Perkins 100 Series: 103-06/103-09/103

Perkins 100 Series: 103-06/103-09/103
Perkins 100 Series: 103-06/103-09/103-10
Perama: M25/M30
3
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
T
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
1
II
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 linerless
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 nonmachined surfaces are sealed to ensure cleanliness.
Crankshaft:
The crankshaft is a chrome-molybdenum steel 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 radiatorcooled and temperature controlled by a conventional
thermostat.
SECTION II
General Engine Data
Type .......................................................................................
Basic Thread and Size .......................................................
Bore ................................................................................
Stroke .............................................................................
Combustion System ............................................................
Compression Ratio .............................................................
Swept Volume ...............................................................
Firing Order ...........................................................................
Rotation ..............................................................................
Injection Pump ...................................................................
Injectors ..............................................................................
Injector Setting ....................................................................
Kilograms/sq. cm (kg/cm2)
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) ............................
Oil Pressure Relief ................................................................
Oil Pressure Switch ...........................................................
Electrical System
Starter .........................................................................
Alternator ....................................................................
Battery 12V .................................................................
Weight, Bare Engine (Industrial) .........................................
Height ............................................................................
Length F/F ....................................................................
Width ................................................................................
Min. Idle Speeds 103-06/103.09/10 ....................................
Perama M25/M30 ...................................
Hurth HBW 50 Reverse Gearbox Oil Capacity ...............
HBW 100 Gearbox Oil Capacity ................................
103-06
103-09
103-10
Vertical in-line 3 Cyl.
4 Stroke naturally aspirated
Metric
64mm (2.52")
72mm (2.83")
75mm (2.95")
64mm (2.52")
72mm (2.83")
72mm (2.83")
I.D.I. Special Swirl
24:1
23.5:1
23:1
0.617 (37.65 3,,) 0.879 (53.643") 0.954 (58.213,,)
1-2-3
Anti-clockwise viewed from flywheel
Flange mounted, Bosch type plunger and barrel
Bosch type throttle
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
71c82 °
Pressure feed with Trochoid pump 3.0
litres
3.8 litres
3.8 litres (
Perama M25/M30 4.3 litres)
42-71 PSI
4.3 PSI
45AH min
64 kg
489mm
442mm
390mm
800 revs/min
1000 revs/min
0.30 litres
0.35 litres
12V
12V
70AHmin
83 kg
539.6mm
489.6mm
410mm
70 AH min.
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
Engine type
Naturally aspirated
(1)
Recommended SAE viscosity grades
Specifications
API CC/SE
MIL-L-46152
CCMC D1
•
ow
API CD/SE
MIL -L-2104C
CCMC D2
(
- -L
5W20
t 0W3o
20W50
(1)
Not recommended during the first 20/50hours of operation
r --~~ I5W40
-30
-22
-20
_4
0
32
i
10
50
20
68
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'.
40
30
86
40
104
I
50°C
122°F
SECTION III
Dismantling Sequence
Rocker Cover
Alternator
A. Remove breather hose. Loosen and remove
three cap nuts with washers. Lift rocker cover
assembly.
A. Remove alternator and adjusting bracket.
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.
Water Pump Assembly
A. Loosen securing bolts and remove water pump
assembly and set plate.
E0005
Rocker Assembly
A Loosen and remove three nuts, lock
washers and flat washers from rocker pillar
stud. Lift rocker assembly.
B. Remove push rods, and valve stem caps.
Rocker arm assembly
PB005
PB007
External Oil Pipe
A. Loosen and remove two banjo bolts at cylinder
block main oil galley and cylinder head
assembly.
Fuel Lift Pump
A. Loosen two cap screws and lift from its bore;
remove joint.
B. Remove clamp from fuel injection pump.
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.
PB011
Fuel Injection Pump Assembly
A. Remove two bolts and nuts securing fuel injection pump to cylinder block. Slowly lift and position 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.
PB009
Tappets
A. Pull tappets from the machined bores in cylinder
block.
P8012
PB010
Crank Pulley
Plate
A. Loosen pulley nut and remove pulley.
Camshaft
PBO16
Front End Plate Assembly
A. Remove retaining bolts and lift front plate off its
locating dowels. Remove joint and discard.
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.
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.
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.
PB019
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.
Remove Oil Seal
PB022
Crankshaft and Main Bearing Assembly
PB020
Flywheel Assembly
A. Loosen bolts, remove flywheel.
PB023
A. Remove bolts fitted through crankcase cross
members.
B. Slide out crankshaft and main bearing assembly.
Remove Relief Valve Assembly
Back Plate
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.
Standard Clearance
Allowable limit
0.032-0.068mm
(.001-.026")
0.2mm
(.008")
C. Pull out the rocker arm, spring and bracket.
Spring pin
PB025
E0027
- 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
11.65-11.67mm (
.459-.460")
Allowable limit
11.57mm (
456 )
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.
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 excessive,
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.
Intake valve 103-09/10/Perama M25/M30
Standard diameter
6.955-6.97mm
(.274")
Intake valve 103-06
Standard diameter
5.960-5.975mm
(.2346-.2352")
Allowable limit
6 89mm
(271 )
Allowable limit
5.9mm (
.2323)
Exhaust valve 103-09/10/Perama M25/M30
Standard diameter
6.94-6.95mm
(.274")
Allowable limit
6.84mm
(.269)
PB029
Exhaust valve 103-06
Standard diameter
5.940-5.955mm
(.2339-2344")
Allowable limit
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.
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.
PB031
c. Thickness of valve head
If valve head thickness is less than allowable
limit, replace valve.
Standard thickness
0.925-1.075mm (
.036"-.042")
Allowable limit
0.5mm
(.020)
b. Check valve stem diameters at positions I, II
and III with a micrometer. If the diameter is
less than allowable limit, replace.
Thickness
t
4
PB127
150"
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
Standard clearance
0.025-0.052mm
(.001-.002")
more than 0.2mm (
.008")
Exhaust valve
Standard clearance
0.045-0.072mm
(.0018-.0028")
Contacting
width
Allowable limit
1068
Allowable limit
more than 0.25mm
(.010")
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
Standard recess
Allowable limit
1 8mm
( 071 ')
0.85-1.15mm (
.034-.045")
Depth
Clearance
1067
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
Standard width
1.7-2.1 mm (.
