Perkins 103-06 Instruction manual

Perkins 100 Series: 103-06/103-09/103-10
Perama: M25/M30

3
T
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

Abbreviations and codes
Engine Build List (Parts List) Numbering System
The standard engine parts list numbering code system is defined as follows:
Code 1II 111 IV V
Example: KC 30226 1 000001 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 = Made in Japan
Code IV Engine Serial Number
Individual engine serial number commencing with 000001 increasing numerically
Code V Year of Manufacture
M = 1985
• = 1986
• is Omitted
• = 1987 Q/S
= 1988

5
FOREWORD
This Workshop Manual has been compiled for use in conjunction with normal workshop practice. Mention of certain accepted
practices, therefore, has been purposely omitted in order to avoid repetition.
Reference to renewing joints and cleaning off joint faces, has to a great extent been omitted from the text, it being understood
that this will be carried out where applicable. Similarly, it is understood that in reassembly and inspection, all parts are to be
thoroughly cleaned, and where present, burrs and scale are to be removed. It follows that any 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 "through" holes into the interior of the engine, a suitable sealant should be used.
Throughout this manual, whenever the "left" or "right" hand side of the engine is referred to, it is that side of the engine when
viewed from the flywheel end.
This publication is produced by the Compact Engines Division of Perkins Engines Ltd. and every endeavour is made
to ensure that the information contained in this manual is correct at the date of publication, but due to continuous
development, the manufacturers reserve the right to alter this specification without notice.

v
Safety Precautions
THESE SAFETY PRECAUTIONS ARE MOST IMPORTANT Reference must also be made to the local
regulations in the country of operation.
Do not use these engines in marine applications (Except Perama versions).
Do not change the specification of the engine.
Do not smoke when you put fuel in the tank.
Clean away any fuel which has spilled and move material which has fuel contamination to a safe place.
Do not put fuel in the tank during engine operation (unless absolutely necessary).
Never clean, lubricate or adjust the engine during operation (unless you have had the correct training when
extreme caution must be used to prevent injury).
Do not make any adjustments you do not understand.
Ensure the engine is not in a position to cause a concentration of toxic emissions. Persons
in the area must be kept clear during engine and equipment or vehicle operation. Do not
permit loose clothing or long hair near parts which move.
Keep away from parts which turn during operation. Note that fans cannot 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 dangerous hot
coolant can be discharged.
Do not use salt water in the fresh water cooling system or any other coolant which can cause corrosion.
Keep sparks or fire away from batteries (especially while during charge) or combustion can occur. The battery
fluid can burn and is also dangerous to the skin and especially the eyes.
Disconnect the battery terminals before you make a repair to the electrical system.
Only one person must be in control of the engine.
Ensure the engine is only operated from the control panel or operators position.
If your skin comes into contact with high pressure fuel, get medical assistance immediately.
Diesel fuel and used engine oils can cause skin damage to some persons. Use protection on the hands (gloves
or special skin protection solutions).
Do not move equipment unless the brakes are in good condition.
Ensure that the transmission drive control is in "Neutral" position before the engine is started.
Fit only genuine Perkins Parts.
Do not use ether to start these engines.

