Description
Perkins 100 Series Workshop Manual covering the 102-05, 103-07, 103-10, 103-13, 103-15, 104-19 and 104-22 two-, three- and four-cylinder diesel engines. This factory publication provides workshop procedures, technical specifications, inspection data and adjustment information for the identified engine range.
Published by Perkins Technical Publications, this manual is intended for professional mechanics, engine rebuilders and machinery workshops undertaking engine servicing and overhaul. Operations include removal, fitting, dismantling, assembly, inspection and adjustment, with model-specific distinctions shown where applicable.
The manual also provides basic engine data, dimensions, recommended tightening torques, injection timing information, electrical diagrams and a special-tools list. It is an engine workshop manual and does not cover the complete host machine in which an engine may be installed.
CYLINDER HEAD ASSEMBLY
The cylinder-head section covers dismantling, inspection and refitting of the valve gear, cylinder head and associated components. Procedures include:
- Rocker cover, inlet manifold and rocker assembly
- Model-specific rocker-shaft dismantling and inspection
- Cylinder-head gasket removal and fitting
- Cylinder-head bolt tightening sequence
- Valve and valve-spring removal and inspection
- Valve-guide clearance checks
- Cylinder-head lower-face distortion checks
- Valve-seat correction, valve depth and lapping
- Valve-tip clearance checking
- Atomisers, glow plugs and associated pipework
PISTONS, CONNECTING RODS AND CRANKSHAFT
Internal engine repair information covers the principal reciprocating and crankshaft assemblies, including relevant inspection and clearance procedures:
- Big-end bearings and caps
- Piston and connecting-rod dismantling and assembly
- Piston and piston-ring inspection
- Piston-ring clearance measurement
- Small-end bush replacement
- Connecting-rod inspection
- Crankshaft pulley removal and fitting
- Flywheel, backplate and oil-seal procedures
- Crankshaft removal and installation
- Main-bearing assembly and bearing-clearance checks
TIMING CASE AND ENGINE TIMING
The timing chapters provide procedures for the timing drive, camshaft and injection-pump installation. Subjects include:
- Fuel-injection pump removal and fitting
- Timing-cover removal and installation
- Camshaft retainer plate
- Camshaft and cam followers
- Camshaft inspection
- Idler gear, idler hub and oil pump
- Gear-tooth backlash measurement
- Oil-pump end-float checking
- Governor-spring checks
- Fuel-injection pump timing adjustment
LUBRICATION, FUEL AND COOLING SYSTEMS
Supporting engine systems are covered through component service procedures and system-specific adjustments. The manual includes:
- Oil-filter canister and pressure-relief valve
- Lubricating-oil sump, strainer and suction pipe
- Lubricating-oil pump inspection
- Oil-pressure switch
- Atomiser removal and fitting
- Fuel lift-pump dismantling and assembly
- Fuel-injection pump removal and fitting
- Fuel-system venting
- Fan and water-pump servicing
- Thermostat removal, testing and inspection
ELECTRICAL EQUIPMENT
Electrical coverage concerns engine-mounted starting, charging and shutdown equipment. It includes:
- Electrical shut-off solenoid
- Alternator removal and fitting
- Starter-motor removal and fitting
- 14- and 15-amp alternator wiring diagrams
- 40-amp alternator wiring diagrams
- 55-amp alternator wiring diagrams
- Model-specific auto-shutdown wiring diagrams
TESTING AND ADJUSTMENT
Workshop data and inspection procedures support accurate assessment during repair and overhaul. Confirmed subjects include compression-test data, torque settings, cylinder-bore dimensions, piston and ring dimensions, crankshaft deflection, journal and crankpin dimensions, bearing information, injection timing, valve measurements, gear backlash and oil-pump end float.
PERKINS 100 SERIES WORKSHOP MANUAL MODEL COVERAGE
- 102-05 – two-cylinder diesel engine
- 103-07 – three-cylinder diesel engine
- 103-10 – three-cylinder diesel engine
- 103-13 – three-cylinder diesel engine
- 103-15 – three-cylinder diesel engine
- 104-19 – four-cylinder diesel engine
- 104-22 – four-cylinder diesel engine
MANUAL DETAILS
- Manufacturer: Perkins Engines Company Limited
- Manual type: Workshop Manual
- Series: Perkins 100 Series
- Publication number: TPD 1377E
- Issue: Issue 3
- Publication date: March 2002
- Page count: 130 pages
- Language: English
The Perkins 100 Series Workshop Manual is suitable for engine repair, inspection and overhaul work where the exact engine model falls within the stated coverage. Its model-specific operations and dimensional data help workshops distinguish between the two-, three- and four-cylinder variants.
Engine identification should be checked before beginning work to ensure the relevant procedure and specification are selected. Coverage is limited to the Perkins engine and its supporting equipment as detailed in the publication.
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