Perkins 100 Series Workshop Manual
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Perkins 100 Series Workshop Manual

Perkins 100 Series Workshop Manual

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Perkins 100 Series
Models 102-05, 103-07, 103-10, 103-13, 103-15, 104-19,
104-22
WORKSHOP MANUAL
102-05
103-07
103-10
103-13
103-15
104-19
104-22
Publication TPD 1377E, Issue 4
© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in September 2003 by Technical Publications.
This document has been printed from SPI². Not for Resale
Two cylinder diesel engines
Three cylinder diesel engines
Four cylinder diesel engines
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Summary of Contents for Perkins 100 Series

  • Page 1 Four cylinder diesel engines 104-22 Publication TPD 1377E, Issue 4 © Proprietary information of Perkins Engines Company Limited, all rights reserved. The information is correct at the time of print. Published in September 2003 by Technical Publications. This document has been printed from SPI². Not for Resale...
  • Page 2 This publication is written in Perkins Approved Clear English Chapters 1 General information 2 Specifications 3 Cylinder head assembly 4 Piston and connecting rod assemblies 5 Crankshaft assembly 6 Timing case and drive assembly 7 Cylinder block assembly 8 Engine timing...

  • Page 3: Table Of Contents

    100 Series Contents 1 General information Introduction ......................1 Safety precautions .
  • Page 4 100 Series 2 Specifications Basic engine data ....................13 Thread Sealant ...
  • Page 5 100 Series Exhaust manifold and gasket Operation 3-6 To remove and to fit ................30 Fuel injection pipes / fuel return pipes Operation 3-7 To remove and to fit ...
  • Page 6 100 Series Valve seat contact face Operation 3-22 Lapping ..................46...
  • Page 7 100 Series Main bearings Operation 5-5 To dismantle and to assemble (two and three cylinder engines) ... .. 62 Operation 5-6 To dismantle and to assemble (four cylinder engines) ......63...
  • Page 8 100 Series Oil seal protector Operation 6-15 To fit ....................80...
  • Page 9 100 Series Oil pressure switch Operation 10-6 To remove and to fit ................ 96 11 Fuel system...
  • Page 10 100 Series 14 Electrical equipment Electrical shut off solenoid (ESOS) Operation 14-1 To remove and to fit ...............115...

  • Page 11: General Information

    This Workshop Manual has been written to provide the trained technician with enough information to service and overhaul all of the latest Perkins 100 Series engines. It has been compiled for use in conjunction with normal workshop practice and information contained in current service bulletins. Certain accepted practices have been purposely omitted in order to avoid repetition.

  • Page 12: Safety Precautions

    100 Series Safety precautions These safety precautions are important. You must refer also to the local regulations in the country of use. Some items only refer to specific applications. Only use these engines in the type of application for which they have been designed.
  • Page 13 Do not use more than 50% anti freeze concentration by volume at high ambients, otherwise engine damage will result. Fit only genuine Perkins Parts. Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...

  • Page 14: Engine Preservation

    If the engine protection is done correctly according to the above recommendations, no corrosion damage will normally occur. Perkins are not responsible for damage which may occur when an engine is in storage after a period in service.

  • Page 15: Powerpart Recommended Consumable Products

    100 Series POWERPART recommended consumable products Perkins have made available the products recommended below in order to assist in the correct operation, service and maintenance of your engine and your machine. The instructions for the use of each product are given on the outside of each container.
  • Page 16 100 Series Part number 21826039. POWERPART Metal repair putty Designed for external repair of metal and plastic. Part number 21820126. POWERPART Pipe sealant and sealant primer To retain and seal pipe connections with coarse threads. Pressure systems can be used immediately.

  • Page 17: Engine I.d. Location

    100 Series Engine I.D. location The engine identification plate (A1) is located on the front right side of the engine, just above the fuel injection pump. It consists of the following: Abbreviations and codes Engine build list (parts list) numbering system...

  • Page 18: Engine Views - 3 Cylinder Front And Rear

    100 Series Engine views - 3 cylinder front and rear Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...

  • Page 19: Engine Views - 2 Cylinder Front And 4 Cylinder Front

    100 Series Engine views - 2 cylinder front and 4 cylinder front Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...

  • Page 20: Engine Lift Equipment

    100 Series Engine lift equipment Special requirements Torque Nm (lbf ft) kgf m Lifting hook bolts (A1) 26 (19) 2,6 Maximum engine weights (dry) with flywheel and housing fitted Engine model 102-05 103-07 103-10 103-13 103-15 104-19 104-22 Engine build code...

  • Page 21: Viton Seals

    100 Series Viton seals Some seals used in engines and in components fitted to engines are made of Viton. Viton is used by many manufacturers and is a safe material under normal conditions of operation. If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this burnt material to come into contact with the skin or with the eyes.

  • Page 22: Compression Test Data

    100 Series Compression test data Tests have shown that many factors affect compression pressures. Battery, starter motor condition, ambient conditions and the type of gauge used can give a wide variation of results for a given engine. Pressure kPa (lbf/in²)

  • Page 23: Specifications

    100 Series Specifications Basic engine data Engine model 102-05 103-07 103-10 103-13 103-15 104-19 104-22 Engine build code Number of cylinders Cylinder arrangement and Vertical in line, four stroke cycle cycle Direction of rotation Clockwise, viewed from front Induction system...