067-.082")
103-06
Standard width
1.59-1.80mm (.
0626-.0709")
Allowable limit
2.5mm
(098 )
Allowable limit
2 5mm
(098)
1069
103 06
Standard recess
0.70-0.90mm (.
0276-.0354")
Allowable limit
1.8mm
(.071')
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 suitable 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.
Cap (not fitted on 103-06)
Insert
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. 10309/10/Perama M25/M30
Standard
value
Allowable
limit
Squareness (mm)
(1.2).047"
(2.0).079"
Spring force (kg)
(when compressed
(8.1) 17.91bf
(7)15.4 lbf
Free length (mm)
(35)1.378"
(33.5)1.319"
Standard
value
Allowable
limit
Squareness (mm)
(1.0).039"
(1.2).047"
Spring force (kg)
(when compressed
to 28.3mm)
(6.9)15.21bf
(6.0)13.21bf
Free length (mm)
Cylinder block
- Inspection and Correction A.
to 30.4mm 1.197")
103-06
- 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.
(33)1.299"
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.
(31.5)1.240"
Standard value
Less than 0.05mm (
.002")
Allowable limit
0.12mm (
005')
B. Cylinder bore
a. Visually inspect cylinder bore. There should
be no scoring, rust or corrosion.
b. Measure the cylinder bore at the upper,
middle and lower areas (Piston ring contact
area) in the direction of the crankshaft (A
direction) and at right angle to the crankshaft
(B direction).
The upper area described in the above (b)
corresponds to the top ring when the piston
is at the TD.C.. (about 10mm below the
cylinder block top surface). The lower area
corresponds to the piston oil ring when the
piston is at the B.D.C. (about 100mm from
top face).
Check the bore using a cylinder gauge.
First re-bore
0.5mm
(.02")
New standard bore
64.5-64.519mm
(2.5394-2.5401 ")
Allowabl limit
e
64.7mm
(2.5472")
Second re-bore
0.5mm
(.02")
New standard bore
65-65.019mm
(2.5591-2.5598")
Allowable limit
65.2mm
(2.5669")
Replace
the
block
PG044
c. If the bore is found to be outside allowable
limit, re-bore to the oversize dimension as
shown.
Grinding stone size: 100L x 4W
Speed: 162 rpm
Feed (shaft direction): 13 m/min
Gauge pressure:
15 kg/cm2 (5 kg/cm 2 - finish)
Finish stroke: 9
Honing depth: 0.04mm (diameter)
Cross hatch angle: 40°
Surface roughness: 2-4 micron
Bore spec 103-06
Standard bore
64-64.019m m (2.
5197-2.5204")
Allowable limit
64 2mm (
25276
)
Bore spec 103-09/Perama M25
Standard bore
Allowable limit
71.99-72.005mm
(2.8342-2.8348")
72.2mm
(2.8425")
I
First re-bore
0.5mm
(.0196")
New standard bore
Allowable limit
New standard bore
Allowable limit
72.49-72.505mm
72.7mm
76-76.019mm
76.2mm
(2.8539-2.8545")
(2.8621")
(2.9921-2.9928")
(2.9999")
Replace
the
block
Second re-bore
0.5mm
(.0196")
Piston and piston rings
New standard bore
Allowable limit
(2.8736-2.8742")
73.2mm
(2.8818")
72.99-73.005mm
- Disassembly
A. Remove piston rings using a piston ring tool.
B. Remove the circlip and extract the gudgeon pin.
Replace
the
block
Bore spec 103-10/Perama M30
Standard bore
75-75.019mm (2.
9527-2.9534")
Allowable limit
75.2mm (
2.9606')
PB040
First re-bore
0.5mm
(.0196")
New standard bore
75.5-75.519mm (2.
9724-2.9731 ")
Allowable limit
75.7mm
(2.9803 )
Second
re-bore
0.5mm
(.0196")
Inspection
A. Piston
a. If outer surface of the piston is excessively
damaged (cracked score, burning, etc.),
replace.
b. Piston skirt
Check the larger diameter of the piston skirt
(10mm from bottom), and check inside
diameter (thrust direction) of the cylinder.
Calculate the clearance between the
cylinder and piston. If this clearance is more
than allowable, or piston diameter is less
than allowable limit, replace the piston.
103-09 Piston/Perama M25
Standard clearance
Allowable limit
0.0525-0.0825mm
(.0021-.0033")
0.25mm
(.0098")
Standard diameter
71.9225-71.9375mm
(2.8316-2.8322")
Allowable limit
Standard diameter
71.7mm
(2.8228")
74.9425-74.9575mm
(2.950-2.951 ")
c. Oversized piston
When the cylinder is oversized, ensure
that oversized piston is used.
Piston
Part
size
number
Standard
115317382
Piston
Part
Larger diameter
0.5mm
115317386
Standard
115317560
71.9225-71.9375mm
1.0mm
115317389
size
0.5mm
oversize
1.0mm
oversize
number
115317564
115317567
of piston skirt
(2.8316-2.8322")
72.4225-72.4375mm
oversize
oversize
72.9225-72.9375mm
(2.8710-2.8716")
103-06 Piston
of piston skirt
74.9425-74.9575mm
(2.950-2.951 ")
75.4425-75.4575mm
(2.970-2.9706")
75.9425-75.9575mm
(2.9898-2.9904")
Allowable limit
Standard diameter
(Piston)
Allowable limit
Piston size
PB041
0.25mm
(.0098")
Largerdiameter
of piston skirt
0.5mm
64.448-64.463mm
oversize
Allowable limit
63 7mm (
2 5079")
63.948-63.963mm
1.0mm
PB042
0 25mm (
.010)
Standard
oversize
0.0425-0.0665mm
(.0017-.0026")
Largerdiameter
Standard clearance
63.948-63.963mm
(2.5176-2.5182")
Standard clearance
74 7mm (2.
9409 )
(2.8513-2.8519")
0.038-0.072mm
(.0015-.0028")
103-10 Piston/Perama M30
Allowable limit
(2.5176-2.5182")
(2.5373-2.5379")
64.948-64.963mm
(2.5570-2.5576")
d. Clearance between gudgeon pin hole and
gudgeon pin.
