Special requirements

Torque Nm (lbf ft) kgf m

102-05, 103-07

11 (8) 1,1

6 (4.4) 0,6

15 (11) 1,5

103-10

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

Caution:  Connections should be blanked off until assembly.

Notes:

For emissions approved engines. If a new fuel injection pump is fitted, shims of the same thickness as the

originals and a pump with the same part number must be fitted.

For emissions approved engines. If the fuel injection pump is put back, it is essential that the fuel

adjustment screw is not altered from the original setting. The maximum No Load Speed should be checked

after assembly.

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100 Series

Banjo Bolt

Operation 11-7

The torque setting for the banjo bolt (A1), fitted to the fuel injection pump, for the 103-10 engines (KD) is

20,0 Nm (14.75 lbf ft) 2,04 kgf m. The torque setting for all other engines is 7,0 Nm (5.16 lbf ft) 0,71 kgf m.

1

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100 Series

Vent points

To eliminate air from the fuel system

Operation 11-8

To vent the 100 series fuel system

1  Identify the location of fuel lift pump (A3).

2  Locate the vent screw on top of the fuel filter (A2) and loosen off.

3  Operate the hand primer on lift pump until air free fuel flows. Tighten the vent screw.

4  Identify the vent screw on the fuel injection pump (A4) and loosen off. Operate the hand primer until air free

fuel flows. Tighten the vent screw.

5  Identify the fuel pipes from fuel injection pump to the atomiser (A1) and loosen them all off at the atomiser

end. Operate the starter motor until fuel flows from the injector pipes. Tighten all pipe connections.

The engine is now ready to start.

Caution:  When the starter motor is operated, do not exceed continuous rotation for more than 15 second

periods. Wait for 30 seconds between periods of turning if fuel does not flow on initial rotation.

1

2

3

4

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100 Series

12

Cooling system

12

Fan and mounting

To remove and to fit

Operation 12-1

Special requirements

Torque Nm (lbf ft) kgf m

Setscrews

11 (8) 1,1

Depress the fan belt at the centre between the crankshaft pulley and the alternator pulley with a finger force of

49 N (11 lbf) 5 kgf, approximately. The belt deflection is shown in the table below:

Engine type

Belt deflection

4 mm Approx.

5 mm Approx.

6 mm Approx.

7 mm Approx.

102-05, 103-07

103-10

103-13, 103-15, 104-19

104-22

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100 Series

Coolant pump

To remove and to fit

Operation 12-2

Special requirements

POWERPART products

Description

Part number

Silicone RTV sealing and jointing compound

1861108

Notes:

On assembly apply Powerpart silicone RTV sealing and jointing compound to the cylinder block of 102-05,

103-07 and 103-10 engines.

A small amount of leakage of coolant across the surface of the face seal in the coolant pump is normal. Its

purpose is to provide lubrication for the seal. There is a hole in the coolant pump body to allow coolant to

drain. Small amounts of coolant might be seen intermittently from the drain hole during the engine operation

cycle.

Signs of a coolant through the drain hole are not an indication that the pump is faulty. Coolant stains or

intermittent drops of coolant from the hole, indicate normal operation of the pump.

102-05

103-07

103-10

A

POWERPART silicone

gasket sealant

Continued

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100 Series

103-13

103-15

104-19

104-22

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12

100 Series

Thermostat

To remove and to fit

Operation 12-3

Note:   The vent hole on the thermostat must be fitted in the "12 o'clock" position.

102-05

103-07

103-10

103-13

103-15

104-19

104-22

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100 Series

To test and inspect

Operation 12-4

Special requirements

Engine model

Temperature when valve

Temperature when fully

(wax pellet type thermostat)

starts to open °C (°F)

open °C (°F)

73 to 77

(163.4 to 170.6)

87

(188.6)

102-05, 103-07

80 to 84

(176 to 183.2)

95

(203)

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

Renew the thermostat if the valve is:

Open at ambient temperature.

Closed at the fully open temperature.

1  Place the thermostat into the water.

2  Increase the water temperature gradually and record the water temperature when the valve starts to open

and the temperature when the valve is fully open. The standard values are given in the table.

Notes:

The "Start to open" temperature will be stamped on the thermostat.

3 to 5 minutes will be required before the valve starts to open.

