Perkins 4.108 Mounting instructions

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Foreword
The Perkins Seryice Data Booklet contains the data which is most commonly useo oy
experienced
mechanics
andtechnicians.
Thebooklet
containsinlormation
forallperkins
peterborough
enginesand is
avaalable
intlvo
parts:
Part 1: Malure products up to 8,85 litres (540 cu in)
4.108
3.152Series
4.203
Series
4.236
Series
6.3544Series
V8.540Series
Parl 2: Current products up to 8,7 litres (530 cu in)
4.41
100Series
Prima,/500
Series
700 Series
900 Series
Phaser/1000
Series
Peregrine/1
300Series
The booklet should be used together with the relevant Use/s Handbook, Workshop Manual
andService
Bulletins.
Any recommendations ,or future issues of the booklet should be sent to Technical
Publications
Department.
Perkins
ServiceDataBookletPad 1, 1997

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Perkins companies unltedKlngdom
Austrataa PerkinsInternalionalLld,
Easttield,PelerboroughPE15NA,
Peftins
Engines
AustraliaPly.Ltd, England.
Suite2,364
MainSlreet, Telephone:[phone]
Morninglon3931,Victoria,Auslralia. Telex: 32501
Perken
G
Telephonei59751877 Fax[phone]
Telex:Perkoil4430816
Fax:[phone] uniled states of america
France PerkinsInternational
-NodhAmenca
12025TechCenterDrive
MotelfsPerkrnsS.4., Lvonia
9-11
AvenueMichelet, [4ichigan48150
93583SanlOuen,Cedex,
France. USA
Telephone:
(1)
40104270 Telephone:[phone]
Ielex:642924F Fax:[phone]
Fax:
(1)
40-10-42'45
Germany PerkinsEnqinesLalinAmericaInc'
sule 620,
PerkinsÄ,4otorenGmbH, 999,Poncede LeonBoulevard,
Saalaeckerslrasse
4, CoralGables,
63801Kleinostheim, Florida33134,U.S.A.
Germany. Telephone:
305
4427413
Telephonei60275010 Telex:32501PerkenG
Fax:6O27
501124 Fax:[phone]
Hong Kong
PerkrnsInlernalionalLtd, In additlon to the above companies, there a.e
VarityAsia./Pacilic, Perklns dlstrlbutors In mosl counlries. Perkins
Suile3301 Inlernatlonal Ltd, Pelerborough or one ol the
Convention
Plaza, above companles can provide detalls.
1Harbourroad,
HongKong.
Telephone:
852
25881883
Fax:[phone]
Italy
MoloriPerkinsS.p.A.,
VraSocrate8,
22070
CasnateconBernale
(Como),
llaly.
Telephone:[phone]or 564625
Teex:380658PerkllI
Fax:[phone]or
564145
Japan
Varity
(Japan)
K.K.,
RenanzakaEuilding,sth
Floor,
142Akasaka,
1-chome,Mrnalo-ku,
Tokyo107,Japan.
Teephone:03 5867377
Ieex:Petkat J2424823
Fax:[phone]
Perkins SeruEe Data Booklei Pad 1. 1997

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POWEBPABTrecommended
consumable
products
Perkinshavemade
availabielheproducts
fecommended
belowif orderlo assist n lhe
cotrecloperalion,serviceandmalnlenance
oi your
€ngrneand
your
machrne.Theinstuctionslor
the
useoleach
product
aregiven onlhe outsideol
eachconlainer.These
products
areavailablelrom
your
Perkins
drstrlbutor.
POWERPARTAntifreeze
Proleclsthe
coolingsyslemagainsttrosland
cotrosron.Pa( nufrber1lilre
21825166or5lilres
21825167.
POWERPABT
Easy Flush
Cleansthecooingsystem.Padnumber
2182501
POWEBPARTJolntlngcompound
Universal
tornting
compound
which
seals
joinls.
CurenllyHylomarPadnumber1
861
1
55or
1861117.
