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

To inspect

Operation 3-16

Special requirements

Free length (A3) mm (in)

Engine model

Standard

Service limit

31,5 (1.240)

33,5 (1.319)

102-05, 103-07

33,0 (1.299)

35,0 (1.378)

103-10, 103-13, 103-15, 104-19, 104-22

Spring rate when compressed to

30,4 mm (1.197 in) N (lbf) kgf

Engine model

Standard

Service limit

102-05, 103-07

68 (15.2) 6,9

79 (17.9) 8,1

59 (13.2) 6,0

69 (15.4) 7,0

103-10, 103-13, 103-15, 104-19, 104-22

1  Visually inspect the valve spring for damage. A new spring (A1) and a worn spring (A2) are shown.

2  Using a spring tester, check spring force and free length. Renew if found to be beyond the service limit.

1

2

3

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Workshop Manual, TPD 1377E, issue 4

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3

100 Series

Valve stem diameter and thickness of valve head

To inspect

Operation 3-17

Valve head thickness

If the valve head thickness is less than the service limit, renew the valve.

Thickness (A1) mm (in)

Standard

Service limit

0,925 - 1,075 (0.03642 - 0.04232)

0,5 (0,020) max

Valve stem diameter

Check the valve stem for excessive wear or damage. If found to be excessively worn or damaged, renew the

valve.

Check the valve stem diameters at positions (B1), (B2) and (B3) with a micrometer. If the diameter is less than

the service limit, renew the valve.

Intake valve

Diameter mm (in)

Engine model

Standard

Service limit

5,9 (0.232)

102-05, 103-07

5,960 - 5,975 (0.23464 - 0.23524)

6,955 - 6,970 (0.27382 - 0.27441)

103-10, 103-13, 103-15, 104-19, 104-22

6,89 (0.271)

Exhaust valve

Engine model

Diameter mm (in)

Standard

Service limit

5,9 (0.232)

102-05, 103-07

5,940 - 5,955 (0.23386 - 0.23445)

6,940 - 6,950 (0.27323 - 0.27362)

103-10, 103-13, 103-15, 104-19, 104-22

6,84 (0.269)

1

2

1

3

Workshop Manual, TPD 1377E, issue 4

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3

100 Series

Valve guide clearance

To inspect

Operation 3-18

Check the clearance between the valve and valve-guide.

If the clearance exceeds the service limit, renew the cylinder head.

Intake valve

Clearance (A1) mm (in)

Engine model

Standard

Service limit

0,2 (0.008) max

0,2 (0.008) max

102-05, 103-07, 103-10

0,025 - 0,052 (0.001 - 0.002)

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

0,03 - 0,06 (0.0012 - 0.0024)

Exhaust valve

Engine model

Clearance (A1) mm (in)

Standard

0,045 - 0,072 (0.0018 - 0.0028)

0,05 - 0,075 (0.002 - 0.003)

Service limit

0,25 (0.010) max

0,25 (0.010) max

102-05, 103-07, 103-10

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

1

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Workshop Manual, TPD 1377E, issue 4

This document has been printed from SPI². Not for Resale

 

3

100 Series

Cylinder head

To check the distortion of the lower face

Operation 3-19

Special requirements

Maximum machine limit mm (in)

Distortion

Max service limit

Max regrind

0,05 (0.002) OR LESS

0,12 (0.005)

0,15 (0.006)

Using a straight edge (A1) and feeler gauge (A2) check the six positions (lines B1 to B6) for distortion. Do not

machine beyond the maximum limit.

1

2

1

3

4

5

6

2

Workshop Manual, TPD 1377E, issue 4

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3

100 Series

Valve seat width

To correct

Operation 3-20

If the contact width (B1) of the valve seat is more than service limit, check wear condition of the valve guide

first.

Using a seat cutter of 45° correct the seat.

Intake valve

Clearance mm (in)

Engine model

Standard

1,59 - 1,80 (0.0626 - 0.0709)

1,70 - 2,10 (0.0670 - 0.0830)

1,66 - 1,87 (0.0653 - 0.0736)

1,50 - 2,00 (0.0591 - 0.0790)

Service limit

2,5 (0,098) max

2,5 (0,098) max

2,5 (0,098) max

2,5 (0,098) max

102-05, 103-07

103-10

103-13, 103-15

104-19, 104-22

Exhaust valve

Clearance mm (in)

Engine model

Standard

1,59 - 1,80 (0.0626 - 0.0709)

1,70 - 2,10 (0.0670 - 0.0830)

1,66 - 1,73 (0.0653 - 0.0681)

1,94 - 2,16 (0.0764 - 0.0850)

Service limit

2,5 (0,098) max

2,5 (0,098) max

2,5 (0,098) max

2,5 (0,098) max

102-05, 103-07

103-10

103-13, 103-15

104-19, 104-22

45°

1

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Workshop Manual, TPD 1377E, issue 4

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3

100 Series

Valve depth

To correct

Operation 3-21

Special requirements

Depth (A1) mm (in)

Engine model

Standard

Service limit

1,8 (0.071) max

1,8 (0.071) max

1,8 (0.071) max

1,8 (0.071) max

102-05, 103-07

103-10

0,70 - 0,90 (0.0276 - 0.0354)

0,85 - 1,15 (0.0335 - 0.0453)

0,85 - 1,15 (0.0335 - 0.0453)

0,65 - 0,95 (0.0256 - 0.0374)

103-13, 103-15

104-19, 104-22

Rectify if the depth is more than the service limit.

1

Workshop Manual, TPD 1377E, issue 4

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3

100 Series

Valve seat contact face

Lapping

Operation 3-22

Correct valve seat contact using a valve lapping tool and lapping compound.