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100 Series

13

Flywheel and housing

13

Flywheel

To remove and to fit

Operation 13-1

Special requirements

Torque Nm (lbf ft) kgf m

Flywheel setscrews

73 (54) 7,4

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100 Series

To inspect

Operation 13-2

If the ring gear is excessively damaged or worn, renew.

When wear is not excessive remove ring gear and reinstall 90° from original position. To install, preheat the

ring gear to 120 °C to 150 °C.

Caution:  Heat evenly, do not locally overheat.

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100 Series

Flywheel housing (if fitted)

To remove and to fit

Operation 13-3

Special requirements

Torque Nm (lbf ft) kgf m

102-05, 103-07

15 (11) 1,5

50 (37) 5,1

25 (18) 2,6

103-10

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

Note:  Only 104-22 engines have the backplate and housing fitted together.

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100 Series

14

Electrical equipment

14

Electrical shut off solenoid (ESOS)

To remove and to fit

Operation 14-1

Special requirements

Torque Nm (lbf ft) kgf m

Solenoid

17 (12) 1,7

Note:  Remember the location of special washer (A1).

1

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100 Series

Alternator

To remove and to fit

Operation 14-2

103-13

103-15

104-19

104-22

102-05

103-07

103-10

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100 Series

Alternator Testing

Operation 14-3

To avoid the return of parts that are not faulty, follow this procedure for all suspected failures. This will isolate

the problem between either the alternator or the main electrical system.

Check that all connections to the alternator are secure and free from contamination. If the alternator is earthed

using the engine block check that there is a good connection between the alternator, the earth connection and

the engine block. If the alternator mounting bracket is of the black painted type, the bracket should be removed

from the engine block and the paint removed from the mounting surfaces between the alternator, the mounting

bracket and the engine block.

If the machine tachometer is not operating, check the security of the ‘W’ terminal (A3, B3).

If the alternator is excessively contaminated by dust or dirt, use an airline and compressed air applied to the

vent holes on the alternator.

If the ignition warning lamp is illuminated, check the phase wiring (A4, B1).

Check the alternator charging voltage with a volt meter between the alternator +Ve (A1, B2) and the alternator

earth terminal (A2) when the engine is operating at idle, with the minimal electrical load. The voltage should

be between 13.6 and 14.7 volts, if it is outside this range then the alternator is faulty.

Notes:

Graphic A - External fan type.

Graphic B - Internal fan type.

4

1

3

2

A

K1242

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100 Series

3

1

2

B

K1243

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14

100 Series

Starter motor

To remove and to fit

Operation 14-4

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14

100 Series

Starter Motor Testing

Operation 14-5

Before removing a suspect faulty starter motor, check the security of all of the electrical connections on the

starter motor.

To test the starter motor use:

12 volt fully charged battery (A5).

Two heavy duty cables with suitable clips.

One small lead with an in-line switch capacity of 5 amperes minimum. The switch (A1) should be of the

push to make type.

Secure the starter motor in a vice.

Connect the leads as shown in the diagram (A2, A3, A4), there should be no operation of the starter motor. If

there is any smoke, buzzing or sparking from the starter motor, it is faulty.

Operate the switch and the solenoid should operate, moving the pinion forward to engage the starter. The

starter motor pinion will then rotate. Releasing the switch will allow the pinion to retract and stop rotating.

If there is any abnormal noise, such as knocking, electrical buzzing, smoke, the starter does not operate, or

the pinion does not move forward or backward, or the pinion does not rotate, the starter motor is faulty.

If the starter motor operates correctly then the machine electrical system is faulty.

A1 - Lead with push button switch.

A2 - Lucar connector for ignition switch.

A3 - Starter earth connection 8.0 - 8.5 Nm

A4 - Solenoid connection 5.6 - 6.2 Nm.

A5 - 12 volt battery.

Note:   The starter motor earth (A3) should be connected directly to B- or via another earth. This should not be

used as the main engine earth.

-

+

5

1

4

2

3

A

K1244

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100 Series

Wiring diagram 14 and 15 amp alternator - 102-05, 103-07, 103-10

Maximum circuit

resistance

Maximum circuit

volt drop

Circuit

Cable number

Circuit current

Remarks

Alternator

charging

14 amp (2 cyl)

15 amp (3 cyl)

0.036 Ù (2 cyl)

0.033 Ù (3 cyl)

See Glow Plugs

Circuit

0.5 Volt

Starter motor

solenoid

See Glow Plugs

Circuit

15.75 amp

0.04 Ù

0.63 Volt

0.5 Volt

(Peak max)

26 amp (2 cyl)

39 amp (3 cyl)

STD glow plugs

(via glow signal)

0.0192 Ù (2 cyl)

0.0128 Ù (3 cyl)

Wiring diagram maximum circuit resistance

The resistance of battery cables 1, 2 and 3 must not exceed 0.0018 Ù.