Check the inside diameter of the gudgeon
pin hole and the outside diameter of the
gudgeon pin, and calculate the clearance
between them.
If the clearance is more than allowable
limit, replace.
Standard
clearance
-0.004-+0.004mm
(.00015±.00015")
Allowable limit
0.02mm
(00078 )
B. Piston ring
a. If the piston ring is worn or damaged, replace
it.
b. Piston ring gap
Insert the rings into the cylinder at right angle to
the cylinder bore and measure the gaps
with a thickness gauge. If the gap is more
than the allowable limit, replace.
No. 1
ring
No.2
Oil
ring
1.0mm
(.039")
0.2-0.35mm
(.0078-.0137")
1.0mm
(.039")
103-06 GAP
No. 1
ring
No.2
Oil
ring
Standard gap
Allowable limit
0.10-0.30mm
(.004-.012")
1.0mm
(.039")
Allowable
limit
No. 1
0.06-0.1 mm
0.25mm
No.2
0.05-0.09mm
0.25mm
0.02-0.06mm
0.15mm
ring
Oil
ring
(.002-.0039")
(.0019-.0035")
(.0007-.002")
115107260
115107265
Piston ring size
Part No.
Standard
115107191
1.0mm oversize (0.39")
115107196
115107194
f. Oversize piston ring - 103-10/Perama M30
If the cylinder is oversized, oversize piston
ring set should be used.
1.0mm
(.039")
c. Measure the clearance between the piston
ring groove and ring. If the clearance
exceeds the allowable limit, replace the ring.
ring
115107263
S.TD.
0.5mm oversize (.019")
1.0mm
(.039")
Standard
clearance
O.S. 0.5mm (.02")
e. Oversize piston ring - 103-09/Perama M25
If the cylinder is oversized, oversize piston
ring set should be used.
1.0mm
(.039")
0.13-0.25mm
(.005-.010")
0.10-.22mm
(.004-.009")
Partcode number
Allowable limit
0.15-0.27mm
(.0059-.0106")
0.12-0.24mm
(.0047-.009")
Piston ring size
0. S. 1.0mm (0.4")
103-09/10/Perama M25/M30
Standard gap
d. Oversize piston ring 103-06
If the cylinder is oversized, oversize piston
ring set should be employed.
Piston ring size
Part No.
Standard
115107201
1.0mm oversize (.039")
115107206
0.5mm oversize (.019")
115107204
g. Mounting position of the piston ring
Confirm that the piston ring is set as shown
in the illustration 1077.
(.0098")
(.0098")
(.0059")
O
Piston ring
Piston End
gap
1076
Expander connecting part
1077
C. Gudgeon pin
Check the outside diameter of the gudgeon pin.
If it is less than the allowable limit, replace.
103-09/10/Perama M25/M30
B. Clearance between small end bush and the
gudgeon pin.
Measure the inside diameter of the connecting
rod small end bush.
If the clearance exceeds the allowable limit.
replace.
Allowable limit
Standard OD
20.98mm
(.8259')
20.998-21.002mm
(.8266-.8268")
103-06 Gudgeon pin
103-09/10/Perama M25/M30
Standard clearance
0.008-0.023mm
(.0003-.0009")
Standard OD
Allowable limit
(.7480-.7481")
(.7472")
18.998-19.002mm
18.98mm
103-06 Clearance
Standard
Allowable limit
(.0005-.0011")
(.0031")
clearance
0.013-0.028mm
Connecting Rod
- Inspection
A. Distortion or damage.
Allowable limit
0.08mm
(.003")
0.08mm
C. Play between the connecting rod and the
Check the connecting rod for distortion between
crankshaft.
the large
and smallrod
ends
of theIfconnecting
rod
with
a connecting
aligner.
the result exceeds
the Assemble the connecting rod to the crankshaft,
allowable limit, replace.
and measure the play in shaft direction. If the
play is more than the allowable limit, replace
the connecting rod.
Standard
Distortion
(for 100mm)
(3.937)
Parallel
(for 100mm)
(3.937")
1.
2.
3.
4.
5.
Allowable
value
limit
Less than
0.08mm
(.003)
Less than
0 05mm (
0019)
Gauge
Gudgeon pin
Distortion
Flat surface of the aligner
Pin
0.1-0.3mm (.
0039-.0118")
0.2mm
(.0078)
I
Standard play
015mm
(0059 )
Allowable limit
0.7mm (
0275 )
D. Oil clearance
Using the plastigauge, check the oil clearance
as follows.
Remove oil or foreign matter from the bearing
and crankshaft.
Cut the plastigauge to the same width as the
bearing. Place it on the crankshaft. Avoid the
oil hole.
1078
PB04
6
Bearing
Bearing Holder
- Disassembly and Inspection A.
Centre bearing
a. Remove the bearing holder, and check it for
peeling, melting, stepped wear and other
damage. If it is excessively damaged,
replace.
b. Using the plastigauge, measure the oil clearance between the crankshaft centre journal
and the bearing.
If the oil clearance is more than the allowable
limit, replace the bearing. Or, grind the
crankshaft centre journal, and use undersized bearing (Refer to "Crankshaft").
size
S.TD.
Standard oil clearance
0.039-0.092mm
(.0015-.0036")
Allowable limit
0 2mm (
0078)
Bearing
Bearing
Crankshaft
Standard
198517101'
45.964-45.975mm
0.25mm
198517105*
size
U.S.
(.0098")
0.50mm
U.S.
(.0196")
Number
198517110
198517114
198517108*
198517117
Crankshaft
No.1
198517330*
42.964-42.975
No. 3
198517101
No.
U.S0.25
(.010")
U.S 0.50
No. 1
No.2
No.3
No. 1
No.2
No.3
Upper bearing
No 3
No. 2
198517340
198517334'
198517344
198517105*
198517108*
198517117
42.714-42.725
(1.6817-1.6821")
(1.7998-1.8002")
42.464-42.475
(1.6718-1.6722")
45.464-45.475
(1.7899-1.7904")
No. 1
Front
(1,8096-1.8100")
45.714-45.725mm
PB049
(1.7997-1.8001")
45.464-45.475mm
(1.7899-1.7903")
B. Thrust clearance 103-06
Check the thrust clearance for wear, poor contact,
burning or other defects.
