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Perkins Manuals
Engine
4.108
Workshop manual
Table Of Contents - Perkins 4.108 Workshop Manual
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Service data
(66 pages)
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Table Of Contents
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Contents
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Table of Contents
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Table of Contents
Safety Precautions
4
Table Of Contents
5
Example Of Service Facilities
6
Engine Views
7
Index To Engine Views
8
View Of Fuel Pump Side Of Engine
9
View Of Camshaft Side Of Engine
10
Technical Data
11
Engine Data
11
Rating Details
11
Engine Weights, Dry
11
Recommended Torque Tensions
12
Service Wear Limits
12
Manufacturing Data And Dimensions
12
Connecting Road Alignment
16
Approved Fuel Oil Specification
21
Static Timing Position
22
Operating And Maintenance
25
Starting The Engine
25
To Operate The Starting Aid
25
Earlier Heat Start Switch
25
Alternative Method
26
Glow Plugs
26
Stopping The Engine
26
Running In Procedure
26
Post Delivery Checkover
27
Protection Of An Engine Not In Service
27
Daily Or Every 8 Hours
27
Every 4.000 Miles, 150 Hours Or 3 Months
27
Engine Coolant
28
To Drain The Cooling System
28
Fault Diagnosis
29
Key To Fault Finding Chart
29
Cylinder Head
31
To Remove The Valves
33
Combustion Chamber Inserts
34
Valve Springs
34
Valve Guides
34
Valves And Valve Seats
35
Hand Grinding
35
Valve Seat Inserts
36
Push Rods
36
To Dismantle The Rocker Shaft Assembly
36
To Re-Assemble The Rocker Shaft Assembly
36
Cylinder Head Gasket
37
4.108 Engines
37
4.107 And 4.99 Engines
37
To Rem Cylinder Head
37
Pistons And Connecting Rods
41
To Remove Pistons And Connecting Rods
41
To Remove Pistons And Rings From The Connecting Rods
41
To Refit The Pistons To The Connecting Rods
42
Fitting The Piston Rings
43
Laminated Segment Rings
44
Spring Loaded Scraper Ring
45
To Fit Piston And Connecting Rod Assemblies
45
Fitting New Pistons
45
Cylinder Block And Liners
47
To Renew Cylinder Liners
47
Oversize Cylinder Liners
48
Crankshaft And Main Bearings
49
To Renew Main Bearings And Thrust Washers
50
To Remove The Crankshaft
51
Crankshaft Regrinding
51
To Refit The Crankshaft
51
Crankshaft Rear End Oil Seal
52
Crankshaft Regrinding Data
53
Timing Case And Drive
55
To Remove The Timing Case Cover
55
To Renew The Crankshaft Front Oil Seal
55
To Refit The Timing Case Cover
55
To Refit The Idler Gear And Hub
56
Hydraulic Pump Gears
56
To Remove The Camshaft Gear
56
To Refit The Camshaft Gear
56
To Remove The Fuel Pump Gear
57
To Refit The Fuel Pump Gear
57
To Fit New Fuel Pump Gear
57
Using Special Tool Ms67B
57
To Remove The Fuel Pump Drive Hub
58
To Refit The Fuel Pump Drive Hub
58
To Remove The Timing Case Back Plate
58
To Refit The Timing Case Back Plate
58
To Remove The Camshaft And Tappets
59
To Refit The Tappets And Camshaft
60
Timing
63
Timing Marks
63
To Reset The Engine To The Original Timing
63
Timing Pin
64
Checking Fuel Pump Timing
64
Checking Valve Timing
64
Lubrication System
65
The Lubricating Oil Pump
65
To Remove The Sump
65
To Refit The Sump
65
To Dismantle The Oil Pump
67
To Re-Assemble The Oil Pump
68
To Refit The Oil Pump
68
Oil Pressure Relief Valve
69
Oil Pressure
69
To Dismantle The Oil Pressure Relief Valve
69
To Renew The Paper Filter Element
69
To Renew The Filter Canister
70
Oil Filter Assembly
70
By-Pass Valve
70
Cooling System
71
Water Pump
71
To Adjust The Fan Belt
71
To Remove The Fan Belt
71
To Dismantle The Separate Bearing Type Pump
72
To Dismantle The Combined Bearing And Shaft Type Pump
72
To Dismantle Earlier Type Pumps
72
To Assemble The Separate Bearing Type Pump
73
To Assemble The Combined Bearing And Haft Type Pump
73
To Assemble Earlier Type Pumps
73
To Refit The Water Pump
74
Water Pump Seals
74
To Remove The Thermostat
74
To Test The Thermostat
74
Air Cleaners And Fuel System
75
Extreme Heavy Duty Two Stage, With Multiple Elements
76
Oil Bath Air Cleaners
76
Fuel Oil Filters
77
Fuel Lift Pump
77
To Renew The Filter Element
77
Testing The Pump In Position
77
Pressure Checking Of Fuel Lift Pump In Position
78
To Remove The Lift Pump
78
To Dismantle The Lift Pump
78
To Re-Assemble The Lift Pump
78
Fuel Injection Pump
79
To Refit The Fuel Lift Pump
79
To Remove The Fuel Injection Pump
79
Fuel Injection Pump Timing
80
To Refit The Fuel Injection Pump
80
To Check Engine Marking Angle On Fuel Pump Drive Housing
80
To Check Marking Angle Of Fuel Injection Pump
81
Alternative Method Where No Tool Is Available
81
Idling Speed Adjustment
83
Maximum Speed Setting
83
Anti-Stall Device
83
Atomisers
84
Testing For Faulty Atomiser
84
Atomiser Pressures
84
Atomiser Identification
84
Fuel Pipes (High Pressure)
85
Priming The Fuel System
85
Flywheel And Flywheel Housing
87
To Remove The Flywheel
87
To Renew The Flywheel Ring Gear
87
To Refit The Flywheel
87
To Remove The Flywheel Housing
88
To Refit The Flywheel Housing
88
Electrical Equipment
89
Alternator
89
Fault Finding On Ac5
89
Fault Finding On 11 Ac
90
Checking The Field Isolating Relay
90
Checking The Alternator And Control Box
90
Checking Or Adjusting The Voltage Setting
90
Check Alternator Output
91
Check Warning Light Control
91
Low-Unsteady Charging Rate
91
Flat Battery Or Low State 01 Charge
91
Alternator Output Test With Regulator Inoperative
92
Regulator Test
92
Routine Maintenance
93
Performance Data
93
Servicing
93
Starter Motors
94
Run-Off Helix Drive
94
"S" Type Starter Drive Assembly
95
Starter Motor - Pre-Engaged Drive
96
Checking Glow Plugs
97
To Check For Continuity Of Glow Plugs
97
Checking Glow Plus Using A Voltmeter
97
Engines For Refrigeration Units
99
Cold Starting Procedure
99
Cylinder Liners
99
Fuel System
99
Timing Gear Cover And Oil Seal
101
Piston
101
Piston Rings
101
Lubricating Oils
103
Mil-L-46152 Oils
103
Mil-L-2104C Oils
104
Approved Service Tools
105
Index
111
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