ENGINE DIAGRAMS

Engine cross sectional views

SECTION I
Perkins 100 Series: 103-06/103-09/103-10
Perama: M25/M30
DESCRIPTION; GENERAL
The Perkins 100 Series is a three cylinder four stroke,
liquid cooled, compression ignition engine, designed
for durability, low weight and compactness.The liner less
cylinder block, three-piece helical gear train and flange
mounted fuel injection pump on the engine cam, reduce
frictional power loss, and engine weight. The special
swirl pre-combustion chamber along with the small
bore multi-cylinder design offers good fuel
consumption, low noise and excellent startability.
The Perkins 100 Series offers easy maintenance with
all service items on the right hand side of engine.
DESCRIPTION; COMPONENT ASSEMBLY
Cylinder Block:
The cylinder block is made from high grade cast iron
with copper and chrome additives and is integral with
the crankcase. The crankcase features four main
bearings of the tunnel block design, with crankcase
walls extending well below the crankshaft centre line
for strength and rigidity. The cylinder bores are plateau
honed for oil retention and extended ring life. The non-
machined surfaces are sealed to ensure cleanliness.
Crankshaft:
The crankshaft is a chrome-molybdenumsteel forging,
fully machined, static and dynamically balanced with
integral counterweights. All bearing surfaces are
induction hardened. The axial location is by thrust
washers at number four main bearing. The four main
journals run in replaceable steel-backed cast copper/
lead alloy bearings. The front of the crankshaft is keyed.
Pistons and Connecting Rods:
Pistons are cast from high silicon aluminium alloy and
are heat treated for low weight with high strength and
good thermal conductivity. The piston 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 alloy hardened by carburizing and
retained by the conventional circlip method. The
connecting rods are machined from high strength forged
steel. The big end bearings are renewable steel-backed,
copper/lead alloy overlay with tin plating. The small end
bearings are a press fit plain bush of tin-backed lead/
bronze.
Camshaft:
The camshaft is made of forged steel and is induction
hardened. Three additional lobes at the front operate the
fuel injection pump. At the rear a fuel lift pump eccentric
is machined. The camshaft is supported by roller and
needle bearings and lubricated by splash feed. The nose
of the camshaft supports the tachometer drive, cam gear,
governor weight cage and governor slider assembly.
Cylinder Head:
The cylinder head is made of high grade copper chrome
cast iron. Lower speed engines have valve seats
machined into the cylinder head, higher speed engines
incorporate replaceable heat resistant alloy steel valve
seats. Inlet and exhaust valves are made of high grade
heat resistant alloy steel with tuftrided stems and
induction hardened heads. Each stem is fitted with a
chrome molybdenum steel cap for long life.
The valves are operated by cold drawn seamless tube
pushrods with hardened steel ball and forged cup ends.
Flat based tappets are made from case carburized
chrome molybdenum steel operating in machined bores
in the cylinder block. The rocker shaft is an induction
hardened hollow steel tube. Valve clearances are
adjusted by hardened ball ended screws and locknuts.
Rocker Cover:
The cover is made of cast aluminium with an integral air
intake, oil filler and crankcase breather. It is located in
position by rocker pillar studs and secured by cap nuts.

Gear Train:
The gear train consists of three helical gears; the
crankshaft gear, located by a woodruff key. The idler
gear houses the lube oil pump and the cam gear
incorporates the governor weight cage.
Fuel System:
A flange mounted, Bosch type fuel injection pump is
mounted in the cylinder block and operated by lobes
machined on the engine cam. The fuel lift pump is
located on the right-hand 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 galley
via a relief valve through a spin-on bypass oil filter to the
main oil galley. The rockers are pressure fed via an
externally mounted oil pipe, from the main oil gallery to
the cylinder head.
Cooling System:
A belt driven centrifugal water pump circulates coolant
via the internal water passages. The coolant is radiator-
cooled and temperature controlled by a conventional
thermostat.

SECTION II
General Engine Data
103-06 103-09 103-10
Type .......................................................................................
Basic Thread and Size.......................................................
Vertical in-line 3 Cyl.
4 Stroke naturally aspirated
Metric
Bore ................................................................................ 64mm (2.52") 72mm (2.83") 75mm (2.95")
Stroke ............................................................................. 64mm (2.52") 72mm (2.83") 72mm (2.83")
Combustion System ............................................................
Compression Ratio.............................................................
23.5:1
I.D.I. Special Swirl
24:1
23:1
Swept Volume ............................................................... 0.617 (37.65 3,,)
0.879 (53.64
3
")
0.954 (58.21
3,,
)
Firing Order ........................................................................... 1-2-3
Rotation ..............................................................................
Injection Pump...................................................................
Injectors ..............................................................................
Anti-clockwise viewed from flywheel
Flange mounted, Bosch type plunger and barrel
Bosch type throttle
Oil Pressure Relief ................................................................
Oil Pressure Switch...........................................................
Electrical System
42-71 PSI
4.3 PSI
Starter ......................................................................... 12V
Alternator.................................................................... 12V
Battery 12V.................................................................
Weight, Bare Engine (Industrial) .........................................
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 100 Gearbox Oil Capacity................................
800 revs/min
1000 revs/min
0.30 litres
0.35 litres
Injector Setting....................................................................
Kilograms/sq. cm (kg/cm
2
)
Atmospheres (atm) .......................................................
Pounds per sq. inch (PSI) ............................................
Governor ................................................................................
Cooling System .....................................................................
Industrial Cooling System Capacity (less radiator) ....
Perama M25/M30 Cooling System Capacity .....................
Thermostat Operating Temperature ....................................
Lubricating System.............................................................
Lubricating Oil Capacity (including filter) ............................
Working Setting
115-125 125-130
111-121 121-126
1636-1778 1778-1850
Mechanical all speed
Liquid with water pump and radiator 1.
3 litre 1.7 litre 1.7 litre
4.0 litre 4.0 litre
71
c
82
°
Pressure feed with Trochoid pump 3.0
litres 3.8 litres 3.8 litres (
Perama M25/M30 4.3 litres)