Note:  If a glow signal is not used - it is still necessary to connect terminal 19 and 17 on the switch.

1 Alternator warning lamp

2 Regulator

9 Thermostat switch

10 Fuse

3 Alternator

11 Key switch

4 Battery

12 Glow signal

5 Starter motor

13 Glow plugs

6 Oil pressure warning lamp

7 Oil pressure switch (1)

8 Water temperature warning lamp

14 Solenoid switch

15 A delayed fuse can be fitted if required

(1) Max current draw for standard oil pressure switch is 0.42 amps (5 Watt lamp max).

= Diode. Capacity: Current 3 amp. Reverse Voltage: 600V. (This is mandatory).

14

1

6

8

Sb

Sb

G

Y

R

B

13

7

9

3

2

10

AC

50

17

19

12

15

30

B

S

11

4

5

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100 Series

Wiring diagram 40 amp alternator - 103-10 (when fitted with optional alternator)

Maximum circuit

resistance

Maximum circuit

volt drop

Circuit

Cable number

Circuit current

Remarks

Alternator

charging

See Glow Plugs

Circuit

40 amp

0.0125 Ùs

0.04 Ùs

0.5 Volt

0.63 Volt

0.5 Volt

Starter motor

solenoid

See Glow Plug

Circuit

15.75 amp

STD glow plugs

(via glow signal)

(Peak max)

39 amp

0.0128 Ùs

Wiring diagram maximum circuit resistance

The resistance of battery cables 1,2 and 3 must not exceed 0.0018 Ù.

1 Alternator warning lamp

2 Alternator

9 Key switch

10 Glow signal

11 Glow plugs

12 Fuse

3 Battery

4 Starter motor

5 Oil pressure warning lamp

6 Oil pressure switch (1)

7 Water temperature warning lamp

8 Thermostat switch

13 Fuse

14 Solenoid switch

15 A delayed fuse can be fitted if required

(1) Max current draw for standard oil pressure switch is 0.42 amps (5 Watt lamp max).

= Diode. Capacity: Current 3 amp. Reverse Voltage: 600V. (This is mandatory).

14

1

5

7

2

11

6

8

N

F

B

12

13

AC

50

17

19

10

B

15

30

S

9

3

4

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100 Series

Wiring diagram 55 amp alternator - 103-15, 104-19, 104-22

Maximum circuit

resistance

Maximum circuit

volt drop

Circuit

Cable number

Circuit current

Remarks

Alternator

charging

See Glow Plugs

Circuit

55 amp

0.009 Ù

0.04 Ù

0.5 Volt

Starter motor

solenoid

See Glow Plugs

Circuit

15.75 amp

0.63 Volt

0.5 Volt

(Peak max)

39 amp (3 cyl)

52 amp (4 cyl)

STD glow plugs

(via glow signal)

0.0128 Ù (3 cyl)s

0.0096 Ù (4 cyl)s

Wiring diagram maximum circuit resistance

The resistance of battery cables 1, 2 and 3 must not exceed 0.0018 Ù.

2

Note:  Maximum cable size for 375 lucar terminals on the alternator is 65/0,3 mm (4,5 mm ) therefore twin

cables are required at the connection to the alternator.

1 Alternator warning lamp

2 Alternator

8 Thermostat switch

9 Key switch

3 Battery

10 Glow signal

4 Starter motor

11 Glow plugs

5 Oil pressure warning lamp

6 Oil pressure switch (1)

7 Water temperature warning lamp

12 Fuse

13 Solenoid switch

14 A delayed fuse can be fitted if desired

(1) Max current draw for standard oil pressure switch is 0.42 amps (5 Watt lamp max).

= Diode. Capacity: Current 3 amp. Reverse Voltage: 600V. (This is mandatory).

