow of engine oil which goes to the main
bearings is divided. Some of the engine oil provides
lubrication between the main bearings and the
bearing surfaces (journals) of the crankshaft. Some
of the engine oil goes through the drilled passages
into the crankshaft. This engine oil provides
lubrication between the connecting rod bearings and
the bearing surfaces (journals) of the crankshaft. The
engine oil provides cooling and lubrication for the
following components:
• Pistons

• Piston pins
• Cylinder walls
• Camshaft bearings

• Pushrods
• Valve lifters
Some of the engine oil lubricates the valve stems.
The remainder of the engine oil drains from the
cylinder head to lubricate the pushrods.
The bearings for the timing gear receive pressurized
engine oil from the oil gallery.
For components on the outside of the engine such as
the turbocharger, engine oil goes through supply
lines from the engine oil gallery.
M0064276 9
Cooling System

Cooling System

i06512674

Cooling System

The coolant is circulated through the engine by a

centrifugal water pump. The water pump is on the
front of the engine. The water pump has a gear that is
driven by the idler gear. Coolant from the inlet line
goes into the water pump. The rotation of the impeller
in the water pump then pumps the coolant through
the system.
The coolant from the water pump goes through the
engine oil cooler to the coolant jackets in the cylinder
block. From the cooling jackets around the cylinders,
the coolant flows upwards into the cylinder heads.
The coolant returns via a water rail to the housing for
the water temperature regulator. The thermostat
housing has three water temperature regulator
elements. The water temperature regulator elements
determine the direction of the coolant flow depending
on the temperature. When cold, the coolant flow is
directed back via a by-pass pipe to the coolant pump
suction to be recirculated.
With the thermostat open, the coolant is allowed to
enter the radiator. The coolant is cooled by air
blowing over the single core cooling matrix. The hot
air from the turbocharger is directed via a large
diameter air pipe to the aftercooler. The hot air flows
through a single core radiator and is directed through
large bore pipes to the engine air inlet manifold. The
cooling of the charge air is achieved by installing an
extra radiator at the side of the normal coolant
cooling radiator and in the airflow of the cooling fan.
The radiator fan forces air through each matrix in
parallel.
The oil cooler comprises of a tubestack enclosed
within a cast body and sealed by O-rings and joints to
the port covers. The covers are secured by bolts,
setscrews, and spring washers to the body. Oil is
delivered from the lubricating oil pump via a flexible
pipe into the inlet port and into cooler body circulating
around the outside of the tubes. Coolant is delivered
from the water pump and passes from the outlet pipe
to the end cover inlet port. Then passes through the
tubes, and makes one pass in both directions. The
coolant then exits from the outlet port to the water
transfer pipe and into the water jacket.
10 M0064276
Basic Engine

Basic Engine Camshaft covers allow access to the camshaft and to

the valve lifters. Crankcase covers allow access to
the crankshaft connecting rods, the main bearings,
and the piston cooling jets. When the covers are
removed, all the openings can be used for inspection
and for service.
i06512668

i06512669
Cylinder Block, Liners and
Heads Pistons, Rings and
Connecting Rods
The cylinders in the cylinder block are arranged in-
line. The main bearing caps that locate the crankcase
are fastened to the cylinder block with four bolts, two The piston is a one-piece piston that is a casting of
through the face and two side bolts. aluminum alloy. The piston crown carries all three
piston rings. Oil from the piston cooling jets flows
The cylinder liners can be removed for replacement. through a chamber which is located directly behind
The top surface of the cylinder block is the seat for the rings. The oil cools the pistons. This maintains
the cylinder liner flange. Engine coolant flows around the correct operating temperature of the piston. The
the cylinder liners to keep the cylinder liners cool. pistons have three rings which include two
Two O-ring seals around the bottom of the cylinder compression rings and one oil control ring. All the
liner make a seal between the cylinder liner and the rings are located above the piston pin bore. Oil is
cylinder block. A sealing compound is applied under removed from the wall of the cylinder and returns to
the cylinder liner flange. This makes a seal between the crankcase through holes in the oil control ring
the top of the cylinder liner and the cylinder block. groove.

The engine has a separate cylinder head for each The pistons should be checked regularly for wear or
cylinder. Two inlet valves and two exhaust valves, damage. Check that the piston rings are free to move
which are controlled by a pushrod valve system, are in the grooves and that the rings are not broken. The
used for each cylinder. Valve guides without clearance of the piston ring should be inspected
shoulders are pressed into the cylinder heads. The regularly. Remove the piston rings and clean the
opening for the unit injector is located between the grooves. Discard the piston rings. Install new piston
four valves. A lobe on the camshaft moves the rings in the piston grooves. Check the clearance for
pushrod that operates the unit injector. Fuel is the piston ring by inserting a suitable feeler gauge
injected directly into the cylinder. between the piston groove and the top of piston ring.
Refer to Specifications, “Piston and Rings” for the
Coolant goes out of the cylinder block and into the dimensions. Use a suitable feeler gauge to measure
cylinder head through four openings in each cylinder the piston ring gap. Refer to Specifications, “Piston
head face. Water seals are used in each opening to and Rings” for the dimensions.
prevent coolant leakage. O-rings seal the engine oil
drain line between the cylinder head and the cylinder The connecting rod has a taper on the pin bore end.
block. This taper gives the rod and the piston more strength
in the areas with the most load. Two bolts hold the
rod cap to the rod. The connecting rod bearing caps
are matched to the connecting rod and must not be
interchanged. There are different weight bands for
the connecting rods. Ensure that the different weight
bands are taken into account when installing
replacement parts.
M0064276 11
Basic Engine

Measure the bores in the connecting rod and ensure

that the bores meet the diameters according to the
correct specifications. When the connecting rod is
installed, follow the instructions for tightening the
bolts. Refer to Specifications, “Connecting Rod”.

i06512670

Crankshaft

The crankshaft changes the combustion forces in the

cylinder into usable rotating torque. A vibration
damper is used at the front of the crankshaft to
reduce torsional vibrations (twist) that can damage
the engine.
The crankshaft drives a group of gears that are on
the front of the engine. The gear group drives the oil
pump, the camshaft, the fuel transfer pump via the oil
pump, the water pump, and the auxiliary drives.
Seals are used at both ends of the crankshaft. The
seals are replaceable. Pressurized oil is supplied to
all main bearings through drilled holes in the webs of
the cylinder block. The oil then flows through drilled
holes in the crankshaft to provide oil to the
connecting rod bearings. The crankshaft is held in
place by nine main bearings. A thrust washer is
installed on either side of the rear main bearing. This
controls the end play of the crankshaft.

