Perkins 4.10SM User manual

handbook
. for marine diesel engines _

Every endeavour has been made to ensure that the information contained in this book
is correct at the date of publication, but due to continuous developments, Perkins
Engines Ltd., reserve the right to alter the contents without notice.
handbookfor
4.10SM
diesel engines
©
1979
U.S.A.
Perkins Engines, Inc.
P.O. Box 697
32500 Van
Born Road
Wayne, Michigan 48184
Phone: (313) 595·9600
Publication No. 201 SER 1079 1108
CANADA
Perkins Engines Canada Limited
425 Horner Ave.
Toronto, Ontario M8W 4W3
Phone: [phone]

PERKINS COMPANIES
AUSTRALIA
Perkins Engines Australia Pry. lid .
P.O . SO)( 156. Oandenong, Victoria 3175. Australia .
Telephone : [phone]. Telex; AA30816. Cables: 'Perkoii' Melbourne.
BRAZIL
Motorss Perkins S.A
Caixa
Postal 30.028, 01000 Sao Paulo , SP- B,az iL
Telephone: [phone]. Telex; 0114013 and 01142S4. Cables: 'Perkoir Sao Paulo
CANADA
P.RJn. ~In .. Can.d. Usltad
425 Horn., .... "' •.
Toronto. Ont.,10 M8W 4""'3
Phon,: ( 4161593 ·3934
FRANCE
Mateurs Perkins S.A.
9711 Ave. Michelet BP 69, 93403 Saint Quen Cede..:, France.
Telephone: 2S7
14 19 Telex: 642924F Cables: 'Perkail' Paris.
GERMANV
Perkins Motoren G.rn.b.H.
8752
Kleinostheim. Posriach 1180. Germany .
Telephone: [phone]. Telex: 4188869.
GREAT BRITAIN
Perkins Engines Limited
Peterborough, England, PE 1SNA.
Telephone: 67474. Telex: 32501. Cables: 'Perkoil' Peterborough_
ITALV
Motori Perkins S.p .A .
Via
Gorizia 11 , P.O. Box 12,22070 Portichel1o /Luisago (Como). Italy.
Telephone: [phone]. Telex: 38()658 . Cables: 'Perkoii' Camerlata.
JAPAN
Perkins Engines INonh Pacific I ltd.
6th Floor , Reinanzaka Building , 14-2 Akasska . 1 chome, Minatu-Ku, Tokyo 107, Japan.
Telephone : 1031 58&-7ID. Telex: 24292 Tokyo.
SOUTH AFRICA
Perkins Engines (PlY.) lid .
P. O. Box 31285. 6th Floor , Noswal Hall. Braamfonlein 2017. Johannesburg, South Africa.
Telephone : Johannesburg 39 28 21. Telex: 8-0037SA . Cables: .Perkoi!,
UNITED STATES OF AMERICA
P.,k, ... ~ Inc.
P.O 80.697
32500 V.n Born Ro.d
W.\ln,. MIchl;,,"
48t84
p.........: IJI3159.!t-9600
Perki ns Engines Latin America Inc.
2600 Douglas Aoad, Suite 600. Coral Gables. Florida 33134, U.S.A .
Telephone : [phone]. Telex: 515680. Cables: 'Perklac'
ASSOCIATE COMPANIES AND MANUFACTURING LICENSEES
ARGENTINA
Perkins Argentina S.A . 1. C.
Bolivar 368, Buenos Aires, Argentina .
Telephone: 338231 . Telex: 121162. Cables: 'Perkinsa'
KOREA
Hyundai Motor Co.
Hyundai Building, 178 Sejong · Ro , Jongro-Ku , Seoul , Korea
Telephone: 74·8311 and 75 ·651 I. Telex: HdmocoK2391 .
MEXICO
Motorss Perkins S.A.
Antlguo Camina San Lorenzo SI N, Aoanado Posta l 194 , Toluca . Es!ado de Me_ico. MeXICO
Telephone ; Toluca 4. 4455. Telex: 00178493. Cables : ' Mopesa· Toluca .
PERU
MOlores Diesel Andinos S.A ..
Antero Aspillaga No . 585, Apartado 111 79, Lima 14, Peru.
Telephone : 406882 _ Telex: 21076.
SINGAPORE
Perkins Engines Easlern lid .
549 Upper Thomson Road. Sin gClpo re 20.
Telephone : [phone] / 4!:J,21841. Telex: Perkoil R23360
SPAIN
MOlor Iberica S. A. (DI ..... ision Zona 21
Carretera del Aero-Club. Carabanchel Al to . Madrid . Spain .
Telephone: [phone]. 208 98-40. T ele. 27324. Cables: 'Perk,-e' Madrid.
URUGUAY
Perkins Rio de la Plaia S. A.
~v . Juan Carlos Gomez 1492. Monle vldeo. Uruguay.
relephone: 290-726. Tele ... : 278. Cables: ' Petluns · MonteVideo
fUGOSLAVIA
ndusltl ja Motora Rako"Ica
::JauI13rha Dlmilrija 7· 13 , Rako ...... ca. Belgrade . Yugoslav i a.
relephone · 562·04 3/562 ·322'562-992 Telex 11341 YU IMA C.ables: Indmoto( Beograd
n addltlun to the above, Ihere are Perkins Distributo rs In the majority of cou nlries throughout Ihe world Fo( further detaIls . apply
a Perkill s f-n91nes Limited. Pelerb o rough . or 10 one !II rhe above c ompanies

