Perkins 4.108 Instruction manual

workshop
manual for
4.108 4.107 and 4.99
diesel engines
©
Perkins Engines Limited
Peterborough England
1983
All Rights Reserved
Publication No. 601 SER 0383 1072
This publication supersedes the previous edition numbered 601 SER 12771072
This publication is written for world wide use. In territories where legal requirements govern smoke emission,
noise, safety
factors etc., then all instructions, data and dimensions given must be applied in such a way that,
after
servicing (preventive maintenance) or repairing an engine, it does not contravene the local regulations
in use.
Published by the Technical Publications Department of Perkins Engines Ltd. and Printed in England by Warners (Midlands) pic

Page 2
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PERKINS COMPANIES
I AUSTRALIA Perkins Engines Australia Pty. Ltd.
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FRANCE
GERMANY
ITALY
JAPAN
SINGAPORE
UNITED KINGDOM
U.S.A.
Suite 2,
364 Main Street, Mornington 3931, Victoria, Australia.
Telephone:
597 51877. Telex: Perkoil AA30816. Fax: [phone].
Moteurs Perkins S.A.
9-11 Avenue Michelet,
93583 Saint Ouen, Cedex, France.
Telephone:
(1) 40104200. Telex: 642924F. Fax: [phone].
Perkins Motoren G.m.b.H.
8752 Kleinostheim, Postfach 1180, West Germany.
Telephone: Kleinostheim
6027 5010. Telex: 4188869A PER D.
Fax: [phone].
Motori Perkins S.p.A.
Via Socrate 8,
22070 Casnate con Bernate (Como), Italy.
Telephon: (031)
452332. Telex: 380658 Perkit I. Fax: [phone].
Massey Ferguson Perkins Engines K.K.
Reinanzaka Building,
6th Floor, 14-2 Akasaka, 1-chome, Minato-ku, Tokyo 107, Japan.
Telephone: (03)
5867377. Telex: Perkoil J2424823. Fax: [phone].
Perkins Engines Asia Pacific,
4 Kian Teck Drive, Singapore
2262.
Telephone: [phone]. Telex Perkoil RS37729. Fax: [phone].
Perkins Engines Limited,
Eastfield, Peterborough,
PE1 5NA, England.
Telephone:
(0733) 67474. Telex 32501 Perken G. Fax: [phone].
Perkins Engines (Shrewsbury) Limited,
Sentinel Works, Shrewsbury
SY1 4DP, England.
Telephone:
(0743) 52262. Telex: 35171/2 PESL G. Fax: [phone].
Perkins Engines Inc.,
1700 Bellemeade Court, Lawrenceville, Georgia 30245, U.S.A.
Telephone:
404 822 3000. Telex: 544141 Perken Law. Fax: [phone].
Perkins Engines Latin America Inc.,
Suite
620,999 Ponce de Leon Boulevard, Coral Gables, Florida 33134, U.S.A.
Telephone:
305 442 7413. Telex: 32501 Perken G. Fax: [phone].
In addition to the above, there are Perkins distributors in most countries. Perkins Engines Ltd., Peterborough or one of the above
companies can give details.

Page 3
FOREWORD
This workshop manual has been compiled for use in conjunction with normal workshop practice.
Mention of certain accepted practices therefore, has been purposely omitted in order to avoid
repetition.
Reference to renewing joints and cleaning off joint faces has to a great extent been omitted from
the text, it being understood that this will be carried out where applicable.
Similarly, it is understood that in reassembly and inspection, all parts are to be thoroughly
cleaned and where present, burrs and scale are to be removed.
It follows that any open ports of high precision components, e.g., fuel injection equipment, ex-
posed by dismantling, will be blanked off until reassembled, to prevent the ingress of foreign
matter.
: When setscrews
or studs are fitted into holes which are tapped through into the inside of
: the engine, a suitable sealant must be used on the threads.
Throughout this manual, whenever the "left" or "right" hand side of the engine is referred to, it is
that side of the engine as viewed from the flywheel end.
The
engine number is stamped on the fuel pump mounting flange as shown in the above
illustration.
Three systems of engine numbering have been used.
On very early engines the serial number consisted of seven digits as follows :-
Engine Type Typical Engine Number
4.108 7300269
4.107 7100399
4.99 7000251
Identification on these engines can be identified by cbserving the first two figures of the engine
number which remain constant depending on engine type.
With later engines, the number consisted of figures and letters
Engine Type Typical Engine Number
4.108 108U251
4.107 107U251
4.99 99U251
The first figures represent the capacity of the engine in cubic inches, the letter "U" signifies that
the engine was built in the United Kingdom and the last group of figures comprises the engine
serial number.
On current engines, the number can consist of up to fifteen letters and figures, a typical number
being ED21512U510256D

