Perkins Engine 4.108, 4.107, 4.99 Service 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
Page 2
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.
Page 3
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
Page4
~
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
Page 6
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
Engine Data
Bore
(nominal-
See Page B.3) ...
Stroke
...
No.
of
Cylinders
Cubic
Capacity
...
Compression Ratio
Firing
Order
Cycle
'"
Combustion
System
Engine Rotation
...
Rating Details
4.99
Maximum
Gross
Rated
Output
Maximum
Gross
Torque
Output
Engine Weights, Dry
48
bhp
(37 kW)
at 4000
rev/min
73 Ibf
ft
(10,1 kgf
m)
at 2250
rev/min
SECTION B
Technical Data
4.108 and 4.107
3.125 in (79,37
mm)
3.5 in (88,9
mm)
Four
107.4 in3 (1,760
litre)
22:1
1,3,4,2.
Four-Stroke
Indirect
Injection
Clockwise
viewed from
front
4.107
41
bhp
(30,6
kW)
at 3000
rev/min
79 Ibf
ft
(10,9
kgf
m)
at 1900
rev/min
4.99
3.00 in (76,2
mm)
3.5 in (88,9
mm)
Four
99 in3 (1,621
litre)
20:1
1, 3, 4, 2.
Four-Stroke
Indirect
Injection
Clockwise
viewed
from
front
4.108
55
bhp
(41 kW)
at 4000
rev/min
83 Ibf
ft
(11,5
kgf
m)
at 2200
rev/min
Approx.
dry
weight, bare engine, i.e.
complete
with
fuel
injection
equipment,
pressed steel
oil
sump, dynamo,
water
pump,
but
not
including
starter
motor,
air
cleaner, fan,
flywheel
or
flywheel housing: 330 Ib (150
kg).
Typical
dry
weight, engine with all accessories: 450 Ib
(204
kg).
Where
engines
are
called
upon to
operate
in rarefied
atmospheres
occasioned
by altitude,
such
engines
should
be
de-rated.
The
following
table
is given as a general guide,
which
may
be
applied
on a
percentage
basis,
where
specific
figures
for a particular
engine
rating are not available.
Altitude
0-
2,000 feet ( 600
metre)
2,000-
4,000
feet
(1,200
metre)
4,000-
6,000
feet
(1,800
metre)
6,000-
8,000 feet (2,400
metre)
8,000-10,000
feet
(3,000
metre)
10,000-12,000
feet
(3,600
metre)
* Measured
at
setting
speed given in
pump
setting
code.
Maximum
fuel
delivery
de-rating*
No
change
6%
12%
18%
24%
30%
Any
necessary
adjustments
in
this
respect
to
the fuel
pump
should
be
carried
01.11
by
the C.A.V.
dealer
or
Perkins
Distributor
for
the
territory
concerned.
For any
further
information
apply
to
Technical
Services
Department,
Perkins
Engines
Limited,
Peterborough
or
to one
of
the Perkins
Companies
listed on Page 2.
TECHNICAL
DATA-B.2
Recommended Torque Tensions
The
following
torque
figures
will
apply
with
the
components
lightly oiled
before
assembly:-
4.107 and
4.99 4.108
Ibf
ft
kgf m
Nm
Ibf
ft
kgf
m
Nm
Cylinder
Head
Nuts
42
5,81
57 60 8,3
81
Connecting
Rod
Setscrews
42
5,81
57
42
5,81
57
*
Main
Bearing
Setscrews
85
11,5 115
85 11,5
115
Flywheel
Setscrews
60
8,3
81
60
8,3
81
Idler
Gear
Hub
Setscrews
36
4,98 49 36 4,98
49
Crankshaft
Pulley
Setscrew-1.56
in (39,6
mm)
long
150 20,7
203
150 20,7
203
with
1.875
in
(47,6
mm)
dia.
washer
Crankshaft
Pulley
Setscrew
-1.68
in (42,7
mm)
long
190
26,3
250
with
1.75 in (44,6
mm)
dia.
washer
(Cadmium
Plated)
Crankshaft
Pulley
Setscrew
(Phosphated)
230
31,5
310
Atomiser
Securing
Nuts
.,
.
12 1,7
16
12
1,7
16
High
Pressure Fuel
Pipe
Nuts 15
2,1
20
15
2,1
20
Dynamo
Pulley
Retaining
Nut
20 2,8 27
20 2,8
27
Alternator
Pulley
Retaining
Nut
30
4,1
41
30
4,1
41
Thermostart
Unit
10 1,38 13
10 1,38
13
Thermostart
Insulating
Adaptor
10 1,38 13
10
1,38
13
*The
tab
and
shim
washers
may be
discarded
where
used
on
earlier
engines, but
the
setscrews
must be
tightened
to
the
torque
loading
indicated.
Service Wear Limits
The
following
"wear
limits"
indicate
the
condition
when it is
recommended
that
the
respective
items
should
be
servicec
or
replaced.
Cylinder
Head
Bow
Cylinder
Head
Bow
Longitud
inal
Transverse
Maximum
Bore Wear
(when
new
liners
are
necessary)
Crankshaft
Main and Big End
Journal
Wear
Crankshaft
Main and Big End
Journal
Ovality
Maximum
Crankshaft
End Float
Valve Stem to
Guide
Clearance
inlet
Valve Stem to
Guide
Clearance
Valve Head
Thickness
at
outer
edge
Rocker
Clearance
on Shaft
Camshaft
Journals
Ovality
and Wear
Camshaft
End Float
Idler
Gear End
Float
exhaust
*Valve Head Depth
below
Head
Face-inlet
and
exhaust
0.006 in (0,15
mm)
0.003
in
(0,08
mm)
concave
0.005 in (0,13
mm)
convex
0.006 in
(0,15mm)
0.001
in
(0,03
mm)
0.0005 in (0,01
mm)
0.020 in (0,51
mm)
0.005
in
(0,13
mm)
0.006
in
(0,15
mm)
0.025 in (0,64
mm)
0.005 in
(0,13mm)
0.002 in (0,05
mm)
0.020 in (0,51
mm)
0.010 in (0,25
mm)
0.048 in (1,22
mm)
*Where
vehicle
engines
have
to
conform
with
the
smoke
density
regulation
B.S.AU
141
a:
1971, then
the
valve
depths
must
not
exceed
production
limits
as given on page B.8.
Manufacturing
Data
and
Dimensions
The
data
regarding
clearances
and
tolerances
are
given for
personnel
engaged
upon
major
overhauls.
Further
information
can
be
obtained
on
request
from
the
Technical
Services
Department,
Perkins Engines Ltd.,
Peterborough.
CYLINDER BLOCK
Total
Height
of
Cylinder
Block
between
Top & Bottom
Faces
Parent
Bore
Dia.
for
Cylinder
Liner
Parent Bore Dia.
for
Cylinder
Liner
Main Bearing Parent
Bore
Camshaft
Bore
Dia.
No.1
Camshaft Bore Dia.
No.2
Camshaft
Bore
Dia.
No.3
Tappet
Bore Dia.
Fuel
Pump
Drive
Hub
Bearing
Bore
Dia.
4.108,4.107,4.99
4.108
4.107,4.99
4.108,4.107,4.99
4.108,4.107,4.99
4.108,4.107,4.99
4.108,4.107,4.99
4.108,4.107,4.99
4.108,4.107,4.99
9.936/9.939
in
(252,374/252,451
mm)
3.249/3.250
in
(82,525/82,550
mm)
Wet
Liners
2.3950/2.3955
in
(60,833/60,846
mm)
1.794/1.7955
in
(45,568/45,606
mm)
1.78411.787
in
(45,314/45,390
mm)
1.776/1.778
in
(45,110/45,161
mm)
0.562/0.56325
in
(14,275/14,307
mm)
1.812511.8141 in
(46,037/46,078
mm)
Cylinder Liner 4.108
Type
Interference
Fit
of
Liners
Inside
Dia. of
Liner
after Finish Boring and Honing
Height
of
Liner
in relation to Cylinder
Block
Top Face
Overall Length
of
Liner
Cylinder Liner 4.107 and 4.99
Type
Inside
Dia.
of
Liner
Pre-Finished
4.99
Inside
Dia.
of
Liner Pre-Finished 4.107
Thickness
of Top
Flange.
4.99
Depth of Recess in
Block
for Liner
Flange.
4.99
Thickness
of Top
Flange..
4,107
Depth of Recess in
Block
for
Liner Flange 4,107
Height
of Liner
in
relation to
Cylinder
Block
Top
Face 4,107 and 4.99
Liner
Flange Outside Dia. 4.99
Cylinder
Block
Top Bore for
Liner
Flange 4.99
Clearance Fit of
Liner
Flange
to
Block
Bore 4.107 and 4.99
Pistons 4.108
Type
Piston Height in relation to Cylinder
B!ock
Top
Face.
Bore Dia.
for
Gudgeon
Pin
Compression Ring Groove
Width-Top
Compression Ring Groove
Width-2nd
Compression Ring Groove
Width-3rd
Oil Control Ring Groove
Width-4th
Oil Control Ring Groove
Width-5th
i With
engines
rated at 3.000
rev/min
or
below,
the
fourth
Note: There is a Steel Insert fitted above the Top Groove.
I Pistons 4.108
(Controlled
Expansion)
I
IType
...
