Every one of the 103 pages in this Perkins 4.108, 4.107, 4.99 Shop Manual PDF (OEM 601 SER 0383 1072) is aimed at one job: putting your Perkins diesel back to factory condition. You get a full technical data section with torque tensions and service wear limits, a fault-finding chart covering misfiring, low oil pressure, and poor compression, plus step-by-step overhaul procedures for the cylinder head, pistons, crankshaft, timing gear, and fuel injection pump. Inside you'll also find the approved service tool list, from valve guide removers to liner pullers. Set valve clearance to 0.010 in (0,25 mm) hot, and confirm 4-7 lbf/in² static pressure at the fuel lift pump before you blame the injection pump. These little Perkins engines outlive their owners when you feed them real specs. Bookmarked chapters, keyword search: find the number, make the fix.
What's Inside This Perkins 4.108, 4.107, 4.99 Manual
| System | Pages | Key Topics |
|---|---|---|
| Engine Views | 7-10 | Dynamo Pulley, Exhaust Manifold, Fuel Injection Pump, Starter Motor, Lubricating Oil Filter |
| Technical Data | 11-23 | Engine Data, Torque Tensions, Service Wear Limits, Cylinder Block, Piston Rings, Fuel Injection Pump |
| Operating and Maintenance | 24-27 | Starting Procedure, Starting Aid, Preventive Maintenance, Cooling System, Engine Protection |
| Fault Finding | 28 | Low Cranking Speed, Misfiring, Low Oil Pressure, Overheating, Poor Compression |
| Cylinder Head | 29-37 | Valves, Valve Seats, Valve Guides, Rocker Shaft Assembly, Cylinder Head Gasket |
| Pistons and Connecting Rods | 38-43 | Pistons, Connecting Rods, Piston Rings, Gudgeon Pin, Laminated Segment Rings |
| Cylinder Block and Liners | 44-45 | Cylinder Liners, Cylinder Block, Sealing Rings, Oversize Cylinder Liners |
| Crankshaft and Main Bearings | 46-50 | Crankshaft, Main Bearings, Thrust Washers, Oil Seal, Crankshaft Regrinding |
| Timing Case and Drive | 51-57 | Timing Case Cover, Crankshaft Front Oil Seal, Idler Gear and Hub, Camshaft Gear, Fuel Pump Gear, Camshaft and Tappets |
| Timing | 58-59 | Timing Marks, Retiming Procedure, Timing Pin, Valve Timing |
| Lubricating System | 60-65 | Lubricating Oil Pump, Oil Pressure Relief Valve, Lubricating Oil Filters, Sump, Oil Pressure |
| Cooling System | 66-69 | Fan Belt, Water Pump, Water Pump Seals, Thermostat |
| Air Cleaners and Fuel System | 70-80 | Air Cleaners, Fuel Oil Filters, Fuel Lift Pump, Fuel Injection Pump, Atomisers, Idling Speed Adjustment |
| Flywheel and Housing | 81-82 | Flywheel, Flywheel Ring Gear, Flywheel Housing |
| Electrical Equipment | 83-91 | Alternator, Dynamo, Starter Motor, Glow Plugs |
| Engines for Refrigeration Units | 92-94 | Cold Starting Procedure, Cylinder Liners, Lubricating System, Fuel System |
| Approved Lubricating Oils | 95 | Api Cc/Se Specification, Api Cd/Se Specification, Sae Viscosity Grades, Fuel Specification |
| Approved Service Tools | 96-99 | Valve Guide Remover, Piston Ring Squeezer, Piston Height Gauge, Fuel Pump Allen Key, Cylinder Liner Remover, Valve Spring Compressor |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Valve Clearance | 0.010 in (0,25 mm) Hot | p. 18 |
| Fuel Lift Pump Total Stroke of Operating Lever | 0.192 in (4,877 mm) | p. 21 |
| Fuel Lift Pump Static Pressure | 4-7 lbf/in² (0,28-0,49 kgf/cm²) | p. 21 |
| Fuel Injection Pump Plunger Dia. | 6 mm | p. 21 |
| Valve in Fuel Pump Drain Connection | 0.71-1.25 lbf/in² (0,0522-0,0875 kgf/cm²) | p. 21 |
| Atomiser Min. Working Pressure (4.108, 4.107) | 135 atm (2000 lbf/in² or 140 kgf/cm²) | p. 23 |
| Atomiser Setting Pressure (4.108, 4.107) | 150 atm (2200 lbf/in² or 155 kgf/cm²) | p. 23 |
| Starter Motor Max. Current | 900A | p. 23 |
| Starter Cable Resistance | 0.0017 ohms (Max.) | p. 23 |
| Inner Rotor to Outer Rotor Clearance | 0.0015/0.003 in (0,038/0,076 mm) | p. 20 |
| Inner Rotor End Clearance | 0.0015/0.0035 in (0,038/0,089 mm) | p. 20 |
| Relief Valve Pressure Setting | 50/65 lbf/in² (3,5/4,6 kgf/cm²) | p. 20 |
Perkins 4.108, 4.107, 4.99 Common Problems This Manual Covers
Perkins 4.108 diesel cranks strong but won't start after changing fuel filters, no smoke from exhaust
Check the fault finding chart on page 28 for no-start causes: empty tank, blocked feed pipe, faulty stop control. Bleed air from the fuel system following the procedure on page 70, then test the lift pump; static pressure should read 4-7 lbf/in2 (0,28-0,49 kgf/cm2) with no delivery. Replace the pump if pressure stays low.