Note: The balance weights that are on the crankshaft

must not be removed. If a balance weight needs to
be replaced, the crankshaft must be returned to
Perkins.

i06512671

Camshaft

There is one camshaft that runs through the cylinder

block. The camshaft is supported by nine bearings.
Oil is fed to the camshaft bearings from the main
gallery through the cylinder block. The camshaft is
driven by the gear group in a clockwise direction
viewed from the flywheel end.
As the camshaft turns, each lobe moves a lifter.
There are three lifters for each cylinder. Each outside
lifter moves a pushrod and two inlet valves or two
exhaust valves. The center lifter moves a pushrod
that operates the fuel injector.
The camshaft must be in time with the crankshaft.
The relation of the camshaft lobes to the crankshaft
position causes the valves and fuel injectors in each
cylinder to operate at the correct time relative to the
piston stroke.
12 M0064276
Electrical System

Electrical System

i02692982

Electrical System

The electrical system may have a charging circuit.

The electrical system will have a starting circuit, and
a low amperage circuit. Some of the electrical system
components are used in more than one circuit.
The charging circuit is in operation when the engine
is running. The alternator for charging the battery (if
equipped) makes electricity for the charging circuit.
An internal voltage regulator in the alternator controls
the electrical output in order to keep the battery at a
full charge.
The starting circuit is in operation only when the start
switch is activated.

Charging System Components

M0064276 13
Electrical System

Alternator

Illustration 3 g01357159
Alternator
(1) Slip rings (3) Stator (5) Brush assembly
(2) Fan (4) Rotor

The alternator is a three-phase charging unit that

contains an integral voltage regulator. The alternator
is driven from a notched auxiliary drive belt.
14 M0064276
Electrical System

Starting System Components

M0064276 15
Electrical System

Starting Motor

Illustration 4 g01357162

(1) Field (4) Pinion (7) Armature

(2) Solenoid (5) Commutator
(3) Clutch (6) Brush assembly

The starting solenoid (2) is an electromagnetic switch When two sets of solenoid windings are used, the
that performs the following basic operations: windings are called the hold-in winding and the pull-in
winding. Both sets of windings have the same
• The starting solenoid (2) closes the high current number of turns around the cylinder, but the pull-in
starting motor circuit with a low current start switch winding uses a wire with a larger diameter. The wire
circuit. with a larger diameter produces a greater magnetic
field (1). When the start switch is closed, part of the
• The starting solenoid (2) engages the pinion of the current flows from the battery through the hold-in
starting motor (4) with the ring gear. windings. The rest of the current flows through the
pull-in windings to the motor terminal. The current
Solenoid (2) has windings (one or two sets) around a then flows through the motor to ground. Solenoid (2)
hollow cylinder. A plunger that is spring loaded is is fully activated when the connection across the
inside the cylinder. The plunger can move forward battery and the motor terminal is complete. When
and backward. When the start switch is closed and solenoid (2) is fully activated, the current is shut off
electricity is sent through the windings, a magnetic through the pull-in windings. At this point, only the
field (1) is made. The magnetic field (1) pulls the smaller hold-in windings are in operation. The hold-in
plunger forward in the cylinder. This moves the shift windings operate for the duration of time that is
lever in order to engage the pinion drive gear with the required in order to start the engine. Solenoid (2) will
ring gear. The front end of the plunger then makes now draw less current from the battery, and the heat
contact across the battery and motor terminals of that is generated by solenoid (2) will be kept at an
solenoid (2). Next, the starting motor begins to turn acceptable level.
the flywheel of the engine.
When the start switch is opened, current no longer
flows through the windings. The spring now pushes
the plunger back to the original position. At the same
time, the spring moves the pinion gear away from the
flywheel.
16 M0064276
Electronic Control System

Testing And Adjusting

Section

Electronic Control System

i02857716

Engine Governing - Adjust

The engine is governed by the Pandaros Digital

Governor. In order to make adjustments to the
Pandaros Digital Governor, refer to Special
Instruction, REHS2806, “Pandoras Digital Governor”
for more information.
M0064276 17
Fuel System

Fuel System 4. Inspect the pressure valve on the fuel return rail.

i02990052

Checking Engine Cylinders

i06551648

General Information (Fuel

When the engine is under load, the temperature of an
System) exhaust manifold port can indicate the condition of a
fuel injector. Low temperature at an exhaust manifold
(Diesel) port is an indication of no fuel to the cylinder. This
can possibly indicate an injector with a defect or a
problem with the control system. An extra high
Either too much fuel or not enough fuel for temperature at an exhaust manifold port can indicate
combustion can be the result of a problem in the fuel too much fuel to the cylinder. High temperatures may
system. Work is often done on the fuel system when also be caused by an injector with a defect.
the problem is really with some other part of the
engine. Finding the cause of the problem can be
difficult, especially when smoke comes from the
exhaust. Smoke that comes from the exhaust can be
caused by a faulty fuel injector. Smoke can also be
caused by one or more of the reasons that follow:

• Not enough air for good combustion

• An overload at high altitudes (if applicable)

• Oil leakage into combustion chamber

• Air inlet and exhaust leaks

• Not enough compression

i02953018

Fuel System Inspection

A problem with the components that supply fuel to

the engine can cause low fuel pressure. This can
decrease engine performance.
1. Check the fuel level in the fuel tank. Look at the
cap for the fuel tank. Make sure that the vent is not
filled with debris.
2. Check the fuel lines for fuel leakage. Be sure that
none of the fuel lines have a restriction or a faulty
bend.
3. Install new main fuel filters.
18 M0064276
Air Inlet and Exhaust System

Air Inlet and Exhaust

System

i06512664

Valve Lash - Adjust

Table 1

Required Tools
Illustration 5 g01359594
Tool Part Number Part Name Qty
Eight cylinder engine
A SE253 Crankshaft Turning Tool 1 (A) Inlet valve
(B) Exhaust valve
B - Feeler gauge 1
Ensure that all power is disconnected to the engine.

NOTICE
Only qualified service personel should perform this
maintenance. Refer to the Service Manual or your au-
thorized Perkins dealer or your Perkins distributor for
the complete valve lash adjustment procedure.
Operation of Perkins engines with incorrect valve
lash can reduce engine efficiency, and also reduce
engine component life.

Ensure that the engine cannot be started while

this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
Illustration 6 g01241573
to turn the flywheel.
Typical example
Hot engine components can cause burns. Allow
additional time for the engine to cool before 1. Remove the capscrews (1).
measuring/adjusting valve lash clearance.
2. Remove the rocker cover (2).

