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Perkins 103-15 User Manual

Perkins 103-15
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 103-15 Specifications

General IconGeneral
Engine TypeDiesel
Number of Cylinders3
AspirationNaturally Aspirated
Displacement1.5 liters
Cooling SystemLiquid Cooled
Engine Model103-15

Summary

General Information

Safety Precautions for Engine Operation

Details critical safety measures to prevent injury and damage.

Engine Identification and Serial Number Location

Explains how to locate and interpret the engine's ID plate and serial number.

Specifications

Basic Engine Data Table

Overview of engine models, cylinders, bore, stroke, capacity, etc.

Recommended Torque Tensions

Specifies standard torque values for various fasteners.

Data and Dimensions - Injection Timing

Details injection timing specifications for different engine models.

Cylinder Bore Dimensions

Provides standard and service limit dimensions for cylinder bores.

Piston and Piston Ring Dimensions

Lists dimensions and clearances for pistons and piston rings.

Crankshaft Deflection and Inspection

Specifies limits and methods for checking crankshaft deflection and wear.

Crankshaft Journal Diameters

Lists standard and service limit diameters for crankshaft journals.

Crankshaft Pin Diameters

Lists standard and service limit diameters for crankshaft pins.

Cylinder Head Assembly

Rocker Shaft Dismantle, Inspect, Assemble (2/3 Cyl)

Detailed procedure for rocker shafts on specific engine models.

Rocker Shaft Dismantle, Inspect, Assemble (4 Cyl)

Detailed procedure for rocker shafts on specific engine models.

Atomisers - Remove and Fit

Instructions for removing and fitting atomisers, including test pressures.

Cylinder Head Gasket - Remove and Fit

Instructions for fitting the cylinder head gasket.

Cylinder Head Gasket Selection

Guide for selecting the correct cylinder head gasket thickness.

Head Bolts Tightening Sequence

Specifies the correct sequence and torques for tightening head bolts.

Cylinder Head Distortion Check

Method for checking cylinder head flatness and machining limits.

Piston and Connecting Rod Assemblies

Big End Bearing and Cap - Remove/Fit

Procedure for removing and fitting big end bearings and caps.

Piston and Connecting Rod - Dismantle/Assemble

Steps for dismantling and assembling pistons and connecting rods.

Measure Piston Ring Clearance

Procedure for measuring clearance between piston rings and grooves.

Piston Ring and Block Gap Measurement

How to measure piston ring gap within the cylinder bore.

Crankshaft Assembly

Flywheel, Backplate and Oil Seal - Remove/Fit

Steps for removing and fitting flywheel, backplate and oil seal.

Crankshaft Retainer Setscrews and Crankshaft

Instructions for removing and fitting crankshaft retainer setscrews.

Bearing Clearance Check

How to check main bearing clearance using Plastigauge.

Main Bearings - Dismantle/Assemble (2/3 Cyl)

Procedure for main bearings on two and three cylinder engines.

Main Bearings - Dismantle/Assemble (4 Cyl)

Procedure for main bearings on four cylinder engines.

Timing Case and Drive Assembly

Camshaft Assembly Inspection

How to inspect camshaft height for various components.

Max Fuel Screw and Max Speed Screw - Remove/Fit

Procedures for removing and fitting tamper-resistant adjustment screws.

Cylinder Block Assembly

Cylinder Block Top Face Inspection

How to inspect the cylinder block top face for damage and distortion.

Engine Timing

Fuel Injection Pump Timing - To Check

Detailed procedure for checking fuel injection pump timing.

Lubrication System

Oil Filter Canister - Remove and Fit

Procedure for replacing the oil filter canister.

Fuel System

Atomisers - To Fit

Procedure for fitting atomisers with torque and test pressures.

Fuel Injection Pump - Remove and Fit

Procedure for removing and fitting the fuel injection pump.

Cooling System

Thermostat - Test and Inspect

How to test and inspect the thermostat's opening temperature.

Electrical Equipment

Alternator Testing

Procedure for testing the alternator's function and voltage output.

Starter Motor Testing

How to test the starter motor's operation and electrical connections.

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