I Piston
Height
above Top Face of
Cylinder
Block
I Bore Dia.
for
Gudgeon Pin
I Compression Ring Groove Width,
Top
1 Compression Ring Groove Width,
Second
and
Third
.. .
I Oil Control Ring Groove Width
...
...
..
.
: Pistons 4.108
(Controlled
Expansion)
: Type
...
I Piston Height above Top Face
of
Cylinder
Block
:
Bore
Dia.
for
Gudgeon Pin
I CompreSSion Ring Groove Width,
Top
: Compression Ring Groove Width,
Second
I Oil Control Ring Groove Width
Pistons 4.107 and 4.99
Type
Piston Height in relation to
Cylinder
Block
Top Face ..
Bore Dia.
for
Gudgeon
Pin
later 4.99 and all 4.107
engines
...
Early 4.99
engines
Compression Ring Groove
Width-Top
Compression Ring Grooves Width 2nd and 3rd
Oil Control Ring Grooves 4th and 5th
TECHNICAL
DATA-B.3
Cast Iron - Dry -
Interference
Fit
0,003/0.005
in
(0,076/0.127
mm)
3.12513.126
in
(79,375179,40
mm)
0.023/0.027
in
(0,584/0,686
mm)
above
6.495/6.505
in
(164,973/165,227
mm)
Cast Iron - Wet Push Fit
3,00/3.001
in
(7620176.225
mm)
3.125/3,126
in
(79,374179.4
mm)
0.312510.3145
in
(7,93717,988
mm)
0.3115/0.3135
in
(7,91217,963
mm)
0.25010,252
in
(6.35/6,4
mm)
0.249/0,251
in
(6.325/6,375
mm)
0.003 in (0,076 mm) Above. 0.001
in
(0.025 mm)
Below
3.61813.621
in
(91.898/91,973
mm)
3.625/3,627
in
(92,075/92,125
mm)
0,00410.009
in
(0,102/0.229
mm)
Flat Topped
0.00210.006
in
(0,051/0.152
mm)
Above
1.06255/1.06275
in
(26,989/26.994
mm)
0.080510.0815
in
(2,045/2,070
mm)
0.0645/0.0655
in
(1,638/1,664
mm)
0.0645/0.0655
in
(1,638/1,664
mm)
0.126/0.127
in
(3.200/3,225
mm)
0.19010.191 in
(4,826/4.851
mm)
ring
groove
is
the
same as
the
fifth
ring
groove.
Flat
Topped
- Four Ring
0.002/0.006
in
(0,05/0,15
mm)
1.062711.0629
in
(26,992/26,999
mm)
0.080110.0821
in
(2,035/2,086
mm)
0.06410.065
in
(1,64/1,65
mm)
0.1887/0.1895
in (4,7914,81
mm)
Flat
Topped -Three
Ring
0.002/0.006
in
(0,05/0,15
mm)
1.062711.0629
in
(26,992/26,999
mm)
0.080/0.082
in
(2,035/2,086
mm)
0.09910.1005
in
(2,53/2,55
mm)
0.1890/0.1900
in
(4,8014,826
mm)
Flat
Topped
0.0085/0.012
in
(0,2210,30
mm)
Above
0.93755/0.93775
in
(23,81/23,82
mm)
0.87505/0.87525
in
(22,22122,23
mm)
0.0801/0.0811
in
(2,034/2,06
mm)
0.0645/0.0655
in
(1,638/1,664
mm)
0.190/0.191
in
(4,826/4,851
mm)
TECHNICAL
DATA-B.4
Piston Rings 4.108
Top-Compression
Second and Third Compression
Fourth-Oil
Control
Fifth-Oil
Control
Top Compression Ring Width
Ring Clearance in
Grove
...
Second and Third Compression Ring Width
Ring Clearance in
Groove
Fifth
Scraper
Ring Width
...
Ring Clearance in
Groove
Ring
Gap-Top
Compression
Ring
Gap-Second
and Third Compression .
Ring
Gap-Fifth
Scraper
...
Parallel Faced
Internally Stepped
Laminated Segment
'*
Slotted Scraper
0.0771/0.0781 in
(1,958/1,984
mm)
0.0024/0.0044 in
(0,061/0,112
mm)
0.0615/0.0625 in (1,562/1,587
mm)
0.00210.004 in
(0,051/0,102
mm)
0.1865/0.1875 in
(4,737/4,762
mm)
0.0025/0.0045 in
(0,063/0,114
mm)
0.00910.017 in
(0,229/0,432
mm)
0.00910.017 in
(0,229/0,432
mm)
0.00910.017 in
(0,229/0,432
mm)
:*
Engines rated at 3,000
revlmin
and
below
have a slotted scraper fitted in the fourth
groove
which
has the same
I width, clearance and gap as the fifth ring.
: Piston Rings
4.108(Controlied
Expansion -
Four
Ring)
, Top Compression
I Second and Third Compression
I Fourth Oil Control
I Top Compression Ring Width
I Ring Clearance in
Groove
...
: Second and Third Compression Ring Width
Ring Clearance in
Groove
I Oil Control Ring Width
...
I Ring Clearance in Groove
J Ring Gap, Top
...
. ..
I Ring Gap, Second and Third
I Ring Gap, Oil Control
Chrome Insert - Parallel Faced
Internally Stepped
Spring Loaded Scraper
0.077/0.078
in
(1,96/1,98
mm)
0.002/0.005 in
(0,05/0,13
mm)
0.0615/0.0625 in (1,5611,59
mm)
0.0015/0.0035
in (0,0410,09
mm)
0.186/0.1865
in
(4,72/4,74
mm)
0.0022/0.0035
in (0,0510.09
mm)
0.012/0.023
in
(0,30/0,58
mm)
0.009/0.020
in
(0,23/0,50
mm)
0.010/0.021 in
(0,25/0,53
mm)
: Piston Rings 4.108
(Controlled
Expansion -
Three
Ring)
I Top Compression
: Second Compression
I Third Oil Control
I Top Compression Ring Width
I Clearance in
Groove
...
: Second Compression Ring Width
I Clearance in
Groove
I Oil Control Ring Width
: Clearance in
Groove
I Ring Gap, Top
...
I Ring Gap, Second
I Ring Gap, Oil Control
Piston Rings
4.99
Vehicle
Top Compression
Second and Third Compression
Fourth and Fifth Oil Control
Piston Rings 4.107
and
4.99
and
Industrial
Top Compression
'Second
and Third Compression
Fourth-Oil
Control
Fifth-Oil
Control
Chrome,
Taper
Faced
Internally Stepped, Taper Faced
Spring Loaded Scraper
0.0765/0.0775
in
(1,943/1,969
mm)
0.0025/0.0055
in
(0,063/0,140
mm)
0.097/0.098
in
(2,46/2,49
mm)
0.0015/0.0035
in
(0,039/0,089
mm)
0.1865/0.1875
in
(4,737/4,763
mm)
0.0015/0.0035
in
(0,039/0,089
mm
0.01210.023 in
(0,31/0,59
mm)
0.009/0.020
in
(0,23/0,51
mm
0.012/0.023
in
(0,31/0,59
mm
Parallel Faced Chrome Plated
Internally Stepped
Slotted
Scraper
Parellel Cast Iron
Internally Stepped
Chrome
Plated Spring Loaded
Scraper
Slotted
Scraper
•
4.99
Agricultural
engines have taper faced cast iron
compression
rings fitted in the second and
third
ring grooves.
Top Compression Ring Width
Ring Clearance in
Groove
Second and
Third
Compression Ring
Width.
Ring Clearance in Groove
Fourth and Fifth Scraper Ring Width
Ring Clearance in Groove
Ring
Gap-Compression
Rings Chrome Vehicle
Ring
Gap-Oil
Control Rings Cast Iron Vehicle
Ring
Gap-Compression
Rings Cast Iron
Agricultural and Industrial
0.0771/0.0781 in
(1,96/1,984
mm)
0.002/0.004
in
(0,051/0,102
mm)
0.0615/0.0625
in
(1,562/1,587
mm)
0.00210.004 in
(0,051/0,102
mm)
0.1865/0.1875
in (4,73714,762
mm)
0.0025/0.0045
in
(0,064/0.114
mm)
0.01210.020 in
(0,30/0,50
mm)
0.009/0.017
in
(0,30/0,432
mm)
0.009/0.017
in
(0,30/0,432
mm)
Gudgeon
Pin 4.108
Type
Outside
Dia.
of
Gudgeon
Pin
Length
of
Gudgeon Pin
Fit
in Piston Boss
Gudgeon
Pin 4.107 and 4.99
Type
Outside Dia.
of
Gudgeon
Pin
(Later
Engines)
Outside
Dia.
of
Gudgeon
Pin
(Earlier
Engines)
Fit
in Piston Boss
Small
End Bush 4.108
Type
Length
of
Small
End
Bush
Outside
Dia.
of
Small
End Bush
Inside
Dia.
before
Reaming
Inside
Dia.
after
Reaming
Clearance
between Small End Bush and Gudgeon Pin
Small
End Bush 4.107 and 4.99
Type
Length
of
Small End Bush
Outside Dia.
of
Small End Bush
on
later
4.99 and all 4.107 engines
Early 4.99
engines
Inside
Dia.
after
Reaming on
later
4.99
and
a/l 4.107 engines
Early 4.99 engines
Clearance
between Small End Bush and Gudgeon Pin
TECHNICAL
DATA-B.S
Fully Floating
1.0625/1.0627 in
(26,987/26,993
mm)
2,673/2,687 in
(67,894/68,250
mm)
Transition
Fully Floating
0.9375
in/0.9377
in
(23,812/23,817
mm)
0.875/0.8752 in
(22,225/22,23
mm)
Transition
Steel Backed, Lead
Bronze
Lined
0.935/0.955
in
(23,749/24,257
mm)
1.221/1.222
in
(31,013/31,039
mm)
1.0495/1.0545 in
(26,657/26,784
mm)
1.06315/1.0632
in
(27,004/27,005
mm)
0.00045/0.0007 in
(0,0114/0,0178
mm)
Steel Backed, Lead
Bronze
Lined
0.865/0.885
in
(22,00/22,48
mm)
1.06511.066 in
(27,05/27,08
mm)
1.0025/1.0035
in (25,46125,49 mm)
0.9382/0.93875
in
(23,83/23,84
mm)
0.8757/0.87625
in
(22,24/22,26
mm)
0.0005/0.00125
in (0,0110,03
mm)
Note. Bushes
to
be reamed
to
suit respective Gudgeon Pins, and are
provided
with
a reaming allowance.
nSI::ti§11n Rod 4.108
Type 'H'
Section
Cap
Location
to
Connecting
Rod
Big End Parent
Bore
Dia.