Note: The valve bridges must be set before the 3. Remove the joint (not shown).
valve lash is adjusted. 4. Repeat steps 1 through 3 for the remaining rocker
covers.
For 4008-30 engine, set the valve lash in the
sequence that is shown in the table 2 .
Table 2
Eight cylinder engine

Set the bridge adjustment and set valve

Top Center Position Engine cylinder with valves on the rock
lash.
1-8 8 1
4-5 5 4

(continued)
M0064276 19
Air Inlet and Exhaust System

(Table 2, contd)
2-7 2 7
3-6 3 6
1-8 1 8
4-5 4 5
2-7 7 2
3-6 6 3

Illustration 7 g06006364
Typical example

5. Remove the blanking plug in the flywheel housing.

Use Tooling (A) to rotate the crankshaft until the
appropriate mark (4) on the flywheel is in
alignment with the pointers (3). Ensure that there Illustration 8 g01241584
is clearance between the rocker arm and the Typical example
bridgepiece.
6. Loosen the locknut (7) on the inlet valve bridge.
Note: The timing window is located in the flywheel
housing. 7. Hold the top edge of the bridge piece (5). Turn the
adjuster screw (6) down until it contacts the valve.
Note: When the contact is made with the valve, the
valve must not move. Only the gap between the valve
tip and the bridge piece must be removed.

8. Tighten the locknut (7) to a torque of 50 N·m

(37 lb ft).
9. Repeat steps 6 through 8 for the exhaust valve
bridge.
20 M0064276
Air Inlet and Exhaust System

Illustration 10 g01241917
Typical example

12. Ensure the rocker cover (2) is clean and free from
damage. Ensure the joint face of the rocker base
(10) is clean and free from damage.
Illustration 9 g01241598
13. Install a new joint (not shown).
Typical example
14. Install the rocker cover (2).
10. Use Tooling (B) to check the valve lash. If
15. Install the capscrews (1). Tighten the capscrews
necessary, follow steps 10.a through 10.f to adjust
to a torque of 4 N·m (35 lb in).
the valve lash. Set the valve lash to 0.4 mm
(0.016 inch). 16. Repeat steps 12 through 15 for the remaining
rocker covers.
a. Loosen the locknut (9) on the rocker arm of
the inlet valve. i02863396

b. Use Tooling (B) to set the valve lash. Turbocharger

c. Turn the adjuster (8) until the pad on the
rocker arm is in contact with Tooling (B).

d. Tighten the locknut (7) to a torque of 50 N·m

(37 lb ft).
Hot engine components can cause injury from
e. Ensure that the valve lash is correct. burns. Before performing maintenance on the en-
gine, allow the engine and the components to
f. Repeat step 10 for the rocker arm of the cool.
exhaust valve.
11. Repeat steps 5 through 10 for the remaining
rockers.
Personal injury can result from rotating and mov-
ing parts.
Stay clear of all rotating and moving parts.
Never attempt adjustments while the machine is
moving or the engine is running unless otherwise
specified.
The machine must be parked on a level surface
and the engine stopped.
M0064276 21
Air Inlet and Exhaust System

4. Inspect the compressor and the compressor wheel

NOTICE
Keep all parts clean from contaminants. housing for oil leakage. An oil leak from the
compressor may deposit oil in the aftercooler.
Contaminants may cause rapid wear and shortened Drain and clean the aftercooler if you find oil in the
component life. aftercooler.
a. Check the oil level in the crankcase. If the oil
NOTICE level is too high, adjust the oil level.
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- b. Inspect the air cleaner element for restriction.
nance, testing, adjusting and repair of the product.
If restriction is found, correct the problem.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids. c. Inspect the engine crankcase breather. Clean
the engine crankcase breather or replace the
Dispose of all fluids according to local regulations engine crankcase breather if the engine
and mandates. crankcase breather is plugged.
Before you begin inspection of the turbocharger, be d. Remove the oil drain line for the turbocharger.
sure that the inlet air restriction is within the Inspect the drain opening. Inspect the oil drain
specifications for your engine. Be sure that the
exhaust system restriction is within the specifications line. Inspect the area between the bearings of
for your engine. Refer to Systems Operation, Testing the rotating assembly shaft. Look for oil
and Adjusting, “Air Inlet and Exhaust System - sludge. Inspect the oil drain hole for oil sludge.
Inspect”. Inspect the oil drain line for oil sludge in the
drain line. If necessary, clean the rotating
The condition of the turbocharger will have definite
effects on engine performance. Use the following assembly shaft. If necessary, clean the oil
inspections and procedures to determine the drain hole. If necessary, clean the oil drain
condition of the turbocharger. line.

• Inspection of the Compressor and the Compressor e. If Steps 4.a through 4.d did not reveal the
Housing source of the oil leakage, the turbocharger has
internal damage. Replace the turbocharger.
• Inspection of the Turbine Wheel and the Turbine
Housing Inspection of the Turbine Wheel
Inspection of the Compressor and and the Turbine Housing
Remove the air piping from the turbine housing.
the Compressor Housing
Remove air piping from the compressor inlet.
1. Inspect the compressor wheel for damage from a
foreign object. If there is damage, determine the
source of the foreign object. As required, clean the
inlet system and repair the intake system. Replace
the turbocharger. If there is no damage, go to Step
3.
2. Clean the compressor wheel and clean the
compressor housing if you find buildup of foreign
material. If there is no buildup of foreign material,
go to Step 3.
3. Turn the rotating assembly by hand. While you turn
the assembly, push the assembly sideways . The
assembly should turn freely. The compressor
wheel should not rub the compressor housing.
Replace the turbocharger if the compressor wheel
rubs the compressor wheel housing. If there is no
rubbing or scraping, go to Step 4.
22 M0064276
Air Inlet and Exhaust System

oil sludge. If necessary, clean the rotating

assembly shaft. If necessary, clean the drain
opening. If necessary, clean the drain line.

b. If crankcase pressure is high, or if the oil drain

is restricted, pressure in the center housing
may be greater than the pressure of turbine
housing (1). Oil flow may be forced in the
wrong direction and the oil may not drain.
Check the crankcase pressure and correct
any problems.

c. If the oil drain line is damaged, replace the oil

drain line.
d. Check the routing of the oil drain line.
Eliminate any sharp restrictive bends. Make
sure that the oil drain line is not too close to
the engine exhaust manifold.

e. If Steps 4.a through 4.d did not reveal the

Illustration 11 g00763164 source of the oil leakage, turbocharger (3) has
Typical example internal damage. Replace turbocharger (3).
(1) Turbine Housing
(2) Turbine Wheel
(3) Turbocharger

