Professional Documents
Culture Documents
December 2016
Systems Operation
Testing and Adjusting
4006-23 and 4008-30 Industrial Engines
SD8 (Engine)
SD6 (Engine)
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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.
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M0064276-01 3
Table of Contents
Basic Engine
Cylinder Block, Liners and Heads .........................10
Pistons, Rings and Connecting Rods ...................10
Crankshaft ......................................................... 11
Camshaft ........................................................... 11
Electrical System
Electrical System ................................................12
Fuel System
General Information (Fuel System) (Diesel)...........17
Fuel System Inspection .......................................17
Checking Engine Cylinders ..................................17
Fuel Injector Adjustment ......................................17
Lubrication System
General Information (Lubrication System) .............32
Engine Oil Pressure - Test ...................................32
Excessive Bearing Wear - Inspect ........................33
Excessive Engine Oil Consumption - Inspect.........34
Increased Engine Oil Temperature - Inspect ..........34
Engine Oil Pressure is Low ..................................34
Engine Oil Pressure is High .................................35
Cooling System
General Information (Cooling System) ..................37
Visual Inspection.................................................38
Water Temperature Regulator - Test .....................38
Basic Engine
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Fuel System
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M0064276-01 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
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Air Inlet and Exhaust System
i06512675
Turbocharger
Rear Mounted
Illustration 3 g01192286
Turbocharger (typical example)
(4) Compressor wheel
(5) Bearing
(6) Oil inlet port
(7) Bearing
(8) Turbine wheel
(9) Oil outlet port
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M0064276-01 7
Lubrication System
Lubrication System
i06512672
Lubrication System
Illustration 4 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
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Lubrication System
• 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.
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M0064276-01 9
Cooling System
Cooling System
i06512674
Cooling System
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10 M0064276-01
Basic Engine
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.
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M0064276-01 11
Basic Engine
Measure the bores in the connecting rod and ensure As the camshaft turns, each lobe moves a lifter.
that the bores meet the diameters according to the There are three lifters for each cylinder. Each outside
correct specifications. When the connecting rod is lifter moves a pushrod and two inlet valves or two
installed, follow the instructions for tightening the exhaust valves. The center lifter moves a pushrod
bolts. Refer to Specifications, “Connecting Rod”. that operates the fuel injector.
The camshaft must be in time with the crankshaft.
i06721524 The relation of the camshaft lobes to the crankshaft
position causes the valves and fuel injectors in each
Crankshaft cylinder to operate at the correct time relative to the
piston stroke.
i06721529
Camshaft
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Electrical System
Electrical System
i02692982
Electrical System
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M0064276-01 13
Electrical System
Alternator
Illustration 5 g01357159
Alternator
(1) Slip rings (3) Stator (5) Brush assembly
(2) Fan (4) Rotor
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Electrical System
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M0064276-01 15
Electrical System
Starting Motor
Illustration 6 g01357162
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.
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Electronic Control System
i02857716
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M0064276-01 17
Fuel System
Fuel System 4. Inspect the pressure valve on the fuel return rail.
i02990052
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18 M0064276-01
Fuel System
Illustration 7 g01359590
Six cylinder engine
(A) Inlet valve
(B) Exhaust valve
Illustration 10 g01236626
Typical example
Illustration 8 g01359594
Eight cylinder engine
(A) Inlet valve
(B) Exhaust valve
Illustration 11 g01236693
Typical example
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M0064276-01 19
Fuel System
3. Install Tooling (A) to the rocker boxes (1). Tighten 5. To calibrate the NO FUEL position of the fuel
the screws on Tooling (A) to compress the fuel injector, position Tooling (B) with the step against
injector springs (2). Compress the fuel injector the control arm (3). Adjust the length of the link to
springs until the control arms (3) are free to move. move the control arm (3). Move the control arm so
that NO FUEL line (5) on Tooling (B) is aligned
with the line on the injector.
6. Repeat step 5 for the remaining fuel injectors.
7. Remove the wedge (4) from the governor.
8. Move the governor actuator to position the control
arm (3) of the injector on cylinder number 1 to the
CALIBRATION position. Align the edge of the
control arm (3) with the line (11) on injector on
cylinder number 1.
