Perkins 103-06 Workshop Manual Download Page 2

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Summary of Contents for 103-06

Page 1: ...Perkins 100 Series 103 06 103 09 103 10 Perama M25 M30...

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Page 3: ...11 Crankshaft 4 12 Crankshaft Rectification 4 13 Flywheel and Ring Gear 4 15 Camshaft 4 15 Timing Gear 4 16 Oil Pump 4 16 Oil Filter 4 17 Water Pump 4 17 Thermostat 4 17 Radiator 4 18 Fuel Filter 4 18...

Page 4: ...001 M Code I Engine Type KB 103 06 KC 103 09 PERAMA M25 KD 103 10 PERAMA M30 Code II Engine Parts List Parts list increases numerically for both OEMS and distributors Code III Country of Manufacture J...

Page 5: ...open ports of high precision components e g fuel injection equipment exposed by dismantling will be blanked off until reassembled to prevent the ingress of foreign matter When fitting setscrews into...

Page 6: ...nnot be seen clearly while the engine is running Do not run the engine with any safety guards removed Do not remove the radiator cap while the engine is hot and the coolant is under pressure as danger...

Page 7: ...ENGINE DIAGRAMS...

Page 8: ...Engine cross sectional views...

Page 9: ...on is fitted with three rings two cast iron chrome faced compression rings and one steel chrome faced controlled oil ring The fully floating gudgeon pin wrist pin is made of chrome molybdenum steel al...

Page 10: ...and side of the cylinder block and also operated by the engine camshaft Lubricating System A trochoid lobe type oil pump located in the centre of the idler gear sends lubricating oil to the main oil g...

Page 11: ...l 45AH min 64 kg 70AHmin 83 kg 70 AH min Height 489mm 539 6mm Length F F 442mm 489 6mm Width 390mm 410mm Min Idle Speeds 103 06 103 09 10 Perama M25 M30 Hurth HBW 50 Reverse Gearbox Oil Capacity HBW 1...

Page 12: ...nded however JP5 and JET A are acceptable providng 5 spindle oil added Lubricating oil Lubricating oil specification Specifications Enginetype APICC SE APICD SE MIL L 46152 CCMCD1 MIL L 2104C CCMCD2 N...

Page 13: ...Remove pipes as an assembly B Remove spring clamp and fuel return hose Atomizer Assembly A Loosen and remove three securing nuts Remove leak off rail Remove three aluminium washers and discard Remove...

Page 14: ...ue Remove head PB009 Tappets A Pull tappets from the machined bores in cylinder block Fuel Injection Pump Assembly A Remove two bolts and nuts securing fuel injec tion pump to cylinder block Slowly li...

Page 15: ...ter Drive A Using access hole in cam gear remove keeper plate B Slide cam shaft with fly weight retainer out of camshaft bore C Pull tachometer drive shaft from its bore Front End Plate Assembly A Rem...

Page 16: ...assembly Flywheel Assembly A Loosen bolts remove flywheel Back Plate Remove Oil Seal Crankshaft and Main Bearing Assembly PB022 PB020 PB023 A Remove bolts fitted through crankcase cross members B Sli...

Page 17: ...r may be corrected using an oil stone Cylinder Head Assembly A Using a valve spring replacer compress the valve spring to remove the valve collets retainer spring and valve Spring pin PB025 Inspection...

Page 18: ...lowable limit 5 940 5 955mm 2339 2344 5 9mm 2323 I PB030 Check six positions A to F lines as shown for warping If found to be warped excessively correct with a surface grinder PB031 Standard value All...

Page 19: ...idth check wear condition of the valve guide first Using the seat cutters of 15 45 and 75 correct the seat 103 09 10 Perama M25 M30 103 06 Standard recess Allowable limit 0 70 0 90mm 0276 0354 1 8mm 0...

Page 20: ...eplace if found to be beyond allowable limit 103 09 10 Perama M25 M30 Cap not fitted on 103 06 Insert Standard value Allowable limit Squareness mm 1 2 047 2 0 079 Free length mm 35 1 378 33 5 1 319 Sp...

Page 21: ...cylinder gauge PG044 c If the bore is found to be outside allowable limit re bore to the oversize dimension as shown First re bore 0 5mm 02 New standard bore Allowabl e limit 64 5 64 519mm 2 5394 2 54...

Page 22: ...5 75 019mm 2 9527 2 9534 75 2mm 2 9606 PB040 First re bore 0 5mm 0196 Inspection A Piston New standard bore Allowable limit 75 5 75 519mm 2 9724 2 9731 75 7mm 2 9803 a If outer surface of the piston i...