1. Inspect the turbine for damage by a foreign object.

If there is damage, determine the source of the
foreign object. Replace turbocharger (3). If there is
no damage, go to Step 2.
2. Inspect turbine wheel (2) for buildup of carbon and
other foreign material. Inspect turbine housing (1)
for buildup of carbon and foreign material. Clean
turbine wheel (2) and clean turbine housing (1) if
you find buildup of carbon or foreign material. If
there is no buildup of carbon or foreign material,
go to Step 3.
3. Turn the rotating assembly by hand. While you turn
the assembly, push the assembly sideways. The
assembly should turn freely. Turbine wheel (2)
should not rub turbine wheel housing (1). Replace
turbocharger (3) if turbine wheel (2) rubs turbine
housing (1). If there is no rubbing or scraping, go
to Step 4.
4. Inspect the turbine and turbine housing (1) for oil
leakage. Inspect the turbine and turbine housing
(1) for oil coking. Some oil coking may be cleaned.
Heavy oil coking may require replacement of the
turbocharger. If the oil is coming from the
turbocharger center housing go to Step 4.a.

a. Remove the oil drain line for the turbocharger.

Inspect the drain opening. Inspect the area
between the bearings of the rotating assembly
shaft. Look for oil sludge. Inspect the oil drain
hole for oil sludge. Inspect the oil drain line for
M0064276 23
Lubrication System

Lubrication System

i06515918

General Information
(Lubrication System)

The following problems generally indicate a problem

in the lubrication system of the engine.
• Excessive consumption of engine oil

• Low engine oil pressure

• High engine oil pressure

• Excessive bearing wear

i02693002

Engine Oil Pressure - Test

Table 3

Required Tools

Tool Part Number Part Description Qty

- Pressure Gauge 1
A Connector
- 1/4 inch BSP 1

Tooling (A) measures the engine oil pressure in the

system.
1. Ensure that the engine is filled to the correct level
with the correct engine oil. Refer to Operation and
Maintenance Manual, “Refill Capacities” for further
information and refer to Operation and
Maintenance Manual, “Fluid Recomendations” for
further information. If any other viscosity of oil is
used, the information in Table 4 cannot be used.
24 M0064276
Lubrication System

Illustration 12 g01371843
Pressure test location
(1) Location for the pressure test

2. Connect the Tooling (A) to location (1) on the Note: A record of engine oil pressure can be used as
engine oil filter housing. an indication of possible engine problems or damage.
A sudden change of 70 kPa (10 psi) in the engine oil
3. Operate the engine. When the engine oil has pressure may indicate a problem. Inspect the engine
achieved a temperature of 99 °C (210 °F), read and correct the problem.
the pressure gauge and record the pressure.
i02693004
4. Refer to Table 4 in order to determine if the engine
oil pressure is acceptable.
Table 4
Excessive Bearing Wear -
Engine Oil Pressure
Inspect
Test RPM Minimum Permissible Pressure
1500 250 kPa (36 psi) When some components of the engine show bearing
wear in a short time, the cause can be a restriction in
If the engine oil pressure is low, determine the a passage for engine oil.
cause and correct the condition. Otherwise,
engine failure or a reduction in engine service life
can result.
5. Compare the recorded engine oil pressure with the
engine oil pressure indicator on the instrument
panel.
A faulty engine oil pressure indicator or a faulty
sensor can provide false indications of low engine
oil pressure or high engine oil pressure. If there is
a notable difference between the engine oil
pressure readings, determine the cause.
M0064276 25
Lubrication System

An engine oil pressure indicator may show that there Excessive consumption of engine oil can also result if
is enough engine oil pressure, but a component is engine oil with the wrong viscosity is used.
worn due to a lack of lubrication. In such a case, look
at the passage for the engine oil supply to the i02693006
component. A restriction in an engine oil supply
passage will not allow enough lubrication to reach a
component. This will result in early wear. Increased Engine Oil
Temperature - Inspect
i02693005

Excessive Engine Oil If the engine oil temperature is higher than normal,
Consumption - Inspect the engine oil cooler may have a restriction. Look for
a restriction in the passages for engine oil in the
engine oil cooler. The engine oil pressure will not
necessarily decrease due to a restriction in the
engine oil cooler.
Engine Oil Leaks on the Outside of
the Engine Make sure that the cooling system is operating
properly. A high coolant temperature in the engine oil
Check for leakage at the seals at each end of the cooler will cause high engine oil temperature.
crankshaft. Look for leakage at the gasket for the
engine oil pan and all lubrication system connections. i02693007
Look for any engine oil that may be leaking from the
crankcase breather. This can be caused by Engine Oil Pressure is Low
combustion gas leakage around the pistons. A dirty
crankcase breather will cause high pressure in the
crankcase. A dirty crankcase breather will cause the
gaskets and the seals to leak.
NOTICE
Engine Oil Leaks into the Keep all parts clean from contaminants.
Combustion Area of the Cylinders Contaminants may cause rapid wear and shortened
Engine oil that is leaking into the combustion area of component life.
the cylinders can be the cause of blue smoke. There
are several possible ways for engine oil to leak into
the combustion area of the cylinders: NOTICE
Care must be taken to ensure that fluids are con-
• Leaks between worn valve guides and valve tained during performance of inspection, mainte-
stems nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
• Worn components or damaged components ers before opening any compartment or disassem-
(pistons, piston rings, or dirty return holes for the bling any component containing fluids.
engine oil)
Dispose of all fluids according to local regulations
• Incorrect installation of the compression ring and/ and mandates.
or the intermediate ring
The following conditions can cause an indication of
• Leaks past the seal rings in the turbocharger shaft low engine oil pressure:

• Overfilling of the crankcase • Low engine oil level

• Wrong dipstick or guide tube • Problem with the engine oil pressure gauge

• Sustained operation at light loads • Contaminated engine oil

• Improper circulation of the engine oil

• Worn components
26 M0064276
Lubrication System

Low Engine Oil Level • There is a problem with the engine oil pump.
Check the gears of the engine oil pump for
Check the engine oil level. If the engine oil level is too excessive wear. Engine oil pressure is reduced
far below the suction tube, the engine oil pump
when gears in the engine oil pump have too much
cannot supply enough lubrication for the engine
components. If the engine oil level is low, add engine wear.
oil in order to obtain the correct level. For the correct
engine oil to use, refer to Operation and Maintenance NOTICE
Manual, “Refill Capacities” and Operation and Perkins oil filters are manufactured to Perkins specifi-
Maintenance Manual, “Fluid Recommendations”. cations. Use of an oil filter that is not recommended
by Perkins could result in severe damage to the en-
Engine Oil Pressure Gauge gine bearings, crankshaft, etc., as a result of the larg-
er waste particles from unfiltered oil entering the
Refer to Testing and Adjusting, “Engine Oil Pressure engine lubricating system. Only use oil filters recom-
- Test”. If the engine oil pressure gauge is incorrect, mended by Perkins.
install a new gauge.

