Perkins 4008-30 SD8 User manual

Systems Operation
Testing and Adjusting
4008-30 Industrial Engine
SD8 (Engine)
M0064276 (en-us)
December 2015

Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate everypossible circumstance that might involve apotential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specificallyrecommended byPerkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you startany job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.

Table of Contents
Systems Operation Section
Fuel System
Fuel System Operation ..........................................4
Fuel Injector Mechanism........................................4
Air Inlet and Exhaust System
Air Inlet and Exhaust System .................................5
Valve Mechanism..................................................5
Lubrication System
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
Flywheel - Inspect ...............................................33
Flywheel Housing - Inspect ..................................34
Crankshaft Thrust - Measure................................35
Vibration Damper ................................................36
Gear Group (Front)..............................................37
Electrical System
Battery ...............................................................38
Charging System ................................................38
Electric Starting System.......................................38
Index Section
Index..................................................................40
M0064276 3
Table of Contents

Systems Operation Section
Fuel System
i06512690
Fuel System Operation
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
displacement gear pump. The fuel transfer pump is
installed to the back of the oil pump.
A fuel priming pump is on the fuel transfer pump to fill
the system. The system must be primed after the
filter changes. The system must be primed after
draining the fuel supply and return manifolds, when
the fuel injectors are replaced.
The fuel flows continuously from the fuel supply
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.
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
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
combustion.
i06551615
Fuel Injector Mechanism
The fuel injector mechanism provides the downward
force that is required to pressurize the fuel in the fuel
injection pump. The mechanically operated fuel
injector allows fuel to be injected into the combustion
chamber.
Force is transmitted from the fuel injector lobe on the
camshaft through the lifter to the pushrod. The force
from the pushrod is transmitted through the rocker
assembly and to the top of the fuel injection pump.
The adjusting nut allows setting of the injector timing.
4 M0064276
Fuel System

Air Inlet and Exhaust
System
i06515116
Air Inlet and Exhaust System
The components of the air inlet and exhaust system
control the quality and the amount of air that is
available for combustion. There are two separate
turbochargers that are installed on the rear of the
engine.
The hot charge air from the turbochargers is directed
by large air pipes to the aftercooler. The cooling of
the charge air is achieved by inserting this additional
radiator in front of the normal radiator that cools
water. The single radiator fan pushes air through
each matrix in series. The air passes through the
matrix for charge air. After the air passes through the
radiator for charge air, the air is directed through
pipes that have a large bore to the air intake
manifolds.
The camshaft controls the movement of the valve
system components and injectors.
Illustration 1 g01188937
Air Inlet And Exhaust System
(1) Exhaust manifold
(2) Aftercooler
(3) Engine cylinder
(4) Air inlet
(5) Turbocharger compressor wheel
(6) Turbocharger turbine wheel
(7) Exhaust outlet
Clean inlet air from the air cleaners is pulled through
air inlet (4) into the turbocharger compressor by
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
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
inlet valves.
There are two inlet valves and two exhaust valves for
each cylinder. Refer to Systems Operation, “Valve
Mechanism”. The inlet valves open 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 downward on the power stroke.
When the piston moves upward again, the piston is
on the exhaust stroke. The exhaust valves open and
the exhaust gases are pushed through the exhaust
port into exhaust manifold (1). After the piston makes
the exhaust stroke, the exhaust valves close and the
cycle starts again.
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.
The crankshaft gear drives the camshaft gears
through idlers. The camshaft must be timed to the
crankshaft in order to get the correct relation between
the piston and the valve movement.
The camshaft has three lobes for each cylinder. Two
lobes operate the valves and one operates the fuel
injector.
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.
M0064276 5
Air Inlet and Exhaust System

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

Lubrication System
i06512672
Lubrication System
Lubrication System Components
Illustration 2 g01372216
Typical example of the lubrication system 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

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.
8 M0064276
Lubrication 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.
M0064276 9
Cooling System