N.B. No thrust washers are fitted.
Standard clearance
Holder
(1.8096-1.8100")
45.714-45.725
198517337*
198517347
(1.6915-1.6919")
45.964-45.975
198517110
198517114
center journal
diameter
centrejournal
diameter (mm)
Upper bearing
103-06
Bearing
Journal
No.
Standard oil
clearance
Allowable limit
No.3
(.0014-.0035")
0.039-0.092
(.008")
0.2
No. 1, 2
Part No.
No.2
(.020")
103-09/10/Perama M25/M30
Journal
0.035-0.088
0.2
(.0015-.0036")
(.008")
0.1 to 0.3mm
(.004-012")
Allowable limit
0.5mm
(.020")
Thrust washers. 103-09/10/Perama M25/M30
Check the thrust washer for wear, poor contact,
burning or other defects. Defective washers
must be replaced.
Standard Thickness
1.95-2.0mm (.
0767-.0787")
Allowable limit
1 8mm (
0708 )
Assemble the connecting rod and connecting
rod cap, and tighten to the specified torque (3.03.5kgf.m) (21.7-25.31bf.ft) - 103-09/10/Perama
M25/M30, (2.1-2.6kgf.m) (15.2-18.81bf.ft) - 10306
NOTE: Never rotate the connecting rod.
Remove the connecting rod cap. Measure the
oil clearance with the scale printed on the gauge
bag.
NOTE: Measure the widest area.
103-06
Bearing
Crankshaftpin
Part No.
size
O.D. dimension (mm)
S.TD.
34.964-34.975mm
198517310
0.25mm
34.714-34.725mm
198517314
34.464-34.475mm
198517317
U. S.
(.010")
0.50mm
U. S.
(.020")
(1.3765-1.3770")
(1.3667-1.3671")
(1.3568-1.3573")
- Reassembly
A. Reassemble the piston on the connecting rod as
follows.
B. With a piston heater or the like, heat the piston to
approximately 100°C. Then, assemble the
piston to the connecting rod by aligning the set
marks.
C. Set the 'SHIBAURA' marks or 'F' mark as
shown in the illustration PB048. Align the set
marks (figures) at (A) on the connecting rod.
PB047
103-09/10/Perama M25/M30
Standard clearance
0.035-0.083mm
(.001-.003")
103-06
Standard clearance
0.031-0.079m m (
.0012-.0031 ")
Allowable limit
0.2mm (.
0078)
Allowable limit
0.2mm (.
0078)
Arrow mark or 'F' (103-06)
If the oil clearance exceeds the allowable limit,
replace the bearing. Or, grind the crankshaft
and use oversize bearing.
NOTE: When grinding the outside diameter of
the crankshaft, ensure that the oil clearance is
correct before reassembly.
103-09/10/Perama M25/M30
Shibaura mark (103-09/10) PB048
Bearing
Partnumber
Crankshaft pin
Standard
198517130
38.964-38.975mm
0.25mm
198517134
0.50mm
198517137
size
U.S.
(.0098")
U. S.
(.0196")
O.D. dimension (mm)
(1.5340-1.5344")
38.714-38.725mm
(1.5241-1.5246")
38.464-38.475mm
(1.5143-1.5147")
D. Replace the piston ring on the piston. Position
scribe mark uppermost.
E. When the connecting rod or piston/gudgeon pin
has been replaced, difference in weight of the
assembly (connecting rod plus piston rings)
should not exceed 10 grams between cylinders.
- Reassembly
A. Reassemble the bearing holder, centre bearing
and thrust washer as follows:
a. Face the chamfered part of the bearing
holder toward front. Install the bearing holder
which has reference bit at the centre. Then
install the bearing holder on which the thrust
washer is to be mounted at the flywheel side (
where fitted).
b. Install the thrust washer. (103.09/10/Perama
M25/M30). Face its oil groove toward thrust
face of the crankshaft.
Tightening torque of the bearing holder: (2.53.0 kgf.m) (18.1-21.71bf ft) - 103-09/10/ Perama
M25/30, (2.0-2.5 kgf m) (14.5-18.1 lbf ft) 103-06.
c. Set the bearing with oil groove to upper part,
while setting the bearing without the groove
to lower part.
103-09/10/Perama M25/M30
Standard oil clearance
Allowable limit
(.0015-.0041")
(.0078")
0.039-0.106mm
103-06
0.035-0.102mm
(.0014-.0040")
0.2mm
0.2mm
(.0078")
PB052
-T
i
Notch
groove
Crankshaft Bearing (bush) Inspection
A. Check the bearing (bush) for peeling, melting,
seizure or poor contact. If found to be defective,
replace.
B. Using cylinder gauge and micrometer, measure
the oil clearance between the bearing (bush)
and the crankshaft journal.
C. Measure inside diameters at positions 1 and 2
(1085). At each position, measure in both directions A and B as shown. The oil clearance can
be obtained by subtracting this value from the
maximum crankshaft journal diameter.
PB053
D. If the oil clearance exceeds the allowable limit,
replace the bearing (bush). Or, grind the
crankshaft journal. In this case, use undersize
bearing (bush).
E. When replacing the crankshaft journal (bush),
use a press to install.
Crankshaft journal (bush)
103-09/10/Perama M25/M30
Size
Cord number
Standard
198517080
0.25mm
198517084
0.50mm
198517087
U. S.
(.0098")
1085
U. S.
(0196")
Outside diameter
45.964-45.975mm
(1.8096-1.8100")
45.714-45.725mm
(1.7997-1.8001 ')
45.464-45.475mm
(1.7899-1.7903")
F After grinding the crankshaft journal, check the
oil clearance.
Crankshaft journal (bush) 103-06
Bush
Bush code No.
Crankshaft journal
S.TD.
198517300
42.964-42.975mm
U.S.O. 25
198517304
U.S.O. 50
198517307
size
(.010")
(.020")
O.D. finished size (o)
(1.6915-1.6919")
42.714-42.725mm
Perama M25/M30 10309/10 103-06
(1.6817-1.6821")
42.464-42.475mm
9mm
(13.5mm
8mm-.t..- 13mm
(1.6718-1.6722")
After grinding the crankshaft journal, confirm
that correct oil clearance.