PI z j)14~qSq4
S'{ 1 S'S¥0
engine guarantee
The guarantee applies to new engines and spare parts only. It does not cover second
hand engines
or parts, spurious parts, accessories and proprietary fittings.
Perkins
do not accept guarantee claims direct from Boat Owners. If a claim under
guarantee becomes necessary, the Boat Owner should
contact the nearest Perkins
Marine Distributor, his approved Dealer
or the Company from whom he purchased his
craft .
The full terms
of Perkins guarantee are set out in the Engine Guarantee Certificate
which is issued with each engine and should be found with the ship's papers, having
been passed
by the Perkins Distributor to the Boatbuilder concerned.
It would assist if the Guarantee Certificate could be produced on any occasion that a
claim
is made.

examples of service facilities
Service Instruction
Perkins Engines, Inc.
P.O. Box 697
32500 Van Born Road
Wayne. Michigan
48184
Phone: [phone]
Service Publications
The following Service Literature may be purchased through
your local Perkins Distributor.
Workshop Manuals
Fault Finding Guide
Crankshaft Regrinding
Installation and Maintenance Guide for Static Standby Engines
etc.
USE ONLY
GENUINE
PERKI,NS PARTS
4

On Board Tools
Engine Photographs
Engine Identification
Data
Opening Instructions
Instruments ...
Preventive Maintenance
Post Delivery Checkover
Preservation
of Laid Up Engine
Frost Precautions
Fuel System .
Cooling System
Lubricating System
Checking Valve Clearances
Gearboxes
Electrics
Approved Lubricating Oils
Fault Finding.. .
Emergency Measures
contents
6
7
12
13
14
17
19
20
21
24
26
30
36
37
38
41
44
46
48
This handbook has been issued to guide operators in the correct use and mainten-
ance
of Perkins Marine Diesel engines. Providing an engine is correctly installed,
correct maintenance and certain precautions are observed, then
no operating diffi-
culties or failures should
be experienced. All matters relating to marine propulsion are
covered, also fault diagnosis and remedy, and minor repairs which the average
marine operator can undertake, whilst his
craft is afloat.

ON BOARD TOOLS
An "on board" tool kit for engine work is available but the following tools and general
spares are suggested to supplement the kit: -
Hose clips, assorted.
Hose, assorted (convoluted type useful).
Fresh water
pump driving belt.
Sea water pump impeller.
Wire (20 SWG).
Insulating tape.
Jointing compound.
Magnet (keep away from compass).
Mechanical fingers.
Self-gripping wrench.
Asbestos lagging.
Low pressure fuel pipe olives.
Small hacksaw
with spare blade.
Assorted files.
For some engines an on board spares kit can be purchased from
your Perkins Marine
Distributor.
Perkins Engines are built to individual requirements
to suit the applications for which
they are intended and the following engine views do not necessarily typify any
particular specification.
6

