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
Three cylinder diesel engines
103-07
103-10
103-13
103-15
104-19
104-22
Four cylinder diesel engines
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.
i
This document has been printed from SPI². Not for Resale

Small end bush

To remove and to fit

Operation 4-7

Special requirements

Clearance mm (in)

Engine model

Standard

Service limit

0,1 (0.004)

0,1 (0.004)

0,1 (0.004)

102-05, 103-07

0,013 - 0,028 (0.00051 - 0.00110)

0,008 - 0,023 (0.00031 - 0.00091)

0,010 - 0,025 (0.00040 - 0.00099)

103-10

103-13, 103-15, 104-19, 104-22

Calculate the clearance between the small end bush and the gudgeon pin. If the clearance exceeds the service

limit, renew.

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4

100 Series

Connecting rod

To inspect

Operation 4-8

Special requirements

Dimension mm (in)

Standard

Service limit

Distortion for 100 (3.937)

Parallel for 100 (3.937)

Less than 0,08 (0.0031)

0,20 (0.0079) max

0,15 (0.0059) max

Less than 0,05 (0.0020)

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Workshop Manual, TPD 1377E, issue 4

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100 Series

5

Crankshaft assembly

5

Crankshaft pulley

To remove and to fit

Operation 5-1

Special requirements

Special tools

Description

Torque Nm (lbf ft) kgf m

Part number

102-05, 103-07

93 (69) 9,5

123 (91) 12,5

304 (224) 31

103-10

Crankshaft pulley remover

21825619

103-13, 103-15, 104-19, 104-22

Note:  Store the key (A1) in a safe place until assembly.

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5

100 Series

Flywheel, backplate and oil seal

To remove and to fit

Operation 5-2

Special requirements

POWERPART products

Description

Part number

Silicone RTV sealing and jointing compound

1861108

Flywheel setscrews : Torque Nm (lbf ft) kgf m

Backplate setscrews : Torque Nm (lbf ft) kgf m

102-05, 103-07

73 (54) 7,4

102-05, 103-07

15 (11) 1,5

50 (37) 5,1

15 (11) 1,5

103-10

73 (54) 7,4

73 (54) 7,4

103-10

103-13, 103-15, 104-19, 104-22

103-13, 103-15, 104-19, 104-22

Notes:

To remove and fit the flywheel, see Operation 13-1.

On assembly, apply Powerpart silicone RTV sealing and jointing compound to the block (around screw

holes) before the backplate is fitted.

103-10, 103-13 and 103-15 engines only: Remember the position of the dowel (A1).

1

POWERPART silicone

gasket sealant

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5

100 Series

Crankshaft retainer setscrews and crankshaft

To remove and to fit

Operation 5-3

Special requirements

Hex hole setscrews (A1) : Torque Nm (lbf ft) kgf m

Hex setscrews (A2) : Torque Nm (lbf ft) kgf m

102-05, 103-07, 103-10

27 (20) 2,7

27 (20) 2,7

102-05, 103-07, 103-10

27 (20) 2,7

51 (38) 5,2

103-13, 103-15, 104-19, 104-22

103-13, 103-15, 104-19, 104-22

Check that the oil ways of the bearings match up with the oil ways in the block.

Caution:  Before removal and fitting of the crankshaft ensure that the pressure relief valve has been removed.

Notes:

For emissions approved engines. The fuel adjustment screw must not be altered from the original setting.

The maximum No Load Speed must be checked after assembly.

If a new crankshaft is fitted, see Operation 3-13.

Continued

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5

100 Series

1

2

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5

100 Series

Bearing clearance

To check

Operation 5-4

Special requirements

Clearance mm (in)

Engine model

Standard

Service limit

0,20 (0.0079)

0,20 (0.0079)

0,20 (0.0079)

102-05, 103-07

0,031 - 0,079 (0.00122 - 0.00311)

0,035 - 0,083 (0.00138 - 0.00327)

0,035 - 0,085 (0.00138 - 0.00335)

103-10

103-13, 103-15, 104-19, 104-22

Use Plastigauge® to check the bearing clearance.

Tighten the main bearings to the torque settings given in Operation 5-5 for two and three cylinder engines or

Operation 5-6 for four cylinder engines.

1.0

2.0

2.5

3.0

4.0

5.0

6.0

7.0

INCH

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5

100 Series

Main bearings

To dismantle and to assemble (two and three cylinder engines)

Operation 5-5

Special requirements

Bearing holder (Aluminium) : Thickness mm (in)

Torque Nm (lbf ft) kgf m

Standard

Service limit

102-05, 103-07, 103-10

Aluminium Bearings

22 (16) 2,2

21,85 - 21,95 (0.8602 - 0.8641)

21,6 (0.8503)

102-05, 103-07, 103-10

Cast Iron Bearings

27 (19.9) 2,7

N/A

N/A

End Float : Clearance mm (in)

Engine model

Standard

Service limit

0,50 (0.0197)

0,50 (0.0197)

102-05, 103-07

103-10

0,10 - 0,30 (0.0040 - 0.0120)

0,05 - 0,30 (0.0020 - 0.0120)

1  Identify position of bearing carriers on shaft.

2  Install bearing carriers on the crankshaft ensuring oil holes align with feed holes in cylinder block.

3  Check end float.

4  Check number 2 bearing holder on 102-05 engines and number 3 bearing holder on 103-07 and 103-10

engines for wear, poor contact, look burnt or other defects. Defective bearing holders must be renewed.

