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Perkins 4.107 User Manual

Perkins 4.107
114 pages
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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

Table of Contents

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Perkins 4.107 Specifications

General IconGeneral
AspirationNaturally aspirated
Fuel TypeDiesel
Compression Ratio22:1
Fuel SystemIndirect injection
Cooling SystemWater-cooled
ConfigurationInline-4
Displacement1.76 liters

Summary

Technical Data

Engine Data

Provides basic specifications like bore, stroke, displacement, and compression ratio.

Rating Details

Outlines maximum gross rated output and torque for different engine models.

Engine Weights, Dry

Specifies the dry weight of the bare engine and with accessories.

De-rating for Altitude

Guides on fuel delivery de-rating percentages for operation at different altitudes.

Operating and Maintenance

Starting the Engine

Details the procedure for starting the engine, including cold weather assistance.

Preventive Maintenance

Outlines general preventive maintenance periods and checks.

Stopping the Engine

Describes the procedure for stopping the engine correctly.

Engine Coolant

Provides guidance on coolant quality, antifreeze mixtures, and corrosion protection.

Fault Diagnosis

Fault Finding Chart Key

Lists numbered causes corresponding to faults for troubleshooting engine issues.

Cylinder Head

To Remove the Cylinder Head

Step-by-step instructions for removing the cylinder head assembly.

VALVES AND VALVE SEATS

Guidance on checking, reconditioning, and fitting valves and valve seats.

CYLINDER HEAD GASKET

Information on selecting and fitting the correct cylinder head gasket.

Pistons and Connecting Rods

To Remove Pistons and Connecting Rods

Procedure for removing pistons and connecting rod assemblies from the cylinder block.

Inspection

Details on inspecting pistons, rings, and connecting rod small end bushes.

Fitting New Pistons

Instructions for fitting new pistons, including height checks and grade selection.

Cylinder Block and Liners

CYLINDER LINERS (4.108 ENGINES)

Description of cylinder liner type, fit, and measurement procedures.

To Renew Cylinder liners

Step-by-step guide for removing and fitting new cylinder liners.

Oversize Cylinder liners

Information on the availability and fitting of oversize cylinder liners.

Crankshaft and Main Bearings

Description

Overview of crankshaft construction, bearings, and end float control.

To Renew Main Bearings and Thrust Washers

Procedure for replacing main bearing shells and thrust washers.

To Remove the Crankshaft

Steps required to safely remove the crankshaft from the engine.

CRANKSHAFT REAR END OIL SEAL

Details on the construction and replacement of the crankshaft rear oil seal.

Timing Case and Drive

To Remove the Timing Case Cover

Instructions for removing the timing case front cover assembly.

To Refit the Timing Case Cover

Procedure for refitting the timing case front cover correctly.

To Fit New Fuel Pump Gear

Steps for fitting a new fuel pump gear and ensuring correct timing.

To Remove the Camshaft and Tappets

Detailed steps for removing the camshaft and tappets from the engine.

Timing

General

Overview of timing gears and their constant factory setting.

TIMING MARKS

Explanation of timing marks stamped on gears for resetting engine timing.

To Reset the Engine to the Original Timing

Procedure for resetting engine timing using gear marks.

Checking Valve Timing

Method for checking valve timing accuracy and identifying potential errors.

Lubrication System

To Refit the Sump

Instructions for refitting the engine sump with new gaskets and sealant.

To Remove the Oil Pump

Procedure for removing the engine's lubricating oil pump assembly.

LUBRICATING OIL FILTERS

Information on lubricating oil filters and their maintenance requirements.

To Renew the Paper Filter Element

Steps for replacing the paper filter element in the oil filter assembly.

Cooling System

FAN BELT

Details on adjusting, removing, and refitting the fan belt.

WATER PUMP

General information and procedures for dismantling and assembling water pumps.

THERMOSTAT

Instructions for removing, testing, and replacing the engine thermostat.

Air Cleaners and Fuel System

AIR CLEANERS

Guidance on servicing different types of air cleaners, including dry and oil bath types.

FUEL OIL FILTERS

Information on fuel oil filters and the procedure for renewing the filter element.

Maximum Speed Setting

Information and warnings regarding the adjustment of the maximum speed screw.

IDLING SPEED ADJUSTMENT

Procedure for adjusting the engine idling speed and the anti-stall device.

Flywheel and Flywheel Housing

To Remove the Flywheel

Steps for removing the flywheel from the crankshaft flange.

To Renew the Flywheel Ring Gear

Procedure for removing and fitting a new flywheel ring gear.

To Refit the Flywheel Housing

Instructions for refitting the flywheel housing and checking alignment.

Electrical Equipment

ALTERNATOR Models AC5, HAC, 15ACR and 17 ACR

Precautions, maintenance, and fault finding for AC alternators.

Fault Finding on 11 AC

Diagnostic tests and procedures for the 11 AC alternator.

DYNAMO

Information and servicing details for the Lucas C40-1 dynamo.

STARTER MOTOR—PRE·ENGAGED DRIVE

Description, maintenance, and testing of pre-engaged drive starter motors.

Engines for Refrigeration Units

Cold Starting Procedure

Specific cold starting procedures for refrigeration unit engines.

Cylinder Liners

Details on cylinder liners for refrigeration unit engines, including rebore options.

Lubricating System

Notes on modifications to the lubricating system for refrigeration units.

Fuel System

Specific fuel system details for refrigeration unit engines.

Lubricating Oils

Approved Service Tools

POWERPART Consumable Products

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