How To Replace Bush
1. Removal of bush
Remove the bush from the housing (Cylinder
Block) using Bush Driving Tool to prevent
damage.
2. Press fitting the bush
2.1 Prior to installing the bush inspect the bush
housing for marks, scratches, etc.
2.2 The bush should be smoothly pressed in
to correct depth by using Bush Driving
Tool, adjusting the oil hole and direction
of bush as per attached PB129 and
following sequence.
(1) Press in the bush to cylinder block from
engine front side.
Note:
Must not press in the bush to cylinder block
from the opposite side. The correct pressing
side is chamfered etc, to allow smooth
operation.
(2) ( Align oil hole of the housing and bush.
install the bush confirming the mark and oil
3)
groove (hole).
(4) Lubricate at outer surface of the bush.
Press in the bushing to the housing until
(5)
Cylinder I
block
i
> Front side
Align
I
PB129
Crankshaft
Inspection
A. Crankshaft deflection
Support the crankshaft with V-block. Position a
dial gauge on the crankshaft centre journal, and
turn the crankshaft gradually by one full turn.
If the gauge reading is more than allowable
limit, correction or replacement of the crankshaft
is needed.
Standard deflection
0.03mm or less (.
0011")
Allowable limit
0.06mm
(.0023')
depth
using Bush Driving Tool.
2.3correct
Confirm
afterby
installation
Confirm the alignment of oil hole of the
housing and the bush, also check inner
diameter is within tolerance.
PB054
B. Oil Seal contact face and oil hole
Check the oil seal contact face for damage
or wear.
Check oil holes for clogging.
103-09/10/Perama M25/M30
Shaft diameter of crankshaft pin
Standard
diameter
C. Crankshaft journal and pin for stepped wear.
Standard
Take four measurements (AA and BB
diameters at positions "1" and "2"). If the
maximum
difference
between
the
measurements is more than allowable limit,
correction is required.
0.25mm U.S.
1
0.50mm U.S.
Allowable
limit
38.90mm
38.96438.975mm
(1.53401.5344")
(1.531 ")
38.65mm
38.71438.725mm
(1.52411.5246")
(1.5216")
38.40mm*
38.46438.475mm
(1.51431.5147")
(1.5118")
If the diameter is less than this value, the
crankshaft must be replaced with new.
103-06
Crankshaft journal shaft diam. (o)
Assy'd std. value
Cross Section of
Pin and Journal
Standard
U.S. 0.25
(.01")
A
Allowable difference (stepped wear)
0.05mm (.0019")
U.S. 0.50
(0.02")
No. 1
No.2
42.964-42.975
No. 1
No.2
42.714-42.725 42.65
(1.6817-1.6821") (1.679"
No.3
No.3
No. 1
No.2
No.3
103-09/10/Perama M25/M30
Standard
0.25mm U.S.
0.50mm U.S.
Standard
diameter
45.964-
45.975mm
(1.80961.8100")
45.71445.725mm
(1.79971.8001 ")
45.464-
45.475mm
(1.78991.7903"')
42.90
(1.6915-1.6919") (1.689")
45.948-45.959 45.90
(1.8090-1.8094") (1.807")
45.698-45.709
45.65
42.464-42.475
42.40*
45.448-45.459
45.40*
(1.7991-1.7996") (1.797")
(1.6718-1.6722") (1.669")
(1.7893-1.7897") (1.787")
LranKsnan pin aiameier to) iu s-uo
When measured diameter is less than the
allowable limit, correct by grinding and use
undersize bearings and bush.
Shaft diameter of crankshaft journal
Repair req. value
Allowable
limit
45.9mm
(1.807")
45.65mm
(1.797")
(45.40mm*
(1.787"*)
O.D. finished size
Standard
U.S. 0.25
(.01")
U.S. 0.50
(.02")
Repair req. valu
34.964.34.975
(1.3765-1.3770")
34.90
(1.374")
34.464-34.475
(1.3568-1.3573")
34.40*
(1.354"
34.714-34.725
(1.3667-1.3671")
34.65
(1.364")
* Replace crankshaft if U.S. 0.50 is exceeded.
1
2
NOTE: When grinding the crankshaft, work with
the following specifications:
103-09/10/Perama M25/M30
(A) Cam height (intake and exhaust cams)
Standard value
Allowable limit
(1.041-1.043")
(1.0275")
26.445-26.5mm
103-06
Standard value
26.565-26.62mm
(1.0459-1.0480")
26.1 mm
I Allowable limit
26 1mm (1.
0275')
PB057
(A)- Radius at pin/journal
3mm ± 0.2mm
118 .0078
(B): Finish precision
1.6Z(`." V)
(C): Radius around oil hole:
0787/2mm in maximum
196 '75mm in minimum
PB059
Use No. 400 emery cloth for final polishing.
Flywheel and Ring gear Inspection
A. Check the ring gear. If it is excessively damaged or
worn, replace it.
B. When wear is not excessive, remove the ring gear
and reinstall 90° from original position. To install,
preheat the ring gear up to 120° to 150°C.
103-09/10/Perama M25/M30
(B) Height of cam for injection pump
Standard height
33.94-34.06mm (
1.336")
103-06
Standard height
34.48-34.52mm (
1.3575-1.3591 ")
I Allowable limit
33 8mm
(1341 )
Allowable limit
34.3mm (
1 3504")
(C) Height of cam for fuel feed pump All engines
Standard height
27.9-28.0mm (
1.098-1.102")
Camshaft Assembly -
Inspection
A. Check the journals and cams for wear and damage.
Replace if the allowable limit is exceeded.
B. Correct uneven wear or small scratches on the
cam surface with oil stone.
Allowable limit
27.0mm
(1.06)
3
C. Camshaft gear and bearing assembly:
6
Oil Pump
- Disassembly
A. Remove the snap ring.
5
8
B. Take out collar spring and shim.
C. Remove idle gear vane and oil pump cover
together.