Illustration 12 g01470285
Typical example
Illustration 15 g02135834
Typical example
Note: If any control arms (3) are below the line (11) at
position (X) on the injectors, move the governor
actuator and use the lowest injector as the calibration
point.
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20 M0064276-01
Fuel System
Note: The timing pin is the reference point for the Typical example
start of the fuel injection process.
Note: The fuel injection timing is shown on the
Set the timing pins on the fuel injectors and adjust the engine serial number plate. The timing window is
valve lash in the sequence that is shown in table 2 located in the flywheel housing. Ensure that the
and table 3 . correct spill timing mark is selected for the correct
Table 2 engine rating.
4006 Engines
3. Use Tooling (C) to rotate the crankshaft
Check and Adjust Set the Fuel Injec- counterclockwise until the correct spill timing mark
Valves on the Rock
Valves. tor Timing.
(16) passes the timing pointer (15). Rotate the
6 1 3 crankshaft in the normal direction of rotation until
2 5 6
the correct spill timing mark (16) is in line with the
timing pointer (15).
4 3 2
1 6 4
5 2 1
3 4 5
Table 3
4008 Engines
8 1 6
5 4 8
2 7 5
3 6 2
1 8 3
4 5 1
7 2 4
6 3 7
Illustration 17 g01236630
Typical example
1. Set the piston (A1) to the top dead center on the
compression stroke. (A8) valves on the rock. 4. Loosen the nut (13).
2. Set the engine valve lash (A1). Refer to System 5. Use Tooling (D) to rotate the adjuster (12) in a
Operation, Testing, and Adjusting, “Valve Lash - counterclockwise direction as far as possible.
Adjust”.
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M0064276-01 21
Fuel System
6. Use a screwdriver to apply light pressure to the Test and Set the Fuel Injectors
timing pin (14). Use Tooling (D) to rotate the Table 4
adjuster (12) in a clockwise direction until the
Required Tools
timing pin just engages into the injector. Ensure
that the timing pin can move out to the normal Tool Part Number Part Name QTY
position.
Fuel Injector Clamp for 14
A T6253/356 1
mm 1500 rpm engine
Note: The engine valve lash and the timing for the
fuel injector are set on the spill marks.
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Fuel System
Illustration 19 g01426264
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M0064276-01 23
Fuel System
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24 M0064276-01
Fuel System
6. Depress the hand lever. Raise the fuel pressure to Inspection of the Break Back Lever
700 kPa (100 psi) below the pressure of
23400 kPa (3400 psi). Maintain the fuel pressure 1. Check the break back lever assemblies for
for 10 seconds. smoothness of operation on the break back lever
pins. Install new components to the assembly of
7. Allow the pressure to drop to 20700 kPa
break back lever when new components are
(3000 psi) and check for leaks. The nozzle tip
required.
should be dry.
2. Check the condition of the break back lever spring.
Note: Do not allow fuel to run down the fuel injector.
This will give a false impression during the test.
Chatter Test
Close the isolator gauge. Operate the lever at the
slowest rate to discharge the nozzle. Under these
conditions, the nozzle must discharge fuel with a
chattering action.
Spray Formation
Close the isolator gauge. Operate the lever at speed.
Check that the atomized fuel from each hole is of a
regular formation. All the formations of spray must be Illustration 21 g01471672
equal and correctly spaced.
3. Place break back lever into a vice (1).
Release Pressure
4. Install spring balance into the input lever bolt hole
Open the isolator gauge valve. check that the fuel (2).
injector opens between the pressure of22800 kPa
(3300 psi) and 23800 kPa (3450 psi). Close the 5. Apply a minimum load of 0.9 kg (2 lb) to the spring
isolator gauge valve. Operate the pump to ensure balance(3). The load will cause break back lever
that all components have settled, and check the fuel to separate.
injector pressure again.
Note: The spring balance load must not be less than
Pressure Gauge 0.9 kg (2 lb). If the spring balance load is less than
0.9 kg (2 lb), the assembly of break back lever must
Before the fuel injector is removed from the test be disassembled. A new spring must be installed.
pump, close the isolator gauge valve to prevent
damage to the pressure gauge, which may result 6. Check the connecting links for damage. If the
from a sudden drop in pressure. If the fuel injector is connecting links are damaged fit new connecting
not being installed immediately, blank off the inlet and links. Do not attempt to straighten the connecting
the leak off holes with masking tape. Install a links.
protective cap over the nozzle assembly.