Page4 ~
Safety precautions
THESE SAFETY PRECAUTIONS ARE IMPORTANT. Reference must also be made to the local
regulations in the country of operation.
Do not use these engines in marine applications.
Do
not change the specification of the engine.
Do
not smoke when you put fuel in the tank.
Clean away any fuel which has fallen and move material which has fuel contamination to a safe
place.
Do
not put fuel in the tank during engine operation (unless really necessary).
Never clean, lubricate
or adjust the engine during operation (unless you have had the correct
training when extreme caution must be used to prevent injury).
Do not make any adjustments you do not understand.
Ensure the engine is not in a position to cause a concentration of toxic emissions.
Persons in the area must be kept clear during
engine and equipment or vehicle operation.
Do not permit loose clothing
or long hair near parts which move.
Keep away from parts which turn during operation. Note that fans can
not be seen clearly while
the engine is run.
Do not run the engine with any safety guards removed.
Do not remove the radiator cap while the
engine is hot and the coolant is under pressure as
dangerous
hot coolant can be discharged.
Do
not use salt water in the cooling system or any other coolant which can cause corrosion.
Keep sparks
or fire away from batteries (especially during charge) or combustion can occur.
The battery fluid can burn and is also dangerous to the skin and especially the eyes.
Disconnect the battery terminals before you make a repair to the electrical system.
Only one person must be in control of the engine.
Ensure the engine is only operated from the
control panel or operators position.
If your skin comes into contact with high pressure fuel, get medical assistance immediately.
Diesel fuel can cause skin damage to some persons. Use protection on the hands (gloves
or
special skin protection solutions).
Do not move equipment unless the brakes are in good condition.
Ensure that the transmission drive control is in "Out of Drive" position before the engine is
started.
Fit only
correct Perkins Parts.

CONTENTS
ENGINE VIEWS
TECHNICAL DATA
OPERATING AND MAINTENANCE
FAULT FINDING
CYLINDER HEAD
PISTONS AND CONNECTING RODS
CYLINDER BLOCK AND LINERS
CRANKSHAFT AND MAIN BEARINGS
TIMING CASE AND DRIVE
TIMING
LUBRICATING SYSTEM
COOLING SYSTEM
AIR CLEANERS AND FUEL SYSTEM
FLYWHEEL AND HOUSING
ELECTRICAL EQUIPMENT
ENGINES
FOR REFRIGERATION UNITS
APPROVED LUBRICATING OILS
APPROVED SERVICE TOOLS
INDEX
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
Appendix
Page 5

Page 6
EXAMPLES OF SERVICE FACILITIES
Service
If any problems occur with your engine or the components fitted to it, your Perkins distributor
can make the necessary repairs and will ensure that only the correct parts are fitted and that the
work is done correctly.
Certain components can be supplied by your Perkins distributor through the Perkins Power
exchange system. These will enable you to red uce the cost of some repairs.
Extended Warranty
The engine warranty period can be extended to two years. For details, get in contact with your
nearest Perkins distributor.
Service Literature
Users handbooks and other service publications are available from your Perkins distributor at a
nominal cost.
Training
Local training on correct engine operation, overhaul and service is available at some Perkins
distributors. If special training is needed, your Perkins distributor can give details on how to
get this at the Product Education Department, Peterborough, or other main centres.

SECTION A
Engine Views

ENGINE VIEWS-A.2
Index to Engine Views
Dynamo Pulley
2 Water
Pump Pulley
3 Water Outlet
4 Exhaust
Manifold
5 Breather
6
Atomiser
7
Thermostat Housing
8 Fuel Injection
Pump
9 Starter Motor
10 Lubricating Oil Filter
11 Timing Pin
12 Crankshaft Pulley
13 Timing Case
14 Fan Belt
15 Water Pump
16 Cylinder Head Cover
17 Fuel Oil Filter
18 Starting Aid
19 Induction Manifold
20 Oil Filter
21 Dipstick
22 Dynamo
23 W?ter
Inlet
24 Lubricating Oil Pump Locating Setscrew
25 Lubricating Oil
26
Sump Drain Plug
27 Flywheel
Housing
28 Cylinder Block Drain Tap
29 Fuel Lift Pump

ENGINE VIEWS-A.3
2 3 4 5
-----7
9
VIEW OF FUEL PUMP SIDE OF ENGINE

ENGINE VIEWS-A.4
1
17
1
20
VIEW OF CAMSHAFT SIDE OF ENGINE