D. Pull out rotor and thrust washer.
E. Pull out the oil pump cover from idle gear.
F Remove spring from the idle gear. Remove the
knock pin.
2. Camshaft gear 3.
Camshaft
4. Tachometer gear
5. Spacer 6. Roller
bearing 7. Shim
8. Slider
1090
If these items have been replaced it is essential
the spacers and shims etc are assembled in the
order illustrated in 1090.
Timing Gear -
Inspection
A. Check the timing gears for wear and damage on
the contact area. Replace if any defect is found.
B. Measure the back-lash of gears with a thickness
gauge or dial gauge. If the allowable limit is
exceeded, replace all timing gears.
Standard back-lash
0.08mm
(.003 )
1. Snap ring
2. Collar
3. Spring
4. Shim
5. Oil pump cover
6. Rotor
7. Spring
8. Idle gear
9. Thrustwasher
PB061
- Inspection
A. Check oil pump cover, rotor and vane for wear. If
excessively worn or damaged; replace.
B. Check the clearance between the rotor and vane.
If the clearance is excessive, replace.
C. If the idler gear hub needs replacing contact
Perkins service department for procedure.
- Reassembly
A. Reassemble the oil pump in reverse order of
disassembly.
B. Align set marks on the crankshaft gear and idle
gear to reassemble.
C. Check the side clearance between the rotor and
vane is 0.01 to 0.15mm (.0004 to.006") for 10309/ 10/Perama M25/M30, and 0.02 to 0.15mm (.
0008 to .0059") for 103-06. Allowable limit 0.
25mm (.0098").
Allowable limit
0.25mm
(.010")
PB060
1094
Oil Filter
- Inspection
- Construction and Function
This engine employs a cartridge type filter.
Pressurized oil from the oil pump enters from (A);
and is filtered by a fuli flow filter, before discharge
through (B).
When the full flow filter is clogged, the safety
valve opens to bypass the oil.
Thermostat
A. Replace the thermostat if the valve opens at ambient
temperature.
B. Place the thermostat into water. Raise the water
temperature gradually and inspect the valve
opening temperature and valve lift. (Standard
values are as described in the "Specifications".)
NOTE: 3 to 5 minutes will be required before the
valve starts operating.
103-09/10/Perama M25/M30
Type
Wax pellet
type
Temperature when
starting to open
Temperature when
fully open
- Maintenance
A. The oil filter must be replaced every 100 hours of
operation.
When installing a new filter, coat its mounting face
with clean oil then hand tighten only.
Water Pump Assembly and Thermostat housing
Valve lift (when the
water temperature
is 82°C
103 06
Wax pellet
type
69 to 73°C
75°C
82°C
90°C
8.0mm
6mm
- Disassembly
A. Remove the set plate and gasket.
B. Take out the thermostat and spring from the
thermostat housing (on the 103-06) and from the
water pump body on the 103-09/10 and Perama
M25/M30.
1
PB066
Water Pump
A. Check for cracks, wear, leaks, bearing roughness or
damage. If defective replace assembly.
103-06
PB064
3
103-06 PB065
- Reassembly
A. Assemble the thermostat and spring in the water pump
casing or housing, as appropriate. Install the gasket
and set plate.
B. Rotate the fan holder to confirm that there is no
fouling.
103-09/10/Perama M25/M30
0,
tim
m
Radiator 103-06/103-09/10
A pressure type radiator cap is employed to
obtain higher cooling efficiency. When the
coolant pressure builds up to the range of 0.9
±0.15kg/cm2 (6.51b/ft to 10.81b/ft) excessive
pressure is relieved from the overflow pipe. (
shown by white arrow).
When coolant temperature falls coolant pressure may become less than atmospheric pressure. As this may fracture the radiator, the
vacuum relief valve opens at 0.04 to 0.05kg/cm2 (
2.9lb/ft to 3.6lb/ft) to protect the radiator. (black
arrow).
N.B. Perama M25/M30 pressure cap is 0.5kg/
cm2
Fuel
tank
Pre-filter
Feed
pum
p
Injection
nozzle
Injection
pump
Fuel
filter
PB068
Inspection
A. Check inside the fuel filter. If water or foreign
matter is found, remove it. If needed, replace the
fuel filter.
- Disassembly/Reassembly
A. Turn the filter ring nut counterclockwise to
remove it. (103-06 only)
NOTE: An O-ring is inserted between the ring
nut and filter body. This ring should be coated
with grease to aid assembly.
B. Coat the mounting face of the element with
grease, and install it hand tight. (All types).
Feed Pump Assembly -
Disassembly
A. Before disassembly see section A, B, C of
Inspection and then note reference marks on
the diaphragm cap, top body assembly and
bottom body as shown in the figure.
Inspection
A. Check the radiator for water leaks. If water
leaks, repair or replace the radiator.
B. Check radiator fins for clogging by mud and/or
other foreign matter. If clogged, clean the fins.
PB069
B. Remove the bolt to remove the cap and top body
assembly.
C. Check the pressure cap and vacuum pressure
relief cap for operating pressure or contacting
condition. If found to be defective, replace.
D. Check the radiator hoses. If damaged or
perished replace.
Fuel Filter
The fuel line is shown in the illustration.
The fuel which lubricated the injection nozzle
needle is returned to the tank through the overflow pipe.
Top body assembly
Cap
PB07
0
C. Remove the diaphragm from the bottom body,
and turn the piston to align the bottom body
groove with the pin hole.
B.
C
Drain all fuel in the feed pump.
Check condition of the top body as follows. Draw air
from IN side with vacuum and put air into
D. Remove the pin from the piston. OUT side. If air stops in both cases, the body
is normal.
NOTE: Pay attention to the inner spring.
\0 LIT
~.
5
IN
Piston
Bottom body
PB07
1
E. Take out the piston, spring and diaphragm from the
bottom body.
PB074
D. Confirm that the diaphragm has no damage, such
as cracks.
Bottom body
Piston
Diaphragm
PB072
- Inspection
A. Before disassembling the feed pump, confirm that the
piston and bottom body are not seized.
PB073
PB075
- Reassembly
A. Reassemble the feed pump in the reverse order of
its disassembly.
Governor
- Construction/Function
Link
0
PB076
A. A mechanical all speed governor is used. It is
housed in the gear case.