Notes:

For emissions approved engines. The fuel adjustment screw must not be altered from the original setting.

The maximum No Load Speed must be checked after assembly.

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5

100 Series

To dismantle and to assemble (four cylinder engines)

Operation 5-6

Special requirements

Torque Nm (lbf ft) kgf m

103-13, 103-15, 104-19, 104-22

51 (38) 5,2

End float : Clearance mm (in)

Thrust washer : Thickness mm (in)

Standard

Service limit

Standard

Service limit

0,10 - 0,40 (0.0040 - 0.0160)

0,50 (0.0197) max

2,95 - 3,00 (0.1161 - 0.1181)

2,80 (0.1102) max

1  Identify position of bearing carriers on shaft.

2  Install bearing carriers on shaft ensuring oil holes align with feed holes in cylinder block.

3  Check end float clearance (A2).

Note:  Ensure that the thrust washers are aligned correctly, and are fitted with their oil grooves towards the

crankshaft.

4  Check the thrust washers for wear, poor contact, look burnt, or have any other defects. Defective washers

must be renewed.

Note:  Item (A1) is only used on 104-19 and 104-22 engines.

1

2

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100 Series

6

Timing case and drive assembly

6

Fuel injection pump

To remove and to fit

Operation 6-1

Special requirements

Torque Nm (lbf ft) kgf m

Solenoid

17 (12) 1,7

When the shim (A1) is not required, assemble using a 0,5 mm bead of silicone sealant.

Note:  Blank off the connections of the fuel injection pump until assembly.

1

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6

100 Series

Timing cover

To remove and to fit

Operation 6-2

For crankshaft pulley removal refer to Operation 5-1.

Notes:

Make sure that the governor springs are correctly attached before the timing cover is fitted, see Operation

6-14.

On assembly hold arm clockwise.

After fitting the timing cover, look through the ESOS mounting holeand check that the linkage moves

correctly when the throttle lever on the fuel injection pump is operated.

For emissions approved engines. The fuel adjustment screw should not be altered from original setting.

The Maximum No Load Speed must be checked after assembly.

If a new timing case is fitted, a new emissions label must be fitted.

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Workshop Manual, TPD 1377E, issue 4

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6

100 Series

Slider

To remove and to fit

Operation 6-3

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6

100 Series

Camshaft retainer plate

To remove and to fit

Operation 6-4

Special requirements

Torque Nm (lbf ft) kgf m

Camshaft retainer plate setscrews

11 (8) 1,1

Notes:

For emissions approved engines. The fuel adjustment screw must not be altered from the original setting.

The maximum No Load Speed must be checked after assembly.

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Workshop Manual, TPD 1377E, issue 4

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6

100 Series

Camshaft and cam followers

To remove

Operation 6-5

Caution:  Remove fuel lift pump and all the cam followers before removing the camshaft.

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6

100 Series

To fit

Operation 6-6

Cautions:

The new camshaft is not interchangeable with the old camshaft.

If a new camshaft is fitted, new cam followers of the correct type must be fitted as well.

From engine serial number 333367J the camshaft and the cam followers fitted to the 103-07 engine have

changed.

The width of the injection cams for N°2 and N°3 cylinders have been increased by 0,5 mm.

To prevent interference with the wider injection cam on the camshaft, the diameter of the tappet end of the

exhaust cam follower for N°1 cylinder has been decreased by 1,0 mm to 17 mm.

Tappet

Ø 18

Ø 18

Ø 17

Current

New

120116100

120116180

B

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6

100 Series

Camshaft assembly

To inspect

Operation 6-7

Cam height (intake and exhaust cams) (A1)

Engine model

Height mm (in)

Standard

Service limit

26,1 (1.028)

26,1 (1.028)

33,7 (1.327)

102-05, 103-07

26,565 - 26,620 (1.04590 - 1.04803)

26,445 - 26,500 (1.04114 - 1.04330)

34,065 - 34,120 (1.34114 - 1.34330)

103-10

103-13, 103-15, 104-19, 104-22

Height of cam for injection pump (A2)

Engine model

Height mm (in)

Standard

Service limit

34,3 (1.351)

33,8 (1.331)

41,8 (1.645)

102-05, 103-07

34,480 - 34,520 (1.3575 - 1.3591)