Small End Parent Bore Dia.
Length from Centre Line
of
Big End
to
Centre Line
of
Small End
Big End
Setscrew
Connecting
Rod End Float
Connecting
Rod 4.107 and 4.99
Type
Cap
Location
to
Connecting
Rod
Big End Parent Bore Dia.
Small End Parent Bore Dia.
on
later
4.99 and all 4.107 engines
Early 4.99
engines
Length from Centre Line
of
Big End to Centre Line
of
Small End
Big End Setscrew
Connecting
Rod End Float
on
later
4.99
and
all 4.107 engines
Early 4.99 engines
Serrations, Offset 45
to
the Horizontal
2.146/2.1465 in
(54,508/54,521 mm)
1.21875/1.21975 in (30,956/30,981
mm)
6.217/6.219
in
(157,912/157,963
mm)
0.375 in
(i
in)
U.N.F.
0.006510.0105 in
(0,165/0,267
mm)
'H'
Section
Serrations,
Offset
45'
to
the
Horizontal
2. i 46/2.1465
in (54,508/54,521 mm)
1.0625/1.0635
in (26,99/27,01
mm)
1.00/1.001
in
(25,4/25,43mm)
6.405/6.407
in
(162,69/162,74
mm)
0.375 in
(i
in)
U.N.F.
0.0065/0.0105
in (0,1610,27
mm)
0.0075/0.0105
in
(0,19/0,27
mm)
TECHNICAL
DATA-B.G
Connecting Road Alignment
4.108,4.107,4.99
Large
and
small
end
bores
must be
square
and
parallel
with
each
other
within
the
limits
of
::'::0.010 in
(0,25
mm)
mea-
sured
5 in (127
mm)
each
side
of
the
axis
of
the
rod
on
test
mandrel
as
shown
in Fig. B.1.
With
the
small
end
bush
fitted, the
limit
of
::'::0.010 in (0,25
mm)
is
reduced
to
::'::0.0025 in (0,60
mm).
-
--
Ej~
.=
E
=
-.::t
Sin
.-It')
-
..
=N
-
~
00
127mm
+1
+.
...J
"
B1
Crankshaft
4.108,4.107,4.99
Overall
Length
Main
Journal
Dia. Nos. 1 and 2
Main
Journal
Dia.
No.3
Main
Journal
Length
No.
Main
Journal
Length
No.2
Main
Journal
Length
NO.3
Main
Journal
Fillet
Radii
Crankpin
Dia.
Crankpin
Length
Crankpin
Fillet
Radii
Surface
Finish-All
Journals
Main
Journal
and
Crankpin
Regrind
Undersizes
Oil Seal
Helix
Dia.
Oil Seal Helix
Width
Oil Seal
Helix
Depth
Flange
Dia.
Flange
Width
Spigot
Bearing
Recess Depth
Spigot
Bearing
Recess
Bore
Crankshaft
End Float
Crankshaft
Thrust
Washers 4.108,
4.1
Type
Position
in
Engine
Thrust
Washer
Thickness
(STD)
Thrust
Washer
Thickness
(O/S)
Thrust
Washer
Outside
Dia.
Thrust
Washer
Inside
Dia.
Main
Bearings
4.108, 4.101, 4.99
Type
Shell
Width
Outside
Dia.
of
Main
Bearing
Inside
Dia.
of
Main
Bearing
Running
Clearance-Nos. 1 and
2 .
Running
Clearance-No.
3
Steel
Thickness
Aluminium
Thickness
,;
i..-
4.99
....
~
-
c:
E
I
.-
E
Sin
=-.::t
--
-
'-It')
-
..
C?N
127mm
=0
+1+.
t-.
...J
'f
-
:..,...
21.125 in (536,575
mm)
2.248/2.2485
in
(57,099/57,112
mm)
2.2475/2.248
in
(57,086/57,099
mm)
1.40625 in (35,719
mm)
1.496/1.504
in
(37,998/38,202
mm)
1.499/1.502
in
(38.075/38,151
mm)
0.12510.141 in
(3,175/3,581
mm)
1.9993/2.0001
in
(50,78/50,80
mm)
1.1875/1.1895
in
(30.162/30,213
mm)
0.15625/0.17187
in
(5/32/11/64
in)
(3,969/4,366
mm)
8-16
micro-in
(0,2
- 0,4
micron)
0.010.0.020,0.030
in (0,25, 0.51.0.76
mm)
2.21075/2.21175
in
(56,153/56.178
mm)
0.050/0.080
in
(1,270/2,032
mm)
0.004/0.008
in
(0,102/0.203
mm)
3.9985/3.9995
in
(101,562/101,587
mm)
0.500 in (12,700
mm)
0.875 in (22,225
mm)
1.250 in (31,750
mm)
0.002/0.015
in
(0.0508/0.381
mm)
Steel
BaCked-Lead
Bronze
Faced
Rear
Main
Bearing
0.089/0.091
in
(2,261/2,311
mm)
0.0965/0.1005
in
(2,451/2,553
mm)
3.24513.255 in
(82,423/82.677
mm)
2.590/2.600
in
(65.786/66,040
mm)
Pre-finished,
Steel
Backed.
Aluminium
Tin
Lined
1.245/1.255
in
(31.623/31.877
mm)
2.3955 in (60,846
mm)
2.2505/2.2515
in
(57,163/57,188
mm)
0.002/0.0035
in
(0.051/0,089
mm)
0.0025/0.004
in
(0,063/0.102
mm)
0.060 in (1,524
mm)
Max.
0.01210.01225
in
(0.305/0,311
mm)
Connecting Rod Bearings 4.108, 4.107, 4.99
Type
Shell
Width
Outside Dia. of Can. Rod Bearing .
Inside Dia.
of
Can. Rod Bearing
Running Clearance
Steel
Thickness
.
Aluminium
Thickness
Camshaft 4.108,4.107,4.99
No. 1
Journal
Length
No.1
Journal
Dia.
No.1
Cylinder
Block
Camshaft Bore Dia.
No. 1
Journal
Running Clearance
No. 2
Journal
Length
No. 2
Journal
Dia.
No.2
Cylinder
Block
Camshaft Bore Dia.
No.2
Journal
Running Clearance
No. 3
Journal
Length
No. 3
Journal
Dia
NO.3
Cylinder
Block
Camshaft Bore Dia.
NO.3
Journal
Running Clearance
...
Cam
Lift
Oilways
for
Rocker Shaft Lubrication
Camshaft Thrust Plates 4.108, 4.107, 4.99
Type
Thrust Plate Outside Dia.
Cylinder
Block
Recess Dia. for Thrust Plate
Clearance Fit of Thrust Plate in Recess
Thrust Plate Inside Dia.
Thrust Plate Thickness
Cylinder
Block
Recess Depth
for
Thrust Plate
Thrust Plate
Height
in relation to
Cylinder
Block
Face
Camshaft End Float
Valve and Fuel Pump Timing
Refer to
later
section on timing (page
K.1
) .
CYLINDER HEAD
4.1
Overall Length of Cylinder Head
Overall Depth
of
Cylinder
Head
4.1
4.99
Skimming
Allowance
on
Cylinder
Head Face
Pressure
for
Water
Leakage Test
Valve Seat
Angle
Bore in
Cylinder
Head for Guide
Bore in
Cylinder
Head
for
Combustion
Chamber
Inserts
Depth of Bore in
Cylinder
Head for
Combustion Chamber Inserts
Combustion Chamber Inserts 4.108, 4.101,4.99
Outside Dia.
of
Insert
Depth
of
Insert
...
Height
of
Insert in relation
to
Cylinder
Head Face
Clerance Fit
of
Insert in
Cylinder
Head Bore
Method
of
Location
in
Cylinder
Head
Valve Guides
(inlet)
4.108,4.107,4.99
Inside Dia.
Outside Dia.
Interference fit
of
Guide in
Cylinder
Head Bore
Overall length of Guide ."