Contaminated Engine Oil Worn Components

Engine oil that is contaminated with another liquid will Excessive clearance at the crankshaft or camshaft
cause low engine oil pressure. High engine oil level bearings will cause low engine oil pressure. Also,
can be an indication of contamination. Determine the inspect the clearance between the rocker arm shafts
reason for contamination of the engine oil and make and the rocker arms. Check the engine components
the necessary repairs. Change the engine oil and the for excessive clearance.
engine oil filters. For the correct engine oil to use,
refer to Operation and Maintenance Manual, “Fluid i02693008
Recommendations”.

Improper Circulation of the Engine Engine Oil Pressure is High

Oil
Several factors could cause improper circulation of
the engine oil: NOTICE
Keep all parts clean from contaminants.
• The engine oil filters are clogged. Replace the
engine oil filters. Contaminants may cause rapid wear and shortened
component life.
• A line or a passage for the engine oil is
disconnected or broken. Replace the line or clear
the passage. NOTICE
Care must be taken to ensure that fluids are con-
• The engine oil cooler is clogged. Thoroughly clean tained during performance of inspection, mainte-
the engine oil cooler. nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
• There is a problem with a piston cooling jet. The ers before opening any compartment or disassem-
piston cooling jets direct engine oil toward the bling any component containing fluids.
bottom of the pistons in order to cool the pistons.
This also provides lubrication for the piston pin. Dispose of all fluids according to local regulations
Breakage, a restriction, or incorrect installation of and mandates.
a piston cooling jet will cause seizure of the piston. Engine oil pressure will be high if the engine oil
• The inlet screen of the suction tube for the engine bypass valves become stuck in the closed position
and the engine oil flow is restricted. Foreign matter in
oil pump can have a restriction. This restriction the engine oil system could be the cause for the
can cause cavitation and a loss of engine oil restriction of the oil flow and the movement of the
pressure. Check the inlet screen on the suction engine oil bypass valves. If the engine oil bypass
tube and remove any material that may be valves are stuck in the closed position, remove each
restricting engine oil flow. bypass valve and clean each bypass valve in order to
correct this problem. You must also clean each
• The suction tube is drawing in air. Check the joints bypass valve bore. Install new engine oil filters. New
of the suction tube for cracks or a damaged O-ring engine oil filters will prevent more debris from
seal. causing this problem. For information on the repair of
the engine oil filter bypass valve, refer to
Disassembly and Assembly, “Engine Oil Filter Base -
Disassemble”.
M0064276 27
Lubrication System

NOTICE
Perkins oil filters are manufactured to Perkins specifi-
cations. Use of an oil filter that is not recommended
by Perkins could result in severe damage to the en-
gine bearings, crankshaft, etc., as a result of the larg-
er waste particles from unfiltered oil entering the
engine lubricating system. Only use oil filters recom-
mended by Perkins.
28 M0064276
Cooling System

Cooling System When the engine is overloaded, the engine will run in
the lug condition. When the engine is running in the
lug condition, the engine is operating at a lower
engine rpm that reduces the coolant flow. Decreased
coolant flow during high load will cause overheating.
i02857803
Coolant can be lost by leaks. Overheated coolant can
be lost through the cooling system's pressure relief
General Information (Cooling valve. Lower coolant levels contribute to additional
overheating. Overheating can result in conditions
System) such as cracking of the cylinder head and piston
seizure.
A cracked cylinder head or cylinder liner will force
This engine has a type of cooling system that is exhaust gas into the cooling system. The additional
pressurized. The cooling system has two pressure causes coolant loss, cavitation of the water
advantages. pump, less circulation of coolant, and further
overheating.
• The pressure helps prevent cavitation.
Overcooling is the result of coolant that bypasses the
• The risk of boiling is reduced. water temperature regulators and flows directly to the
radiator or to the heat exchanger. Low load operation
The boiling point is affected by three factors: in low ambient temperatures can cause overcooling.
pressure, altitude and concentration of glycol in the Overcooling is caused by water temperature
coolant. The boiling point of a liquid is increased by regulators that remain open. Overcooling reduces the
pressure. The boiling point of a liquid is decreased by efficiency of operation. Overcooling enables more
a higher altitude. Illustration 13 shows the effects of rapid contamination of the engine oil. This results in
pressure and altitude on the boiling point of water. the formation of sludge in the crankcase and carbon
deposits on the valves.
Cycles of rapid heating and cooling can result in
cracked cylinder heads, gasket failure, accelerated
wear, and excessive fuel consumption.
If a problem with the cooling system is suspected,
perform a visual inspection before you perform any
tests on the system.

Pressure Test on the Oil Cooler

Table 5
Required Tools

Tool Part Number Part Description Qty

Illustration 13 g00286266
A - Pressure Gauge 1
The boiling point of the coolant also depends on the
type of coolant and the concentration of glycol. A
greater concentration of glycol has a higher boiling
temperature. However, glycol transfers heat less
effectively than water. Because of the boiling point
and the efficiency of heat transfer, the concentration
of glycol is important.
Three basic problems can be associated with the
cooling system:

• Overheating
• Coolant loss
• Overcooling
If the cooling system is not properly maintained,
solids such as scale and deposits reduce the ability
of the cooling system to transfer heat. The engine
operating temperature will increase.
M0064276 29
Cooling System

2. Look for leaks in the system.

3. Look for bent core fins or debris between the fins
of the radiator (if equipped). Be sure that air flow
through the radiator is not restricted.
4. Check for damage to the fan blades (if equipped).
5. After the engine is cool, remove the filler cap
slowly. This will allow any pressure out of the
cooling system. Inspect the filler cap and the
surface that seals the cap. This surface must be
clean and the seal must not be damaged.
6. Check the pressure relief valve. Contact your OEM
for further information.

i06551650

Water Temperature Regulator -

Test
Illustration 14 g01426580
Typical example

1. Make a blanking plate (1). Make a blanking plate

with a connection for an air pipe. Personal injury can result from hot coolant,
2. Fill the oil cooler with clean hot water until the steam and alkali.
water is level within the outlet flange. At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
3. Install new joints to blanking plates (1) and (3). heaters or the engine contain hot coolant or
Install blanking plates (1) and (3) to the oil cooler. steam. Any contact can cause severe burns.
4. Connect compressed air to the oil cooler. Use Remove filler cap slowly to relieve pressure only
Tooling (A). Set the pressure at 345 kPa (50 psi). when engine is stopped and radiator cap is cool
The pressure should stay constant for three enough to touch with your bare hand.
minutes.
Cooling System Conditioner contains alkali.
i02858317
Avoid contact with skin and eyes.

