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Perkins 4.108M Workshop Manual

Also See for 4.108M

Handbook - 49 pages
Handbook - 50 pages

Table Of Contents

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17

Technical Data

See also: Handbook

Table of Contents

5
Contents
6
Unified Threads and Engine No. Location
7
Engine Identification - New Series
7
Engine Family and Type Codes
7
Country of Origin Code
7
Year of Manufacture Code
12
Index to Engine Photographs
13
View of Fuel Pump Side of Low-Line Engine
14
View of Camshaft Side of Low-Line Engine
15
View of Fuel Pump Side of Engine
16
View of Camshaft Side of Engine
17
Technical Data
18
Engine Weights
19
Recommended Torque Tensions
19
Service Wear Limits
20
Manufacturing Data and Dimensions
22
Connecting Rod Alignment
31
Operating and Maintenance
32
Priming the Fuel System
32
Preparing & Starting the Engine
32
To Operate the Cold Start Aid
32
Earlier Heat Start Switch
33
Stopping the Engine
33
Running in
34
Preventive Maintenance
34
Keep Engine Clean
34
Post-Delivery Checkover
34
Preservation of Laid-Up Engine
35
Preparing the Engine for Return to Service
36
Heat Exchanger Cooled Engines
37
Frost Precautions
39
Fault Finding
40
Fault Finding Chart
41
Cylinder Head
42
To Remove the Cylinder Head
43
To Remove the Valves
43
Combustion Chamber Inserts
44
Cleaning
44
Valve Springs
44
Valve Guides
45
Valves and Seats
45
Hand Grinding
46
Valve Seat Inserts
47
To Dismantle the Rocker Shaft Assembly
48
To Re-Assembly the Rocker Shaft Assembly
48
Push Rods
48
To Refit the Valves
48
Valve Seals
49
Cylinder Head Gasket
49
To Refit the Cylinder Head
51
Adjusting Valve Clearances
51
Valve Adjusting Sequence
53
Pistons and Connecting Rods
54
To Remove Pistons and Connecting Rods
54
To Remove Pistons and Rings From the Connecting Rods
55
Pistons and Connecting Rods Inspection
55
To Refit Pistons to Connecting Rods
56
Fitting the Piston Rings
57
To Fit Piston and Connecting Rod Assemblies
58
Fitting New Pistons
59
Cylinder Block and Liners
60
Cylinder Liners (4.108 Engines)
60
To Renew Cylinder Liners
61
Cylinder Liners (4.99 and 4.107)
61
To Remove Liners
62
To Fit New Liners
63
Crankshaft and Main Bearings
64
Crankshaft and Main Bearings Description
65
To Renew Main Bearings and Thrust Washers
67
To Remove the Crankshaft
67
To Refit the Crankshaft
67
Crankshaft Regrinding
67
Crankshaft Rear End Oil Seal
69
Crankshaft Regrind Data
71
Timing Case and Drive
72
To Remove the Timing Case Cover
72
To Remove the Crankshaft Front Oil Seal
72
To Refit the Timing Case Cover
72
To Remove the Idler Gear and Hub
73
To Refit the Idler Gear and Hub
73
To Remove the Camshaft Gear
74
To Refit the Camshaft Gear
74
To Remove the Fuel Pump Gear
74
To Refit the Fuel Pump Gear
74
To Remove the Fuel Pump Drive Hub
75
To Refit the Fuel Pump Drive Hub
75
To Remove the Timing Case Back Plate
75
To Refit the Timing Case Back Plate
75
To Remove the Camshaft and Tappets
77
To Refit the Tappets and Camshaft
79
Timing
80
Timing Marks
80
Fuel Pump Timing Marks
81
To Reset Engine to Its Original Timing
81
Check Valve Timing
82
Checking Fuel Pump Timing Using Tool MS67B
85
Lubricating System
87
Draining the Sump
87
The Lubricating Oil Pump
87
To Remove/Refit the Sump
87
To Remove the Oil Pump
88
To Dismantle the Oil Pump
88
Oil Pump Inspection
88
To Re-Assemble the Oil Pump
89
To Refit the Oil Pump
89
To Dismantle Oil Pressure Relief Valve
90
To Re-Assemble Oil Pressure Relief Valve
90
Oil Pressure
90
Lubricating Oil Filters
90
To Remove the Filter Element
91
To Remove Oil Filter Head Casting
91
By-Pass Valve
91
To Renew the Filter Element
91
To Renew Screw Type Oil Filter Canister
93
Cooling System
94
Open Circuit Cooling
94
Closed Circuit Cooling
95
Sea Water Pump
95
To Remove Pump
95
Dismantling
96
Alignment of Sea Water Pump Adaptor Plate
97
Fresh Water Pump
97
Fresh Water Pump Seals
97
To Remove Water Pump
97
To Dismantle Water Pump
98
Cooling System Inspection
98
To Re-Assemble the Water Pump
99
To Refit the Water Pump
99
Heat Exchanger and Oil Cooler
100
Exploded View of Heat Exchanger
101
Heat Exchanger Dismantling
101
Heat Exchanger Cleaning
102
To Remove Thermostat
102
To Test/Refit Thermostat
102
Checking for Correct Adjustment
102
Water Pump Belt Adjustment
103
Air Filter and Fuel System
104
Fuel Oil Filters
104
To Renew the Oil Filter Element
105
Pressure Testing of Fuel Lift Pump in Position
105
To Remove the Lift Pump
105
To Dismantle Lift Pump
106
To Re-Assemble the Lift Pump
106
To Refit the Lift Pump
107
To Remove Fuel Injection Pump
107
To Refit Fuel Injection Pump
107
Maximum Speed Setting
107
Idling Speed Adjustment
108
Anti-Stall Device
108
Atomisers
109
Testing for Faulty Atomiser
109
Atomiser Pressures
109
Atomiser Identification
109
Fuel Pipes
110
Bleeding the Fuel System
111
Priming Procedure After Changing Filter Element
111
Fuel Oil
113
Flywheel and Flywheel Housing
114
Alignment of the Adaptor Plate, Flywheel Housing and Flywheel
114
Alignment of the Adaptor Plate Face
114
Fitting Flywheel and Checking Alignment
115
Alignment of Flywheel Housing Bore
115
Alignment of the Flywheel Housing Face
117
Electrical System
118
Alternator Models AC5 and 11AC
118
Alternator Maintenance
118
Alternator Fault Finding On AC5
119
Warning Lamp Does Not Light Up When Switched "On"
119
Checking the Field Isolating Relay
119
Checking or Adjusting the Voltage Setting
119
Checking the Alternator and Control Box
120
Adjustment of Voltage Setting
120
Check of Alternator Output
120
Fault Diagnosis Procedure for 11AC Alternator Fails to Charge
120
Noise Alternator
121
DYNAMO Description
121
DYNAMO Routine Maintenance
121
DYNAMO Performance Data
121
DYNAMO Servicing
122
Brush Gear
122
Starter Motors
123
Checking Freedom of Brush Movement
124
Electrical System Servicing
124
'S' Type Starter Drive Assembly
127
Lubricating Oils
129
Approved Service Tools
131
Valve Seat Cutters
133
Index