Guide Protrusion Above
Top
Face
of
Cylinder
Head
TECHNICAL
DATA-B.7
Pre-finished, Steel Backed,
Aluminium
Tin
Lined
0.870/0.880 in (22,098/22,325
mm)
2.1465 in (54,521
mm)
2.0015/2.0025 in (50,838/50,863
mm)
0.0014/0.0032 in (0,036/0,081
mm)
0.060 in (1,524
mm)
Max_
0.012/0.01225 in (0,305/0,311
mm)
1.347/1.351 in (34,214/34,315
mm)
1.791/1.792 in (45,491/45,517
mm)
1.794/1.7955 in (45,568/45,606
mm)
0.002/0.0045 in (0,051/0,114
mm)
1,250 in (31,750
mm)
1.781/1.782 in (45,237/45,26'3
mm)
1,784/1,787 in (45:314/45,390
mm)
0.002/0.006 in (0,051/0,152
mm)
1.000 in (25,400
mm)
1.773/1.774 in (45,034/45,060
mm)
1.776/1.778 in (45,110/45,161
mm)
0.002/0.005 in (0,051/0,127
mm)
0.2592/0.2622 in
(6,58/6,66
mm)
No. 2
Journal
180'
Oil Impregnated Sintered Iron
2.555/2.557 in (64,897/64,948
mm)
2.5585/2.5685 in (64,986/65,240
mm)
0.0015/0.013 in (0,038/0,330
mm)
1.500 in (38,100
mm)
0.160/0.162 in (4,060/4,115
mm)
0.158/0.164 in (4,009/4,166
mm)
0.004 in (0,102
mm)
above
or
below
0.003/0.009 in (0,076/0,228 mm)
20.000 in (508,000
mm)
2.617
/2.633
in (66,472/66,878
mm)
NIL-On
no
account
can the
cylinder
head face be
skimmed
20
Ibflin
2
(1,4
kgflcm2)
-138
kN/m
2
45°
0.4995/0.5005 in (12,687/12,713
mm)
1.250/1.252
in (31,750/31,801
mm)
0.373/0.376
in (9,474/9,550
mm)
1.248/1.249
in (31,699/31,724
mm)
0.374/0.375
in (9,499/9,525
mm)
0.002 in (0,051
mm)
above
or
below
0.001/0.004
in
(0,025/0,102
mm)
By
Cylinder
Block
Face and Expansion Washer
0.3141/0.3155 in (7,978/8,014
mm)
0.5021/0.5026 in (12,753/12,766
mm)
0.0016/0.0031 in (0,041/0,079
mm)
2.130
in
(54,102
mm)
6.800/0.815
in
(20,320/20,701
mm)
TECHNICAL
DATA-B.B
Valve Guides (Exhaust)
4.10B,
4.107, 4.99
Inside Dia.
Outside
Dia.
Interference
fit
of
Guide in Cylinder Head Bore
Depth
of
Counterbore
Overall Length
of
Guide
'"
Guide
Protrusion above Top Face
of
Cylinder
Head
Valves (Inlet) 4.10B, 4,107, 4.99
Valve Stem Dia.
Clearance fit of Valve Stem in Guide
Valve Head Dia.
Valve Face Angle
Valve Head Depth
Below
Cylinder Head Face
Overall Length of Valve
Sealing Arrangement
Valve (Exhaust) 4.108,4.107,4.99
Valve Stem Dia.
Clearance Fit of Valve Stem in Guide
Valve Head Dia.
Valve Face Angle
Valve Head Depth
Below
Cylinder Head Face
Overall Length
of
Valve
Sealing Arrangement
Inner Valve Springs (where fitted)
Fitted Length
Load
at
Fitted Length
Fitted Position
Outer Valve Springs
Fitted Length
Load
at
Fitted Length
Fitted Position
4.10B,
4.107, 4.99
Rockel'
level's
4.108, 4.107, 4.99
Length between Centre Line of
Adjusting
Screw and
Centre Line of Rocker Shaft
Length between Centre Line of Rocker Lever
Pad and
Centre Line of Rocker Shaft
Inside Dia. of Rocker Lever Bore
Outside Dia. of Rocker Lever Bush
Interference Fit
of
Bush in Rocker Lever
Finished Inside Dia. of Rocker Lever Bush
Clearance of Rocker Lever Bush on
Rocker
Shaft
Valve Clearances 4.108, 4.107, 4.99
Clearance between Valve Stem Tip and Rocker Lever
Rocker
Shaft 4.108, 4.107, 4.99
Overall Length of Shaft
Outside Dia. of Shaft
Lubrication
Push Rods
Overall Length
Outside Dia.
4.108, 4.107, 4.99
0.3141/0.3155 in
(7,978/8,014
mm)
0.5021/0.5026 in
(12,753/12,766
mm)
0.001610.0031 in
(0,041/0,079
mm)
0.380 in (9,650
mm)
2.440 in (61,980
mm)
0.80010.815 in (20,320/20,701
mm)
0.312/0.313
in (7,92511,950
mm)
0.0011/0.0035 in
(0,028/0,089
mm)
1.410/1.414
in
(35,814/35,916
mm)
45'
0.028/0.039 in (0,711/0,991
mm)
4.592/4.608
in
(116,637/117,043
mm)
Rubber Oil Seal
0.3115/0.3125 in (7,91217,937
mm)
0.0016/0.004
in
(0,041/0,102
mm)
1.19111.195 in
(30,251/30,353
mm)
45°
0.021/0.032
in (0,53'3/0,813
mm)
4.60014.616 in
(116,840/117,246
mm)
No Seal fitted to Exhaust Valve
1.530 in (38,862
mm)
28.6 Ibf::'::: 2 Ibf (13,0 kgf::':::
0,91
kgf)
Damper Coil to
Cylinder
Head
1.780 in (45,212
mm)
56.0
Ibf::':::2.8
Ibf (25,4 kgf::':::1,27
kg!)
Damper Coil to
Cylinder
Head
1.042/1.058
in
(26,467/26,873
mm)
1.567/1.583
in
(39,802/40,208
mm)
0.71825/0.71950
in
(18,243/18,275
mm)
0.720510.7215 in
(18,301/18,326
mm)
0.00110.00325 in
(0,025/0,082
mm)
0.6245/0.62575
in
(15,862/15,894
mm)
0.00075/0.0035
in (0,01910,089 mm)
0.012 in (0,30
mm)
Cold
14.5625 in (369,887
mm)
0.62225/0.62375
in
(15,805/15,843
mm)
Oil Feed from
Cylinder
Head through Central
Passage
to
Individual
Rocker Levers
8.527/8.560
in
(216,58/217,42
mm)
0.250 in (6,350
mm)
Tappets 4.108, 4.107, 4.99
Overall Length
Outside Dia: of
Tappet
Shank
Cylinder
Block
Tappet Bore Dia.
Tappet Running Clearance in Cylinder
Block
Bore
Outside Dia. of
Tappet
Foot
TIMING GEARS 4.108, 4.107, 4.99
TECHNICAL
DATA-B.9
2.250
in
(57,150
mm)
0.560/0.561 in
(14,224/14,249
mll'l)
0.56210.56325 in
(14,275/14,307
mm)
0.001/0.00"325 in
(0,025/0,082
mm)
1.245/1.255
in
(31,623/31,877
mm)
Note:
Some
engines
are fitted with spur gears instead of helical gears, in
which
case the
number
of teeth
on
each
gear
are given
in
brackets.
Camshaft Gear
Number
of Teeth
Inside Dia.
of
Gear
Boss
...
Outside Dia. of Camshaft Hub
Transition
Fit
of
Gear and Hub
Fuel Pump Gear
Number
of Teeth
Inside Dia.
of
Cylinder
Block
Bore for Fuel Pump
Drive Hub Bearing
Outside Dia.
of
Fuel Pump Drive Hub Bearing
Interference Fit
of
Drive Hub
Bearing in
Cylinder
Block
Bore
...
Inside Dia.
of
Fuel Pump Drive Hub Bearing
Outside Dia.
of
Fuel Pump Gear Drive Hub
...
Running Clearance
of
Drive Hub in Bearing
Drive Hub End
Float
Idler Gear and Hub
Number
of
Teeth
Inside Dia.
of
Gear
Boss
...
Inside Dia.
of
Gear
Boss with Bush Fitted ...
Outside Dia. of
Gear
Hub
Running Clearance
of
Gear on Hub
Idler
Gear Width
Hub Width
Idler
Gear End Float
Crankshaft Gear
Number
of
Teeth
Inside Dia.
of
Gear
Crankshaft Dia.
for
Gear
...
Transition Fit of
Gear
on Crankshaft
Timing Gear Backlash
Clearance between
Crankshaft!ldler
and
Camshaft!
Idler
Gear
LUBRICATING SYSTEM
4.108,4.107,4.99
48
(50)
1.750/1.7514 in
(44,450/44,486
mm)
1.7496/1.7509 in
(44,430/44,473
mm)
0.000910.0018 in
(0,023/0,046
mm)
48
(50)
1.8125/1.8141 in
(46,037/46,078
mm)
1.814511.8152 in
(46,088/46,106
mm)
0.0004/0.0027 in
(0,010/0,069
mm)
1.3125/1.3135
in
(33,34/33,78
mm)
1.3105/1.3115 in
(33,287/33,312
mm)
0.0031/0.0051 in
(0,079/0,129
mm)
0.00210.010 in
(0,051/0,254
mm)
57
(42)
1.7187/1.7197
in
(43,655/43,680
mm)
1.562511.5641 in (39,687139,728
mm)
1.5612/1.5619
in
(39,654/39,668
mm)
0.0003/0.0016
in (0,008/0,041
mm)
1.3105/1.3135
in
(33,287/33,363
mm)
1.316511.3195 in
(33,439/33,52
mm)
0.00310.008 in
(0,076/0,208
mm)
24
(25)
1.25011.2512 in
(31,750/31,780
mm)
1.250/1.2506
in
(31,750/31,756
mm)
0.000610.0012 in
(0,015/0,030
mm)
0.0015/0.0025
in
(0,038/0,064
mm)
Lubricating Oil Pressure
...