  • Page 24: Thread Sealant

    100 Series Thread Sealant When setscrews or studs are fitted into holes which are tapped through the cylinder block, a suitable sealant must be used to prevent leakage. Micro encapsulated anaerobic sealant (M.E.A.S) fasteners have been introduced instead of jointing compounds or other sealants when the fasteners are fitted in through holes into oil or coolant passages.

  • Page 25: Data And Dimensions

    100 Series Data and dimensions Note: The information in this Workshop Manual is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in production. Injection timing Engine build list...

  • Page 26: Cylinder Bore Dimensions

    100 Series Cylinder bore dimensions Bore dimension mm (in) Engine model/Block specification Standard Service limit 102-05, 103-07 New Block 67,000 - 67,019 (2.63780 - 2.63854) 67,2 (2.646) 1st oversize bore 0,5 mm (0.2 in) 67,500 - 67,519 (2.65750 - 2.65822) 67,7 (2.666)

  • Page 27: Piston And Piston Ring Dimensions

    100 Series Piston and piston ring dimensions Piston If the outer surface of the piston is excessively damaged (cracked, scored, or it shows signs of being burnt etc.) it must be renewed. Piston skirt 1 Check the larger diameter of the piston skirt (10 mm from bottom) with reference to the following tables.

  • Page 28: Gudgeon Pin

    100 Series Gudgeon pin 1 Check the outside diameter of the gudgeon pin. If it is less than the service limit, renew the pin. Diameter mm (in) Engine model Standard Service limit 102-05, 103-07 18,998 - 19,002 (0.74795 - 0.74811) 18,98 (0.7472)

  • Page 29: Crankshaft Deflection

    100 Series Crankshaft deflection 1 Support the crankshaft with a V-block. 2 Position a dial gauge on the crankshaft centre journal, and turn the crankshaft gradually by one full turn. 3 If the gauge reading is more than the service limit correction or replacement of the crankshaft is needed.

  • Page 30: Crankshaft Journal Diameters

    100 Series Crankshaft journal diameters Diameter mm (in) Journal Engine model/Journal type Standard Service limit 102-05 42,964 - 42,975 (1.69150 - 1.69193) 42,90 (1.689) Standard 45,948 - 45,959 (1.80897 - 1.80941) 45,90 (1.807) 42,714 - 42,725 (1.68165 - 1.68210) 42,65 (1.679) Undersize 0,25 mm (0.01 in)

  • Page 31: Crankshaft Pin Diameters

    100 Series Crankshaft pin diameters Diameter mm (in) Engine model/Pin type Standard Service limit 102-05, 103-07 Standard 34,964 - 34,975 (1.37653 - 1.37697) 34,90 (1.374) Undersize 0,25 mm (0.01 in) 34,714 - 34,725 (1.36669 - 1.36712) 34,65 (1.364) Undersize 0,50 mm (0.02 in) 34,464 - 34,475 (1.35685 - 1.35728)

  • Page 32: Bearing Holder

    100 Series Bearing holder Centre bearing 1 Remove the bearing holder and check it for stepped wear and other damage. If it is excessively damaged renew. 2 Using the Plastigauge ®, measure the oil clearance between the crankshaft centre journal and the bearing.

  • Page 33: Undersize Bearing Shell Chart

    100 Series Undersize bearing shell chart Journal Crankshaft centre Engine model/Bearing size journal diameter mm (in) 102-05 42,964 - 42,975 (1.69150 - 1.69193) Standard 45,948 - 45,959 (1.80897 - 1.80941) 42,714 - 42,725 (1.68165 - 1.68210) Undersize 0,25 mm (0.01 in) 45,698 - 45,709 (1.79913 - 1.79956)

  • Page 34: Crankshaft Bearing Bush

    100 Series Crankshaft bearing bush 1 Check the bearing (bush) for damage or poor contact. If found to be defective, renew. 2 Using a cylinder gauge and micrometer, measure the clearance between the bearing (bush) and the crankshaft journal (B).

  • Page 35: Cylinder Head Assembly

    100 Series Cylinder head assembly Rocker cover and inlet manifold To remove and to fit Operation 3-1 Special requirements Torque Nm (lbf ft) kgf m 102-05, 103-07, 103-10 11 (8) 1,1 103-13, 103-15 10 (7) 1,0 104-19, 104-22 14 (10) 1,4 Note: Inspect the joint, renew if necessary.

  • Page 36: Rocker Assembly

    100 Series Rocker assembly To remove and to fit Operation 3-2 Special requirements Torque Nm (lbf ft) kgf m 102-05, 103-07, 103-10 23 (17) 2,3 103-13, 103-15 23 (17) 2,3 104-19, 104-22 33 (24) 3,3 Bolts (A2) 6 (4) 0,6 Note: Ensure that the valve stem caps (A1) remain on the valve stems.