Recommended Engine Fluids
Coolant ............................................................................
Fuel
.....................................
Clean soft water. Maximum antifreeze concentration
50% (ethanediol base - ethylene glycol with corrosion
inhibitor to BS 6850:1985 orASTM D3306-74 or AS
2108-1977)
Cetane number-45 minimum Viscosity
- 2.5/4.5 centistokes at 40
°
C Density-0.
835/0.855 kg/litre Sulphur-0.5% of
mass maximum Distillation 85% at 350
°
C
(Aviation fuel JP4 is not recommended, however JP5
and JET -A are acceptable providng 5% spindle oil
added)
Lubricating oil
Lubricating oil specification
Specifications
Engine type API CC/SE API CD/SE
MIL-L-46152
CCMC D1
MIL -L-2104C
CCMC D2
Naturally aspirated
•
( 1)
(1) Not recommended during the first 20/50hours of operation
Ambient temperature
NB: Ensure correct fluids are used and oil and coolant are filled SLOWLY and to the correct
quantities. Hurth Gearbox Oil: Automatic transmission fluid ATF Type `A'.
Recommended SAE viscosity grades
ow
(
5W20
- -L
t 0W3o
r --~~ I5W40
20W50
i 40
-30
-22
-20
_ 4
010
32 50
20
68
30
86
40
104
I
50
°
C
122
°
F

PB005 PB007
Alternator
SECTION III
Dismantling Sequence
Rocker Cover
A. Remove alternator and adjusting bracket.
A. Remove breather hose. Loosen and remove
three cap nuts with washers. Lift rocker cover
assembly.
Rocker cover
PB004
Remove Cooling Fan and Pulley
Fuel Injection Pipe
A. Loosen fuel pipe nuts from fuel injection pump
and injectors. 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 atomizers.
Contact Switches
A. Remove water and oil sender units.
A
Water Pump Assembly
A. Loosen securing bolts and remove water pump
assembly and set plate. B.
E0005
Rocker Assembly
Loosen and remove three nuts, lock
washers and flat washers from rocker pillar
stud. Lift rocker assembly.
Remove push rods, and valve stem caps.
Rocker arm assembly

External Oil Pipe
Fuel Lift Pump
PB010
A. Loosen and remove two banjo bolts at cylinder A. Loosen two cap screws and lift from its bore;
block main oil galley and cylinder head remove joint.
assembly.
B. Remove clamp from fuel injection pump.
PB011
PB008
Cylinder Head Assembly
A. Loosen cylinder head bolts starting from the
centre, in a circular pattern using several
steps of equal torque. 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 lift and posi-
tion fuel injection pump until access to link snap
pin is gained.
B. Remove snap pin and remove link from control
rack. Remove fuel injection pump and shim
pack.
NOTE: Injection timing is determined by the
shim pack between fuel injection pump flange
and cylinder block mounting face. The thickness
and number of shims should be checked and
recorded to aid re-assembly.
P8012

PB019
Crank Pulley
A. Loosen pulley nut and remove pulley.
Oil Filter
A. Remove spin-on type oil filter and discard.
Gear Cover and Governor Assembly
A. Remove securing bolts and lift cover assembly off
the locating dowels.
Idler Gear and Oil Pump Assembly
A. Remove circlip. Remove entire assembly.
PBO1
5
Camshaft Assembly, Tachometer 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. Remove retaining bolts and lift front plate off its
locating dowels. Remove joint and discard.
PB017
Dipstick Assembly
A. Loosen fixing bolt and remove assembly. Oil
Sump
A. Remove all bolts, lower sump and discard joint.
Suction Pipe and Strainer
A. Remove two securing bolts. Rotate suction pipe
out of its bore.
Plate
Camshaft
PBO16

Connecting Rod and Piston
A. Loosen connecting rod nuts and remove rod
cap.
B. Remove carbon from cylinder bore. Push piston
and connecting rod through cylinder block.
Replace rod cap to piston 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. Slide out crankshaft and main bearing assem bly.
Remove Relief Valve Assembly
A. Loosen two starter retaining nuts; remove starter.
B. Loosen back plate retaining bolts and remove
back plate.
PB024

SECTION IV
Disassembly, inspection, fits and
clearances of component assemblies
Rocker Arm Assembly
- Disassembly
A. Remove the bolt at the rocker arm shaft end.
B. Pull out the pin located in No. 1 cylinder rocker
arm bracket.
C. Pull out the rocker arm, spring and bracket.
Standard Clearance Allowable limit
0.032-0.068mm
(.001-.026")
0.2mm
(.008")
E0027
C. Wear on valve stem contact face of the rocker
arm.
Check the face for step wear or score. Slight
wear 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 and Correction
A. Wear of rocker arm shaft
Using a micrometer, check outside diameter of the
rocker arm shaft. If the rocker arm shaft is worn
beyond allowable limit, replace.
Standard dimension Allowable limit
11.65-11.67mm (
.459-.460")
11.57mm (
456 )
PB026
B. Rocker arm-to-shaft clearance
Measure the inside diameter of the rocker arm.
Calculate the clearance between the rocker arm and
rocker arm shaft. If the clearance is exces sive,
replace.
PB028