14

1

5

7

2

11

B

B

6

8

N

F

12

13

AC

50

17

19

10

B

S

15

30

9

3

4

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100 Series

Wiring diagram 40 amp alternator - 103-13

Maximum circuit

resistance

Maximum circuit

volt drop

Circuit

Cable number

Circuit current

Remarks

Alternator

charging

See Glow Plugs

Circuit

40 amp

0.0125 Ù

0.04 Ù

0.5 Volt

0.63 Volt

0.5 Volt

Starter motor

solenoid

See Glow Plugs

Circuit

15.75 amp

STD glow plugs

(via glow signal)

(Peak max)

39 amp

0.0128 Ù

Wiring diagram maximum circuit resistance

The resistance of battery cables 1,2 and 3 must not exceed 0.0018 Ù.

1 Alternator warning lamp

2 Alternator

9 Key switch

10 Glow signal

11 Glow plugs

12 Fuse

3 Battery

4 Starter motor

5 Oil pressure warning lamp

6 Oil pressure switch (1)

7 Water temperature warning lamp

8 Thermostat switch

13 Fuse

14 Solenoid switch

15 A delayed fuse can be fitted if desired

(1) Max current draw for standard oil pressure switch is 0.42 amps (5 Watt lamp max).

= Diode. Capacity: Current 3 amp. Reverse Voltage: 600V. (This is mandatory).

13

1

5

7

2

11

W

6

8

F

B

12

65A 80/0.4 (10)

AC

50

17

19

14

10

B

30

S

9

3

4

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100 Series

Auto shutdown wiring diagram

55 Amp alternator charge lamp

Note:  Alternator charge lamp rating: 12V - 2.2W at 850 rev/min.

When the engine is at rest the alternator charge lamp is illuminated via the battery and it extinguishes when

the alternator operates.

The use of a lower wattage bulb than the above will increase the speed at which self excitation occurs upon

initial run up, e.g. a charge lamp with a lower wattage bulb will have a rating of 12V - 1.2W at 1300 rev/min.

Pin number

connector

Wire colour

Connection

Red

Key Switch - AC

Orange

Red / Black

Brown

Key Switch - 50

Solenoid

Oil Pressure Switch

Water Temperature Switch

Ground (earth)

Blue

Black

3

4

2

5

1

6

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100 Series

Auto shutdown wiring diagram 14 and 15 amp alternator - 102-05, 103-07, 103-10

Auto shutdown operation conditions

If the conditions below last for more than 10 seconds during the start operation, the engine will shut down.

If the conditions below last for more than 2 seconds while the engine is operated, the engine will shut down.

Warning!  There is no protection against low water levels.

Conditions

Water temperature switch: If the water temperature exceeds 105 °C ± 4 °C.

Oil Pressure Switch: If the oil pressure falls below 0,3 kgf/cm² (4.27 lbf/in²).

1 Alternator warning lamp

2 Regulator

9 Thermostat switch

10 Fuse

3 Alternator

11 Key switch

4 Battery

12 Glow signal

5 Starter motor

13 Glow plugs

6 Oil pressure warning lamp

7 Oil pressure switch (1)

8 Water temperature warning lamp

14 Solenoid switch

15 Auto shutdown device

16 A delayed fuse can be fitted if desired

(1) Max current draw for standard oil pressure switch is 0.42 amps (5 Watt lamp max).

= Diode. Capacity: Current 3 amp. Reverse Voltage: 600V. (This is mandatory).

6

4

5

1

2

3

15

14

1

6

8

Sb

Sb

G

Y

R

B

13

7

9

3

2

10

AC

50

17

B

16

30

12

19

S

11

4

5

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100 Series

Auto shutdown wiring diagram 40 amp alternator - 103-10

(when fitted with optional alternator)

Auto shutdown operation symptoms

If the conditions below last for more than 10 seconds during the start operation, the engine will shut down.

If the conditions below last for more than 2 seconds while the engine is operated, the engine will shut down.

Warning!  There is no protection against low water levels.

Conditions

Water temperature switch: If the water temperature exceeds 105 °C ± 4 °C.

Oil Pressure Switch: If the oil pressure falls below 0,3 kgf/cm² (4.27 lbf/in²).

1 Alternator warning lamp

2 Alternator

9 Key switch

10 Glow signal

3 Battery

11 Glow plugs

4 Starter motor

12 Fuse

5 Oil pressure warning lamp

6 Oil pressure switch (1)

7 Water temperature warning lamp

8 Thermostat switch

13 Fuse

14 Solenoid switch

15 Auto shutdown device

16 A delayed fuse can be fitted if desired

(1) Max current draw for standard oil pressure switch is 0.42 amps (5 Watt lamp max).