  • Page 37: Rocker Shaft

    100 Series Rocker shaft (102-05, 103-07, 103-10) To dismantle, to inspect and to assemble Operation 3-3 Special requirements Diameter (A) mm (in) Clearance (B1) mm (in) Standard Service limit Standard Service limit 11,65 - 11,67 (0.4587 - 0.4595) 11,57 (0.4555) max 0,032 - 0,068 (0.00126 - 0.00268)

  • Page 38: Rocker Shaft

    100 Series Rocker shaft (103-13, 103-15, 104-19, 104-22) To dismantle, to inspect and to assemble Operation 3-4 Special requirements Diameter (A) mm (in) Engine model Standard Service limit 103-13, 103-15 11,65 - 11,67 (0.4587 - 0.4595) 11,57 (0.4555) max 104-19, 104-22 14,95 - 14,97 (0.5886 - 0.5894)

  • Page 39: Fan And Mounting

    100 Series Fan and mounting To remove Operation 3-5 Special requirements Tension Nm (lbf ft) kgf m Bolts (A1) 11 (8) 1,1 To fit and tension the fan belt refer to Operation 12-1. Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...

  • Page 40: Exhaust Manifold And Gasket

    100 Series Exhaust manifold and gasket To remove and to fit Operation 3-6 Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...

  • Page 41: Fuel Injection Pipes / Fuel Return Pipes

    100 Series Fuel injection pipes / fuel return pipes To remove and to fit Operation 3-7 Special requirements Torque Nm (lbf ft) kgf m 102-05, 103-07, 103-10 22 (16) 2,2 103-13, 103-15, 104-19, 104-22 20 (15) 2,0 Notes: Be aware of holes in washers (A1).

  • Page 42: Oil Pipes

    100 Series Oil pipes To remove and to fit Operation 3-8 Special requirements Torque Nm (lbf ft) kgf m 102-05, 103-07, 103-10 11 (8) 1,1 103-13, 103-15, 104-19, 104-22 12 (9) 1,2 Notes: Be aware of the oil restriction in the banjo bolts (A1).

  • Page 43: Atomisers

    100 Series Atomisers To remove and to fit Operation 3-9 Special requirements Torque Nm (lbf ft) kgf m Test Pressure kgf/cm² (lbf/in²) ats 102-05, 103-07 64 (47) 6,5 102-05, 103-07 120 (1707) 116 103-10 81 (60) 8,2 103-10 120 (1707) 116...

  • Page 44: Busbar / Glowplugs

    100 Series Busbar / glowplugs To remove and to fit Operation 3-10 Special requirements Torque Nm (lbf ft) kgf m Glowplugs 17 (12) 1,7 Contacts 17 (12) 1,7 Note: The diagram below shows a typical arrangement only. Workshop Manual, TPD 1377E, issue 4...

  • Page 45: Head Bolts

    100 Series Head bolts To remove and to fit Operation 3-11 For recommended torques and tightening sequences refer to Operation 3-14. Notes: Lubricate bolts with engine lubricating oil. For emissions approved engines. It is essential that the fuel adjustment screw is not altered from the original setting.

  • Page 46: Cylinder Head Gasket

    100 Series Cylinder head gasket To remove and to fit Operation 3-12 Align gasket on dowels, gasket must only be assembled with markings (A1) facing up. Notes: Always fit dry. For emissions approved engines. If the cylinder block, crankshaft, connecting rods or pistons are changed, the piston height must be checked and the correct thickness gasket used, refer to operation 3-13.
  • Page 47 100 Series To select the correct thickness of cylinder head gasket Operation 3-13 Caution: If the correct piston height above or below the cylinder block is not obtained, damage to the engine can occur. The difference between the highest and the lowest piston height must not exceed 0.1 mm.

  • Page 48: Head Bolts - All Variants

    100 Series Head bolts - all variants Tightening sequence Operation 3-14 Special requirements Torque Nm (lbf ft) kgf m 102-05, 103-07 37 (27) 3,7 103-13, 103-15, 104-19, 104-22 100 (74) 10,2 103-10 51 (38) 5,2 Note: All torques should be rechecked after tightening. Item (C1) is present on 104-19 models only.

  • Page 49: Valve And Valve Springs

    100 Series Valve and valve springs To remove and to fit Operation 3-15 Special requirements Special tools Description Part number Description Part number Valve spring remover 21825663 Stem seal replacer - 103-10, 103-13, 21825623 103-15, 104-19, 104-22 Stem seal replacer - 102-05, 103-07 21825622 Caution: Always wear safety glasses.

  • Page 50: Valve Spring

    100 Series Valve spring To inspect Operation 3-16 Special requirements Free length (A3) mm (in) Engine model Standard Service limit 102-05, 103-07 33,0 (1.299) 31,5 (1.240) 103-10, 103-13, 103-15, 104-19, 104-22 35,0 (1.378) 33,5 (1.319) Spring rate when compressed to 30,4 mm (1.197 in) N (lbf) kgf...

  • Page 51: Valve Stem Diameter And Thickness Of Valve Head

    100 Series Valve stem diameter and thickness of valve head To inspect Operation 3-17 Valve head thickness If the valve head thickness is less than the service limit, renew the valve. Thickness (A1) mm (in) Standard Service limit 0,925 - 1,075 (0.03642 - 0.04232)

  • Page 52: Valve Guide Clearance

    100 Series Valve guide clearance To inspect Operation 3-18 Check the clearance between the valve and valve-guide. If the clearance exceeds the service limit, renew the cylinder head. Intake valve Clearance (A1) mm (in) Engine model Standard Service limit 102-05, 103-07, 103-10 0,025 - 0,052 (0.001 - 0.002)

  • Page 53: Cylinder Head

    100 Series Cylinder head To check the distortion of the lower face Operation 3-19 Special requirements Maximum machine limit mm (in) Distortion Max service limit Max regrind 0,05 (0.002) OR LESS 0,12 (0.005) 0,15 (0.006) Using a straight edge (A1) and feeler gauge (A2) check the six positions (lines B1 to B6) for distortion. Do not machine beyond the maximum limit.