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M0064276-01 25
Air Inlet and Exhaust System
Restriction of Air Inlet and 4. Use Tooling (A) for this test.
Exhaust
Differential Pressure
A - 1
Gauge
The air flow through the engine air cleaner must not
be more than the following amount:
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26 M0064276-01
Air Inlet and Exhaust System
Illustration 24 g01359590
Six cylinder engine
Illustration 23 g06103704 (A) Inlet valve
Typical example (B) Exhaust valve
i06721787
Table 7
Required Tools
B - Feeler gauge 1
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M0064276-01 27
Air Inlet and Exhaust System
Illustration 25 g01359594
Eight cylinder engine
(A) Inlet valve
(B) Exhaust valve
Illustration 26 g01241573
Typical example
(continued)
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28 M0064276-01
Air Inlet and Exhaust System
(Table 8, contd)
2-5 2 5
3-4 4 3
1-6 1 6
2-5 5 2
3-4 3 4
Table 9
Eight cylinder engine
Illustration 27 g06006364
Typical example
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M0064276-01 29
Air Inlet and Exhaust System
Illustration 30 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.
13. Install a new joint (not shown).
14. Install the rocker cover (2).
15. Install the capscrews (1). Tighten the capscrews
to a torque of 4 N·m (35 lb in).
Illustration 29 g01241598
Typical example 16. Repeat steps 12 through 15 for the remaining
rocker covers.
10. Use Tooling (B) to check the valve lash. If
necessary, follow steps 10.a through 10.f to adjust i02863396
the valve lash. Set the valve lash to 0.4 mm
(0.016 inch). Turbocharger
a. Loosen the locknut (9) on the rocker arm of the
inlet valve.
b. Use Tooling (B) to set the valve lash.
Hot engine components can cause injury from
c. Turn the adjuster (8) until the pad on the rocker burns. Before performing maintenance on the en-
arm is in contact with Tooling (B). gine, allow the engine and the components to
cool.
d. Tighten the locknut (7) to a torque of 50 N·m
(37 lb ft).
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30 M0064276-01
Air Inlet and Exhaust System
• Inspection of the Turbine Wheel and the Turbine Inspection of the Turbine Wheel
Housing
and the Turbine Housing
Inspection of the Compressor and 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.
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M0064276-01 31
Air Inlet and Exhaust System
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Lubrication System
Lubrication System
i06515918
General Information
(Lubrication System)
i02693002
Table 10
Required Tools
- Pressure Gauge 1
A Connector
- 1/4 inch BSP 1
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M0064276-01 33
Lubrication System
Illustration 32 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 11 in order to determine if the
engine oil pressure is acceptable.
Table 11
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
a passage for engine oil.
If the engine oil pressure is low, determine the
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.
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34 M0064276-01
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:
• Wrong dipstick or guide tube • Problem with the engine oil pressure gauge
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M0064276-01 35
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.
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36 M0064276-01
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.
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M0064276-01 37
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 33 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.
• 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.
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38 M0064276-01
Cooling System
i06723181
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.
pressure.
For six cylinder engines, the opening temperature of
1. Check the coolant level in the cooling system. the water temperature regulator is the following
Read the two indicators for the coolant level in the value. . . . . . . . . . . . . . . . . . . . . . . . . . 71° C ((160° F))
top of the radiator (if equipped).
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M0064276-01 39
Cooling System
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40 M0064276-01
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
i02862425
Cylinder Block
Illustration 35 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.
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M0064276-01 41
Basic Engine
Illustration 37 g01425720
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42 M0064276-01
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 14
Required Tools
i02693029
Tool Part Number Part Description QTY
Illustration 39 g01377841
Typical example for checking the bore runout of the
flywheel
(1) Dial indicator group
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M0064276-01 43
Basic Engine
i02858320
Table 15
Required Tools
Illustration 41 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.
Illustration 40 g00285931
Checking face runout of the flywheel housing
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44 M0064276-01
Basic Engine
Illustration 43 g00285936
Illustration 44 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 16
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
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M0064276-01 45
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.