POWERPARTSlllconerubbersealanl
Silrconerubbersealantwhch
prevenls
leakage
through
gaps.Cutrenlly
HylosiPannumber
1
861108.
POWERPARTLay-Up1
Adreselluel
addnive
lor
prolect
onagansl
corosion.Pannumber1772204.
POWERPARTLay-Up2
Prolectsthe nsdeolthe
eng
ne
andolother
closedsyslems.Pannumber1762811
POWERPARTLay-Up3
Protecls
outsdemelal
pans.
Padnumber1734115.
POWERPART
ChiseI
Alows
easyremovalol od gaskets and
jornls.
Cu(entlyLocllechiselPadnumber21825163.
POWEBPARTRepel
Daesdampequrpmenland
gives
proteclron
againsi
corosron.Passesthroughdinandcorosionto
!bncaleandtoassistremovalotcomponents.
CutrenllyLoclilerepel.Pann!mber21825164.
POWEBPARTThreadlock
Toretainsmalltaslenerswhereeasyremovalis
necessary
Cutrenl
y Loctite222e.Pannumber
21820222
POWERPARTStudlock
To
permanently
retan largelasteners
andstuds.
Cutrenl
y Loctile270.Pannumber
21820270 1824222
POWERPART
NuTIocK
To retain
andsealthreaded
tastenersandcup
plugs
whereeasy removal
ls necessary,
Curently
Loctile242e.Pannumber21820242
POWERPART
Llquld
gasket
To sealtlallacesoJcomponentswherenojointis
used.Especiallysuilablelor
aluminium
components.
CutrentlyLoclite
518.Pannumber
21
820518
POWERPART
Threadlock (hydraull./pnuemafi c)
Toretain
andseal
pipe
conneclionswrlhfine
threads.Especiallysuilablelorhydraulic
and
pneumatic
syslems.
Cu(ently Loctile542.Pail
number21820542
POWERPARTThreadlock (plpe)
To retarn
andseal
pipe
connections
withcoarse
threads-Pressure
syslemscan be used
immedialely.
CurentlyLoclite
575.
Pan
number
21A20575.
POWERPARTRetainer
(oll tolerant)
To retarn
componentswhichhave
a fansition lil.
CutrentlyLoctile603.Pan
number21820603.
POWERPARTRelainer (high stength)
To relain
componentswhichhavean inlerlerence
lit.CurentlyLoctile
638.
Pad
number21820638.
POWEBPARTAlomiser th.ead sealant
Toseallhethreads
oltheatomiserinto
lhecylinder
head.CurientlyHylomar
AdvanceFormulation.
POWERPARTCompound
Tosealtheoulerdiameler
olseals.Currently
LoctileFormaGasketNo
2.Padnumber1861147.
POWERPART
Platelock
Ärediumslrengthanaerobic
lhreadlocklor tight
finedmetal
s!rlaces.SuitableIofmetal
plaled
surtaces
andstainlesssteel,CutrenllyLoctile
243
Pannumber
21826039.
POWERPART
Gaskel ellmlnator
lmprovestlangesealingwhen
a gaskelisnotused.
11
provides
a sealwrthlemperatureresistance
that
isllexibe in
posilions
wherevibration
and
pressure
occur,CutrentlyLocllte515.Pannumber
21826040
POWERPARTSilicone
adheslve
An RTVsliconeadhesivelor applicationwherelow
pressure
lestsoccur
beloretheadhesivesets.
Used'orsealng
llange
where
or res slalceiö
neededandmovement
olthe
joinl
occurs,.Cutrenlly
Loctile5900 Padnumber
21826038.