  • Page 54: Valve Seat Width

    100 Series Valve seat width To correct Operation 3-20 If the contact width (B1) of the valve seat is more than service limit, check wear condition of the valve guide first. Using a seat cutter of 45° correct the seat.

  • Page 55: Valve Depth

    100 Series Valve depth To correct Operation 3-21 Special requirements Depth (A1) mm (in) Engine model Standard Service limit 102-05, 103-07 0,70 - 0,90 (0.0276 - 0.0354) 1,8 (0.071) max 103-10 0,85 - 1,15 (0.0335 - 0.0453) 1,8 (0.071) max 103-13, 103-15 0,85 - 1,15 (0.0335 - 0.0453)

  • Page 56: Valve Seat Contact Face

    100 Series Valve seat contact face Lapping Operation 3-22 Correct valve seat contact using a valve lapping tool and lapping compound. Note: When using a new cylinder head, obtain correct seat contact width and seat recess using the seat cutter, then carry out a final lap.

  • Page 57: Valve Tip Clearance

    100 Series Valve tip clearance To check Operation 3-23 The valve sequence is viewed from the front of the engine. Rotate the crankshaft clockwise when viewed from the front. Adjust the clearance of both intake and exhaust valves to 0,2 mm (0.0078 in).
  • Page 58 This page is intentionally blank This document has been printed from SPI². Not for Resale...

  • Page 59: Piston And Connecting Rod Assemblies

    100 Series Piston and connecting rod assemblies Big end bearing and cap To remove and to fit Operation 4-1 Special requirements Torque Nm (lbf ft) kgf m Clearance mm (in) 102-05, 103-07 23 (17) 2,3 Standard Service limit 103-10 32 (24) 3,2 0,1 - 0,3 (0.004 - 0.012)

  • Page 60: Piston And Connecting Rod

    100 Series Piston and connecting rod To dismantle and to assemble Operation 4-2 Align Shibaura logo (A1) with stamped number on con rod. Align numbers to match (A2). Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...
  • Page 61 100 Series To fit Operation 4-3 Special requirements Torque Nm (lbf ft) kgf m 102-05, 103-07 23 (17) 2,3 103-13, 103-15, 104-19, 104-22 52 (38) 5,3 103-10 32 (24) 3,2 For positioning of connecting rod assembly refer to Operation 4-2.

  • Page 62: Piston And Piston Ring

    100 Series Piston and piston ring To inspect Operation 4-4 Any letters or marks on a surface of a ring (A1) will always be to the upper face. The piston profile shows the No.1 ring (A2), No.2 ring (A3) and the oil scraper ring (A4).
  • Page 63 100 Series To measure piston ring clearance Operation 4-5 By use of feeler gauges, measure the clearance between the piston ring groove and ring. If the clearance exceeds the service limit, renew the piston and rings. 102-05, 103-07, 103-10 103-13, 103-15, 104-19, 104-22...

  • Page 64: Piston Ring And Block

    100 Series Piston ring and block To inspect Operation 4-6 Note: If the piston ring is worn or damaged, renew it. Piston ring gap Insert the rings into the cylinder at right angles to the cylinder bore and measure the gaps with a feeler gauge.

  • Page 65: Small End Bush

    100 Series Small end bush To remove and to fit Operation 4-7 Special requirements Clearance mm (in) Engine model Standard Service limit 102-05, 103-07 0,013 - 0,028 (0.00051 - 0.00110) 0,1 (0.004) 103-10 0,008 - 0,023 (0.00031 - 0.00091) 0,1 (0.004) 103-13, 103-15, 104-19, 104-22 0,010 - 0,025 (0.00040 - 0.00099)

  • Page 66: Connecting Rod

    100 Series Connecting rod To inspect Operation 4-8 Special requirements Dimension mm (in) Standard Service limit Distortion for 100 (3.937) Less than 0,08 (0.0031) 0,20 (0.0079) max Parallel for 100 (3.937) Less than 0,05 (0.0020) 0,15 (0.0059) max Workshop Manual, TPD 1377E, issue 4...

  • Page 67: Crankshaft Assembly

    100 Series Crankshaft assembly Crankshaft pulley To remove and to fit Operation 5-1 Special requirements Special tools Torque Nm (lbf ft) kgf m Description Part number 102-05, 103-07 93 (69) 9,5 103-10 123 (91) 12,5 Crankshaft pulley remover 21825619 103-13, 103-15, 104-19, 104-22 304 (224) 31 Note: Store the key (A1) in a safe place until assembly.

  • Page 68: Flywheel, Backplate And Oil Seal

    100 Series Flywheel, backplate and oil seal To remove and to fit Operation 5-2 Special requirements POWERPART products Description Part number Silicone RTV sealing and jointing compound 1861108 Flywheel setscrews : Torque Nm (lbf ft) kgf m Backplate setscrews : Torque Nm (lbf ft) kgf m...