Visual Inspection Note: This information only applies to engine-

mounted fresh water temperature regulators.

Cooling systems that are not regularly inspected are 1. Remove the water temperature regulator from the
a cause for increased engine temperatures. Make a engine.
visual inspection of the cooling system before a test 2. Heat the coolant gradually in a suitable container.
is made with test equipment.
3. Hang the water temperature regulator in the
container of coolant. The water temperature
regulator must be below the surface of the coolant
Pressurized System: Hot coolant can cause seri- and away from the sides and the bottom of the
ous burns. To open the cooling system filler cap, container.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system 4. Keep the coolant at the correct temperature for 10
pressure cap slowly in order to relieve the minutes. The opening temperature of the water
pressure. temperature regulator is 84° C (183° F).
5. After 10 minutes, remove the water temperature
1. Check the coolant level in the cooling system.
regulator. Ensure that the valve on the water
Read the two indicators for the coolant level in the
temperature regulator is fully open.
top of the radiator (if equipped).
30 M0064276
Cooling System

Replace the water temperature regulator if the

valve on the water temperature regulator is not
open at the specified temperature. Refer to
Operation and Maintenance Manual, “Water
Temperature Regulator - Replace” for further
information.
M0064276 31
Basic Engine

Basic Engine 3. The top deck of the cylinder block must not be
machined. This will affect the depth of the cylinder
liner flange and the piston height above the
cylinder block.
i02857720 4. Check the front camshaft bearing for wear. Refer
to Specifications, “Camshaft Bearings” for the
Connecting Rod Bearings correct specification of the camshaft bearing. If a
new bearing is needed, use a suitable adapter to
press the bearing out of the bore. Ensure that the
Before you install the piston and piston pin, measure oil hole in the new bearing faces the front of the
the bore in the piston pin bearing. Before you install block. The oil hole in the bearing must be aligned
the connecting rod, measure the bore in the bearing with the oil hole in the cylinder block. The bearing
for the crankshaft. The bores must be within must be aligned with the face of the recess.
specifications or the bearings will not fit properly. This
will cause wear and damage to the connecting rod,
i06516674
the bearing for the piston pin, the bearing for the
crankshaft, the piston pin, and the crankshaft.
Cylinder Head
After the bearings are installed, measure the bores in
the bearings. Refer to Specifications, “Connecting
Rod” for the correct measurements.
1. Visually examine the valve face for damage (1).
The length of a connecting rod can be altered by use. Examine the valve stem for score marks, wear, or
After the bearings are installed, measure the distance
from the center of the piston pin bearing to the center damage near the groove for the valve keepers (3).
of the crankshaft bearing. Refer to Specifications,
“Connecting Rod” for the correct measurements.
Connecting rod bearings are available with 0.25 mm
(0.0010 inch) and 0.51 mm (0.020 inch) smaller
inside diameter than the original size bearing. These
bearings are for crankshafts that have been ground.

i02859895

Main Bearings

Main bearings are available with an inside diameter

that is 0.25 mm (0.010 inch) or 0.51 mm
(0.020 inch) smaller than the inside diameter of the
original bearings. These bearings are for crankshafts
that have been ground. Refer to Specifications,
“Connecting Rod” for further information.
If necessary, replace the main bearings. Refer to
Disassembly and Assembly, “Crankshaft Main
Bearings - Remove and Install” for the correct
procedure.

i02862425

Cylinder Block
Illustration 15 g01425719
Typical example
1. Clean all of the coolant passages and the oil
passages. 2. Check the dimension of the valve stem (2). Refer
to Specifications, “Cylinder Head Valves”.
2. Check the cylinder block for cracks and damage.
32 M0064276
Basic Engine

3. If the valve is within the service limit but with slight

damage to the valve face (1), the valve can be
refaced at an angle of 20 degrees (4).
Note: If the dimension (5) is less than 1 mm
(0.04 inch) after refacing, the valve must be
discarded.

Illustration 17 g01425720

Illustration 16 g01425718 Typical example

Typical example
2. Support the cylinder head on two blocks of wood
1. Install a valve into the cylinder head. Use a straight (8). Install the valve into the cylinder head. Hold
edge (6) to check the valve depth. If the depth the valve seat so the valve seat protrudes 10 mm
exceeds 1 mm (0.040 inch) (7) the valve must be (0.40 inch) from the surface of the cylinder head
replaced. (9). Use a straight edge (10) and check the
clearance between the valve and valve guide. If
the clearance exceeds 0.5 mm (0.02 inch) the
valve guide must be replaced.
3. Check the free length of the valve spring. If the
valve spring is less than 55.6 mm (2.2 inch), the
valve spring must be replaced.

Inspection and Pressure Test

1. Remove the valves and springs.

Note: Do not scratch any machined surface on the

cylinder head.

2. Clean the carbon deposits from the cylinder head

and the ports of the cylinder head.
3. Wash the cylinder head with a solvent. The solvent
must be used in accordance with the instructions
of the manufacturer. Use compressed air to dry
the cylinder head.
4. Test the cylinder head for leaks.
M0064276 33
Basic Engine

5. When the cylinder head is thoroughly clean, check Bore Runout (Radial Eccentricity)
the cylinder head for cracks. Inspect the area of the Flywheel
around the valve seats. Check around the hole for
the fuel injector. Table 7
Required Tools
i02693029
Tool Part Number Part Description QTY

Flywheel - Inspect A 21825617 Dial Indicator Group 1

Face Runout (Axial Eccentricity) of

the Flywheel
Table 6
Required Tools

Tool Part Number Part Description QTY

A 21825617 Dial Indicator Group 1

Illustration 19 g01377841
Typical example for checking the bore runout of the
flywheel
(1) Dial indicator group

Illustration 18 g00812156 1. Install Tooling (A). Make an adjustment of Tooling

Typical example for checking face runout of the (A) so the dial indicator makes contact on the
flywheel flywheel.
(1) Dial indicator group
2. Set the dial on Tooling (A) to read zero.
1. Refer to Illustration 18 and install Tooling (A). 3. Turn the flywheel at intervals of 90 degrees and
Always put a force on the crankshaft in the same read the dial.
direction before the dial indicator is read. This will
remove any crankshaft end clearance. 4. Take the measurements at all four points. The
difference between the lower measurements and
2. Set the dial on Tooling (A) to read zero. the higher measurements that are performed at all
3. Turn the flywheel at intervals of 90 degrees and four points must not be more than the following
read the dial. values for the maximum permissible bore runout
(radial eccentricity) of the flywheel.
4. Take the measurements at all four points. The
difference between the lower measurements and
the higher measurements that are performed at all
four points must not be more than 0.13 mm
(0.005 inch), which is the maximum permissible
face runout (axial eccentricity) of the flywheel.
34 M0064276
Basic Engine

