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Perkins 104-22 User Manual

Perkins 104-22
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 104-22 Specifications

General IconGeneral
BrandPerkins
Model104-22
CategoryEngine
LanguageEnglish

Summary

Perkins 100 Series Workshop Manual

General Information

Safety Precautions

Essential safety guidelines for engine operation and maintenance.

Engine Preservation

Engine Lifting Procedures

Safety and Emissions Information

Compression Testing

Compression Test Data and Procedure

Compression pressure values and step-by-step testing instructions.

Engine Specifications

Basic Engine Data Table

Table of fundamental engine data for various models.

Torque Specifications and Sealants

Standard Torque Values for Fasteners

Table of standard torque values for setscrews, studs, and nuts.

Engine Data and Dimensions

Injection Timing Specifications

Specific injection timing settings for different engine models.

Cylinder Bore Specifications

Piston and Ring Specifications

Gudgeon Pin Specifications

Crankshaft Inspection and Tolerances

Crankshaft Wear and Grinding Specs

Procedure for inspecting crankshaft for wear and grinding specifications.

Crankshaft Journal Dimensions

Crankshaft Pin Dimensions

Bearing Holder Specifications

Crankshaft Bearing Bush

Cylinder Head Assembly

Rocker Assembly Removal/Fit

Rocker Shaft Dismantle/Inspect/Assemble (Models 102-05, 103-07, 103-10)

Rocker Shaft Dismantle/Inspect/Assemble (Models 102-05, 103-07, 103-10)

Steps for dismantling, inspecting, and assembling rocker shafts for specific models.

Rocker Shaft Dismantle/Inspect/Assemble (Models 103-13 to 104-22)

Rocker Shaft Dismantle/Inspect/Assemble (Models 103-13 to 104-22)

Steps for dismantling, inspecting, and assembling rocker shafts for specific models.

Cylinder Head Gasket Removal/Fit

Head Bolt Tightening Sequence

Head Bolt Tightening Sequence

Correct sequence for tightening cylinder head bolts.

Valve Train Components

Valve Stem and Head Inspection

Cylinder Head Distortion Check

Valve Tip Clearance Adjustment

Piston and Connecting Rods

Big End Bearing and Cap Removal/Fit

Procedure for removing and fitting big end bearings and caps.

Piston and Connecting Rod Dismantle/Assemble

Piston and Connecting Rod Dismantle/Assemble

Steps for dismantling and assembling pistons and connecting rods.

Piston and Connecting Rod Fit

Piston and Piston Ring Inspection

Piston and Piston Ring Inspection

Inspection of piston and piston rings for wear or damage.

Piston Ring Clearance Measurement

Piston Ring Gap Inspection

Crankshaft Assembly

Crankshaft Pulley Removal/Fit

Procedure for removing and fitting the crankshaft pulley.

Flywheel, Backplate, Oil Seal Removal/Fit

Flywheel, Backplate, Oil Seal Removal/Fit

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

Crankshaft Retainer Setscrews Removal/Fit

Bearing Clearance Check

Bearing Clearance Check

Using Plastigauge to check main bearing clearance.

Main Bearing Dismantle/Assemble (2 & 3 Cylinder Engines)

Main Bearing Dismantle/Assemble (2 & 3 Cylinder Engines)

Procedure for dismantling and assembling main bearings for 2/3 cylinder engines.

Main Bearing Dismantle/Assemble (4 Cylinder Engines)

Main Bearing Dismantle/Assemble (4 Cylinder Engines)

Procedure for dismantling and assembling main bearings for 4 cylinder engines.

Timing Case and Drive Assembly

Timing Cover Removal/Fit

Camshaft and Cam Followers Removal

Camshaft and Cam Followers Fit

Camshaft Assembly Inspection

Camshaft Assembly Inspection

Inspection of camshaft height for intake, injection, and fuel feed pumps.

Max Fuel/Speed Screw Location

Max Fuel/Speed Screw Removal/Fit

Max Fuel/Speed Screw Removal/Fit

Procedure for removing and fitting tamper-resistant fuel/speed adjustment screws.

Idler Gear and Oil Pump Removal/Fit

Cylinder Block Assembly

Cylinder Block Top Face Inspection

Engine Timing

Fuel Injection Pump Timing Check

Procedure for checking and setting fuel injection pump timing.

Aspiration System

Lubrication System

Oil Filter Canister Removal/Fit

Procedure for removing and fitting the oil filter canister.

Pressure Relief Valve Removal/Fit

Lubricating Oil Pump Removal/Fit/Inspect

Fuel System

Atomiser Removal

Procedure for removing atomisers.

Atomiser Fit

Atomiser Fit

Procedure for fitting atomisers.

Early Fuel Lift Pump Removal/Fit

Latest Fuel Lift Pump Removal/Fit

Fuel Injection Pump Removal/Fit

Fuel Injection Pump Removal/Fit

Procedure for removing and fitting the fuel injection pump.

Cooling System

Fan and Mounting Removal/Fit

Procedure for removing and fitting the fan and its mounting.

Coolant Pump Removal/Fit

Coolant Pump Removal/Fit

Procedure for removing and fitting the coolant pump.

Thermostat Removal/Fit

Thermostat Test and Inspection

Flywheel and Housing

Electrical Equipment

ESOS Removal/Fit

Procedure for removing and fitting the Electrical Shut Off Solenoid (ESOS).

Alternator Removal/Fit

Alternator Removal/Fit

Procedure for removing and fitting the alternator.

Alternator Testing Procedure

Alternator Testing Procedure

Steps for testing the alternator's functionality and output.

Starter Motor Removal/Fit

Starter Motor Testing Procedure

Starter Motor Testing Procedure

Method for testing the starter motor's operation.

Wiring Diagram: 14/15A Alternator (Models 102-05, 103-07, 103-10)

Wiring Diagram: 40A Alternator (Model 103-10 Optional)

Wiring Diagram: 55A Alternator (Models 103-15, 104-19, 104-22)

Wiring Diagram: 40A Alternator (Model 103-13)

Auto Shutdown Wiring Diagram: 55A Alternator

Auto Shutdown Wiring Diagram: 55A Alternator

Wiring diagram for auto shutdown system with 55A alternator.

Auto Shutdown Wiring Diagram: 14/15A Alternator (Models 102-05, 103-07, 103-10)

Auto Shutdown Wiring Diagram: 14/15A Alternator (Models 102-05, 103-07, 103-10)

Wiring diagram for auto shutdown on 14/15A alternators for specific models.

Auto Shutdown Wiring Diagram: 40A Alternator (Model 103-10 Optional)

Auto Shutdown Wiring Diagram: 40A Alternator (Model 103-10 Optional)

Wiring diagram for auto shutdown with 40A optional alternator on model 103-10.

Auto Shutdown Wiring Diagram: 40A Alternator (Model 103-13)

Auto Shutdown Wiring Diagram: 40A Alternator (Model 103-13)

Wiring diagram for auto shutdown with 40A alternator on model 103-13.

Auto Shutdown Wiring Diagram: 40A Alternator (Models 103-15, 104-19, 104-22)

Auto Shutdown Wiring Diagram: 40A Alternator (Models 103-15, 104-19, 104-22)

Wiring diagram for auto shutdown with 40A alternators on specific models.

Auxiliary Equipment

Special Tools

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