Illustration 46 g01519076
Typical example
i06554414
Vibration Damper
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.
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46 M0064276-01
Basic Engine
i06515929
Illustration 47 g06005826
Typical example
(1) Idler gear
(2) Camshaft gear
(3) Crankshaft gear
(4) Oil Pump Gear
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M0064276-01 47
Electrical System
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.
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48 M0064276-01
Electrical System
• A short circuit
• Loose connections
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M0064276-01 49
Index Section
Index
A Fuel System Operation ..........................................4
Air Inlet and Exhaust System ........................... 5, 25
G
B Gear Group (Front)..............................................46
General Information (Cooling System) ..................37
Basic Engine................................................. 10, 40 Pressure Test on the Oil Cooler.........................37
Battery ...............................................................47 General Information (Fuel System) (Diesel)...........17
General Information (Lubrication System) .............32
C
Camshaft............................................................ 11 I
Charging System ................................................47 Important Safety Information ..................................2
Checking Engine Cylinders ..................................17 Increased Engine Oil Temperature - Inspect ..........34
Connecting Rod Bearings ....................................40
Cooling System............................................... 9, 37
Crankshaft.......................................................... 11 L
Crankshaft Thrust - Measure................................44
Cylinder Block.....................................................40 Lubrication System.......................................... 7, 32
Cylinder Block, Liners and Heads .........................10 Engine Oil Flow in the Engine .............................8
Cylinder Head .....................................................40 Engine Oil Flow Through the Engine Oil Filter and
Inspection and Pressure Test............................41 Engine Oil Cooler .............................................8
Lubrication System Components.........................7
E
M
Electric Starting System.......................................47
Electrical System .......................................... 12, 47 Main Bearings.....................................................40
Charging System Components .........................12 Measuring Inlet Manifold Pressure........................26
Starting System Components ...........................14
Electronic Control System....................................16
Engine Governing - Adjust ...................................16 P
Engine Oil Pressure - Test ...................................32 Pistons, Rings and Connecting Rods ....................10
Engine Oil Pressure is High .................................35
Engine Oil Pressure is Low ..................................34
Contaminated Engine Oil..................................35 R
Engine Oil Pressure Gauge ..............................35
Improper Circulation of the Engine Oil ...............35 Restriction of Air Inlet and Exhaust .......................25
Low Engine Oil Level .......................................35 Air Inlet Restriction...........................................25
Worn Components ...........................................35
Excessive Bearing Wear - Inspect ........................33 S
Excessive Engine Oil Consumption - Inspect.........34
Engine Oil Leaks into the Combustion Area of the Systems Operation Section....................................4
Cylinders .......................................................34
Engine Oil Leaks on the Outside of the Engine ...34
T
F Table of Contents ..................................................3
Testing and Adjusting Section ..............................16
Flywheel - Inspect ...............................................42 Turbocharger .................................................. 6, 29
Bore Runout (Radial Eccentricity) of the Inspection of the Compressor and the Compressor
Flywheel........................................................42 Housing.........................................................30
Face Runout (Axial Eccentricity) of the Inspection of the Turbine Wheel and the Turbine
Flywheel........................................................42 Housing.........................................................30
Flywheel Housing - Inspect ..................................43 Rear Mounted....................................................6
Bore Runout (Radial Eccentricity) Of The Flywheel
Housing.........................................................43
Face Runout (Axial Eccentricity) Of The Flywheel V
Housing.........................................................43 Valve Lash - Adjust..............................................26
Fuel Injector Adjustment ......................................17 Valve Mechanism ..................................................5
Adjust the Fuel Injectors ...................................17 Vibration Damper ................................................45
Test and Set the Fuel Injectors ..........................21 Viscous Damper ..............................................45
Fuel Injector Mechanism........................................4 Visual Inspection.................................................38
Fuel System ................................................... 4, 17
Fuel System Inspection .......................................17
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50 M0064276-01
Index Section
W
Water Temperature Regulator - Test .....................38
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M0064276
©2016 Perkins Engines Company Limited
All Rights Reserved
52 December 2016
This document has been printed from SPI2. NOT FOR RESALE