Perkins SetoKe Dala Booklel Pan 1. 1997

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Enginenumber
guide
For
enginesmadeatler1974
Eramp
eolanenginen!mber
isTU20300U510256F
TU . .. . . EngineFamity
andtypecode,seeTabte
1
20300 .. . . . parlslislnumber
or SOSorderrelerence
number
Countryof manulacture
code,
seeTable
2
510256... Engine
serialnumber
F ............ yearof
manuJaclure
code,
seeTabte3
Table 1 - Englne Family and Type Code
AB
AD
AE
AH
AK
AQ
B
BA
A Phaser/1004
AG
Nalurally
Tubocharged
Compensated
Charge cooled
Fed Charge
cooteo
Narrow Jronl end
nalurally aspiraled
Narrow fronl end
lurbocharged
New Phaser/l004
Naturally
asprraleo
Tuöocharged
turbocharged
Inlercooteo
Naturally
asptrareo
Tuöocharged
Prima/500
BB
AC
c 3.152
CA
CB
CC
CD
CE
CF
CG
CJ
ct\,4
CN
Nalurally
asprraleo
Tuöocharged
Gasolene
P3
3.144
P3.144
3.152
03.152
G3.152
P3.1
52
3.1522
3.1524
T3.1524
C 900Series
cP 3.27
cR 13.27
cs 3.25
4.192
P4.192
4.203
04.203
G4.203
4.2032
H
HA
io
JB
JC
JD
JE
JG
K
KB
KC
KD
KE
KF
E 4.108
EA 4.99
EB 4.101
EC 14.107
ED 4.108
EE T4.108
G 4.15/V200
GA 4.154
GB 4.135
GC 4.182
GD 4.25
GE 4.30
4.165 4.165
4.203 P4
Perama/l00
2 cyl.0,4lilres
3 cy].0,6lilres
3 cyi-0,9lilres
3 cyl.1,0lites
3cyl.1,5lites
4cyl.1,9litres
3cyl.1,2
lires
3cyl.1,3
lifes
3cyl.1,5litres
D
4cyl.1,9litres
D
3 cyl.0,7litres
2 cyl.
0,5lites
4cyl.2,2lites
4.236 4.212
G4.212
4.224
4.236
KG
KH
KJ
KK
KL
KN
KR
;
LB
LC
LD
LE G4.236
LF 4.24A
LG 4.24A2
LH C4.236
LJ T4.236
LK D4.236
LL 4.38
Ll\,1 4.41
N 4.318
NA 4.270
NB 4.300
NC 4.318
ND 4.31A2
P 6.305
PA P6
PB 6.288
PC 6.305
PD PF6.3O5
R 6-247
RA 6.247
SD Sabre CC6.68
T 6.3s4
TA 6.306
TB 6.33s
TC 6.354
TD H6.3s4
TE T6.3s4
TF H6.354
TG 6.3541
TH T6.3s41
TJ 6.3542
TK C6.3542
TL 6.3s43
TM C6.3543
TN H6.3543
TP T6.3543
TQ HT6.3543
TB 6.372
TS 6.3723
TT TC6.3541
IU T6.3544
TV 6.3724
TW 6.3544
TX C6.3544
ry H6.3544
rz HT6.3544
U 700Serles
uA 704-26
uB 704-30
W P€regrlne/l300
wA 6.466
wB T6.466
wc cc6.466
WD T6.67
wE cc6.67
WF T6,76
wG cc6.76
wH T6.87
wJ cc6.87
x v8.540
xA v8.510
XB TV8,51O
xc v8.540
xD v8.605
XE TV8.54O
Y Phaser/l006
Nalurally
aspiraled
Turbocharged
Compensated
Charge cooled
Fed. Charge
cooteo
N€w Phaser/1006
Naturally
asprrated
Tuöocharged
Tuöocharged
Inlercooled
z v8.640
zA v8.640
zB TV8.640
YB
YC
YD
YE
YG
YH
YK
Perk ns Seruice Data Booklet Pad 1. 1997
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Basictault-tinding
guide
The
chart
belowis
grven
to
assisl
in
thecorectdiagnosrsolbasicenginelaults
Problemsand
possible
causes
Problem Possible causes
ftse slade'nolor turls ltse
e^gire loo sLowL, 1.2.3.4
The eng ne does nol siai 5,6, 7,
8,9,10,12,13,14,15,17,34,
35,36,37,38,
40,42.43,
44
lhe engrne s dfiicull lo slad 5,7,8,
9,
1
0,
11.12,
13.14,15,16,17,19,34,36,
37,
34.