30/60
Ibflin
2
(2,1/4,2
kgflcm2)
-2071414
kN/m
2
at
Sump
Dipstick
Position
Strainer Location
Typical Sump Capacities
Refill
Capacities-Engine
Level
Standard Sump
...
Vauxhall
Motors
Chrysler Cars
Ford
Motor
Co
....
maximum
engine
speed and normal
working
tempera-
ture.
Camshaft side
of
engine
opposite
No.2
cylinder
End
of
suction
pipe
to
lubricating
oil pump.
Imp.
pt
U.S.
pt
Litre
7.0
8.4
4.0
9.0
10.8
5.1
8.6
10.3
4.9
8.75
10.5
5.0
Note: The above sump
capacities
are intended
to
be used as a gUide and
actual
capaCities should be governed by
the level
indicated
on the
dipstick.
When refilling the engine
after
an overhaul has been
carried
out a further
2 imp. pints,
2!
U.S.
pints
or 1 litre
approxi-
mately should be added
to
the
capacities
quoted,
to
allow
for
filling
the pipes, oilways,
filter
assembly, etc.
TECHNICAL
DATA-B.10
Lubricating Oil Pump
Type
Number
of
Lobes-Inner
Rotor
Number
of
Lobes-Outer
Rotor
Method
of
Drive
Pump Clearances
Inner
Rotor
to
Outer Rotor
Outer Rotor
to
Pump Body
Inner Rotor End Clearance
Outer
Rotor End Clearance
Inside Dia.
of
~ore
for
Pump Shaft
Outside Dia.
of
Pump Shaft
Running Clearance, Shaft in Bore ...
Lubricating Oil Pump Drive Gear
Number
of
Teeth
Inside Dia. of Gear
Bore
...
Outside Dia.
of
Oil Pump Drive Shaft
Interference Fit of Gear on Shaft ...
Lubricating Oil Pump Drive Gear Backlash
...
Relief Valve
Type
Pressure Setting
Length
of
Plunger
Outside Dia.
of
Plunger
...
Inside Dia.
of
Valve Housing Bore ...
Clearance
of
Plunger in Bore
Outside Dia.
of
Spring
Spring-Free
Length
Lubricating Oil Filter
Type
Element Type
By-Pass Valve Setting
COOLING SYSTEM 4.108, 4.101, 4.99
Type
Cylinder
Block
and Head
Engine Water Capacity (Less Radiator)
Thermostat
Type
Opening Temperature
Fully open
at
Minimum
Travel
at
Fully Open Temp.
Water Pump
Type
Outside Dia.
of
Shaft
for
Pulley (Separate Bearing
Pump)
Inside Dia.
of
Pulley Bore (Separate Bearing Pump)
Outside Dia.
of
Shaft
for
Pulley
(Combined
Bearing
and
Shaft)
Inside Dia.
of
Pulley Bore
(Combined
Bearing
and
Shaft Pump)
...
Interference Fit
of
Pulley on
Shaft
.. .
Outside Dia. of Shaft
for
Impeller
.. .
Inside Dia.
of
Impeller Bore
Interference Fit
of
Impeller on Shaft
Rotor Type
Three
or
Four
Four
or
Five
By
Spiral Gears from the
Camshaft
0.0005/0.0025 in
(0,013/0,063
mm)
0.01110.013 in
(0,28/0,33
mm)
0.0015/0.003 in
(0,038/0,076
mm)
0.0005/0.0025 in
(0,013/0,063
mm)
0.50010.501 in
(12,700/12,725
mm)
0.4983/0.4986 in
(12,655/12,664
mm)
0.0014/0.0027 in
(0,036/0,069
mm)
12
0.496510.4970 in
(12,611/12,624
mm)
0.4983/0.4986 in
(12,655/12,664
mm)
0.001310.0021 in
(0,033/0,053
mm)
0.0155/0.019
in
(0,394/0,483
mm)
Spring Loaded Plunger
50/65
Ibflin2 (3,5/4,6
kgflcm2) -344/448
kN/m
2
0.9375 in (23,813
mm)
0.5585/0.5595 in (14,19/14,21
mm)
0.5605/0.5625 in (14,24/14,29
mm)
0.001/0.004 in (0,025/0,102
mm)
0.368/0.377 in (9,347/9,576
mm)
1.5 in (38,10
mm)
Full Flow
Paper
or
Canister
Open between 13-17
Ibflin
2
(0,91-1,2
kgflcm2)
90-117
kN/m
2
pressure
differential
Water Cooled
Thermo-Syphon
Impeller
Assisted
6 Imp.
pt
(7.2 U.S.
pt
or
3,4
Litre)
Wax Capsule
175-182°F (79,5-83,5°C)
200-205°F (93,5-96°C)
0.3125 in (7,94
mm)
Centrifugal-Belt
driven
from
Crankshaft
0.5905/0.5908 in (14,999/15,006
mm)
0.588/0.589 in (14,935/14,961
mm)
0.6262/0.6267 in (15,808/15,920
mm)
0.6239/0.6247 in (15,849/15,869
mm)
0.0015/0.0028 in (0,038/0,071
mm)
0.498/0.499 in (12,649/12,675
mm)
0.497/0.4975
in (12,624/12,636
mm)
0.0005/0.002 in (0,013/0,051
mm)
Outside
Dia. of
Impeller
Water
Pump Seal Type
FUEL SYSTEM 4.108,4.107,4.99
Approved Fuel Oil Specification
United Kingdom 8S.2869:1967
United States VV-F-800a
AS.T.M.lD975-66T
France
(J.O.
14/9/57)
India
IS: 1460/1968
Germany DIN-51601 (1967)
TECHNICAL
DATA-B.11
3.094/3.125 in (78,588179,375
mm)
Synthetic
Rubber-Carbon
Faced
Class
A1
or
A2
Grades OF-A,
or
DF-2.
Nos.
1-0
or
2-D.
Gas Oil
or
Fuel Domestique
Grade
Special
or
Grade A
Italy CUNA-Gas Oil NC-630-01 (1957)
Sweden SIS.
155432
(1969)
Switzerland Federal
Military
Spec.
9140-335-1404 (1965)
Fuel
oils
available in territories
other
than those listed
above
which are to an
equivalent
specification
may be used.
Fuel Lift Pump
Type
Spring
Colour
Code
Method
of
Drive
Total Stroke
of
Operating Lever
Static
Pressure-No
Delivery
Pump to Distance Piece Gasket Thickness
...
Distance
Piece-Lift
Pump
to
Tappet Inspection Cover
Final Fuel Filter
Element Type
Overflow Valve Type
Valve in Fuel Pump Drain Connection
Fuel Injection Pump
Make
Type
Rotation
Plunger Dia.
Hydraulically Governed
Timing Letter
No. 1
Cylinder
Outlet
Mechanically Governed
Timing Letter
No. 1
Cylinder
Outlet
AC
Delco
Diaphragm 'Y J' Series
Green
From
Eccentric
on Camshaft via Push rod
0.192 in (4,877
mm)
4-7
Ibflin
2
(0,28-0,49
kgflcm2)
- 28-48
kN/m
2
0.018/0.022 in (0,457/0,559
mm)
0.256 in (6,502
mm)
Paper
Gravity
8all
Check
Valve
Spring Loaded Non-Return Valve set
at
0.71-1.25
Ibflin
2
(0,0522-0,0875
kgflcm2)
- 5-9
kN/m
2
CAV.
D.P.A.
Clockwise
(Viewed
from Drive End)
6 mm
4.108
A
W
C
W
4.107
c
W
4.99
A
W
C
W
TECHNICAL
DATA-B.12
Static Timing Position
The static timing position varies according
to
application, but can
be
obtained by referring
to
the first group
of
letters
and digits
of
the
fuel pump setting code (stamped on the fuel pump identification plate).
IOn the latest
4.108
engines the setting codes start
with
the fuel pump part number followed by
the
two
code letters. Only
the
Itwo
code letters are used
in
the table for identification purposes.