A flyweight assembly is mounted on the
camshaft. The movement of the flyweight is
transmitted to the injection pump control rack
by way of the slider, control lever and link. A
spring which is hooked to the arm and tension
lever regulates the movement of the flyweight.
By changing the set angle of the governor lever,
tension on this spring is changed. Thus, the
engine speed can be regulated by the governor
lever.
bolt limits the movement of the arm and has
been adjusted and sealed at the factory.
C. Max. fuel and start spring.
These are built into the cylinder block, to regulate fuel injection at high speed. Regulation of
fuel injection in the middle speed range is by
torque spring to realize higher torque.
A start spring is placed between the gear case
and link. This spring automatically functions to
increase fuel during the start mode.
An idling spring at the gear case stabilizes
engine idling speed.
The max. fuel has been adjusted at the factory
and sealed.
B. Maximum speed set bolt.
Set bolt is mounted on the cylinder block. This
Nozzle and Holder Specification
Item
Part code
Perama M25/M30/103-09/103-10
103-06
093500-3320
093500-2240
131406330
Assembly number
Nozzle holder
093100-3320
(ND-KCA46SD332)
Nozzle
Nozzle type
Needle valve diameter
Pintle diameter
Valve opening pressure
Spraying angle
093400-5010
(ND-4PDI)
6mm
3.5mm
Throttle type
115-125kg/cm2
4°
(111-121 ats)
A. The nozzle has been machined to inject fuel,
which is pressure-fed from the injection pump
to the combustion chamber. Fuel is pressure-fed
from the oil hole of the nozzle holder to the
nozzle body and sprayed from the nozzle
compressing the spring when the pressure
exceeds the specified value. Some fuel lubricates and cools the nozzle and nozzle body, and
returns via the return pipe.
Valve open
093100-2240
093400-1460
(ND-DN4SDND146)
Construction/Function
Valve closed
131406340
Full opening
(main jet)
6
,
M
qL7111
11Y
11
17
Throttle type
1mm
115-125kg/cm2
4°
- Disassembly/Inspection
A. Place the nozzle holder (body) in a vice and turn
the nozzle nut to disassemble.
NOTE: Care should be taken so that the needle
valve does not fall when the nozzle is removed.
B. Wash the nozzle body and needle valve and
inspect the nozzle for seizure, sticking and fuel
leakage on the seat surface. If fuel leakage is
detected, replace the nozzle.
C. Inspect the upper and lower contact surfaces of
the distance piece and correct so that positive
contact can be obtained.
D. Check the nozzle needle valve-contact surface
on the push rod for wear, and spring seat for
cracks.
Air Cleaner
Reassembly/Adjustment
A. Before fitting a new nozzle assembly, soak it in - Construction/Function
heated light oil (50°-60°C) to remove anti-corroThe cyclonic air cleaner houses a paper element
sive agent from the nozzle. Then, slide the body
which removes dirt or dust from air drawn in.
on the needle valve so that they slide smoothly.
B. Turn the nozzle body upside down, fit the shim,
spring, rod, piece and nozzle in this order, and - Inspection/Replacement
A. At every 100-200 hours of operation, take out the
tighten with a nozzle nut.
element and clean it by blowing compressed air (
pressure lower than 100psi.)
B. When oil or soot is stuck to the element, soak it
in synthetic detergent for approximately 15
minutes. Then, rinse it in the detergent
8. 9' several times, and wash it in clean water.
Finally, leave to dry.
7.
C. When operating the machine in dusty environ5. 6.
ment, increase service frequency.
4.
D. At every sixth cleaning or every year, replace the
3.
element.
2.
1118
1. Gasket
2 Nozzle nut
. Tightening
torque 8 - 10
kgf.m
3. Nozzle
4. Spacer
5. Rod
6. Spring
7. Shims
8. Body
9. Nut
C. After reassembly, inspect the injection
pressure of the nozzle.
Adjust the pressure with adjusting shims using a
nozzle tester so that the injection starts at 120kg/
cm2 1,707psi 116ats. (The pressure increases or
decreases about 10kg/cm2 142psi 9.7ats with a
shim of 0.1 mm thick.)
D. Spray condition
a. Fuel drops should not be mixed in the spray
pattern.
b. Fuel should be sprayed in conical shape with
respect to the nozzle axis.
c. Check that the fuel is sprayed in a circular
shape when tested.
d. Hold the pressure at 100kg/cm2, 97ats, lower
by 20kg/cm2, 20ats, than specified (120kg/ cm
2) and check that no test oil drops from the
nozzle tip.
E. After cleanina the element, put a light inside
element, and check it the
for cracks, holes or wear.
If damage is found or the gasket is broken,
replace the element.
F
Do not install the element until completely dry.
SECTION V
Reassembly
Precautions Before Assembling
A. Wash parts before assembling. (Especially, oil
gallery, bearings, pistons and cylinder bores
should be washed thoroughly.)
B. Apply new oil to sliding and rotating surfaces of
cylinder bores, pistons and bearings, etc.
C. Replace gasket, packing, etc. Use liquid gasket to
prevent oil leakage where necessary.
D. Never overtighten bolts and nuts used on
aluminium alloy: tighten to specified tightening
torques.
103-06
Standard play
0.1-0.3mm (
.004-.012")
Allowable limit
0.5mm
(.020")
Relief Valve Assembly
A. Install an 0-ring on the relief valve assembly.
Relief valve tightening torque: 6.
0 to 7.Okgf.m (43 to 501bf/ft.)
Crankshaft and Bearing Holder Assembly
A. Install the bearing holders on the crankshaft.
Insert this in the bush at the front end of the
cylinder block.
B. Align the bolt hole at lower part of the cylinder
block with thread hole on the bearing holder, and
tighten with bolts. For flywheel end, use two
special bolts, hex. recess in its head.
Bearing holder tightening torque:
2.5 to 3.Okgf.m (18 to 221bf/ft) Perama M25/M30/
103-09/10, 2.0 to 2.5kgf.m (14 to 181bf/ft) 103-06.