40.42.
43.44
Not enough power 8,9,10,11,12,13,16,17,18,19,20,21,34,36,37,
38,39,42,43,44,61
,
63,64
Mislre 8,9,10,12,13,15,20,22,34,36.
37,38,39,
40,
4
High fue consumplon 11,1
3,1 5,1 7,18,19,21,22,34,36,37,38,39,40,
42.
43.44.63
Black exhaust smoke 1l, 13,15,17,19,21,22,34.36,s7,38,
39,40,
42,
43,44,61,
63
Elueor
wh(e
exhaustsmoke 4, 15,21,23.36,37.34,35,42,44,4s,52,5A.62
The pressure ol the lubricatinqo I s loo low 4,24,25,26, 46.47.44,50,51,59
The
engrneknocks 9,
1
3,1 5 17. 20,22.23.36,37,40,42,44,46,s2,53,
60
The engine runs eralrca ly 7,8,9,10,11,12,13,15,
16,14,20,22,23,34,s8,
40,41,44,52,64
Vrbralon 13.18,20,2
/.2A,34,3a,39,
40,41,44,
52,54
-l e p e>s-'e ol he lLbriLal-q o I s loo h q' ,25,
49
The engrne temperalure is too high 11,13,15,19,27,29,30,
32,34,36,37,39,52,55,
56.57.64
Crankcase
pressure 31,33,39,42,44,45,52
Bad compression 11. 22.37.39.40.
42.
43.44 45.53.60
The engrne slans and stops 10,11,12
Perkins
ServiceDataBookletPan1.1997

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Turbocharger
taultguide
The chan below is given lo asslsl in the corecl diagnosis ol luöocharger fallts.
li the inside ol the induclion manilold s wet, check that there is nol a fuel leak trom the tuelled stadinq
a d. I there is one fined.
Problems and Dosslble causes
Problem Possible causes
Not enough power 1,4,5,6,7,8,
9,
10,
11
,1A,20,21,22,25,26,27,
28,34,3s,36
Black
smoke 1.4,5,6,7,
8,9,10,11,1A,
20,21,22,
25.26,27,
28,34,35,36
Buesmoke 1,2,4,
6,8,9,17,19,20,
21,22,30,
31,32,34
H gh ubrcalng oilconsumption 2,4,15,17,19,
20,2A,29,
31.32,34
Too much iubncatng orlal turbtne end 2,7,A,17,19,20,22.28.
30.
31.32
Too much lubncating oil ai compressor end 1,
2,4,5,6,8,19,
20,21,2A,31,
32
Not enough lubrication 8,12,14,15,
16,23,24,
29.32.33.
37.38
Lubncal ng oil in the exhausl manitold 2,7,17,
18.19.20.22.2A.31.32
nsrde ol lhe Induction manfold wel 1,
2,3,4,s,6,8,1
0,11,17,1A,19,20,21,2A,32,
34,39,40
Damagedcompressor
impeller 3,4,
6,8,12,15,16,20.21,23,24,29,
32,33,
37,38
Damaged turbine rolor 7,A,12,
13.14,15,1
6,1 a,20,22,23,
24,25,27,29,
32,33.37,38
Bolalng assemblydoesnot
tumlreely 3,6,7,4,12,1
3,
1
4,15,16,18,
20,21,22,23,24,29,
32,33,37,38
Wornbearings
bearingbores,
journals 6,7,
8,12,13,14,15,16,23,24,29,33.37,3A
No se iiom lurbocharger 1,3,4,5,6,7,8,9,
10,
11,12,13,14,
15,16,18,20,
21,22.23,24,29,
32,33.34,37,
38
Sludge or carbo- deposrt r^ beanrg houstnE 2.11,13,14,
15,17.18.24.29.