33,940 - 34,060 (1.3362 - 1.34094)

41,940 - 42,060 (1.65120 - 1.65590)

103-10

103-13, 103-15, 104-19, 104-22

Height of cam for fuel feed pump (A3)

Engine model

Height mm (in)

Standard

Service limit

27,0 (1.063)

30,0 (1.181)

102-05, 103-07, 103-10

27,900 - 28,000 (1.09842 - 1.10236)

31,900 - 32,000 (1.25590 - 1.25984)

103-13, 103-15, 104-19, 104-22

3

2

1

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6

100 Series

Max fuel screw and max speed screw

To locate

Operation 6-8

Notes:

The max fuel screw (A1) and max speed screw (A2) should not be adjusted by the operator.

An anti tamper device (A3) may be fitted. Where this device is present, see Operation 6-9.

If adjustment of the maximum fuel screw or the no load speed is necessary, the adjustment must be done

on an engine test facility by personnel approved by Perkins Engines Company Ltd.

1

2

3

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6

100 Series

To remove and to fit

Operation 6-9

A requirement of emissions legislation is that access to adjustments (A1, A2) that affect the engine's exhaust

emissions is limited to personnel approved by Perkins Engines Company Ltd.

The fuel adjustment screw (B2) and maximum speed adjustment (B5) are affected. The fuel adjustment screw

has a tamper resistant body (B1) fitted over the screw and the maximum speed adjustment is protected by a

tamper evident plastic cap (B4).

To remove the tamper resistant body

1  Strike the tamper resistant device metal body (B1) with a suitable cold chisel approximately 10-15 mm from

the cylinder block flange. This will deform the body against the screw lock nut. This operation is necessary until

the metal tube cannot freely rotate around the fuel adjustment screw.

2  Rotate the metal body and the fuel adjustment screw together using a pair of pliers at the D-plug (B3) end

of the tube.

3  Remove the fuel adjustment screw (B2) as a single assembly completely from the cylinder block.

As the removal procedure for the original fuel adjustment screw and tamper resistant device body will cause

permanent damage to both these items, replacements must be obtained from PDC Irlam.

To re-fit a new fuel screw and service tamper resistant body

1  The fuel adjustment screw assembly (B2) may vary according to the engine build code. The appropriate

replacement must be obtained from PDC Irlam.

1

2

3

1

2

4

5

A

B

Continued

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6

100 Series

A special service version of the tamper evident body (D) must be fitted when a new fuel screw is fitted. A kit

part number U5MK0619 is available from PDC. This kit will be supplied only to permitted personnel and must

not be supplied to end users. A groove (D4) around the circumference of the tamper evident body is used to

identify it as a service part.

2  Fit the fuel adjustment screw assembly (C3) to the engine ensuring that there is a metal snap ring (C1)

located in the lock nut groove and a o-ring (C2) fitted.

3  On a suitable calibrated test facility, reset the engine performance parameters to the certified specification

indicated on the engine's emissions control information label mounted on the timing case.

4  Having set the full load fuel delivery to the certified specification and ensuring the lock nut is correctly

tightened, insert the D-plug (D2) into the service tamper resistant body (D3) at the opposite end of the internal

groove (D1). Fit the new service tamper resistant body assembly (D) over the fuel adjustment screw.

5  Tap on the tube until the internal groove (D1) in the body engages over the metal snap ring (C1) in the lock

nut.

To remove and re-fit the tamper evident maximum engine speed cap

The maximum speed adjustment has a plastic cap (B4) fitted by Perkins. The length of this fitted cap will be

either 22mm or 30mm in length depending on the original protrusion of the maximum speed adjustment screw

(B5). The cap is pressed by hand onto the adjustment screw and an internal lip locates into a groove on the

lock nut.

1  Remove the plastic cap (B4) from the maximum speed bolt (B5) with a suitable lever, taking care not to

damage the seal between the cylinder block and the locknut.

2  Make the necessary adjustment to maximum (no load) engine speed by rotating bolt clockwise to reduce

speed and anti-clockwise to increase speed with the engine throttle lever fully open.

Note:   The only permitted adjustment to the maximum engine speed is to correct the speed in accordance with

the high idle speed shown on the emissions compliance label mounted on the engine timing case.

3  After adjustment to within the certified maximum speed range, a new service cap of the appropriate length

can be obtained from PDC Irlam. The replacement service cap will be red in colour part number 131276440 -

30mm length or 131276450 - 22 mm length. This cap will be supplied only to permitted personnel and must

not be supplied to end users.

4  Hand press the replacement service cap onto maximum speed bolt (C4) lock nut.

A warranty claim will not be accepted if it can be seen that an adjustment to the maximum engine speed setting

(B5) or the fuel adjustment screw (B2) has been made by personnel not approved by Perkins.

1

2

3

4

1

3

2

4

c

C

D

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