(USING TIMING TOOL MS67B)
ALTERNATIVE DROP VALVE METHOD
First
Group
of
Engine
Checking
Fuel Pump
Marking
Static
Timing
Piston
Displacement
Fuel
Pump
Code
Angle
(Degrees)
Angle
(Degrees)
(Degrees)
BTDC
in
(mm)
BTDC
4.99
AH28
282
29S
26
0.226
(5,74)
BH26
287
300
26
0.226
(5,74)
CH3S
280~
290 19
0.120
(3,05)
DH19
287
300
26
0.226
(5,74)
LH20 }
282
292
20
0.134
(3,40)
LH26
LH29
281
292
22
0.160
(4,06)
MH26
281
290
18
0.110
(2,79)
4.107
CH3S
280~
290
19
LH23}
0.120
(3,05)
LH28
282
292
20
LH29
0.134
(3,40)
LH31
(exceptions
below)
LH31
1900/2/2770
}
LH31
1900/2/3130
281
292
22
0.160
(4,06)
LH31
1900/9/1880
MH27}
PH28
281
290
18
0.110
(2,79)
PH30
PH34
280
290
20
0.134
(3,40)
iEH
4.108
EH34E
281
290
18
0.11
°
(2,79)
EH39
LH30
281
292
22
0.160
(4,06)
IpH
281
290 18
0.1 0
(2,79)
PH23E
(exceptions
281
290 18
0.110
(2,79)
PH25E
below)
PH2SESOO/S/24S0}
PH2SESOO/9/1990
279~
290
21
0.150
(3,81)
PH2SESOO/9/2090
PH27
~
-
281
290
18
'0.110
(2,79)
i PH28
(exceptions
PH30 be/ow)
PH30/S00/5/24SO }
PH30/S00/6/1S70
279t
290
21
0.150
(3,81)
PH30/S00/9/1990
PH30/S00/9/2090
:RH
1
RH30E
279~
290
21
0.150
(3,81)
SH33E
ITH }
281
291
20
0.134
(3,40)
ITH23E .
Note:
For 4.107
and
4.99
mechanically
governed
engines r aled
above 3,000
and
2,SOO
rev I
min
respectively, the
static
timing
is
altered
to
22'
B.T.C.D.'
piston
displacement
0.160 in
(4,06
mmJ.
For
4.108
engines
prior
to
engine
numbers
108U15973
and
108UD20214, the
static
timing
was
19'
B.T.D.C.·,
piston
displacement
0.120 in (3,05
mm).
When re,
setting
these pumps,
it
is
advisable
to
set
at
the figures
quoted
in
above
table.
For 4.107
industrial
engines
having
a fuel
pump
coding
of
PH30
and
an
idling
speed
at
1,000
rev/min,
the
static
timing
is
21'
B.T.D.C.
and a piston
displacement
of
0.147 in
(3,73
mm).
I
I
I
",-(I!I'"
I
Atomisers
4.108 Veh., M., Ind., Comb.
4.107 M., Ind.,
TA
Make
...
Holder
Type
Nozzle Type
Code Letter
Min.
Working
Pressure
Setting Pressure
4.108M, Ind., Comb.
Make
...
Holder
Type
Nozzle Type
Code Letter
! Min. Working Pressure
I Setting Pressure
CAV.
BKB40S05224
BON 12S06236
BG
TECHNICAL
DATA-B.13
135 atm (2000
Ibflin2
or
140
kgf/cm2)
150 atm (2200
Ibf/in2
or
155 k9f1cm2)
CAV.
BKB40S05224
BDN4SD6769
GY
135 atm (2000
Ibflin2 or
140
kgflcm2)
150 atm (2200
Ibflin2 or
155
kgflcm2)
Note: Earlier atomisers bearing the identification code
letter
'J' had a setting pressure
of
140 atm. When
servicing
of
these atomisers is
carried
out, they should be reset in
accordance
with the settings quoted above.
Make
Holder
Type
Nozzle Type
Code Letter
Min. Working Pressure
Setting Pressure
Starting Aid
Make
Type
Voltage
Maximum Current Consumption
Fuel Flow Rate
through
Unit
Height of Reservoir (where fitted) above Centre of
Thermostart
...
Make ...
Type
...
Max. Output
Alternator
Make
Type
...
Max. Output
(hot)
AC5 (12V)
AC5 (24V)
11AC (12V)
..
11AC (24V)
15ACR
17ACR
Starter
Motor
Make
...
Type
...
Max.
Current
Starter Cable Resistance ...
No. of Teeth on Pinion
...
4.99 Veh 4.99
Veh
4.99 Ind. & 4.107 Ind.
CAV. CAV.
CAV.
BKB40S5223 BKB40S5224
BKB40S5224
BON12SD6236 BDN12SD6236 BDN4S6157
BK
120
130
CAV.
Thermostart
12
Volt
BL
125
130
12.9 Amperes
at
11.5 Volts
4.3-4.9 cm
3
min
at
70"F
(21'C)
4.5-10 in (11,4-25,4
cm)
Lucas
C40
11A
Lucas
or
C.A.V.
BE
130
135
AC5
(12Vor24V),
11AC
(12Vor24Vj,
15ACR (12V) and 17ACR
(12V)
53A
30A
43A
23A
28A
36A
Lucas
MG45
or
2M113
900A
0.0017
ohms
(Max.)
10
SECTION C
Operating and Maintenance
Starting the Engine
If
the
weather
is warm
or
the engine has only been
stopped
for a little
while, place the
accelerator
in the
fully open
position
and engage the
starter
motor
by
turning the
starter
switch
in a
clockwise
direction
to
the
"HS"
position
(See Fig. C.1).
If
the
battery
is
well
up, enough to turn the
starter
motor
quickly,
the
engine
should start.
Always be sure
that
the
starter
pinion
and flywheel
have
stopped
revolving before re-engaging the starter,
otherwise
the
ring
or
pinion
may be damaged.
C1
1.
Off Position
2.
Run Position
3.
Heat Position
4.
Heat and Start Position
To
Aid
In
cold
weather
the
procedure
for
the use
of
this
equipment
is as
follows:-
Ensure
that
the
engine
stop
control
is in the
"run"
position.
Turn on the fuel supply
tap
of
the starting aid reser-
voir, where fitted.
Tum
start
switch
in
direction
to
"H"
position
for
fifteen
to
twenty
seconds.
As soon as the engine starts, the
switch
should
be
returned to the
"R"
position,
and
the
tap
on
the
start-
ing reservoir, when fitted,
turned
off.
NOTE: The above
procedure
is
not
necessary
when
the
engine
is hot.
To
re-start,
turn
the
switch
in a
clockwise
direction
to the
"HS"
position
which
will
engage
the
starter
motor.
Earlier Heat Start Switch
The
cold
start
switch
fitted
to
earlier
engines
is
shown
in Fig. C.2.
With this
switch,
starting a warm
engine
is
effected
by
turning
the
switch
in a
clockwise
direction
to
the
"S"
position.
In
cold
weather, the
switch
should
be
turned
to
the
"H"
position
for
fifteen
to
twenty
seconds
and
then
to
the
"HS"
position
in
order
to
engage
the
starter
motor.
As
soon
as the
engine
starts,
the
switch
should
be
returned
to
the
"0"
position.
Where
this
type
of
switch
is used,
it
was
customary
to
have a
separate
switch
for
the
electrical
circuits
and
this
should
be
turned
on
before
starting
the
engine
and
turned
off
after
stopping
the
engine.
With
accelerator
in the fully
open
position,
turn
the C2
switch a further
clockwise
movement
to
the
"HS"
position
thereby
engaging
the
starter
motor.
If the engine
does
not start
after
fifteen seconds, return
switch
to
"H"
position
for
ten
seconds
and
then re-
engage
the
starter
motor.
1.
Off Position
2.
Start Position
3.
Heat Position
4.
Heat and
Start
Position
OPERATING AND
MAINTENANCE-C.2
Alternative Method
With some engines, a different starter switch is pro-
vided
and the cold
start
aid is operated by means
of
a
separate push button switch.
The
cold
starting
procedure
is the same i.e.
Switch
on by turning the starter switch in a
clockwise
direction
to the first position.
Press the heater button for fifteen
to
twenty seconds
and then,
with
the
heater
button still pressed, turn the
starter
switch
in a
further
clockwise
direction
to engage
the
starter
motor. As
soon
as the engine starts, release
switch
and heater button.
I Glow Plugs
Glow
plugs are sometimes fitted to engines in applica-
tions
such as refrigeration units, fork
lift
trucks
and
other
certain 4.108
mechanically
governed engines
rated at 3,000
rev/min
and below. As the buss bar
connecting
these
glow
plugs may not be insulated,
extreme care must be exercised to keep pipes, clips
or
other
metal
objects
well clear
as
the consequences
of a
direct
short of this buss
bar
to
earth when
energised are obvious.
It must be noted
that
in
no
circumstances
should
either
or
any other unauthorised starting aids be used
at the same time as
glow
plugs.
To operate, use the
following
procedure
:-
Before operating the starter motor, press the
"Heat"
button for
20
to
30
seconds.
I With the
"Heat"
button still pressed, engage the
I starter
motor
until the
engine
starts.
I Continue
to
press the
"Heat"
button
for
a few seconds
I after the engine has started until even running has
: been obtained.
Ilf
the engine does not start, disengage the starter
I motor,
but
keep the
"Heat"
button pressed
for
a
I
further
10
to
15 seconds, when a
further
attempt should
I be made
to
start the engine, keeping the
glow
plugs
I energised whilst starting and for a few seconds after
ithe
engine
has fired until even running is obtained.
Points
to
Note
Ensure
that
the
electrical
connection
to the starting aid
is
correctly
made.
Always ensure
that
the reservoir feeding fuel
to
the
starting aid is fully primed and is not leaking. With
some
later
engines, this fuel
reservoir
has been deleted,
the
cold
start
aid being fed
direct
from the fuel filter
through
a non-return valve.