Basic Engine
i06512668
Cylinder Block, Liners and
Heads
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
through the face and two side bolts.
The cylinder liners can be removed for replacement.
The top surface of the cylinder block is the seat for
the cylinder liner flange. Engine coolant flows around
the cylinder liners to keep the cylinder liners cool.
Two O-ring seals around the bottom of the cylinder
liner make a seal between the cylinder liner and the
cylinder block. A sealing compound is applied under
the cylinder liner flange. This makes a seal between
the top of the cylinder liner and the cylinder block.
The engine has a separate cylinder head for each
cylinder. Two inlet valves and two exhaust valves,
which are controlled by a pushrod valve system, are
used for each cylinder. Valve guides without
shoulders are pressed into the cylinder heads. The
opening for the unit injector is located between the
four valves. A lobe on the camshaft moves the
pushrod that operates the unit injector. Fuel is
injected directly into the cylinder.
Coolant goes out of the cylinder block and into the
cylinder head through four openings in each cylinder
head face. Water seals are used in each opening to
prevent coolant leakage. O-rings seal the engine oil
drain line between the cylinder head and the cylinder
block.
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.
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 correct operating temperature of the piston. The
pistons have three rings which include two
compression rings and one oil control ring. All the
rings are located above the piston pin bore. Oil is
removed from the wall of the cylinder and returns to
the crankcase through holes in the oil control ring
groove.
The pistons should be checked regularly for wear or
damage. Check that the piston rings are free to move
in the grooves and that the rings are not broken. The
clearance of the piston ring should be inspected
regularly. Remove the piston rings and clean the
grooves. Discard the piston rings. Install new piston
rings in the piston grooves. Check the clearance for
the piston ring by inserting a suitable feeler gauge
between the piston groove and the top of piston ring.
Refer to Specifications, “Piston and Rings” for the
dimensions. Use a suitable feeler gauge to measure
the piston ring gap. Refer to Specifications, “Piston
and Rings” for the dimensions.
The connecting rod has a taper on the pin bore end.
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.
10 M0064276
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.
M0064276 11
Basic Engine

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
12 M0064276
Electrical System

Alternator
Illustration 3 g01357159
Alternator
(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

Starting System Components
14 M0064276
Electrical System

Starting Motor
Illustration 4 g01357162
(1) Field
(2) Solenoid
(3) Clutch
(4) Pinion
(5) Commutator
(6) Brush assembly
(7) Armature
The starting solenoid (2) is an electromagnetic switch
that performs the following basic operations:
• The starting solenoid (2) closes the high current
starting motor circuit with a low current start switch
circuit.
• The starting solenoid (2) engages the pinion of the
starting motor (4) with the ring gear.
Solenoid (2) has windings (one or two sets) around a
hollow cylinder. A plunger that is spring loaded is
inside the cylinder. The plunger can move forward
and backward. When the start switch is closed and
electricity is sent through the windings, a magnetic
field (1) is made. The magnetic field (1) pulls the
plunger forward in the cylinder. This moves the shift
lever in order to engage the pinion drive gear with the
ring gear. The front end of the plunger then makes
contact across the battery and motor terminals of
solenoid (2). Next, the starting motor begins to turn
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.
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 larger diameter. The wire
with a larger diameter produces a greater magnetic
field (1). When the start switch is closed, part of the
current flows from the battery through the hold-in
windings. The rest of the current flows through the
pull-in windings to the motor terminal. The current
then flows through the motor to ground. Solenoid (2)
is fully activated when the connection across the
battery and the motor terminal is complete. When
solenoid (2) is fully activated, the current is shut off
through the pull-in windings. At this point, only the
smaller hold-in windings are in operation. The hold-in
windings operate for the duration of time that is
required in order to start the engine. Solenoid (2) will
now draw less current from the battery, and the heat
that is generated by solenoid (2) will be kept at an
acceptable level.
M0064276 15
Electrical 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.
16 M0064276
Electronic Control System

Fuel System
i06551648
General Information (Fuel
System)
(Diesel)
Either too much fuel or not enough fuel for
combustion can be the result of a problem in the fuel
system. Work is often done on the fuel system when
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.
4. Inspect the pressure valve on the fuel return rail.
i02990052
Checking Engine Cylinders
When the engine is under load, the temperature of an
exhaust manifold port can indicate the condition of a
fuel injector. Low temperature at an exhaust manifold
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
temperature at an exhaust manifold port can indicate
too much fuel to the cylinder. High temperatures may
also be caused by an injector with a defect.
M0064276 17
Fuel System

Air Inlet and Exhaust
System
i06512664
Valve Lash - Adjust
Table 1
Required Tools
Tool Part Number Part Name Qty
ASE253 Crankshaft Turning Tool 1
B-Feeler gauge 1
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
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 example
1. Remove the capscrews (1).
2. Remove the rocker cover (2).
3. Remove the joint (not shown).
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
Top Center Position Engine cylinder with valves on the rock Set the bridge adjustment and set valve
lash.
1-8 8 1
4-5 5 4
(continued)
18 M0064276
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
is clearance between the rocker arm and the
bridgepiece.
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. 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.
M0064276 19
Air Inlet and Exhaust System

Illustration 9 g01241598
Typical example
10. Use Tooling (B) to check the valve lash. If
necessary, follow steps 10.a through 10.f to adjust
the valve lash. Set the valve lash to 0.4 mm
(0.016 inch).
a. Loosen the locknut (9) on the rocker arm of
the inlet valve.
b. Use Tooling (B) to set the valve lash.
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).
e. Ensure that the valve lash is correct.
f. Repeat step 10 for the rocker arm of the
exhaust valve.
11. Repeat steps 5 through 10 for the remaining
rockers.
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.
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 injury from
burns. Before performing maintenance on the en-
gine, allow the engine and the components to
cool.
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.
20 M0064276
Air Inlet and Exhaust System