Table of Contents

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Table of Contents

5
Contents
6
Unified Threads and Engine No. Location
7
Engine Identification - New Series
7
Engine Family and Type Codes
7
Country of Origin Code
7
Year of Manufacture Code
12
Index to Engine Photographs
13
View of Fuel Pump Side of Low-Line Engine
14
View of Camshaft Side of Low-Line Engine
15
View of Fuel Pump Side of Engine
16
View of Camshaft Side of Engine
17
Technical Data
18
Engine Weights
19
Recommended Torque Tensions
19
Service Wear Limits
20
Manufacturing Data and Dimensions
22
Connecting Rod Alignment
31
Operating and Maintenance
32
Priming the Fuel System
32
Preparing & Starting the Engine
32
To Operate the Cold Start Aid
32
Earlier Heat Start Switch
33
Stopping the Engine
33
Running in
34
Preventive Maintenance
34
Keep Engine Clean
34
Post-Delivery Checkover
34
Preservation of Laid-Up Engine
35
Preparing the Engine for Return to Service
36
Heat Exchanger Cooled Engines
37
Frost Precautions
39
Fault Finding
40
Fault Finding Chart
41
Cylinder Head
42
To Remove the Cylinder Head
43
To Remove the Valves
43
Combustion Chamber Inserts
44
Cleaning
44
Valve Springs
44
Valve Guides
45
Valves and Seats
45
Hand Grinding
46
Valve Seat Inserts
47
To Dismantle the Rocker Shaft Assembly
48
To Re-Assembly the Rocker Shaft Assembly
48
Push Rods
48
To Refit the Valves
48
Valve Seals
49
Cylinder Head Gasket
49
To Refit the Cylinder Head
51
Adjusting Valve Clearances
51
Valve Adjusting Sequence
53
Pistons and Connecting Rods
54
To Remove Pistons and Connecting Rods
54
To Remove Pistons and Rings From the Connecting Rods
55
Pistons and Connecting Rods Inspection
55
To Refit Pistons to Connecting Rods
56
Fitting the Piston Rings
57
To Fit Piston and Connecting Rod Assemblies
58
Fitting New Pistons
59
Cylinder Block and Liners
60
Cylinder Liners (4.108 Engines)
60
To Renew Cylinder Liners
61
Cylinder Liners (4.99 and 4.107)
61
To Remove Liners
62
To Fit New Liners
63
Crankshaft and Main Bearings
64
Crankshaft and Main Bearings Description
65
To Renew Main Bearings and Thrust Washers
67
To Remove the Crankshaft
67
To Refit the Crankshaft
67
Crankshaft Regrinding
67
Crankshaft Rear End Oil Seal
69
Crankshaft Regrind Data
71
Timing Case and Drive
72
To Remove the Timing Case Cover
72
To Remove the Crankshaft Front Oil Seal
72
To Refit the Timing Case Cover
72
To Remove the Idler Gear and Hub
73
To Refit the Idler Gear and Hub
73
To Remove the Camshaft Gear
74
To Refit the Camshaft Gear
74
To Remove the Fuel Pump Gear
74
To Refit the Fuel Pump Gear
74
To Remove the Fuel Pump Drive Hub
75
To Refit the Fuel Pump Drive Hub
75
To Remove the Timing Case Back Plate
75
To Refit the Timing Case Back Plate
75
To Remove the Camshaft and Tappets
77
To Refit the Tappets and Camshaft
79
Timing
80
Timing Marks
80
Fuel Pump Timing Marks
81
To Reset Engine to Its Original Timing
81
Check Valve Timing
82
Checking Fuel Pump Timing Using Tool MS67B
85
Lubricating System
87