  • Page 69: Crankshaft Retainer Setscrews And Crankshaft

    100 Series Crankshaft retainer setscrews and crankshaft To remove and to fit Operation 5-3 Special requirements Hex hole setscrews (A1) : Torque Nm (lbf ft) kgf m Hex setscrews (A2) : Torque Nm (lbf ft) kgf m 102-05, 103-07, 103-10...
  • Page 70 100 Series Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...

  • Page 71: Bearing Clearance

    100 Series Bearing clearance To check Operation 5-4 Special requirements Clearance mm (in) Engine model Standard Service limit 102-05, 103-07 0,031 - 0,079 (0.00122 - 0.00311) 0,20 (0.0079) 103-10 0,035 - 0,083 (0.00138 - 0.00327) 0,20 (0.0079) 103-13, 103-15, 104-19, 104-22 0,035 - 0,085 (0.00138 - 0.00335)

  • Page 72: Main Bearings

    100 Series Main bearings To dismantle and to assemble (two and three cylinder engines) Operation 5-5 Special requirements Bearing holder (Aluminium) : Thickness mm (in) Torque Nm (lbf ft) kgf m Standard Service limit 102-05, 103-07, 103-10 22 (16) 2,2 21,85 - 21,95 (0.8602 - 0.8641)
  • Page 73 100 Series To dismantle and to assemble (four cylinder engines) Operation 5-6 Special requirements Torque Nm (lbf ft) kgf m 103-13, 103-15, 104-19, 104-22 51 (38) 5,2 End float : Clearance mm (in) Thrust washer : Thickness mm (in) Standard...
  • Page 74 This page is intentionally blank This document has been printed from SPI². Not for Resale...

  • Page 75: Timing Case And Drive Assembly

    100 Series Timing case and drive assembly Fuel injection pump To remove and to fit Operation 6-1 Special requirements Torque Nm (lbf ft) kgf m Solenoid 17 (12) 1,7 When the shim (A1) is not required, assemble using a 0,5 mm bead of silicone sealant.

  • Page 76: Timing Cover

    100 Series Timing cover To remove and to fit Operation 6-2 For crankshaft pulley removal refer to Operation 5-1. Notes: Make sure that the governor springs are correctly attached before the timing cover is fitted, see Operation 6-14. On assembly hold arm clockwise.

  • Page 77: Slider

    100 Series Slider To remove and to fit Operation 6-3 Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...

  • Page 78: Camshaft Retainer Plate

    100 Series Camshaft retainer plate To remove and to fit Operation 6-4 Special requirements Torque Nm (lbf ft) kgf m Camshaft retainer plate setscrews 11 (8) 1,1 Notes: For emissions approved engines. The fuel adjustment screw must not be altered from the original setting.

  • Page 79: Camshaft And Cam Followers

    100 Series Camshaft and cam followers To remove Operation 6-5 Caution: Remove fuel lift pump and all the cam followers before removing the camshaft. Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...
  • Page 80 100 Series To fit Operation 6-6 Cautions: The new camshaft is not interchangeable with the old camshaft. If a new camshaft is fitted, new cam followers of the correct type must be fitted as well. From engine serial number 333367J the camshaft and the cam followers fitted to the 103-07 engine have changed.

  • Page 81: Camshaft Assembly

    100 Series Camshaft assembly To inspect Operation 6-7 Cam height (intake and exhaust cams) (A1) Height mm (in) Engine model Standard Service limit 102-05, 103-07 26,565 - 26,620 (1.04590 - 1.04803) 26,1 (1.028) 103-10 26,445 - 26,500 (1.04114 - 1.04330) 26,1 (1.028)

  • Page 82: Max Fuel Screw And Max Speed Screw

    An anti tamper device (A3) may be fitted. Where this device is present, see Operation 6-9. If adjustment of the maximum fuel screw or the no load speed is necessary, the adjustment must be done on an engine test facility by personnel approved by Perkins Engines Company Ltd. Workshop Manual, TPD 1377E, issue 4...
  • Page 83 A requirement of emissions legislation is that access to adjustments (A1, A2) that affect the engine's exhaust emissions is limited to personnel approved by Perkins Engines Company Ltd. The fuel adjustment screw (B2) and maximum speed adjustment (B5) are affected. The fuel adjustment screw has a tamper resistant body (B1) fitted over the screw and the maximum speed adjustment is protected by a tamper evident plastic cap (B4).
  • Page 84 To remove and re-fit the tamper evident maximum engine speed cap The maximum speed adjustment has a plastic cap (B4) fitted by Perkins. The length of this fitted cap will be either 22mm or 30mm in length depending on the original protrusion of the maximum speed adjustment screw (B5).

  • Page 85: Idler Gear And Oil Pump

    100 Series Idler gear and oil pump To remove and to fit Operation 6-10 Special requirements Clearance (B1) mm (in) Standard Service limit 0,01 - 0,15 (0.0004 - 0.0060) 0,25 (0.0098) max Extra shims may be required to achieve the standard clearance. To check the end float refer to Operation 6-13.