Page 23: ...75 4575mm oversize 2 970 2 9706 1 0mm 115317389 75 9425 75 9575mm oversize 2 9898 2 9904 103 06 Piston Standard diameter Piston 63 948 63 963mm 2 5176 2 5182 Piston size Largerdiameter of piston skir...

Page 24: ...limit No 1 0 06 0 1mm 0 25mm ring 002 0039 0098 No 2 0 05 0 09mm 0 25mm ring 0019 0035 0098 Oil 0 02 0 06mm 0 15mm ring 0007 002 0059 d Oversize piston ring 103 06 If the cylinder is oversized oversiz...

Page 25: ...ay between the connecting rod and the Check the connecting rod for distortion between crankshaft the large and small ends of the connecting rod with a connecting rod aligner If the result exceeds the...

Page 26: ...o 2 198517347 1 6718 1 6722 020 No 3 198517108 45 464 45 475 198517117 1 7899 1 7904 Standard oil clearance Allowable limit Upper bearing 0 039 0 092mm 0015 0036 0 2mm 0078 No 3 No 2 No 1 Bearing Bear...

Page 27: ...1 5246 0098 0 50mm 198517137 38 464 38 475mm U S 1 5143 1 5147 0196 103 06 Bearing size Crankshaftpin O D dimension mm Part No S TD 34 964 34 975mm 198517310 1 3765 1 3770 0 25mm 34 714 34 725mm 1985...

Page 28: ...mm 0 2mm 0014 0040 0078 PB052 T i groove Notch Crankshaft Bearing bush Inspection A Check the bearing bush for peeling melting seizure or poor contact If found to be defective replace B Using cylinder...

Page 29: ...ush to cylinder block from engine front side Note Must not press in the bush to cylinder block from the opposite side The correct pressing side is chamfered etc to allow smooth operation Align oil hol...

Page 30: ...rnal Standard diameter Allowable limit Standard 45 964 45 9mm 45 975mm 1 8096 1 807 1 8100 0 25mm U S 45 714 45 65mm 45 725mm 1 7997 1 797 1 8001 0 50mm U S 45 464 45 40mm 45 475mm 1 7899 1 787 1 7903...

Page 31: ...g gear If it is excessively damaged or worn replace it B When wear is not excessive remove the ring gear and reinstall 90 from original position To install preheat the ring gear up to 120 to 150 C Cam...

Page 32: ...gears with a thickness gauge or dial gauge If the allowable limit is exceeded replace all timing gears PB061 1 Snap ring 6 Rotor 2 Collar 7 Spring 3 Spring 8 Idle gear 4 Shim 9 Thrustwasher 5 Oil pum...

Page 33: ...06 PB064 3 103 06 PB065 Inspection Thermostat A Replace the thermostat if the valve opens at ambient temperature B Place the thermostat into water Raise the water temperature gradually and inspect th...

Page 34: ...103 06 only NOTE An O ring is inserted between the ring nut and filter body This ring should be coated with grease to aid assembly B Coat the mounting face of the element with grease and install it ha...

Page 35: ...stops in both cases the body is normal 0 LIT 5 IN Piston NOTE Pay attention to the inner spring Bottom body E Take out the piston spring and diaphragm from the bottom body Bottom body Piston Diaphrag...

Page 36: ...131406330 131406340 Assembly number 093500 3320 093500 2240 Nozzle holder 093100 3320 ND KCA46SD332 093100 2240 Nozzle 093400 1460 ND DN4SDND146 093400 5010 ND 4PDI Nozzle type Throttle type Throttle...

Page 37: ...ly leave to dry C When operating the machine in dusty environ ment increase service frequency D At every sixth cleaning or every year replace the element 3 Nozzle 1118 4 Spacer 5 Rod 6 Spring F 7 Shim...

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Page 39: ...is in the bush at the front end of the cylinder block B Align the bolt hole at lower part of the cylinder block with thread hole on the bearing holder and tighten with bolts For flywheel end use two s...

Page 40: ...30 and the F mark towards the front of the engine on the 103 06 Also face the connecting rod mark towards the fuel pump side PB087 NOTE Install pistons from front in ascending order D Tighten the conn...

Page 41: ...Install the thrust washer on the idle gear shaft B Assemble the vane knock pin and spring on the idle gear Thrust washer Oil pump cover PB092 F Adjust with shim 0 1 0 15 0 2 0 5mm so that the side cl...

Page 42: ...pump bolts and nuts PB093 1 1 I Crankshaft Pulley A Align the key way and key on the crankshaft pulley and crankshaft and assemble them Crankshaft pulley tightening torque 12 to 13kgf m 87 to 94Ib ft...