6 5 4 3
"NEW" 4. 108M ENGINE
1. Oil Filler
2. Generator (Alternator)
3. Relay (C.A.V.)
4. Lubricating Oil Sump Drain Pump
5. Fuel Oil Lift Pump
6. Fuel Oil Filter
7. Ahead and Astern Engagement Lever
8. Gearbox Output Flange
9. Gearbox (Hurth Mechanical)
10. Gearbox Filler Plug and Dipstick
11. Exhaust Outlet
12. Seawater Cooled Exhaust Outlet Pipe
7

"NEW" 4.1DBM ENGINE
13. Fresh Water Filler Cap
14. Heat Exchanger, Fresh Water Header Tank and Exhaust Manifold (Fresh Water
Cooled)
15. Lubricating Sump Oil Level Dipstick
16. Seawater Pipe from Heat Exchanger Tube Stack to Exhaust Outlet Seawater
Ejection Point
17. Gearbox Oil Drain Plug
18 . Starter Motor
19. Lubricating Oil Filter Canister
20. Fuel Injection Pump
21. Seawater Pump Inlet (from
sea cock)
22. Seawater Pump
23. Fresh Water Pump
8

1 2 3 4 5 6
LOWLINE 4.108M ENGINE
1. Fresh Water Header Tank
2. Fresh
Water Filler Cap
3. Fuel Injection Pump
4. Fuel Oil Leak-off Pipe
5. Atomiser (injector)
6. Sea Water Pipe from Heat Exchanger to Manifold
7. Engine Lubricating Oil Dipstick
8. Exhaust Manifold
9. Engine Lubricating Oil Cooler
10. Gearbox Lubricating Oil Filter
11. Reduction Gearbox Lubricating Oil Filler
12. Starter
Motor
13. Engine Lubricating Oil Sump
14 . Sea Water Pipe from Sea Water Pump to Lubricating Oil Cooler
15. Engine Lubricating Oil Filter
16.
Sea Water Pump Inlet (from Sea Water Cock)
17. Sea
Water Pump
18. Fresh
Water Pump
9

LOWLINE 4.108M ENGINE
19. Sea Water Pipe from Lubricating Oil Cooler to Gearbox
20. Sea Water Pipe from Gearbox to Heat Exchanger
21. Heat Exchanger
22. Fuel Oil Filter
23. Fuel Oil Lift Pump
24.
Air Filter
25. Engine Lubricating Oil Filler
26. Fresh Water Pipe from Header Tank to Heat Exchanger
27. Generator (alternator)
28. Fresh Water Pipe from Cylinder Block to Header Tank
29. Lubricating Oil Sump Drain Pump
30. Cylinder Block Fresh
Water Drain Tap
31. Flywheel Housing
32. Gearbox Lubricating Oil Combined Dipstick and Filler
33. Gearbox
34. Gearbox Water Drain Plug
35. Reduction Gearbox Oil Level Plug
1n

HIGHLINE 4.108M ENGINE
1. Fresh Water Filler Cap
2. Heat Exchanger
3. Oil Filler
4. Air Filter
5. Fuel Injection Pump
6. Atomiser Leak Off Pipe
7. Pressure Pipes, Injection Pump
to Atomisers
8. Atomiser
9. Fuel Pipes, Filter to Injection Pump
10. Exhaust Manifold
11. Ahead and Astern Engagement Lever
12 . Gearbox Oil Filter
13. Reduction Gearbox Oil Filler
14.
Output Flange
15. Rear Engine Support
16. Water Pipe, Gearbox to Sea Water Pump
17. Lubricating Oil Filter
18. Connection for Oil Sump Pump
19. Sump
20.
Oil Cooler Pipes
21. Front Engine
Support
22. Crankshaft Pulley
23.
Sea Water Pump
24.. Water Pipe Exhaust Manifold to Cylinder Block
25. Fresh Water Pump
11

engine identi'fication
The engine type with which this handbook is associated is designated 4.1 08M.
The first figure in the engine designation denotes the number
of cylinders. The
second
group of figures denotes the engine capacity in cubic inches. The letter "M"
is for "marine".
Engine Serial Number
The serial number is stamped vertically on the fuel pump mounting flange of the
cylinder block
as shown in Fig. 1.
With earlier engines, the first three figures of the engine number represented the
capacity
of the engine in cubic inches, the letter "U" signified that the engine was
built in the United Kingdom and the last group of figures comprised the engine serial
number.
With current engines, the number consists of up to fifteen letters and figures
e.g. EDl3541U510123D.
Where information, spare parts
or assistance is required, this number should
always
be quoted in full.
Fig. 1
Engine No. Location 4.10BM.
12