= Diode. Capacity: Current 3 amp. Reverse Voltage: 600V. (This is mandatory).

6

4

5

1

2

3

15

1

5

7

14

2

11

6

8

N

F

B

13

12

AC

17

19

B

16

30

10

50

S

3

9

4

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100 Series

Auto shutdown wiring diagram 40 amp alternator - 103-13

Auto shutdown operation symptoms

If the conditions below last for more than 10 seconds during the start operation, the engine will shut down.

If the conditions below last for more than 2 seconds while the engine is operated, the engine will shut down.

Warning!  There is no protection against low water levels.

Conditions

Water temperature switch: If the water temperature exceeds 105 °C ± 4 °C.

Oil Pressure Switch: If the oil pressure falls below 0,3 kgf/cm² (4.27 lbf/in²).

1 Alternator warning lamp

2 Alternator

9 Key switch

10 Glow signal

3 Battery

11 Glow plugs

4 Starter motor

12 Fuse

5 Oil pressure warning lamp

6 Oil pressure switch (1)

7 Water temperature warning lamp

8 Thermostat switch

13 Fuse

14 Solenoid switch

15 Auto shutdown device

16 A delayed fuse can be fitted if desired

(1) Max current draw for standard oil pressure switch is 0.42 amps (5 Watt lamp max).

= Diode. Capacity: Current 3 amp. Reverse Voltage: 600V. (This is mandatory).

6

4

5

1

2

3

15

1

5

7

14

2

11

N

6

8

N

F

B

13

12

AC

17

19

B

16

30

10

50

S

9

3

4

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100 Series

Auto shutdown wiring diagram 40 amp alternator - 103-15, 104-19, 104-22

Auto shutdown operation symptoms

If the conditions below last for more than 10 seconds during the start operation, the engine will shut down.

If the conditions below last for more than 2 seconds while the engine is operated, the engine will shut down.

Warning!  There is no protection against low water levels.

Conditions

Water temperature switch: If the water temperature exceeds 105 °C ± 4 °C.

Oil Pressure Switch: If the oil pressure falls below 0,3 kgf/cm² (4.27 lbf/in²).

1 Alternator warning lamp

2 Alternator

9 Key switch

10 Glow signal

3 Battery

11 Glow plugs

4 Starter motor

12 Fuse

5 Oil pressure warning lamp

6 Oil pressure switch (1)

7 Water temperature warning lamp

8 Thermostat switch

13 Solenoid switch

14 Auto shutdown device

15 A delayed fuse can be fitted if desired

(1) Max current draw for standard oil pressure switch is 0.42 amps (5 Watt lamp max).

= Diode. Capacity: Current 3 amp. Reverse Voltage: 600V. (This is mandatory).

6

4

5

1

2

3

14

1

5

7

13

2

W

11

F

6

8

B

IND

12

55A 80/0.4 (10)

AC

17

19

B

15

30

10

50

S

3

9

4

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100 Series

15

Auxiliary equipment

15

Radiator Anti-Vibration mountings

A new radiator mounting (part number 2638D017) has been introduced from engine serial number

KD-----141489H for 103-10 engines, and from engine serial number KE\KF\KR-----954917H for 103-15, 104-

19, and 104-22 engines.

Caution:  New mountings should not be mixed with older mountings. The new mounting is identified with a

yellow mark, the old mounting is identified with an orange mark. If it is necessary to replace any of the three

radiator anti-vibration mountings, then all three should be replaced at the same time using the new

specification mounting.

Note:  All mountings supplied via Perkins Parts Distribution Centre (PDC), Irlam, England will be to the latest

specification.

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100 Series

16

Special tools

16

Special tools list

These tools are available through your nearest Perkins Dealer/Distributor.

Description

Illustration

Valve spring remover

Part number 21825663

Valve stem seal replacer

102-05, 103-07: Part number 21825622

103-10, 103-13, 103-15, 104-19, 104-22: Part number 21825623

Crankshaft pulley remover

Part number 21825619

Idler hub assembly tool

102-05, 103-07: Part number 21825624

103-10: Part number 21825625

103-13, 103-15, 104-19, 104-22: Part number 21825626

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16

100 Series

Description

Illustration

Fuel pump spill pipe

Part number: 21825680

Front oil seal protector

102-05, 103-07, 103-10: Part number 21825620

103-13, 103-15, 104-19, 104-22: Part number 21825621

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