Page 43: ...KC30225 26 27 24 23 23 22 24 28 31 32 KD30237 38 39 40 43 44 KB30221 22 28 25 27 24 5 26 5 KB30216 17 18 29 26 28 25 5 27 5 23 70 KB30219 20 24 30 27 29 26 5 28 5 71 i E Then slowly turn the crankshaf...

Page 44: ...bolts Tappet A Coat the tappet with oil and assemble Cylinder Head A Set the piston to the top dead center measure the amount of protrusion above the cylinder block with depth gauge or dial gauge 103...

Page 45: ...240 viewed from the front to adjust clearance of intake valve of No 2 cylinder and intake exhaust valves of No 3 cylinder PB103 Cylinder Head Cover A Evenly tighten the cylinder head cover Ensure gask...

Page 46: ...groove align ment V Belt Fan Pulley and Cooling Fan A After mounting the fan pulley and cooling fan install the V belt B Depress the belt at the center between the crankshaft pulley and the alternato...

Page 47: ...than 1600rpm at13V Regulator RS5101 Part number 185046160 18 16 14 12 10 8 6 4 2 0 103 06 Type GP8146 Direction of rotation Clockwise Viewed from pulley Speed 1600 5600rpm Charging capacity 14 15Aat14...

Page 48: ...rminal voltage at alternator 5200rpm 2 14A 0 5A at 14 15V Charge current OA Defective alternator or regulator or improper connection Flowing charge current but low battery voltage Defective battery ov...

Page 49: ...d with new Disassembly When the alternator is defective or the flywheel turns abnormally disassemble the alternator as explained below A Remove the dust cap 6 using a screw driver B Hold the pulley si...

Page 50: ...at plate Then press the bearing from rear side of the coil plate using a rod of 31 mm diameter Apply a rod on the outer face of the bearing b Tighten the nut 7 with the torque of 2 5 to 3 Okgf m c Cla...

Page 51: ...the wider part the pinion and clutch outer turn idly but when the roller rotates in the narrower part the roller works as a key to transmit the rotation Charge Lamp Load Head Lampp etc Condense E0109...

Page 52: ...hten it firmly Insufficient tightening causes larger contact resistance and makes starting difficult B Precautions for starting a Ensure battery is charging Insufficient charging will make starting mo...

Page 53: ...ontinuity is indicated it shows poor insulation Then replace the coil Proper measurement with a circuit tester is impossible Be sure to use a 500 V megger for checking If the test result is more than...

Page 54: ...ws disconnection Then replace the coil C Pinion a Check the pinion teeth for wear and other damages Replace faulty pinion b Check the pinion for smooth sliding If scratches or burr is found on the pin...

Page 55: ...is placed in the sintered magnesium oxide powder enclosed by stainless sheath One end of the heat wire is welded to the sheath end and the other end to the central electrode By setting the starter swi...

Page 56: ...WIRING DIAGRAMS Perama 103 06 103 09 103 10 15 amp alternator 103 09 103 10 35 amp alternator...

Page 57: ...cuit Cable No Circuit current Maximum circuit resistance Maximum circuit volt drop Remarks Alternator Charging 4 7 8 9 13 15amp 0 0333 ohm 0 5 volt See glow plugs circuit Starting Motor Solenoid 4 5 6...

Page 58: ...rcuit Cable No Circuit Maximum Maximum Remarks current circuit resistance circuit volt drop Alternator 0 5 volt See glow plugs circuit Charging 7 35 amp 0 0143ohm Starting 4 See glow plugs circuit Mot...

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Page 60: ...tem Uneven fuel injection Troubled fuel injection pump Clogged fuel filter Defective governor Engine itself defective Bleed the air Repair at authorized shop Replace Check and correct Repair in a serv...

Page 61: ...ring Inspect Dropped voltage of the battery Char Damaged starter motor Repaair Broken fusible link Replace REMEDY Inspect and replace to correct grade Inspect and adjust in a service shop Repair in a...

Page 62: ...stortion of upper face of cylinder block 75 2 952 75 75 019 2 95 2 954 less than 0 05 002 75 2 76 2 Oversize 0 5 1 0 2 960 3 0 020 040 0 12 005 PISTON 103 09 Skirt diameter longer diameter 72 2 835 71...

Page 63: ...No 2 ring 1 5 1 47 1 49 Oversize 0 5 1 0 060 058 059 020 040 Oil ring 4 3 97 3 99 157 156 157 CONNECTING ROD Twist between small and large end holes per 100mm less than 0 08 003 0 2 0007 Straightness...