  • Page 86: Idler Hub

    100 Series Idler hub To fit Operation 6-11 Special requirements Special tools Description Part number Idler hub assembly tool - 102-05, 103-07 21825624 Idler hub assembly tool - 103-10 21825625 Idler hub assembly tool - 103-13, 103-15, 21825626 104-19, 104-22 Caution: If the idler hub is removed, it must be renewed.

  • Page 87: Gear Teeth Backlash

    100 Series Gear teeth backlash To check backlash Operation 6-12 Special requirements Timing gear tolerances mm (in) Standard Service limit 0,08 (0.0032) 0,25 (0.0098) 1 Align the set marks. 2 Measure the clearance with a feeler gauge. Workshop Manual, TPD 1377E, issue 4...

  • Page 88: Oil Pump End Float

    100 Series Oil pump end float To check Operation 6-13 Special requirements Clearance mm (in) Standard Service limit 0,10 - 0,15 (0.0040 - 0.0060) 0,20 (0.0079) Use a feeler gauge to check the end float clearance of the oil pump. Adjust with 0,1. 0,15. 0,2. and 0,5 mm shims.

  • Page 89: Governor Spring

    100 Series Governor spring To locate and to check Operation 6-14 The main governor springs are colour coded to assist with identification. The colour code is as follows: Part Number Description Colour Code 198217580 Main Spring Black 198217570 Main Spring...
  • Page 90 100 Series Oil seal protector To fit Operation 6-15 Note: Fit the oil seal protector before the timing cover is fitted. Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...
  • Page 91 100 Series Timing cover To fit Operation 6-16 1 Ensure the oil pin (A1) locates in the hole (A2) in the idler gear. 2 Remove the oil seal protector after the timing cover is fitted. Fit the key onto the crankshaft nose, refer to Operation 5-1.
  • Page 92 This page is intentionally blank This document has been printed from SPI². Not for Resale...

  • Page 93: Cylinder Block Assembly

    100 Series Cylinder block assembly Front bush To fit Operation 7-1 The bush must be fitted with the chamfered side (A2) into the block first, with the joint (A1) uppermost. To remove, use the tool from the inside of the cylinder block.

  • Page 94: Cylinder Block Top Face

    Note: For emissions approved engines. If a new cylinder block is fitted, the engine should be tested on an engine test brake and the fuel adjustment screw set. This procedures is only done by a Perkins approved dealer. This will ensure that the engine will conform with emissions legislation.

  • Page 95: Engine Timing

    100 Series Engine timing Fuel injection pump timing To check timing Operation 8-1 Special requirements Special tools Torque Nm (lbf ft) kgf m Description Part number Fuel pump spill pipe 21825680 Delivery valve holder 42 (31) 4,2 1 Set the piston for number 1 cylinder to TDC on the compression stroke. Turn the crankshaft counter- clockwise a quarter of a revolution.
  • Page 96 100 Series 5 Connect a suitable tank, which has a tap and contains 0,2 litres (¼ pint) of clean fuel, to the pump inlet. 6 Connect the fuel pump spill pipe to the delivery valve holder for number 1 cylinder. Put a suitable waste fuel container below the pipe neck and open the tap, if correctly set fuel should flow (B).
  • Page 97 100 Series 9 If engine timing is incorrect adjust the thickness of shim (D2) to correct. Note: If the shim thickness is adjusted by 0,1 mm, the timing will alter by approximately one degree. An increase in the number of shims will retard the timing, but if the number of shims are decreased this will advance the timing.
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  • Page 99: Aspiration System

    100 Series Aspiration system Breather system To clean and renew Operation 9-1 Cautions: Failure to change a damaged, blocked or restricted engine breather hose may cause a back pressure in the crankcase, causing premature failure of the rear engine oil seal.
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  • Page 101: Lubrication System

    100 Series Lubrication system Oil filter canister To remove and to fit Operation 10-1 1 Remove the filter canister with a strap wrench or a similar tool and then discard the canister. 2 Clean the seal face of the filter head.
  • Page 102 100 Series Pressure relief valve To remove and to fit Operation 10-2 Special requirements Torque Nm (lbf ft) kgf m Pressure relief valve 64 (47) 6,5 Renew the 'O' ring when the pressure relief valve is fitted to the cylinder block.
  • Page 103 100 Series Lubricating oil sump To remove and to fit Operation 10-3 Special requirements Torque Nm (lbf ft) kgf m Sump setscrews 11 (8) 1,1 Note: When the sump is fitted renew the joint (A1). Workshop Manual, TPD 1377E, issue 4...
  • Page 104 100 Series Strainer and suction pipe To remove and to fit Operation 10-4 Special requirements Torque Nm (lbf ft) kgf m Filter setscrews (A1) 11 (8) 1,1 Note: On assembly renew the 'O' ring (A2). Workshop Manual, TPD 1377E, issue 4...
  • Page 105 100 Series Lubricating oil pump To remove, to fit and to inspect Operation 10-5 For the tolerances see "Idler gear and oil pump" on page 75 and "Oil pump end float" on page 78. Note: Extra shims (A1) may be needed to achieve the standard clearance.
  • Page 106 100 Series Oil pressure switch To remove and to fit Operation 10-6 Special requirements POWERPART products Torque Nm (lbf ft) kgf m Description Part number Platelock 21826039 Oil pressure switch 11 (8) 1,1 Powerpart Platelock must be applied to the thread (A1) when the oil pressure switch is fitted to the cylinder block.

