1983+ Perkins 4.108/4.107/4.99 Diesel Engines OEM Service & Repair 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

I PERKINS COMPANIES I AUSTRALIA Perkins Engines Australia Pty. Ltd. I I I I I I I I I I I I I I I I I I 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: 597 58793. Moteurs Perkins S.A. 9-11 Avenue Michelet, 93583 Saint Ouen, Cedex, France. Telephone: (1) 40104200. Telex: 642924F. Fax: (1) 40104245. Perkins Motoren G.m.b.H. 8752 Kleinostheim, Postfach 1180, West Germany. Telephone: Kleinostheim 6027 5010. Telex: 4188869A PER D. Fax: 6027 501124. Motori Perkins S.p.A. Via Soc rate 8, 22070 Casnate con Bernate (Como), Italy. Telephon: (031) 452332. Telex: 380658 Perkit I. Fax: (031) 452335. 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: (03) 582-1596. Perkins Engines Asia Pacific, 4 Kian Teck Drive, Singapore 2262. Telephone: 2656333/2653223. Telex Perkoil RS37729. Fax: 2641188. Perkins Engines Limited, Eastfield, Peterborough, PE1 5NA, England. Telephone: (0733) 67474. Telex 32501 Perken G. Fax: (0733) 582240. Perkins Engines (Shrewsbury) Limited, Sentinel Works, Shrewsbury SY1 4DP, England. Telephone: (0743) 52262. Telex: 35171/2 PESL G. Fax: (0743) 69911. Perkins Engines Inc., 1700 Bellemeade Court, Lawrenceville, Georgia 30245, U.S.A. Telephone: 404 822 3000. Telex: 544141 Perken Law. Fax: 4048223006. 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: 305 442 7419. 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.

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

~ 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

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

1983+ Perkins 4.108/4.107/4.99 Diesel Engines OEM Service & Repair Manual

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