Draining the Sump
87
The Lubricating Oil Pump
87
To Remove/Refit the Sump
87
To Remove the Oil Pump
88
To Dismantle the Oil Pump
88
Oil Pump Inspection
88
To Re-Assemble the Oil Pump
89
To Refit the Oil Pump
89
To Dismantle Oil Pressure Relief Valve
90
To Re-Assemble Oil Pressure Relief Valve
90
Oil Pressure
90
Lubricating Oil Filters
90
To Remove the Filter Element
91
To Remove Oil Filter Head Casting
91
By-Pass Valve
91
To Renew the Filter Element
91
To Renew Screw Type Oil Filter Canister
93
Cooling System
94
Open Circuit Cooling
94
Closed Circuit Cooling
95
Sea Water Pump
95
To Remove Pump
95
Dismantling
96
Alignment of Sea Water Pump Adaptor Plate
97
Fresh Water Pump
97
Fresh Water Pump Seals
97
To Remove Water Pump
97
To Dismantle Water Pump
98
Cooling System Inspection
98
To Re-Assemble the Water Pump
99
To Refit the Water Pump
99
Heat Exchanger and Oil Cooler
100
Exploded View of Heat Exchanger
101
Heat Exchanger Dismantling
101
Heat Exchanger Cleaning
102
To Remove Thermostat
102
To Test/Refit Thermostat
102
Checking for Correct Adjustment
102
Water Pump Belt Adjustment
103
Air Filter and Fuel System
104
Fuel Oil Filters
104
To Renew the Oil Filter Element
105
Pressure Testing of Fuel Lift Pump in Position
105
To Remove the Lift Pump
105
To Dismantle Lift Pump
106
To Re-Assemble the Lift Pump
106
To Refit the Lift Pump
107
To Remove Fuel Injection Pump
107
To Refit Fuel Injection Pump
107
Maximum Speed Setting
107
Idling Speed Adjustment
108
Anti-Stall Device
108
Atomisers
109
Testing for Faulty Atomiser
109
Atomiser Pressures
109
Atomiser Identification
109
Fuel Pipes
110
Bleeding the Fuel System
111
Priming Procedure After Changing Filter Element
111
Fuel Oil
113
Flywheel and Flywheel Housing
114
Alignment of the Adaptor Plate, Flywheel Housing and Flywheel
114
Alignment of the Adaptor Plate Face
114
Fitting Flywheel and Checking Alignment
115
Alignment of Flywheel Housing Bore
115
Alignment of the Flywheel Housing Face
117
Electrical System
118
Alternator Models AC5 and 11AC
118
Alternator Maintenance
118
Alternator Fault Finding On AC5
119
Warning Lamp Does Not Light Up When Switched "On"
119
Checking the Field Isolating Relay
119
Checking or Adjusting the Voltage Setting
119
Checking the Alternator and Control Box
120
Adjustment of Voltage Setting
120
Check of Alternator Output
120
Fault Diagnosis Procedure for 11AC Alternator Fails to Charge
120
Noise Alternator
121
DYNAMO Description
121
DYNAMO Routine Maintenance
121
DYNAMO Performance Data
121
DYNAMO Servicing
122
Brush Gear
122
Starter Motors
123
Checking Freedom of Brush Movement
124
Electrical System Servicing
124
'S' Type Starter Drive Assembly
127
Lubricating Oils
129
Approved Service Tools
131
Valve Seat Cutters
133
Index

Also See for Perkins 4.108M

Perkins 4.107(M) Handbook

Perkins 4.107(M) Handbook 50 pages

Perkins 4.10SM Handbook

Perkins 4.10SM Handbook 49 pages

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This manual is also suitable for:

4.107m 4.99m