  • Page 107: Fuel System

    100 Series Fuel system Atomisers To remove Operation 11-1 Cautions: Deep sockets should always be used for this procedure. Connections should be blanked off until assembly. 103-13 103-15 104-19 104-22 102-05 103-07 103-10 Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...
  • Page 108 100 Series To fit Operation 11-2 Special requirements Torque Nm (lbf ft) kgf m Test pressures kgf/cm² (lbf/in²) ats 102-05, 103-07 64 (47) 6,5 102-05, 103-07 120 (1707) 116 103-10 81 (60) 8,2 103-10 120 (1707) 116 103-13, 103-15, 104-19, 104-22...

  • Page 109: Fuel Lift Pump

    100 Series Fuel lift pump To remove and to fit early fuel lift pump Operation 11-3 Note: Camshaft eccentric must be in the maximum lift position for the priming lever to operate correctly. Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...
  • Page 110 100 Series To remove and to fit the latest fuel lift pump Operation 11-4 Engine Torque Nm (lbf ft) kgf m Lift pump setscrew 6 (4.4) 0,6 All models Lift pump inlet adjusting bolt (A1) 2,5 (1.8) 0,25 The fuel inlet for the fuel lift pump can rotate 360° and is adjustable in 15° increments.
  • Page 111 100 Series To dismantle and to assemble the early fuel lift pump Operation 11-5 Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...

  • Page 112: Fuel Injection Pump

    100 Series Fuel injection pump To remove and to fit Operation 11-6 Special requirements Torque Nm (lbf ft) kgf m 102-05, 103-07 11 (8) 1,1 103-10 6 (4.4) 0,6 103-13, 103-15, 104-19, 104-22 15 (11) 1,5 Caution: Connections should be blanked off until assembly.
  • Page 113 100 Series Banjo Bolt Operation 11-7 The torque setting for the banjo bolt (A1), fitted to the fuel injection pump, for the 103-10 engines (KD) is 20,0 Nm (14.75 lbf ft) 2,04 kgf m. The torque setting for all other engines is 7,0 Nm (5.16 lbf ft) 0,71 kgf m.

  • Page 114: Vent Points

    To eliminate air from the fuel system Operation 11-8 To vent the 100 series fuel system 1 Identify the location of fuel lift pump (A3). 2 Locate the vent screw on top of the fuel filter (A2) and loosen off.

  • Page 115: Cooling System

    100 Series Cooling system Fan and mounting To remove and to fit Operation 12-1 Special requirements Torque Nm (lbf ft) kgf m Setscrews 11 (8) 1,1 Depress the fan belt at the centre between the crankshaft pulley and the alternator pulley with a finger force of 49 N (11 lbf) 5 kgf, approximately.

  • Page 116: Coolant Pump

    100 Series Coolant pump To remove and to fit Operation 12-2 Special requirements POWERPART products Description Part number Silicone RTV sealing and jointing compound 1861108 Notes: On assembly apply Powerpart silicone RTV sealing and jointing compound to the cylinder block of 102-05, 103-07 and 103-10 engines.
  • Page 117 100 Series 103-13 103-15 104-19 104-22 Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...
  • Page 118 100 Series Thermostat To remove and to fit Operation 12-3 Note: The vent hole on the thermostat must be fitted in the "12 o'clock" position. 102-05 103-07 103-10 103-13 103-15 104-19 104-22 Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...
  • Page 119 100 Series To test and inspect Operation 12-4 Special requirements Engine model Temperature when valve Temperature when fully (wax pellet type thermostat) starts to open °C (°F) open °C (°F) 73 to 77 102-05, 103-07 (163.4 to 170.6) (188.6) 80 to 84 103-10, 103-13, 103-15, 104-19, 104-22 (176 to 183.2)
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  • Page 121: Flywheel And Housing

    100 Series Flywheel and housing Flywheel To remove and to fit Operation 13-1 Special requirements Torque Nm (lbf ft) kgf m Flywheel setscrews 73 (54) 7,4 Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...
  • Page 122 100 Series To inspect Operation 13-2 If the ring gear is excessively damaged or worn, renew. When wear is not excessive remove ring gear and reinstall 90° from original position. To install, preheat the ring gear to 120 °C to 150 °C.
  • Page 123 100 Series Flywheel housing (if fitted) To remove and to fit Operation 13-3 Special requirements Torque Nm (lbf ft) kgf m 102-05, 103-07 15 (11) 1,5 103-10 50 (37) 5,1 103-13, 103-15, 104-19, 104-22 25 (18) 2,6 Note: Only 104-22 engines have the backplate and housing fitted together.
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  • Page 125 100 Series Electrical equipment Electrical shut off solenoid (ESOS) To remove and to fit Operation 14-1 Special requirements Torque Nm (lbf ft) kgf m Solenoid 17 (12) 1,7 Note: Remember the location of special washer (A1). Workshop Manual, TPD 1377E, issue 4...
  • Page 126 100 Series Alternator To remove and to fit Operation 14-2 103-13 103-15 104-19 104-22 102-05 103-07 103-10 Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...
  • Page 127 100 Series Alternator Testing Operation 14-3 To avoid the return of parts that are not faulty, follow this procedure for all suspected failures. This will isolate the problem between either the alternator or the main electrical system. Check that all connections to the alternator are secure and free from contamination. If the alternator is earthed using the engine block check that there is a good connection between the alternator, the earth connection and the engine block.
  • Page 128 100 Series K1243 Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...
  • Page 129 100 Series Starter motor To remove and to fit Operation 14-4 Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...
  • Page 130 100 Series Starter Motor Testing Operation 14-5 Before removing a suspect faulty starter motor, check the security of all of the electrical connections on the starter motor. To test the starter motor use: 12 volt fully charged battery (A5). Two heavy duty cables with suitable clips.

