Perkins 4.99M Diesel Engine Manuals

Manuals and User Guides for Perkins 4.99M Diesel Engine. We have 2 Perkins 4.99M Diesel Engine manuals available for free PDF download: Workshop Manual

Perkins 4.99M Workshop Manual (135 pages)

Brand: Perkins | Category: Engine | Size: 9 MB

Contents
5
Unified Threads and Engine No. Location
6
Engine Identification - New Series
7
Engine Family and Type Codes
7
Country of Origin Code
7
Year of Manufacture Code
7
Index to Engine Photographs
12
View of Fuel Pump Side of Low-Line Engine
13
View of Camshaft Side of Low-Line Engine
14
View of Fuel Pump Side of Engine
15
View of Camshaft Side of Engine
16
Technical Data
17
Engine Weights
18
Recommended Torque Tensions
19
Service Wear Limits
19
Manufacturing Data and Dimensions
20
Connecting Rod Alignment
22
Operating and Maintenance
31
Priming the Fuel System
32
Preparing & Starting the Engine
32
To Operate the Cold Start Aid
32
Earlier Heat Start Switch
32
Stopping the Engine
33
Running in
33
Preventive Maintenance
34
Keep Engine Clean
34
Post-Delivery Checkover
34
Preservation of Laid-Up Engine
34
Preparing the Engine for Return to Service
35
Heat Exchanger Cooled Engines
36
Frost Precautions
37
Fault Finding
39
Fault Finding Chart
40
Cylinder Head
41
To Remove the Cylinder Head
42
To Remove the Valves
43
Combustion Chamber Inserts
43
Cleaning
44
Valve Springs
44
Valve Guides
44
Valves and Seats
45
Hand Grinding
45
Valve Seat Inserts
46
To Dismantle the Rocker Shaft Assembly
47
To Re-Assembly the Rocker Shaft Assembly
48
Push Rods
48
To Refit the Valves
48
Valve Seals
48
Cylinder Head Gasket
49
To Refit the Cylinder Head
49
Adjusting Valve Clearances
51
Valve Adjusting Sequence
51
Pistons and Connecting Rods
53
To Remove Pistons and Connecting Rods
54
To Remove Pistons and Rings from the Connecting Rods
54
Pistons and Connecting Rods Inspection
55
To Refit Pistons to Connecting Rods
55
Fitting the Piston Rings
56
To Fit Piston and Connecting Rod Assemblies
57
Fitting New Pistons
58
Cylinder Block and Liners
59
Cylinder Liners (4.108 Engines)
60
To Renew Cylinder Liners
60
Cylinder Liners (4.99 and 4.107)
61
To Remove Liners
61
To Fit New Liners
62
Crankshaft and Main Bearings
63
Crankshaft and Main Bearings Description
64
To Renew Main Bearings and Thrust Washers
65
To Remove the Crankshaft
67
To Refit the Crankshaft
67
Crankshaft Regrinding
67
Crankshaft Rear End Oil Seal
67
Crankshaft Regrind Data
69
Timing Case and Drive
71
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
72
To Refit the Idler Gear and Hub
73
To Remove the Camshaft Gear
73
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
74
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
75
To Refit the Tappets and Camshaft
77
Timing
79
Timing Marks
80
Fuel Pump Timing Marks
80
To Reset Engine to Its Original Timing
81
Check Valve Timing
81
Checking Fuel Pump Timing Using Tool MS67B
82
Lubricating System
85
Draining the Sump
87
The Lubricating Oil Pump
87
To Remove/Refit the Sump
87
To Remove the Oil Pump
87
To Dismantle the Oil Pump
88
Oil Pump Inspection
88
To Re-Assemble the Oil Pump
88
To Refit the Oil Pump
89
To Dismantle Oil Pressure Relief Valve
89
To Re-Assemble Oil Pressure Relief Valve
90
Oil Pressure
90
Lubricating Oil Filters
90
To Remove the Filter Element
90
To Remove Oil Filter Head Casting
91
By-Pass Valve
91
To Renew the Filter Element
91
To Renew Screw Type Oil Filter Canister
91
Cooling System
93
Open Circuit Cooling
94
Closed Circuit Cooling
94
Sea Water Pump
95
To Remove Pump
95
Dismantling
95
Alignment of Sea Water Pump Adaptor Plate
96
Fresh Water Pump
97
Fresh Water Pump Seals
97
To Remove Water Pump
97
To Dismantle Water Pump
97
Cooling System Inspection
98
To Re-Assemble the Water Pump
98
To Refit the Water Pump
99
Heat Exchanger and Oil Cooler
99
Exploded View of Heat Exchanger
100
Heat Exchanger Dismantling
101
Heat Exchanger Cleaning
101
To Remove Thermostat
102
To Test/Refit Thermostat
102
Checking for Correct Adjustment
102
Water Pump Belt Adjustment
102
Air Filter and Fuel System
103
Fuel Oil Filters
104
To Renew the Oil Filter Element
104
Pressure Testing of Fuel Lift Pump in Position
105
To Remove the Lift Pump
105
To Dismantle Lift Pump
105
To Re-Assemble the Lift Pump
106
To Refit the Lift Pump
106
To Remove Fuel Injection Pump
107
To Refit Fuel Injection Pump
107
Maximum Speed Setting
107
Idling Speed Adjustment
107
Anti-Stall Device
108
Atomisers
108
Testing for Faulty Atomiser
109
Atomiser Pressures
109
Atomiser Identification
109
Fuel Pipes
109
Bleeding the Fuel System
110
Priming Procedure after Changing Filter Element
111
Fuel Oil
111
Flywheel and Flywheel Housing
113
Alignment of the Adaptor Plate, Flywheel Housing and Flywheel
114
Alignment of the Adaptor Plate Face
114
Fitting Flywheel and Checking Alignment
114
Alignment of Flywheel Housing Bore
115
Alignment of the Flywheel Housing Face
115
Electrical System
117
Alternator Models AC5 and 11AC
118
Alternator Maintenance
118
Alternator Fault Finding on AC5
118
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
119
Adjustment of Voltage Setting
120
Check of Alternator Output
120
Fault Diagnosis Procedure for 11AC Alternator Fails to Charge
120
Noise Alternator
120
DYNAMO Description
121
DYNAMO Routine Maintenance
121
DYNAMO Performance Data
121
DYNAMO Servicing
121
Brush Gear
122
Starter Motors
122
Checking Freedom of Brush Movement
123
Electrical System Servicing
124
'S' Type Starter Drive Assembly
124
Lubricating Oils
127
Approved Service Tools
129
Valve Seat Cutters
131
Index
133

Perkins 4.99M Workshop Manual (134 pages)

Brand: Perkins | Category: Engine | Size: 7 MB

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Perkins 4.99M Workshop Manual (135 pages)

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