Extended use
of
the
cold
starting
equipment
above the
time
periods already stated should be avoided, other-
wise the starting aid in the
induction
manifold
may be
damaged also continuous flaming
will
starve the
engine
of oxygen.
In the event
of
difficult
starting,
check
that
fuel is
reaching the starting aid in the
induction
manifold
by
unscrewing
the
inlet
fuel
connection.
If fuel is reaching
it
satisfactorily, then
it
may be that the
starting
aid it-
self
is not
working
correctly. This can be
checked
by
removing the
air
cleaner
and
watching
the starting
aid
whilst
the
equipment
is used. When the
starting
switch
is turned
to
the
"heat"
position,
the
element
should
become red hot, and upon
engagement
of
the
starter
motor
ignition
of
the fuel
should
take
place.
4.108, 4.107 and 4.99 engines are
fitted
with
efficient
starting
equipment
and
no
responsibility
can be
accepted
for
any damage caused
by
unauthorised
start-
ing aids.
To prevent thermostart damage,
it
is
essential
that
the
thermostart is not operated DRY.
After
any
operation
which allows fuel to drain from
the the
thermostart
feed
pipe, the pipe must be
disconnected
at
the
thermostart
and all air bled from the pipe before the
thermostart
is
operated.
Where a
thermostart
starting aid has to be replaced,
care must be taken
not
to
exceed
the
torque
figure
quoted on Page B.2. Excessive
torque
loading
can
crack
the
insulator
adaptor
causing an
electrical
short
and
hard starting characteristics.
Stopping the Engine
A spring
loaded
stop
control
is
located
near
the
normal
engine
controls
and
functions
by
cutting
off
the fuel
at
the fuel
injection
pump.
To
operate, pull the
knob
and
hold
in
mis
position
until
the engine ceases
to
rotate. Ensure
that
the
control
returns to the
"run"
position,
otherwise
difficutly
may
be
experienced
in re-starting the engine.
Return latest
cold
start
switch
to
the
"0"
position.
Some
engines
may have an
electric
solenoid
stop
control on the fuel
injection
pump
operated
by a switch
on the
control
panel.
Running In Procedure
It is not necessary
to
gradually
run-in a
new
or
factory
rebuilt
engine
and any
prolonged
light
load running
during the early life of the
engine
can in
fact
prove
harmful
to
the
bedding in of piston rings and liners.
Full load can be applied
On
a new
or
factory
rebuilt
engine as soon as the
engine
is used,
provided
that
the
engine
is
first
allowed to reach a
temperature
of
at
least
140°F
(60°C).
PREVENTIVE MAINTENANCE
I These preventive
maintenance
periods
are general in
I
application.
Check
the
periods
given by the manu-
I
facturer
of the
equipment
in
which
the engine is
1 installed and,
where
necessary, use the
shorter
periods.
I These
periods
and
procedures
must also be adapted
I
to
ensure
correct
operation
for
any local machine
I regulations.
I It is good
maintenance
to
check
for
leakage and loose
I fasteners at each service interval.
I 1 hese
maintenance
periods
are
only
for
engines that
I are
operated
with fuel and
lubricating
oil to the
I
specifications
given in
this
manual.
I The
schedules
which
follow
must be applied at the
I interval
(miles,
kilometres, hours
or
months)
which
I
occurs
first.
I On
stop
start
low
mileage
work,
the
hours
run are
more
applicable
than
the
mileage
covered.
Daily or every 8 hours
Check
coolant
level.
Check
sump oil level.
Check
oil pressure
(where
gauge is
fitted).
In extreme dust conditions, clean oil bath
air
cleaner
and empty dust
bowl
on dry type
air
cleaner.
Every 4,000 miles (6,000 km),
150 hours or 3 months
t Drain and renew
lubricating
oil (see list of approved
lubricating
oils
Appendix).
t Renew lubricating
oil
filter
element
or
canister.
Clean oil bath
air
cleaner.
Empty dust bowl on
dry
type
air
cleaner.
'Check
drive
belt tension.
Clean
water
trap.
Lubricate
dynamo
rear
bush (where
applicable).
Every 12,000 miles (18,000 km)
450 hours or 12 months
t Renew final fuel
filter
element -
agricultural
and in-
dustrial
applications.
Clean element
of
dry
type
air
cleaner
or
renew
(if
not
indicated
earlier).
Every 24,000 miles (36,000
km)
or 900 hours
Renew final fuel
filter
element -vehicle
applications.
miles (108,000
or
hours
Arrange
for
examination
and service
of
proprietary
equipment, i.e., compressor, exhauster, starter,
dynamo
etc.
Service atomisers.
Check
and
adjust
valve clearance.
t I
Refrigeration
unit
engines
have a larger
capacity
I
sump
and
larger
lubricating
oil
filter
canister,
therefore
the
lubricating
oil
and
filter
change
can
be
extended
to
1000
hours.
Also
with a primary
fuel
oil
filter
fitted,
the
main
fuel
filter
element
change
period
can
be
extended
to
1000
hours.
'The
drive belt
tension
should be
checked
monthly
on
engines rated
above
3,000
rev/min.
POST DELIVERY CHECKOVER
After a customer
has taken
delivery
of his Perkins
Diesel engine, it is advisable,
in
his own interest, that
a general
checkover
of
the engine be
carried
out
after
4.108
Series Workshop Manual, June
1986
OPERATING AND
MAINTENANCE-C.3
the first 500/1000 miles
(800/1600
km)
or
25/50
hours
in service.
It is also recommended
that
the
following
procedure
be adopted where an
engine
has been
laid
up
for
a
considerable period before it is again
put
into
service.
With the engine
thoroughly
warmed
through,
this
checkover
should
comprise
the
following
points.
1.
Drain
lubricating
oil sump. Renew
lubricating
oil
filter
element
or
canister.
(Refer
to
Page L.5
or
L.6)
.
2.
Remove the
rocker
assembly,
check
that
the
cylinder
head nuts are
to
the
correct
torque.
(Refer
to Page
B.2).
3.
Refit
rocker
assembly and set valve
clearances.
(Refer to Page
B.8).
4.
Refill
lubricating
oil sump
with
clean
new
oil
to
the
correct
level.
(Do
not
overfill).
5.
Check fan belt tension.
(Refer
to Page
M.1).
6.
Check
coolant
level in radiator,
inspect
for
any
coolant
leaks.
7.
Check
security of all external nuts, setscrews,
hose
clips, mountings, etc.
8.
Start engine and
check
for
any fuel
or
lubricating
oil leaks.
9.
Carry
out
test to
check
general
performance
of
engine.
Thereafter routine
maintenance
should be in
accord-
ance with Periodical Attentions
which
are given on
previous Page.
NOTE: If the
cylinder
head
is
removed
for
any
reason
e.g. top overhaul, then
it
is
recommended
that
the
cylinder
head
nuts are
retorqued
as
shown
in Fig. E.23
after
500/1000
miles
(800/1600
km)
or
25/50
hours
with the engine hot, to the
setting
given on Page B.2.
It
is
assumed
that
electrical
equipment
will
have
already
been
checked
for
such
points
as
dynamo
rate
of
charge, effectiveness
of
connections
and
circuits,
etc.
ProtecUon
of
an engine
not
in
service
The
recommendations
given
below
are
to
ensure
that
damage
is prevented when an
engine
is removed from
service
for
an
extended period. Use these
procedures
immediately
the
engine
is removed from service. The
instructions
for
the
use
of
POWERPART
products
are
given on the
outside
of
each
container.
1.
Thoroughly
clean
the
outside
of
the
engine.
2.
Where a preservative fuel is
to
be
used,
drain
the
fuel system and fill
with
the
preservative fuel.
POWERPART
lay-Up
1 can
be
added
to
the
normal
fuel
to
change
it
to
a preservative fuel. If
preservative fuel
is
not
used, the system can
be
Kept charged
with
normal fuel
but
this
will have
to
be
drained
and
discharged
at
the end of the
period
together
with
the fuel filter.
3.
Run the
engine
until
it
is warm.
Correct
any fuel,
lubricating
oil
or
air
leakage. Stop the
engine
and
drain
the
lubricating
oil
sump.
4.
Renew the
lubricating
oil filter canister.
5.
Fill
the
sump
to
the
tull
mark
on the
dipstick
with
c,ean
new
lubricating
oil
or
with a correct
preservative fluid. POWERPART
lay-Up
2 can be
added
to
the
lubricating
oil
to
give protection
against
corrosion
curing
the
period
in storage.
If a preservative fluid is used, this must be
drained
and
normal
lubricating
oil used when the
engine
is
returned
to service.
OPERATING
AND
MAINTENANCE-C.4
6.
Drain the
cooling
system, see below. To give
protection against corrosion, it
is
better to fill the
cooling system with a coolant that has a corrosion
inhibitor, see 'Engine Coolant' below.
If frost
protection is needed, use
an
antifreeze mixture.
If no frost protection is needed, use water with
an
approved corrosion inhibitor mixture.
7.
Run the engine
for
a short period
to
send the
lubricating oil and coolant around the engine.
8.
Clean out the engine breather pipe and seal the
end of the pipe.
9.
Remove the atomisers and spray POWERPART
Lay-Up 2 into each cylinder bore. If this is not
available, clean engine lubricating oil will give a
degree of protection. Spray into the cylinder
bores 140 ml
L1-
pint)
of lubricating oil divided
evenly between the
four
cylinders.