Note:   When using a new cylinder head, obtain correct seat contact width and seat recess using the seat

cutter, then carry out a final lap.

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Workshop Manual, TPD 1377E, issue 4

This document has been printed from SPI². Not for Resale

 

3

100 Series

Valve tip clearance

To check

Operation 3-23

The valve sequence is viewed from the front of the engine.

Rotate the crankshaft clockwise when viewed from the front.

Adjust the clearance of both intake and exhaust valves to 0,2 mm (0.0078 in).

Note:  Always adjust when the engine is cold.

Engine model

Valve overlap

Adjust valves

No.1 Cyl

No.2 Cyl

No.1 Cyl

No.2 Cyl

No.3 Cyl

No.4 Cyl

No.2 Cyl

No.1 Cyl

No.3 Cyl

3 and 4

1 and 2

3 and 6

2 and 5

1 and 4

1 and 2

5 and 6

7 and 8

3 and 4

2 Cylinder engines

3 Cylinder engines

4 Cylinder engines

Workshop Manual, TPD 1377E, issue 4

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This document has been printed from SPI². Not for Resale

 

100 Series

4

Piston and connecting rod assemblies

4

Big end bearing and cap

To remove and to fit

Operation 4-1

Special requirements

Torque Nm (lbf ft) kgf m

Clearance mm (in)

102-05, 103-07

23 (17) 2,3

32 (24) 3,2

52 (38) 5,3

Standard

Service limit

103-10

0,1 - 0,3 (0.004 - 0.012)

0,7 (0.276)

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

Ensure that when the connecting rods are fitted an axial play (clearance) is provided.

During assembly apply a thin layer of clean engine lubricating oil to the crank pins with.

Notes:

Identify each rod/piston/cylinder pair on disassembly.

For emissions approved engines. The fuel adjustment screws must not be altered from the original settings.

For emissions approved engines. The maximum No Load Speed must be checked after assembly.

If new connecting rods are fitted, see Operation 3-13.

Workshop Manual, TPD 1377E, issue 4

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4

100 Series

Piston and connecting rod

To dismantle and to assemble

Operation 4-2

Align Shibaura logo (A1) with stamped number on con rod.

Align numbers to match (A2).

1

2

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Workshop Manual, TPD 1377E, issue 4

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4

100 Series

To fit

Operation 4-3

Special requirements

Torque Nm (lbf ft) kgf m

102-05, 103-07

103-10

23 (17) 2,3

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

52 (38) 5,3

32 (24) 3,2

For positioning of connecting rod assembly refer to Operation 4-2.

Note:  Pistons must be fitted with Shibaura name toward the fuel injection pump.

Workshop Manual, TPD 1377E, issue 4

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4

100 Series

Piston and piston ring

To inspect

Operation 4-4

Any letters or marks on a surface of a ring (A1) will always be to the upper face.

The piston profile shows the No.1 ring (A2), No.2 ring (A3) and the oil scraper ring (A4).

1

2

3

4

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Workshop Manual, TPD 1377E, issue 4

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4

100 Series

To measure piston ring clearance

Operation 4-5

By use of feeler gauges, measure the clearance between the piston ring groove and ring. If the clearance

exceeds the service limit, renew the piston and rings.

102-05, 103-07, 103-10

Clearance mm (in)

Standard

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

Clearance mm (in)

Piston ring

Service limit

Piston ring

Standard

Service limit

0,06 - 0,1

(0.0024 - 0.0039)

0,25

(0.0098)

0,07 - 0,11

(0.0028 - 0.0043)

0,25

(0.0098)

No. 01 ring

No. 01 ring

0,05 - 0,09

(0.0020 - 0.0035)

0,25

(0.0098)

0,04 - 0,08

(0.0016 - 0.0032)

0,25

(0.0098)

No. 02 ring

No. 02 ring

0,02 - 0,06

(0.0008 - 0.0024)

0,15

(0.0059)

0,02 - 0,06

(0.0008 - 0.0024)

0,15

(0.0059)

Oil control ring

Oil control ring

Workshop Manual, TPD 1377E, issue 4

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4

100 Series

Piston ring and block

To inspect

Operation 4-6

Note:   If the piston ring is worn or damaged, renew it.

Piston ring gap

Insert the rings into the cylinder at right angles to the cylinder bore and measure the gaps with a feeler gauge.

If the gap is more than the service limit, renew the ring.

102-05, 103-07

Gap mm (in)

Standard

103-10

Gap mm (in)

Standard

Piston ring

Service limit

Piston ring

Service limit

0,13 - 0,25

(0.0051 - 0.0100)

1,0

(0.040)

0,15 - 0,27

(0.0059 - 0.0106)

1,0

(0.040)

No. 01 ring

No. 01 ring

0,10 - 0,22

(0.0040 - 0.0087)

1,0

(0.040)

0,12 - 0,24

(0.0047 - 0.0094)

1,0

(0.040)

No. 02 ring

No. 02 ring

0,10 - 0,30

(0.0040 - 0.0120)

1,0

(0.040)

0,20 - 0,35

(0.0079 - 0.0138)

1,0

(0.040)

Oil control ring

Oil control ring

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

Gap mm (in)

Piston ring

Standard

Service limit

0,20 - 0,35

(0.0079 - 0.0138)

1,0

(0.040)

No. 01 ring

0,20 - 0,40

(0.0079 - 0.0158)

1,0

(0.040)

No. 02 ring

0,20 - 0,40

(0.0079 - 0.0158)

1,0

(0.040)

Oil control ring

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Workshop Manual, TPD 1377E, issue 4

This document has been printed from SPI². Not for Resale