33.37.38
Perkrns Seryice Data Booklet Pad 1. 1997

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General safety precautions
These satety precautions are lmporlant. You
must reler also 10the local regulations in the
country ol use. Some items only reler to specitic
apprcarons.
. Only use these engines in lhe type ol
app icalion10rwhich lhey have been designed.
t Do no'rndnqe I e spac{rcälron o'lhe engine
' Do not smoke when you pul iuel in the tank.
. Cledr dwayluelwFrch has bee_ sorll.
Material
whrch has been conlaminated by luel musl be
moved to a saie place.
. 0o not pul lue in the lank wh le the eng ne runs
(uness t s absolutey necessary).
' Do not clean, add lubricatng oil, or adjust the
engine while il runs (unless you have had the
correcltalnrng; even then exlreme cafe musi oe
used lo prevenl nlury).
. Do nol make adjuslmenls thal yo! do not
undersland.
. Ensure lhal the engine does nol run n a local on
where { can cause a concentation ol loxrc
. Olher persons musl be kept al a sale d slance
whre Ihe engine or aux liary equipmenl ls rn
. Do nol permil oose clolh ng or long halr near
movrng pads
. Keep away trom movtng pans during engtne
opetaltan Waning! Some movtng pads cannot
be seen cleaily while the engine runs
. Do not operale the engine il a salely guard has
' Do nol remove lhe lillercap or any componenl ol
the cooing syslem while the engine is hol and
wh le lhe coolanl s under pressure, because
dangerous hot coo ant can be discharged.
. Do not use sa t waler or any other coolanl whrch
can cause cotrosion In
lhe closed crrcuiloi lhe
cool ng system
. Do nol allow sparks or Jirenear the banenes
(especially
when lhe baflefes are 0n charge)
because the gases lrom lhe eleclro yte are h gh y
I ammable The batlery liuid is dangerous 10the
sk n and especia ly lo the eyes.
. D sconnecl lhe batlery lerm na s belore a repa r
s made to lhe e ectncal syslem.
' On y one person musl contol the englne
. Ens!re thal the engrne rsoperaled only lrom lne
conlro pane or trom lhe operators posilron
. l io- \h n LoTps Inlo , onldcl w Ih h th
pressure tuel. oblarn medtcal assrslance
mmedrately
. Diesel Juel and ubilcalng oil (especially used
lubricatingoil) can damage the skin of cerlain
persons. Prolect your hands wilh gloves or a
special solulion lo prolecl lhe skin.
. Do not wear clothing which is contam nated by
lubricating oil. Do not pul malerial which is
conlaminated with oil ioto lhe pockets of clothing.
. Discard used lubricating oi1in accordance with
local reg!lat ons lo prevenl conlamination.
. Ensure lhat lhe control lever ol the transmission
drive is in the "oufof-drive position before lhe
englne rsstaned.
. The combustible maierial ol some componenis
ol the engine (lorexample cedain seals) can
become e(remely dangerous il il rsburned.
Never a low lhis burnl maleral lo come inlo
contact wilh the skin orwth the eyes.
. Read and use the nstruclions relevanl lo lill
equ pmenl.
' Wear a face mask il lhe glass fibre cover of lhe
turbocharger is lo be removed or lifted.
. Always use a salely cage io prolect lhe operalor
when e component Ls lo be pressure tesled in a
conta ner ol waler. Fil salety wires to secure ihe
plugs which seal the hose conneclions of a
componeni which is to be pfessure tesled.
. Do nol al ow compressed arr to contact your
sk n. ll compressed air enlers your skin, obtain
medicai help immediately.
. Turbochargers operale al high speed and at high
temperatures. Keep lingers, lools and debris
away lrom the inlet and outlet poils of lhe
turbocharger and prevent conlacl wilh hot
sudaces.
. Fil only genuine Perkins pads.