10. Slowly turn the crankshaft one revolution and then
install the atomisers complete with
new
seat
washers.
11. Remove the air filter and any pipe installed
between the air filter and induction manifold.
Spray
POWERPART Lay-Up 2 into the induction
manioold. Seal the manifold with waterproof tape.
12. Remove the exhaust pipe. Spray
POWERPART
Lay-Up 2
into the exhaust manifold. Seal the
manifold with waterproof tape.
13. Remove the lubricating oil
filler
cap. Spray
POWERPART Lay-Up 2 around tne
rocker
shaft
assembly. Fit the filler cap. Where the oil filler
cap is not on the cylinder head cover, remove
the cover to spray the rocker shaft assembly.
14. Disconnect the battery and put
it
into safe storage
in a fully charged condition. Before the battery is
put into storage, give the battery terminals a pro-
tection against corrosion.
POWERPART Lay-Up 3
can be used on the terminals.
15. Seal the vent pipe of the fuel tank
or
the fuel
filler
cap with waterproof tape.
16. Remove the fan belt and
put
it
into storage.
17. To prevent corrosion, spray the engine with
POWERPART Lay-Up 3. Do not spray inside the
alternator cooling fan area.
NOTE:
Before the engine is started after a period
in storage, operate the starter
motor
with the
engine stop control in the 'off' position until
oil pressure shows on the oil pressure gauge
or
the oil warning
light
goes out. If a solenoid
stop control is used, this will have
to
be
disconnected
for
this operation.
If the engine protection is done correctly
accoding
to
the above recommendations, no
corrosion damage will
normally
occur.
Perkins Engines Ltd. are
not
responsible
for
any damage that
occurs
in relation
to
a
service storage period.
Engine Coolant
1 he quality
of
the coolant used can have a large
effect on the efficiency and life
of
the
cooling
system.
The recommendations given
below
can be of assistance
in the maintenance of a good
cooling
system with
frost
and/or
corrosion protection.
1.
Where possible, use clean soft water.
I
2.
If
an
antifreeze
mixture,
other
than
Perkins
POWERPART, is
used
to
prevent
frost
damage,
it
must
have
an
ethanediol
(ethylene
glycol)
base
with a corrosion
inhibitor.
It
is
recommended
that
the
corrosion
inhibitor
is
of
the
sodium
nitrate/benzoate
type.
The
antifreeze
mixture
must
provide
cooling/corrosion
protection
at
least as
good
as
the
requirements
of
the
standards
below:
UK:
8S.6580:
1985:
"Specification
for
corrosion
inhibiting,
engine
coolant
concentrate
(antifreeze)".
U.S.A. ASTM 03306-74 'Ethylene Glycol Base Engine
Coolant'.
Australia
AS 2108-1977 'Antifreeze
Compounds
and
Corrosion
Inhibitors
for
Engine
Cooling
Systems'.
When Perkins POWER PART antifreeze is used, the
correct
mixtures of antifreeze and water are as
given below. Perkins POWERPART Antifreeze
fully passes the above standards.
Lowest
Temperature
of
Protection
Needed
-12°C ( 10°F)
-18°C
( O°F)
25°C (
13°F)
-37°C
(-34°F)
%Volume
of
POWERPART
Antilreeze
25
33
40
50
Mixture
Ratio
by
Volume
POWERPART
Antifreeze:Water
1:3
1:2
1:1.5
1
:1
The quality of the antifreeze coolant must be
checked at least once a year,
for
example, at
the start of the cold period.
3.
When frost protection is
not
necessary, it is still
an
advantage
to
use an approved antifreeze
mixture as
this
gives a protection against
corrosion and also raises
the
boiling
point
of the
coolant. A minimum
concentration
of 25% by
volume of antifreeze is necessary, but
it
is our
recommendation that
33%
concentration by
volume is used.
If an antifreeze is not used, add a
correct
corrosion
inhibitor
mixture
to
the water.
Change the
water/corrosion
inhibitor
mixture
every six
months
or
check
according
to
the
inhibitors manufacturer's recommendations.
Note:
Some corrosion
inhibitor
mixtures contain
soluble oil
which
can have an adverse effect on
some types of water hose.
If the
correct
procedures
are
not
used, Perkins Engines
Ltd., can
not
be held responsible
for
any frost
or
corrosion damage.
To Drain the Cooling System
1.
Ensure that
the
vehicle or machine is on level
ground.
2.
Remove
the
radiator filler cap.
3. Remove
the
drain
plug
from
the side of the
cylinder
block
(see engine views)
to
drain the
engine. Ensure that the drain hole does not
have any restriction.
4.
Open the tap
or
remove the drain plug at the
bottom
to
drain the radiator. If a tap
or
plug is
not fitted
to
the radiator, disconnect the bottom
radiator hose.
5.
Where necessary, flush the system with clean
water.
6. Fit the
drain
plugs and radiator cap. Where
necessary,
close
the radiator tap or connect the
radiator hose.
SECTION D
Fault Diagnosis
Fault
Possible Cause
Low
cranking
speed
1,
2,
3,
4.
Will not
start
5,
6,
7,
8,
9,
10, 12,
13, 14, 15,
16,
17, 18, 19,
20,
22,
31, 32,
33.
Difficult starting
5,7,8,9,10,11,12,13,14,15,16,18,19,20,21,22,24,29,
31,
32, 33.
Lack
of
power
8,9,
10, 11,
12, 13,
14,
18,
19,
20, 21,
22, 23, 24,
25, 26,
27,31,
32, 33.
Misfirjng
8,
9,
10,
12,
13, 14, 16,
18, 19,
20, 25,
26,
28, 29,
30,
'32.
Excessive fuel
consumption
11,
13, 14, 16, 18, 19,
20, 22,
23, 24,
25,
27, 28, 29,
31, 32, 33.
Black
exhaust
11,13,14,16,18,
19,20,22,24,25,27,28,29,31,32,33.
Blue/white
exhaust
4,
16, 18, 19, 20, 25,
27,
31,
33, 34, 35,
45,
56.
Low
oil pressure
4,
'36,
37, 38,
39,
40,
42,
43,
44, 58.
Knocking
9,
14, 16, 18, 19, 22,
26,
28,
29,
31,
33,
35, 36,
45,
46, 59.
Erratic
running
7,
8,
9,
10, 11, 12, 13,
14,
16,
20, 21, 23, 26,
28,
29,
30,
33, 35,
45, 59.
Vibration
13, 14,
20,
23,
25,
26,
29,
30,
33,
45, 47,
48,
49.
High oil pressure
4,
38,
41.
Overheating
11,
13, 14, 16,
18,
19,
24,
25,
45,
50, 51, 52, 53,
54,57.
Excessive crankcase pressure
25,
31, 33, 34,
45, 55, 60.
Poor compression
11,19,25,28,29,31,32,33,34,46,59.
Starts and stops
10, 11, 12.
Key
to Fault Finding Chart
1.
Battery
capacity
low.
31. Worn
cylinder
bores.
2.
Bad
electrical
connections.
32.
Pitted
valves and seats.
3. Faulty starter motor.
33. Broken,
worn
or
sticking
piston ring/so
4.
Incorrect
grade
of
lubricating oil.
34.
Worn valve stems
and
guides.
5.
low
cranking
speed.
'35.
Overfull
air
cleaner
or
use
of
incorrect
grade
of
6. Fuel
tank
empty.
oil.
7.
Faulty stop
control
operation.
36. Worn
or
damaged bearings.
8.
Blocked
fuel feed pipe.
37.
Insufficient
oil
in sump.
9.
Faulty fuel
lift
pump.
38.
Inaccurate
gauge.
10. Choked fuel filter.
39.
Oil
pump
worn.
11. Restriction in air
cleaner
or
induction
system.
40. Pressure relief valve
sticking
open.
12.
Air
in fuel system.
41.
Pressure relief valve
sticking
closed.
13. Faulty fuel
injection
pump.
42.
Broken
relief
valve spring.
14. Faulty atomisers
or
incorrect
type.
43. Faulty
suction
pipe.
15.
Incorrect
use
of
cold
start
equipment.
44.
Choked
oil filter.
16. Faulty
cold
starting equipment.
45. Piston
seizure/pick
up.
17. Broken fuel
injection
pump drive.
46.
Incorrect
piston
height.
18.
Incorrect
fuel pump timing.
47.
Damaged
fan.
19.
Incorrect
valve timing. 48. Faulty
engine
mounting
(Housing).
20.
Poor
compression. 49.
Incorrectly
aligned
flywheel housing,
or
flywheel.
21.
Blocked
fuel tank vent. 50. Faulty thermostat.
22.
Incorrect
type
or
grade
of fuel. 51.
Restriction
in
water
jacket.
23.
Sticking
throttle
or
restricted movement.
52.
Loose
fan belt.
24. Exhaust
pipe
restriction. 53.
Choked
radiator.
25.
Cylinder
head
gasket
leaking.
54. Faulty
water
pump.
26. Overheating.
55.
Choked
breather
pipe.
27. Cold running. 56.
Damaged
valve stem oil deflectors
(if
fitted).
28.
Incorrect
tappet
adjustment. 57.
Coolant
level
too
low.
29.
Sticking
valves.
58.
Blocked
sump
strainer.
30.
Incorrect
high pressure pipes. 59.
Broken
valve
spring.
60.
Defective
exhauster/leaking
vacuum pipe.
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