Page 64: ...020 Clearance between crankshaft journal and center bearing 0 039 0 092 0015 004 0 2 009 Oil clearance Tightening allowance of center bearing 0 008 0 048 0003 0018 Crush height VALVE SYSTEM CAMSHAFT...

Page 65: ...30240 KD30243 KD30244 Type 131017310 Diameter of plunger 5 0mm Stroke of plunger 6mm Injection timing Before T D C 23 Piston movement before T D C 3 750mm 1476 INJECTION PUMP KC30233 KC30234 KD30245 K...

Page 66: ...OTOR Type S114 381 185086321 No of teeth of pinion gear 9 Shifting method of pinion Magnetic Wear of commutator diameter 43 1 7 40 1 6 Stepped wear of commutator 0 05 002 0 4 015 Bending allowance of...

Page 67: ...04 Distortion of upper face of cylinder less than 0 05 0 12 block 002 0047 MAIN REVOLVING SYSTEM Type Dry type single piece PISTON Skirt diameter longer diameter 64 63 948 63 963 63 7 Oversize 0 5 1 0...

Page 68: ...nd crank pin 0 1 0 3 004 012 0 7 028 Connecting rod metal to crank pin clearance 0 031 0 079 0012 0031 0 2 008 Oil clearance Crush height of large end bearing 0 01 0 03 0004 0012 300kg 661 4lbs Connec...

Page 69: ...46 1 811 0 0 055 0 0022 300kg 661 4lbs VALVE SYSTEM CAMSHAFT Height of cam For intake exhaust 26 565 26 620 1 0459 1 0480 26 1 1 028 For injection pump 34 48 34 52 1 3575 1 3591 34 3 1 389 For feed p...

Page 70: ...587 4594 4555 Clearance between rocker arm and 0 032 0 068 0 2 Oil clearance shaft 0013 0027 008 LUBRICATION SYSTEM OIL PUMP Oil pressure switch operating pressure 0 3 0 2 0 4 kg cm2 psi 4 27 2 844 5...

Page 71: ...ure C 90 Pump discharge lit min at 2500rpm engine speed at cold 40 ELECTRICAL SYSTEM STARTER MOTOR Type M003T32589 Part No 185086370 No of teeth of pinion gear 8 Shifting method of pinion Magnetic Wea...

Page 72: ...Injection pump bolts 0 9 1 3 7 9 0 9 1 3 7 9 Injection pump nut 0 9 1 3 7 9 0 9 1 3 7 9 Rocker arm nuts 2 0 2 5 15 19 2 0 2 5 15 19 Head cover nuts 1 0 1 2 7 9 1 0 1 2 7 9 Cooling fan bolts 0 9 1 3 7...

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Page 74: ...to check lubricate the impeller and the drive of the raw water pump Attention Do not loosen the drive housing of the raw water pump The alignment of this housing has been carefully adjusted with a spe...

Page 75: ...ilter canister 3 Operate the engine until it is warm Then correct leakages of fuel lubricating oil or air Stop the engine and drain the lubricating oil from the sump 4 Renew the canister of the lubric...

Page 76: ...ternator clean To clean the alternator use a material which is damp with kerosene or a special fluid used for this purpose Ensure that the fluid does not enter the cover of the alternator 3 Ensure tha...

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Page 78: ...40 290 370 M10 7T 8T 8 8 1 5 450 570 1 25 500 640 10T 11T 550 710 590 750 4T 4 8 380 480 440 560 M12 4T 8T 8 8 1 75 670 850 1 25 760 960 10T 11T 940 1 180 1 010 1 290 4T 4 8 640 820 710 890 M14 7T 8T...

Page 79: ...3 57 9 73 6 4T 4 8 27 5 34 7 37 3 47 1 31 8 40 5 43 2 54 9 M12 7T 8T 8 8 1 75 55 7 61 5 65 7 83 4 1 25 55 0 69 5 74 5 94 1 10T 11T 68 0 85 4 92 2 116 73 1 93 3 99 1 127 4T 4 8 46 3 59 3 62 8 80 4 51 4...

Page 80: ...45 1 34 0 46 1 34 7 47 0 35 4 48 0 5 36 2 49 0 36 9 50 0 37 6 51 0 38 3 51 9 39 1 52 9 39 8 53 9 40 5 54 9 41 2 55 9 42 0 56 8 42 7 57 8 6 43 4 58 8 44 1 59 8 44 8 60 8 45 6 61 7 46 3 62 7 47 0 63 7...

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Perkins 103-06, Workshop Manual

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Summary of Contents for 103-06

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