PerkrnsSeru
ceDataBookletPad1.1997

166t I UPd lallooS Pteo acrruas surliad
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2
q:oa
Basic technical data
HOrSepowet
Number ol cylinders
Cycle .. ...
Induclon syslem
Combuslion sysiem
Nominal bore
Stoke ... ..
Compresston ralio
C!bic capacity
Finngorder ...
Valve lip clearances
- Inlel icold) .
' Exhaust (cold)
Lubricating oi1pressure
- al maxrmum engine speed and
normal engrne temperature . .. ...
Coolant temperalure
Thermoslat slans lo open
' berows rype
'waxlype ....
Thermoslat tully open
- bel ows lype
- wax type . .
Dreclion of rotation
ldlrngspeed
Localion ol maximum noload speed
Location
ol number 1 cy|nder .....
Location ol engine liming marks . . .
Alom ser codes
Fuel pump codes
Localonotluel
pumpcode .......
Localon ol luel pump timing marks
Be[lensron ..
Belt delleclion al longesl run . . . .
. 35,0kW(47bhp)
...........
4
,..,, rourslroxe
Naturallyaspirated
. . Indirect
inieclion
79,37mm
(3.125
in)
. 88,90mm
(3.500
in)
.. ..........22:1
1,760lilfes
(107.4
in3)
1-3-4-2
0.30mm
(0.012
in)
. 0,30mm
(0.012
in)
. . . . 207/414kN/n' l30t61
tbl/in
l 2,1/4,2kl|cm,
... ..... . 60'c (140"F)
... 67n5'C (152/167.F)
.. . 77l85'C (170/185"F)
. 85/88"C(185n
90.F)
. 92l98'C (197/208.F)
. Clockwis€lromtroni
.-.... .. 550rev/min
. . .. . Fuelinjection
pump
dataplate
.. Crankshafl
pulley
end
Scribelinesonluelinjeclion
pump
and
pump
llange
... . CAV
=
BG,
GY,OMAP
=
YB
EH34E,EH39,PH3O
......... Dala
plateontuelpump
..... . . Fuel
pump
mounlingllange
45N (10 lbr)4,5ksf
.. .... 10mm
(3/8
in)
Pelkins Seruice Dala Booklel Pad 1. 19972.O2
t

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(t) ran I ro6u rec rqn aql lc rais upc aql Maua8
(t) ro6u lecrqnl au 6ua aql Maua8
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duns aqi u lro
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(pau I areqa) qsnq r€ar oueu^p alec rqn-l
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(z) lue o03 lo tunoue aql !lcaqc
(s3tru 00021) ut 00080t ro srnoq 0012 rua^f 3
(salru 000t2) ul 00090 ro srnoq 006 tua^: O
(saru 0002t) u) OO08!
rosqtuou Zt )o srnoq
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srnoq 8 fue^a ro ^Ep fua^: v
salnpaqss a3ueualulPy!
atrruas qcpe tp sraualsel asooL
pup aOelea rol fcaqc ol acueualu eu a^qua^ard poob s ll
'eur6ue eql lo uolerado t3aroa arnsua ot paldepp aq ot paau
Äeu sarnpacord pue sporad asaqt suortelnOar
leco aq] ol uroluoc ]snu autbua aql lo !ol€iado aql uaqM
'lsa!oqs ar€ qc qa spo rad aqt asn pailEtsu sreur6ua aql qcrqM u iuaud nba aql lo rarnlselrruPU aql ^q
ua^ 6 spo rad aqt lsaqO uo lerado lo suoq puoc a6ere^e ot ^ldde spoDad acueualu eu a^q!a^ard asaql
agu49p aq) ueqt lueyodat
aaa ae uauetada p tnoq eql sdals pue sle)s uenba! qla ualaado aouelstD poqs ua :uolneJ
sporiad scueualuleu a^llua^ald
uorlersdo
tsrI lncro qoqa (sqluou )o s)noq) lpruetu aql le pa dde aq lsnu Molol qa qa sslnpaqis aq-I
z goti,