Perkins 103-06, Workshop Manual

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CONTENTS
PAGE
ABBREVIATIONS and CODES .......................................................................................................................4
FOREWORD .....................................................................................................................................................5
SAFETY PRECAUTIONS ................................................................................................................................ 6
ENGINE PHOTOGRAPHS ......................................................................................................................... 7
SECTION I
Description .........................................................................................................................................1-1
SECTION 11
General Engine Data .............................................................................................................................2-1
SECTION III
Dismantling Sequence .....................................................................................................................3-1
SECTION IV
Disassembly, inspection, fits and clearances of component assemblies 4-1 ..........................................
Rocker Arm and Lever 4-1 .............................................................................................................................
Cylinder Head and Valves 4-2 .......................................................................................................................
Valve Guide and Seats 4-3 ............................................................................................................................
Piston 4-6 ........................................................................................................................................................
Piston Ring 4-6 ..........................................................................................................................................
Piston Rod 4-9 ...........................................................................................................................................
Oil Running Clearance 4-9 ........................................................................................................................
Main Bearing 4-11 ......................................................................................................................................
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 ..................................................................................................................................................
Fuel Lift Pump 4-18 .........................................................................................................................................
Governor 4-19 ..................................................................................................................................................
Atomizers 4-20 ................................................................................................................................................
Air Cleaner 4-21 ..............................................................................................................................................
SECTION V
Reassembly ........................................................................................................................................... 5-1
Timing .................................................................................................................................................... 5-4
SECTION VI
Electrical Systems ............................................................................................................................ 6-1
Alternator ................................................................................................................................................6-1
Starter .....................................................................................................................................................6-5
Troubleshooting ......................................................................................................................................6-8
Glow Plug .........................................................................................................................................6-9
Thermoswitch ...................................................................................................................................6-9
Oil Pressure Switch .......................................................................................................................... 6-9
Wiring Diagrams ..............................................................................................................................6-11
SECTION VII
Troubleshooting ......................................................................................................................................7-1
SECTION VIII
Service Standards ............................................................................................................................8-1
SECTION IX
Recommended Torque Settings ...........................................................................................................9-1
SECTION X
Perama Supplement ...................................................................................................................... 10-1
SECTION XI
Conversion Formulas ..................................................................................................................... 11-1