Perkins 4008-30 SD8, Systems Operation, Testing And Adjustment

Page 1: ...Systems Operation Testing and Adjusting 4008 30 Industrial Engine SD8 Engine M0064276 en us December 2015 ...

Page 2: ...ning 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 o...

Page 3: ...ders 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 V...

Page 4: ...res 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 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 spee...

Page 5: ...n when the piston moves down on the inlet stroke The cooled compressed air is forced into the cylinder from the inlet chamber The inlet valves close and the piston starts to move up on the compression stroke When the piston is near the top of the compression stroke fuel is injected into the cylinder The fuel mixes with the air and combustion starts The force of the combustion pushes the piston dow...

Page 6: ...Valve springs cause the valves to close when the lifters move downward 6 M0064276 Air Inlet and Exhaust System ...

Page 7: ... components A Oil pressure circuit B Oil circuit for piston cooling C Oil pressure relief D Oil return to sump 1 Oil supply line for rocker shafts 2 Engine oil pump 3 Engine oil relief valve 4 Strainer 5 Oil cooler 6 Oil filters 7 Engine oil pan 8 Oil supply line for turbocharger 9 Oil return line for turbocharger M0064276 7 Lubrication System ...

Page 8: ... 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 th...

Page 9: ...t 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 ...

Page 10: ...ets When the covers are removed all the openings can be used for inspection and for service i06512669 Pistons Rings and Connecting Rods The piston is a one piece piston that is a casting of aluminum alloy The piston crown carries all three piston rings Oil from the piston cooling jets flows through a chamber which is located directly behind the rings The oil cools the pistons This maintains the co...

Page 11: ...o 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 ...

Page 12: ...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 Compon...

Page 13: ...ernator 1 Slip rings 2 Fan 3 Stator 4 Rotor 5 Brush assembly The alternator is a three phase charging unit that contains an integral voltage regulator The alternator is driven from a notched auxiliary drive belt M0064276 13 Electrical System ...

Page 14: ...Starting System Components 14 M0064276 Electrical System ...

Page 15: ...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 When two sets of solenoid windings are used the windings are called the hold in winding and the pull in winding Both sets of windings have the same number of turns around the cylinder but the pull in winding uses a wire with a la...

Page 16: ...6 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 16 M0064276 Electronic Control System ...

Page 17: ...at 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 4 Inspect the pressure valve on the fu...

Page 18: ...arting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before measuring adjusting valve lash clearance Note The valve bridges must be set before the valve lash is adjusted Illustration 5 g01359594 Eight cylinder engine A Inlet valve B Exhaust valve Ensure that all power is disconnected to the engine Illustration 6 g01241573 Typical exam...

Page 19: ...iece Note The timing window is located in the flywheel housing Illustration 8 g01241584 Typical example 6 Loosen the locknut 7 on the inlet valve bridge 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 Tig...

Page 20: ...le 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 16 Repeat steps 12 through 15 for the remaining rocker covers i02863396 Turbocharger Hot engine components can cause injur...

Page 21: ...r 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 sc...

Page 22: ...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 oil slu...

Page 23: ...red Tools Tool Part Number Part Description Qty A Pressure Gauge 1 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 info...

Page 24: ... 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 Note A record of engine oil pressure can...

Page 25: ...ression ring and or the intermediate ring Leaks past the seal rings in the turbocharger shaft Overfilling of the crankcase Wrong dipstick or guide tube Sustained operation at light loads Excessive consumption of engine oil can also result if engine oil with the wrong viscosity is used i02693006 Increased Engine Oil Temperature Inspect If the engine oil temperature is higher than normal the engine ...

Page 26: ...drawing in air Check the joints of the suction tube for cracks or a damaged O ring seal There is a problem with the engine oil pump Check the gears of the engine oil pump for excessive wear Engine oil pressure is reduced when gears in the engine oil pump have too much wear NOTICE Perkins oil filters are manufactured to Perkins specifi cations Use of an oil filter that is not recommended by Perkins...

Page 27: ...ilter 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 M0064276 27 Lubrication System ...

Page 28: ...dition the engine is operating at a lower engine rpm that reduces the coolant flow Decreased coolant flow during high load will cause overheating Coolant can be lost by leaks Overheated coolant can be lost through the cooling system s pressure relief valve Lower coolant levels contribute to additional overheating Overheating can result in conditions such as cracking of the cylinder head and piston...

Page 29: ...r 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 Personal injury can result from hot coolant steam and alkal...

Page 30: ...e 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 30 M0064276 Cooling System ...

Page 31: ...maller 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 1 Clean all of the coolant passages and the oil passage...

Page 32: ...valve seat protrudes 10 mm 0 40 inch from the surface of the cylinder head 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 t...

Page 33: ...erence 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 Bore Runout Radial Eccentricity of the Flywheel Table 7 Required Tools Tool Part Number Part Description QTY A 21825617 Dial Indicator Group 1 Illustration 19 g01377841 Typica...

Page 34: ...rce on the crankshaft toward the rear before the dial indicator is read at each point Illustration 21 g00285932 Checking face runout of 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 poi...

Page 35: ...dial indicator at position C Write the measurement in the chart 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 ...

Page 36: ...mper 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 If the fluid leak is engine oil inspect the crankshaft seals for leaks If a leak is observed replace the crankshaft seals Inspect the damper Replace the damper fo...

Page 37: ...ween 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 bac...

Page 38: ...ery must be at least 75 percent 1 225 Sp 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 cables must be free of corrosion Wires and cables must have cable support clamps in order to prevent stress on battery connections ter...

Page 39: ...art 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...

Page 40: ...city of the Flywheel 33 Face Runout Axial Eccentricity of the Flywheel 33 Flywheel Housing Inspect 34 Bore Runout Radial Eccentricity Of The Flywheel Housing 34 Face Runout Axial Eccentricity Of The Flywheel Housing 34 Fuel Injector Mechanism 4 Fuel System 4 17 Fuel System Inspection 17 Fuel System Operation 4 G Gear Group Front 37 General Information Cooling System 28 Pressure Test on the Oil Coo...

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Page 42: ...M0064276 2015 Perkins Engines Company Limited All Rights Reserved 42 December 2015 ...