Manual Section: Fault Finding p. 28Oil pressure warning light flickers at idle when hot, gauge reads low at operating temperature
Verify sump level first, then compare gauge readings against the correct range: 30/60 lbf/in2 (2,1/4,2 kgf/cm2) at maximum engine speed and normal working temperature. Inspect the relief valve using the procedure on page 60; it should hold 50/65 lbf/in2 and the spring free length must measure 1.5 in (38,10 mm). Renew worn oil pump rotors.
Manual Section: Lubricating System p. 60Engine overheats under load in warm weather, coolant boiling in the header tank
Check coolant level; the engine holds 6 Imp. pt (3,4 litre) less radiator, so even a small loss matters. Test the thermostat and inspect the water pump seals following the cooling system procedures on page 66. Adjust fan belt tension, then look for restriction in the water jacket or a choked radiator core before condemning the pump.
Manual Section: Cooling System p. 66Hard starting on cold mornings with white smoke, down on power once warm
Set valve clearances to 0.010 in (0,25 mm) with the engine hot, then run a compression check. Low readings on all cylinders point to worn bores or broken rings; one weak cylinder usually means pitted valves or seats. Follow the cylinder head overhaul procedure on page 29 to recut seats and renew guides.
Manual Section: Cylinder Head p. 29Black exhaust smoke under load with diesel knock and rough uneven idle
Remove the atomisers and test them on a pop tester; setting pressure is 150 atm (2200 lbf/in2) and the spray must be even with no dribble at the nozzle tip. Clean or renew faulty nozzles per the fuel system procedures on page 70, then torque the high pressure pipe nuts to 15 lbf ft (20 Nm) on refitting.
Manual Section: Air Cleaners and Fuel System p. 70Starter motor just clicks or turns the engine over too slowly to fire
Test the battery under load, then measure total starter cable resistance; it must not exceed 0.0017 ohms. Inspect the brushes and renew any worn to 14 mm, and check brush spring tension against the 0.85-1.13 kgf specification on page 90. Work through the starter motor maintenance procedures on page 83 before buying a new motor.
Manual Section: Electrical Equipment p. 83Frequently Asked Questions
How do I bleed the fuel system on a Perkins 4.108, 4.107, or 4.99 engine?
To bleed the fuel system, first loosen the vent screw on top of the fuel filter. Operate the priming lever on the fuel lift pump until fuel free of air flows from the vent, then tighten the screw. Next, loosen the vent screw on the control gear housing (or governor housing) and the locking bolt of the hydraulic head, operate the priming lever again until air-free fuel flows, and tighten the screws. Finally, loosen the high-pressure pipe connections at two atomisers and crank the engine until fuel flows, then tighten the connections. p. 80
What are the cylinder head torque specifications for the Perkins 4.108, 4.107, and 4.99 engines?
For the 4.107 and 4.99 engines, the cylinder head nuts should be tightened to 42 lbf ft (5.81 kgf m, 57 Nm). For the 4.108 engine, the cylinder head nuts should be tightened to 60 lbf ft (8.3 kgf m, 81 Nm). p. 12
What does low oil pressure indicate on a Perkins 4.108, 4.107, or 4.99 engine?
Low oil pressure can be caused by several factors, including the use of an incorrect grade of lubricating oil, a worn or damaged bearing, insufficient oil in the sump, an inaccurate gauge, a worn oil pump, or a pressure relief valve that is sticking open or has a broken spring. p. 28
What is the correct valve clearance for the Perkins 4.108, 4.107, and 4.99 engines?
The valve clearance for all these engines is 0.010 inches (0.25 mm) when the engine is hot. p. 18
What is the lubricating oil pressure for the Perkins 4.108, 4.107, and 4.99 engines?
The lubricating oil pressure should be between 30 and 60 lbf/in² (2.1 to 4.2 kgf/cm²) at maximum engine speed and normal working temperature. p. 19
How will I receive this Perkins 4.108 Shop Manual?
Straight to your device: 103 pages of searchable Shop Manual, downloadable the moment payment goes through.
Am I able to print pages from this Perkins 4.108 manual?
You can. The PDF is unlocked and carries no copy protection, so print the sections you want and keep the file as your backup.
Reviews
There are no reviews yet.