engine data
Type
No.
of Cylinders
Nominal Bore
Stroke
Cubic Capacity
Compression Ratio
Firing Order
Four Stroke, Indirect Injection
4
3.125 in (79,37 mm)
3.5 in (88,90 mm)
107.4 in3 (1,76 litre)
22 : 1
1,3,4,2.
0.012 in (0,30 mm) Cold
Valve Tip Clearance
Oil Pressure 30 -
60 Ibf/in' (2,1 -4,2 kgf/cm2) or 207 -414 kN/m'
at max. speed and normal operating temperature.
Sump Capacities Imp. Pts. Litres us Quarts
"New" 4.108 and Low-line Engines (Refill) 7.9 4,5
4.8
"New" 4.108 and Low-line Engines (Total) 9.4 5,3
4.7
High-Line Engines (Refill) 7 4
4.2
High-Line Engines (Total) 8.5
4,8
5.1
Rating Details
Pleasure Craft (High Speed) 47 shp (51 bhp or 38 kW) at 4,000 rev/min
Pleasure Craft 45 shp (48 bhp or 36 kW) at 3,600 rev/min
Commercial Craft 37 shp (40 bhp or 30 kW) at 3,000 rev/min
Note:
Maximum rev/min is dependant on hull design as the correct engine rating should
be matched
to the duty of the boat.
13

operating instructions
PREPARATION FOR STARTING
ENSURE FUEL IS TURNED ON !
Open engine coolant seacocks (does not apply with keel cooled engine).
Check coolant level in header tank (does not apply
with direct cooled engines).
Check engine and gearbox lubricating oil levels (see pages
38 and 44 for approved
oils).
Ensure
that the fuel tank contains considerably more than sufficient fuel for the
intended voyage. The fuel oil should
conform to one of the specifications given on
page 26.
Fig. 2. Typical engine control panel.

Starting the Engine
Place gearbox control in neutral gear.
Turn starter switch to position
"R" fig.3 and ensure that the engine stop control is
in the run position (i.e., pushed fully home).
Place engine speed control
in maximum speed position.
If the engine or weather is warm, turn starter switch in a clockwise direction to
the "HS" position.
As soon
as the engine starts, release the switch to the "R" position.
Be sure that the starter pinion and engine have stopped rotating before
re-
engaging the starter motor, otherwise damage may result.
If weather is cold, ensure cold start aid reservoir contains fuel oil. Turn on tap
between reservoir and cold start aid. Current engines have a direct feed cold start
aid where fuel is supplied from the fuel filter and
no tap is fitted.
Turn starter switch
to the "H" position and hold it there for fifteen to twenty
seconds.
Then turn the starter switch to the
"HS" position, thereby engaging the starter
motor.
If the engine does not start after twenty seconds, return the switch to the "H"
position for ten seconds and then re-engage the starter motor by switching to the
"HS" position.
As soon
as the engine starts, release the switch to the "R" position and turn off
the tap on the cold start aid reservoir (where fitted).
Earlier Heat Start Switch
The cold start switch supplied with earlier engines is shown in fig. 4.
Fig. 3 Fig. 4
15

With this switch, starting a warm engine is eHected by turning the switch in a
clockwise direction to the
"S" position.
In cold weather, the switch should be turned
to the "H" position for fifteen to
twenty seconds and then to the "HS" position in order to engage the starter motor.
As soon as the engine starts, the switch should be returned to the "0" position.
Where this type of switch is used, it was sometimes customary to have a separate
switch for the electrical circuits and this should be turned on before starting the
engine and turned
off after stopping the engine.
Starting the Engine (Alternative Method)
With some engines, a diHerent starter switch is provided and the cold start aid is
operated by means of a separate push button switch.
The cold starting procedure however is the same, i.e.
Switch on by turning the starter switch in a clockwise direction to the first
position.
Press the heater
button for fifteen to twenty seconds and then, with the heater
button still pressed, turn the starter switch in a further clockwise direction to engage
the starter
motor. As soon as the engine starts, release both starter switch and heater
button.
TO STOP ENGINE
A spring loaded stop control is located near the normal engine controls and
functions by
cutting oH the fuel at the fuel injection pump.
To operate, pull the knob and hold in this position until the engine ceases to
rotate. Ensure
that the control returns to the run position, otherwise difficulty may be
experienced
in restarting the engine.
Switch off by turning switch to position "0".
Note. Where an engine is fitted with an electrical operated stop solenoid, the stop
button on the engine control panel should be operated by pressing and holding there
until the engine has stopped.

