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Perkins 4.108 User Manual

Perkins 4.108
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 4.108 Specifications

General IconGeneral
Fuel SystemIndirect Injection
Cooling SystemWater-cooled
Configuration4-cylinder
Displacement1.76 L (108 cu in)
Bore79.4 mm (3.125 in)
Stroke88.9 mm (3.5 inches)

Summary

Foreword

Safety precautions

Examples of Service Facilities

SECTION A Engine Views

Index to Engine Views

Lists components shown in engine view diagrams.

SECTION B Technical Data

Engine Data and Specifications

Basic specs, ratings, weights, and de-rating for engine models.

Torque and Wear Limits

Torque values for fasteners and acceptable wear limits for components.

Component Dimensions and Tolerances

Detailed dimensions for liners, pistons, rings, pins, rods, bearings.

Crankshaft and Main Bearings

Data on crankshaft dimensions, thrust washers, and main bearings.

Timing Gears and Fuel System

Specifications for timing gears, fuel pump, and lift pump.

Cooling System and Thermostat

Data for water pump, thermostat, and cooling system types.

Electrical Components Specifications

Specifications for atomisers, starting aids, alternators, and starter motors.

SECTION C Operating and Maintenance

Starting the Engine and Cold Weather Aids

Procedures for starting the engine, including cold weather assistance.

Preventive Maintenance Schedule

General maintenance periods and checks for engine upkeep.

Daily and Periodic Maintenance Tasks

Routine checks and tasks for different service intervals.

Engine Coolant and Storage Procedures

Coolant requirements and steps for engine protection during storage.

SECTION D Fault Diagnosis

Fault Identification and Possible Causes

Table correlating engine faults with potential causes and a key.

SECTION E Cylinder Head

To Remove the Cylinder Head

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

Valves and Valve Seats

Checking valve wear, reconditioning seats, and refitting valves.

Rocker Shaft and Gasket Procedures

Instructions for rocker shaft assembly and cylinder head gasket replacement.

SECTION F Pistons and Connecting Rods

To Remove Pistons and Connecting Rods

Steps to remove pistons and connecting rod assemblies from the engine block.

Piston and Ring Inspection and Fitting

Guidelines for inspecting pistons/rings and fitting new pistons.

SECTION G Cylinder Block and Liners

To Renew Cylinder Liners

Step-by-step guide for removing and replacing cylinder liners.

SECTION H Crankshaft and Main Bearings

To Renew Main Bearings and Thrust Washers

Procedures for replacing main bearings and thrust washers.

Crankshaft Regrinding Procedures

Information and data for regrinding crankshaft journals.

SECTION J Timing Case and Drive

Timing Case Cover Procedures

Instructions for removing, renewing, and refitting the timing case cover.

Camshaft and Tappets Removal/Refitting

Procedure for removing and refitting the camshaft and tappets.

SECTION K Timing

Timing Marks and Resetting Engine Timing

Identifying timing marks and resetting engine timing procedures.

Checking Valve Timing

Method for checking the engine's valve timing accuracy.

SECTION L Lubrication System

Oil Pump and Sump Procedures

Steps for removing and refitting the oil pump and engine sump.

Lubricating Oil Filter Procedures

Information on oil filters and procedures for renewing filter elements.

SECTION M Cooling System

Water Pump Procedures

Instructions for removing and refitting the water pump assembly.

Thermostat Procedures

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

SECTION N Air Cleaners and Fuel System

Air Cleaner Servicing

Maintenance procedures for various types of air cleaners.

Fuel Lift Pump and Injection Pump Procedures

Testing, removing, and refitting fuel lift pump and injection pump.

Idling Speed and Maximum Speed Adjustment

Procedures for adjusting engine idling and maximum speed settings.

Atomiser and Fuel Pipe Procedures

Information on atomisers, testing, and high-pressure fuel pipe installation.

SECTION P Flywheel and Flywheel Housing

Flywheel and Housing Procedures

Instructions for flywheel removal, ring gear renewal, and housing refitting.

SECTION Q Electrical Equipment

Alternator Precautions and Fault Finding

Vital precautions, maintenance, and troubleshooting for alternators.

Starter Motor Servicing and Testing

Procedures for servicing and testing starter motors in position.

Glow Plugs Testing

Methods for checking glow plug continuity and supply voltage.

SECTION R Engines for Refrigeration Units

Refrigeration Unit Engine Differences

Key differences in components and systems for refrigeration unit engines.

Approved Service Tools

Specialized Tools for Engine Servicing

Tools for valve guides, pistons, fuel pumps, liners, and timing.

Timing Tool and Injector Pump Timing Tools

Tools for timing case alignment and fuel injection pump timing checks.

POWERPART Consumable Products

POWERPART Fluids and Adhesives

Coolant additives, fuel protection, adhesives, and cleaning solvents.

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