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Perkins 100 Series Repair Manual

Perkins 100 Series
144 pages
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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 Two cylinder diesel engines
103-07 Three cylinder diesel engines
103-10
103-13
103-15
104-19 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

Table of Contents

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Perkins 100 Series Specifications

General IconGeneral
AspirationNaturally Aspirated
Engine TypeDiesel
ConfigurationInline
Cooling SystemLiquid-cooled
Cylinders3

Summary

General Information and Engine Views

Safety Precautions

Essential safety guidelines for operating and maintaining the engine.

Engine Preservation Procedures

Procedures to prevent engine damage during prolonged periods of storage.

Compression Test Data and Procedure

Data and procedure for performing engine compression tests.

Engine Specifications

Basic Engine Data

Table of fundamental engine specifications for various models.

Data and Dimensions

Information on dimensions and data for engine components and assembly.

Injection Timing Specifications

Table detailing injection timing specifications for different engine models.

Cylinder Bore Dimensions

Specifications for cylinder bore dimensions and service limits.

Piston and Piston Ring Dimensions

Dimensions for pistons and piston rings, including clearance checks.

Crankshaft Deflection and Inspection

Procedure and specifications for checking crankshaft deflection and journals.

Crankshaft Journal Diameters

Table of crankshaft journal diameters and service limits.

Crankshaft Pin Diameters

Table of crankshaft pin diameters and service limits.

Cylinder Head Assembly Procedures

Atomiser Removal and Fitting

Procedure for removing and fitting atomisers, including torque specifications.

Cylinder Head Gasket Replacement

Procedure for removing and fitting the cylinder head gasket.

Cylinder Head Gasket Thickness Selection

Procedure for selecting the correct cylinder head gasket thickness based on piston height.

Valve and Valve Springs Service

Procedure for removing and fitting valves and valve springs.

Valve Stem and Head Thickness

Inspection of valve stem diameter and valve head thickness.

Valve Guide Clearance Check

Procedure for checking valve guide clearance for intake and exhaust valves.

Valve Tip Clearance Adjustment

Procedure for checking and adjusting valve tip clearance for intake and exhaust valves.

Piston and Connecting Rod Assemblies

Big End Bearing and Cap Service

Procedure for removing and fitting the big end bearing and cap.

Piston and Connecting Rod Dismantle/Assemble

Procedure for dismantling and assembling pistons and connecting rods.

Piston and Piston Ring Inspection

Procedure for inspecting piston and piston rings.

Piston Ring Clearance Measurement

Procedure for measuring clearance between piston ring groove and ring.

Crankshaft Assembly Procedures

Crankshaft Retainer Setscrew Service

Procedure for removing and fitting crankshaft retainer setscrews and the crankshaft.

Bearing Clearance Check

Procedure for checking main bearing clearance using Plastigauge.

Main Bearing Service (2 & 3 Cylinder Engines)

Procedure for dismantling and assembling main bearings for two and three cylinder engines.

Main Bearing Service (4 Cylinder Engines)

Procedure for dismantling and assembling main bearings for four cylinder engines.

Timing Case and Drive Assembly

Camshaft and Cam Follower Removal

Procedure for removing camshaft and cam followers.

Camshaft Assembly Inspection

Procedure for inspecting camshaft height for different components.

Cylinder Block Assembly

Engine Timing Procedures

Fuel Injection Pump Timing Check

Procedure for checking and adjusting fuel injection pump timing.

Lubrication System

Oil Filter Canister Service

Procedure for removing and fitting the oil filter canister.

Lubricating Oil Pump Service

Procedure for removing, fitting, and inspecting the lubricating oil pump.

Fuel System Procedures

Atomiser Removal

Procedure for removing atomisers, including special requirements and cautions.

Fuel Injection Pump Service

Procedure for removing and fitting the fuel injection pump.

Cooling System Maintenance

Electrical Equipment

Alternator Testing Procedures

Procedure for testing the alternator and diagnosing faults.

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