Things to Note
When the engine starts, check the following points:
(a) That oil pressure is registered on gauge(s).
(b) That charging rate
is indicated on ammeter/generator light goes out.
(c) That coolant is discharging overboard.
Instruments (see Fig. 5)
These serve to give the operator important information about the running of the
engine, fuel state, temperature etc.
Generally speaking instruments have
not the accuracy that a laboratory meter has
and this should be borne in
mind when reading them: nevertheless they may be used
to ensure correct functioning of the engine(s).
~ Perkin. marine
eng In ••
Fig. 5
Typical Instrument Panel.
@
(!)
:':.~
I~
\ 't;"
@

Engine Oil Pressure Gauge
This is one of the most important instruments and should be checked for correct
operation as soon
as the engine starts. Normal oil pressure is 30/60 Ibf/in2 (2,1/4,2
kgf/cm2) or 207/414 kN/m2 at maximum engine speed and normal operating
temperature. However
it should be remembered that during the life of the engine
there will be a gradual
drop in oil pressure. This is perfectly normal as bearing sur-
faces wear. There
will also be a slight drop in pressure when the oil is hot or if the
wrong grade of oil is used in certain climatic conditions . See page 44 for correct
oil grades.
Gearbox Oil Pressure Gauge
Where this is fitted the pressure should be within the ranges given on page 39.
Here again there
will be a slight pressure drop when the oil is hot.
Tachometer
This provides the operator with the engine revolutions per minute (rev/min). The
number indicated has usually
to be multiplied by one hundred to give engine rev/min,
e.g. 20 x 100 = 2,000 rev/min.
Water Temperture Gauge
This indicates the temperature of engine coolant. Coolant temperatures should
remain
within the ranges given on page 30. If high temperatures are experienced
investigate
the cause immediately (see page 40).
Running In
It is not necessary to gradually run-in a new or factory rebuilt engine and any
prolonged
light load running during the early life of the engine can in fact prove
harmful
to the bedding in of piston rings and liners.
Full load can be applied on a
new or factory rebuilt engine as soon as the engine
is used,
provided that the engine is first allowed to reach a coolant temperature
of at least 140°F (60o CI.
Angle of Heel - Sailing Boats
Auxiliary yacht installations may require the engine to be run whilst beating to
windward. Under these conditions, the boat may heel up to 25° without adverse
effect on the lubricating system, providing the boat is righted occasionally in order
to
lubricate the valve assembly.

preventive maintenance
If a Perkins marine diesel engine is to give long and trouble free service, it is
imperative that it be maintained in accordance
with the following Periodical Atten-
tions:-
Daily or Every 8 hours (whichever occurs first)
Check coolant level.
Check sump oil level.
Check oil pressure (where gauge fitted).
Check gearbox oil level.
Every 100 hours or 2 months (whichever occurs first)
Drain and renew lubricating oil (see pages 36 and 45).
Renew lubricating oil filter canister (see page 36).
Clean air intake gauze.
'Check drive belt tension.
Clean
water trap.
Check engine
for leakage of oil and water.
Lubricate
dynamo rear bush (where fitted).
Every 400 hours or 12 months (whichever occurs first)
Renew final fuel filter element.
Check hoses and clips.
Drain and clean fuel tank.
Change gearbox oil.
Service atomisers.
Check and adjust valve clearances.
Every 2.400 hours
Arrange for examination and service of proprietary equipment, i.e. ~tarter motor ,
generator, etc.
An operator is usually familiar with the type of water he is operating in. It is there-
for left to his own discretion to check the weed trap, in the water intake, at appro-
priate intervals.
•Drive belt tension should be checked
monthly on engines rated above 3,000
rev/min.
19