Maximum flywheel bore runout

. . . . . . . . . . . . . . . . . . . . . . . . 0.13 mm ((0.005 inch))

i02858320

Flywheel Housing - Inspect

Table 8

Required Tools

Tool Part Number Part Description Qty

A 21825617 Dial Indicator Group 1

Illustration 21 g00285932

Face Runout (Axial Eccentricity) Of Checking face runout of the flywheel housing
The Flywheel Housing 3. Turn the flywheel while the dial indicator is set at
0.0 mm (0.00 inch) at location (A). Read the dial
indicator at locations (B), (C) and (D).
4. The difference between the lower measurements
and the higher measurements that are performed
at all four points must not be more than 0.38 mm
(0.015 inch), which is the maximum permissible
face runout (axial eccentricity) of the flywheel
housing.

Bore Runout (Radial Eccentricity)

Of The Flywheel Housing

Illustration 20 g00285931
Checking face runout of the flywheel housing

If you use any other method except the method that

is given here, always remember that the bearing
clearance must be removed in order to receive the
correct measurements.
1. Fasten a dial indicator to the flywheel so the anvil
of the dial indicator will contact the face of the
flywheel housing.
2. Put a force on the crankshaft toward the rear
before the dial indicator is read at each point.
Illustration 22 g00285934
Checking bore runout of the flywheel housing

1. Fasten a dial indicator to the flywheel so the anvil

of the dial indicator will contact the bore of the
flywheel housing.
M0064276 35
Basic Engine

7. Turn the flywheel counterclockwise in order to put

the dial indicator at position (D). Write the
measurement in the chart.
8. Add the lines together in each column.
9. Subtract the smaller number from the larger
number in column B and column D. Place this
number on line III. The result is the horizontal
eccentricity (out of round). Line III in column C is
the vertical eccentricity.

Illustration 23 g00285936

2. While the dial indicator is in the position at location

(C) adjust the dial indicator to 0.0 mm (0.00 inch).
Push the crankshaft upward against the top of the
bearing. Refer to the illustration 23 . Write the
measurement for bearing clearance on line 1 in
column (C).

Note: Write the measurements for the dial indicator

with the correct notations. This notation is necessary
for making the calculations in the chart correctly.

3. Divide the measurement from Step 2 by two. Write

this number on line 1 in columns (B) and (D).
4. Turn the flywheel in order to put the dial indicator
at position (A). Adjust the dial indicator to 0.0 mm
(0.00 inch). Illustration 25 g00286046
Graph for total eccentricity
(1) Total vertical eccentricity
(2) Total horizontal eccentricity
(3) Acceptable value
(4) Unacceptable value

10. On the graph for total eccentricity, find the point of

intersection of the lines for vertical eccentricity and
horizontal eccentricity.
11. The bore is in alignment, if the point of
intersection is in the range that is marked
“Acceptable”. If the point of intersection is in the
range that is marked “Not acceptable”, the
flywheel housing must be changed.

Illustration 24 g00285932
i02995981
Checking bore runout of the flywheel housing
Crankshaft Thrust - Measure
5. Turn the flywheel counterclockwise in order to put
the dial indicator at position (B). Write the
measurements in the chart. Table 9
6. Turn the flywheel counterclockwise in order to put Required Tools
the dial indicator at position (C). Write the
Tool Part Number Part Description QTY
measurement in the chart.
A 21825617 Dial Indicator Group 1
36 M0064276
Basic Engine

A thrust washer is installed on either side of the rear If the fluid leak is engine oil, inspect the crankshaft
main bearing. This controls the end play of the seals for leaks. If a leak is observed, replace the
crankshaft. crankshaft seals.
Force the crankshaft toward the front of the engine Inspect the damper. Replace the damper for any of
and back to the rear of the engine. the following reasons:
• The damper has been dropped.

• The damper has been subject to an impact.

• The damper is dented, cracked, or leaking.
• The paint on the damper is discolored from heat.

• The engine has had a failure because of a broken

crankshaft.

• Analysis of the engine oil has revealed that the

front main bearing is badly worn.
• There is a large amount of gear train wear that is
not caused by a lack of engine oil.

Illustration 26 g01519076
Typical example

1. Check the end play of the crankshaft with Tooling

(A).
2. To check the tolerance of the crankshaft end play,
refer to Specifications, “Crankshaft”.

i06554414

Vibration Damper

The damper is mounted to the crankshaft on the front

of the engine. Damage to the damper will increase
torsional vibration. The increase in vibration may
result in damage to the crankshaft and to other
engine components.

Viscous Damper
Inspect the damper for evidence of fluid leaks. If a
fluid leak is found, determine the type of fluid. The
fluid in the damper is silicone. Silicone is transparent,
smooth, and viscous. It is difficult to remove silicone
from most surfaces.
M0064276 37
Basic Engine

i06515929

Gear Group (Front)

Illustration 27 g06005826
Typical example
(1) Idler gear
(2) Camshaft gear
(3) Crankshaft gear
(4) Oil Pump Gear

1. Inspect the gears for wear or for damage. If the

gears are worn or damaged, use new parts for
replacement.
2. Make sure that the timing marks on the gears (1),
(2), (3) and (4) are in alignment.
3. Measure the backlash between idler gear (1) and
oil pump gear (4). Refer to Specifications, “Gear
Group (Front)” for the backlash measurement.
4. Measure the backlash between oil pump gear (4)
and crankshaft gear (3). Refer to Specifications,
“Gear Group (Front)” for the backlash
measurement.
5. Measure the backlash between idler gear (1) and
crankshaft gear (3). Refer to Specifications, “Gear
Group (Front)” for the backlash measurement.
6. Measure the backlash between camshaft gear (2)
and idler gear (1). Refer to Specifications, “Gear
Group (Front)” for the backlash measurement.
38 M0064276
Electrical System

Electrical System To check for correct output of the alternator, refer to

Specifications.
Before the start of on-engine testing, the charging
system and the battery must be checked according to
the following steps.
i02693049
1. The battery must be at least 75 percent (1.225 Sp
Battery Gr) of the full charge. The battery must be held
tightly in place. The battery holder must not put too
much stress on the battery.
2. Cables between the battery, the starter, and the
engine ground must be the correct size. Wires and
Never disconnect any charging unit circuit or bat- cables must be free of corrosion. Wires and cables
tery circuit cable from the battery when the charg- must have cable support clamps in order to
ing unit is operated. A spark can cause an prevent stress on battery connections (terminals).
explosion from the flammable vapor mixture of
hydrogen and oxygen that is released from the 3. Inspect the drive components for the charging unit
electrolyte through the battery outlets. Injury to in order to be sure that the components are free of
personnel can be the result. grease and oil. Be sure that the drive components
The battery circuit is an electrical load on the have the ability to operate the charging unit.
charging unit. The load is variable because of the
condition of the charge in the battery. i06551613

NOTICE Electric Starting System

The charging unit will be damaged if the connections
between the battery and the charging unit are broken
while in operation. Damage occurs because the load
from the battery is lost and because there is an in- One starting motor is installed to the engine.
crease in charging voltage. High voltage will damage
the charging unit, the regulator, and other electrical Use a suitable multimeter in the DCV range to find
components. the starting system components which do not
function.