- Inspection and Correction A.
Cylinder head
With a straight edge and a thickness gauge,
check for warping of the cylinder head lower
face.
PB029
Intake valve 103-09/10/Perama M25/M30
Standard diameter Allowable limit
6.955-6.97mm
(.274")
6 89mm
(271 )
Intake valve 103-06
Standard diameter Allowable limit
5.960-5.975mm
(.2346-.2352")
5.9mm (
.2323)
Exhaust valve 103-09/10/Perama M25/M30
Standard diameter
Allowable limit
6.94-6.95mm
(.274")
6.84mm
(.269)
Exhaust valve 103-06
Standard diameter Allowable 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 Allowable limit
0.05mm or less
(.002")
0.12mm
(.005")
B. Valve guide and valve stem
a. Check the valve stem for excessive wear or
damage. If found to be excessively
damaged, replace.
b. Check valve stem diameters at positions I, II
and III with a micrometer. If the diameter is
less than allowable limit, replace.
c. Thickness of valve head
If valve head thickness is less than allowable
limit, replace valve.
0.925-1.075mm (
.036"-.042")
Standard thickness Allowable limit
0.5mm
(.020)
Thickness
t
4
PB127

d. Valve to valve-guide clearance
Check the clearance between the valve and
valve guide. If the clearance exceeds the
allowable limit, replace.
Intake valve
0.025-0.052mm
(.001-.002")
Exhaust valve
150"
Standard clearance Allowable limit
more than 0.2mm (
.008")
Contacting
width
Standard clearance
Allowable limit
0.045-0.072mm
(.0018-.0028")
more than 0.25mm
(.010")
1068
b. Recess of valve seat
If the recess is more than allowable limit,
replace the valve seat (if fitted).
103-09/10/Perama M25/M30
0.85-1.15mm (
.034-.045")
Depth
Standard recess Allowable limit
1 8mm
( 071 ')
Clearance
1067
1069
C. Valve seat
a. Valve seat contact width
If the contact width of the valve seat is more
than allowable width, 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
(.071')
Standard width
Allowable limit
1.7-2.1 mm (.
067-.082")
2.5mm
(098 )
103-06
Standard width
Allowable limit
1.59-1.80mm (.
0626-.0709")
2 5mm
(098)
Replacement of valve seat insert (where
fitted):
Either 1. Using gas burner (700 to 800°C),
heat diagonally across the valve seat insert.
Leave in air for 3 to 5 minutes and remove
the valve seat insert by light tapping (
ensuring the head is not damaged).
Or 2. Machine the insert out taking care not
to damage the head.
Clean up the insert bore and fit new insert
using a press (1,000 to 1,500kgf) and a suit-
able smooth surface tool. To assist process,
chill the valve seat insert with liquid nitrogen
etc or heat the head to between 60 and
100°C.

c. Lapping of contact face of the valve seat
Correct valve seat contact using a valve
lapper and lapping compound.
When using a new cylinder head, obtain
correct seat contact width and seat recess
using the seat cutter. Then, carry out lapping.
Squareness
4~
'
I
OP
W
PB128
E. Inner face of combustion chamber
Pull out the cap and insert from the cylinder
head. Check and clean the combustion chamber.
f
w. PB036
D. Valve spring
Visually inspect the valve spring for damage.
Position the valve spring on a flat surface and
check the squareness of it using a square, as
shown in the illustration. If it exceeds allowable limit,
replace the spring.
Using a spring tester, check spring force and
free length.
Replace 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"
Spring force (kg)
(when compressed
(8.1) 17.91bf (7)15.4 lbf
to 30.4mm 1.197")
103-06
Standard
value
Allowable
limit
Squareness (mm) (1.0).039" (1.2).047"
Free length (mm) (33)1.299" (31.5)1.240"
Spring force (kg)
(when compressed
to 28.3mm)
(6.9)15.21bf (6.0)13.21bf
- Reassembly
Reassemble the parts in the reverse order of
disassembly.
NOTE: When assembling the valve spring,
retainer and collets, take care not to damage
the valve guide seal.
Cylinder block
- Inspection and Correction A.
Cylinder block top face
Inspect the cylinder block top face for cracks,
damage and warping in the same way as for
the cylinder head.
If outside limit, replace cylinder block.
Standard value Allowable limit
Less than 0.05mm (
.002")
0.12mm (
005')