  • Page 131: Wiring Diagram 14 And 15 Amp Alternator - 102-05, 103-07, 103-10

    100 Series Wiring diagram 14 and 15 amp alternator - 102-05, 103-07, 103-10 Maximum circuit Maximum circuit Circuit Cable number Circuit current Remarks resistance volt drop Alternator 14 amp (2 cyl) 0.036 Ù (2 cyl) See Glow Plugs 0.5 Volt...

  • Page 132: Wiring Diagram 40 Amp Alternator - 103-10 (When Fitted With Optional Alternator)

    100 Series Wiring diagram 40 amp alternator - 103-10 (when fitted with optional alternator) Maximum circuit Maximum circuit Circuit Cable number Circuit current Remarks resistance volt drop Alternator See Glow Plugs 40 amp 0.0125 Ùs 0.5 Volt charging Circuit Starter motor See Glow Plug 15.75 amp...
  • Page 133 100 Series Wiring diagram 55 amp alternator - 103-15, 104-19, 104-22 Maximum circuit Maximum circuit Circuit Cable number Circuit current Remarks resistance volt drop Alternator See Glow Plugs 55 amp 0.009 Ù 0.5 Volt charging Circuit Starter motor See Glow Plugs 15.75 amp...

  • Page 134: Wiring Diagram 40 Amp Alternator - 103-13

    100 Series Wiring diagram 40 amp alternator - 103-13 Maximum circuit Maximum circuit Circuit Cable number Circuit current Remarks resistance volt drop Alternator See Glow Plugs 40 amp 0.0125 Ù 0.5 Volt charging Circuit Starter motor See Glow Plugs 15.75 amp 0.04 Ù...

  • Page 135: Auto Shutdown Wiring Diagram

    100 Series Auto shutdown wiring diagram 55 Amp alternator charge lamp Note: Alternator charge lamp rating: 12V - 2.2W at 850 rev/min. When the engine is at rest the alternator charge lamp is illuminated via the battery and it extinguishes when the alternator operates.

  • Page 136: Auto Shutdown Wiring Diagram 14 And 15 Amp Alternator

    100 Series Auto shutdown wiring diagram 14 and 15 amp alternator - 102-05, 103-07, 103-10 Auto shutdown operation conditions If the conditions below last for more than 10 seconds during the start operation, the engine will shut down. If the conditions below last for more than 2 seconds while the engine is operated, the engine will shut down.

  • Page 137: (When Fitted With Optional Alternator)

    100 Series Auto shutdown wiring diagram 40 amp alternator - 103-10 (when fitted with optional alternator) Auto shutdown operation symptoms If the conditions below last for more than 10 seconds during the start operation, the engine will shut down. If the conditions below last for more than 2 seconds while the engine is operated, the engine will shut down.

  • Page 138: Auto Shutdown Wiring Diagram 40 Amp Alternator - 103-13

    100 Series Auto shutdown wiring diagram 40 amp alternator - 103-13 Auto shutdown operation symptoms If the conditions below last for more than 10 seconds during the start operation, the engine will shut down. If the conditions below last for more than 2 seconds while the engine is operated, the engine will shut down.

  • Page 139: Auto Shutdown Wiring Diagram 40 Amp Alternator - 103-15, 104-19, 104-22

    100 Series Auto shutdown wiring diagram 40 amp alternator - 103-15, 104-19, 104-22 Auto shutdown operation symptoms If the conditions below last for more than 10 seconds during the start operation, the engine will shut down. If the conditions below last for more than 2 seconds while the engine is operated, the engine will shut down.
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  • Page 141: Auxiliary Equipment

    Note: All mountings supplied via Perkins Parts Distribution Centre (PDC), Irlam, England will be to the latest specification. Workshop Manual, TPD 1377E, issue 4...
  • Page 142 This page is intentionally blank This document has been printed from SPI². Not for Resale...
  • Page 143 100 Series Special tools Special tools list These tools are available through your nearest Perkins Dealer/Distributor. Description Illustration Valve spring remover Part number 21825663 Valve stem seal replacer 102-05, 103-07: Part number 21825622 103-10, 103-13, 103-15, 104-19, 104-22: Part number 21825623...
  • Page 144 100 Series Description Illustration Fuel pump spill pipe Part number: 21825680 Front oil seal protector 102-05, 103-07, 103-10: Part number 21825620 103-13, 103-15, 104-19, 104-22: Part number 21825621 Workshop Manual, TPD 1377E, issue 4 This document has been printed from SPI². Not for Resale...

This manual is also suitable for:

103-10103-13103-15102-05103-07104-19 ... Show all

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