Use a suitable battery load tester in order to test the Move the start control switch to activate the starting
battery that does not maintain a charge when the solenoids. The operation of the starting solenoids can
battery is active. be heard as the pinions of the starting motors are
engaged with the ring gear on the engine flywheel.
i02995102
If a solenoid for a starting motor will not operate, it is
possible that the current from the battery did not
Charging System reach the solenoid. Fasten one lead of the multimeter
to the connection terminal for the battery cable on the
solenoid. Put the other lead to the battery negative. A
zero reading indicates that there is a broken circuit
Note: This procedure is only applicable if a charging from the battery. More testing is necessary when
system is installed. The charging system must be there is a voltage reading on the multimeter.
driven by the engine.
The solenoid operation also closes the electric circuit
The condition of charge in the battery at each regular to the motor. Connect one lead of the multimeter to
inspection will indicate whether the charging system the connection terminal of the solenoid that is
operates correctly. An adjustment is necessary when fastened to the motor. Fasten the other lead to the
battery negative. Activate the starting solenoid and
the battery is constantly in a low condition of charge look at the multimeter. A reading of the battery
or a large amount of water is needed. voltage shows that the problem is in the motor. The
Test the charging unit and the voltage regulator on motor must be removed for further testing. A zero
the engine. Use wiring and components that are a reading on the multimeter shows that the solenoid
permanent part of the system. This testing will give contacts do not close. Repair the solenoid if the
contacts do not close. The clearance on the pinion
an indication of needed repair. After repairs are
gear for the starting motor may also need adjusting.
made, perform a test in order to prove that the units
have been repaired to the original condition of
operation.
M0064276 39
Electrical System

Fasten one multimeter lead to the connecting

terminal for the small wire to the solenoid and fasten
the other lead to the battery negative. Look at the
multimeter and activate the starting solenoid. A
voltage reading shows that the problem is in the
solenoid. A zero reading indicates that the problem is
in the start switch or in the wires for the start switch.
Fasten one multimeter lead to the start switch at the
connection terminal for the wire from the battery.
Fasten the other lead to the battery negative. A zero
reading indicates a broken circuit from the battery.
Check the circuit breaker and wiring. If there is a
voltage reading, the problem is in the start switch or
in the wires for the start switch.
Starting motors that operate too slowly can overload
because of too much friction in the engine that is
being started. Slow operation of the starting motors
can also be caused by the following conditions:

• A short circuit
• Loose connections

• Dirt in the motors

40 M0064276
Index Section

Index
A G
Air Inlet and Exhaust System ........................... 5, 18 Gear Group (Front)..............................................37
General Information (Cooling System) ..................28
Pressure Test on the Oil Cooler.........................28
B General Information (Fuel System) (Diesel)...........17
Basic Engine................................................. 10, 31 General Information (Lubrication System) .............23
Battery ...............................................................38
I
C Important Safety Information ..................................2
Camshaft............................................................ 11 Increased Engine Oil Temperature - Inspect ..........25
Charging System ................................................38
Checking Engine Cylinders ..................................17 L
Connecting Rod Bearings ....................................31
Cooling System............................................... 9, 28 Lubrication System.......................................... 7, 23
Crankshaft.......................................................... 11 Engine Oil Flow in the Engine .............................8
Crankshaft Thrust - Measure................................35 Engine Oil Flow Through the Engine Oil Filter and
Cylinder Block.....................................................31 Engine Oil Cooler .............................................8
Cylinder Block, Liners and Heads .........................10 Lubrication System Components.........................7
Cylinder Head .....................................................31
Inspection and Pressure Test............................32
M
E Main Bearings.....................................................31
Electric Starting System.......................................38
Electrical System .......................................... 12, 38 P
Charging System Components .........................12 Pistons, Rings and Connecting Rods ....................10
Starting System Components ...........................14
Electronic Control System....................................16
Engine Governing - Adjust ...................................16 S
Engine Oil Pressure - Test ...................................23
Engine Oil Pressure is High .................................26 Systems Operation Section....................................4
Engine Oil Pressure is Low ..................................25
Contaminated Engine Oil..................................26
Engine Oil Pressure Gauge ..............................26 T
Improper Circulation of the Engine Oil ...............26 Table of Contents ..................................................3
Low Engine Oil Level .......................................26 Testing and Adjusting Section ..............................16
Worn Components ...........................................26 Turbocharger ......................................................20
Excessive Bearing Wear - Inspect ........................24 Inspection of the Compressor and the Compressor
Excessive Engine Oil Consumption - Inspect.........25 Housing.........................................................21
Engine Oil Leaks into the Combustion Area of the Inspection of the Turbine Wheel and the Turbine
Cylinders .......................................................25 Housing.........................................................21
Engine Oil Leaks on the Outside of the Engine ...25
V
F
Valve Lash - Adjust..............................................18
Flywheel - Inspect ...............................................33 Valve Mechanism ..................................................5
Bore Runout (Radial Eccentricity) of the Vibration Damper ................................................36
Flywheel........................................................33 Viscous Damper ..............................................36
Face Runout (Axial Eccentricity) of the Visual Inspection.................................................29
Flywheel........................................................33
Flywheel Housing - Inspect ..................................34
Bore Runout (Radial Eccentricity) Of The Flywheel W
Housing.........................................................34
Face Runout (Axial Eccentricity) Of The Flywheel Water Temperature Regulator - Test .....................29
Housing.........................................................34
Fuel Injector Mechanism........................................4
Fuel System ................................................... 4, 17
Fuel System Inspection .......................................17
Fuel System Operation ..........................................4
M0064276
©2015 Perkins Engines Company Limited
All Rights Reserved

42 December 2015