Rear Oil Seal
PB08
3
A. This is a pressfit, retained by the back plate.
PB082
C. Measure crankshaft end float.
103-09/10/Perama M25/M30
Standard play
Allowable limit
0.05-0.3mm
(.002-.012")
0.5mm
(.020")
Back Plate
PB084
A. Coat the area around the M10 threaded holes
with liquid packing solvent based sealant and
fix the back plate with bolts.
Back plate tightening torque:
4.7 to 5.5kgf.m (34 to 401bf/ft) 103-09/10/
Perama M25/M30.
1.3 to 1.7kgf.m (9 to 121bf/ft) 103-06.
103-06
PB087
PB085
Flywheel
A. Fit the flywheel, note location of the spring pin.
Flywheel tightening torque:
6.0 to 7.Okgf.m (43 to 501bf/ft) 103-09/10/ Perama
M25/M30.
7.0 to 8.Okgf.m (51 to 581bf/ft) 103-06.
NOTE: Install pistons from front in ascending
order.
D. Tighten the connecting rod cap to specified
torque.
Connecting rod tightening torque:
3.0 to 3.5kgf.m (22 to 251bf/ft) 103-09/10/
Perama M25/M30.
2.1 to 2.6kgf.m (15 to 191bf/ft) 103-06.
NOTE: After installation ensure that the
crankshaft moves freely. Ensure the axial play
of 0.1 to 0.3mm (.004 to .012) is provided.
Suction Pipe and Suction Filter
A. Fix an O-ring on the suction pipe, and insert the
pipe into the cylinder block.
B. Fit the end of the suction pipe to the oil strainer
and fix the oil strainer.
Suction filter tightening torque:
0.9 to 1.3kgf.m (6.5 to 101bf/ft).
Piston and Connecting Rod
A. Coat bearing face, piston and piston ring with
clean engine oil.
B. Slide the piston ring to permit sufficient amount
of oil to be applied in the groove. Set piston ring
gaps 90 degrees apart from each other.
However, do not position these gaps toward the
gudgeon pin or the right angle of the pin.
C. Insert the piston using a ring compressor. Face
the reference mark (SHIBAURA) on the piston
toward the injection pump side. (103-09/10/
Perama M25/M30) and the 'F' mark towards
the front of the engine on the 103-06. Also face
the connecting rod mark towards the fuel pump Sump
side.
A. Tighten the bolts diagonally and evenly.
Dipstick and tube
A. Install the dipstick and tube using two O-rings.
Front Plate
Camshaft Assembly, Tachometer Shaft and
Plate A. Install the tachometer shaft.
B. Install the camshaft assembly. Avoid damaging
bearings.
C. Fix the tachometer shaft and camshaft with the
retaining plate.
Plate tightening torque:
0.9 to 1.3kgf.m (6.5 to 101bf/ft).
PB09
1
D. Install the rotor.
E. Install the oil pump cover, shim, spring and
collar. Fix them with the circlip.
PB089
Idle Gear and Oil Pump Assembly (
See Section IV Oil Pump)
A. Install the thrust washer on the idle gear shaft.
B. Assemble the vane, knock pin and spring on the
idle gear.
Thrust washer
PB092
F Adjust with shim 0.1, 0.15, 0.2, 0.5mm so that the
side clearance of oil pump, rotor and vane is in
the range of 0.1 to 0.15mm.
NOTE: Coat both faces of the rotor and vane
with grease for assembly.
NEVER TURN the crankshaft until the timing
gear case is fitted.
By turning the oil pump cover to either direction,
set the spring pin insert hole to the middle position. Then, fit the gear case.
Oil pump cover
PB090
C. Align set marks on idle gear, crankshaft gear and
camshaft gear, and assemble on the idle gear
shaft.
Timing Gear Case
A. Install the start spring.
B. Insert link through hole in cylinder block. Rotate
oil pump cover to position spring pin hole to
centre position. Install cover locating pin in oil
pump cover plate. (PB094).
NOTE: 1. Do not damage the oil seal when
fitting.
2. Turn the mechanical stop lever
clockwise to assist assembly.
PB095
Injection Pump Assembly
A. Reinstall the shim. Connect the control rack of the
injection pump with the link, and fix with the
snap pin.
B. Tighten the injection pump bolts and nuts.
PB093
PB096
1
I
1
Crankshaft Pulley
A. Align the key way and key on the crankshaft
pulley and crankshaft, and assemble them.
Crankshaft pulley tightening torque:
12 to 13kgf.m (87 to 94Ib/ft) 103-09/10/Perama
M25/M30.
9 to 10kgf.m (65 to 721b/ft) 103-06.
Adjusting the Fuel Injection Timing
Normally this procedure provides correct injection timing. However, when new injection pump,
camshaft assembly, or cylinder block is used,
fuel injection timing should be adjusted as
explained below.
A. Reassemble the injection pump according to the
procedures above. Use the shim of 0.5mm thickness.
B. Remove the delivery valve holder at the front side (
radiator side) of the injection pump.
NOTE: When re-assembling the delivery holder,
adjust the location of the delivery valve (OUT)
to correct position using a wire.
D. Move the governor control lever to "Maximum
Fuel" position, and send fuel with the No 1
piston at around 'X' degrees BTDC in its
compression stroke. At this time, fuel flows from
the delivery holder.
Injection Timing and crankshaft positions
Engine Model
PB097
C. Pull out the delivery valve (IN), and reinstall the
spring and delivery valve holder.
Injection
Timing
X
Y
Z
KC30229, 30, 35,
23
22
22
21.5-23.5
KC30225, 26, 27,
24
23
23
22-24
KB30221, 22
28
25
27
24.5-26.5
30
27
29
26.5-28.5
KC30233, 34
KD 30245, 46
36
KD30241, 42, 47,
48
28, 31, 32
KD30237, 38, 39,
40, 43, 44
KB30216, 17, 18,
23,70
KB30219, 20, 24,
71
-i
Degrees Crank BTDC
20
29
18
26
18
17.5-19.5
28
25.5-27.5
i
E. Then slowly turn the crankshaft clockwise until flowing
fuel from delivery holder is stopped. Check the piston
position at this point. If the position is later than 'Y'
BTDC, use thinner shim. If the position exceeds 'Z'
BTDC, use thicker shim.
Piston Position in relation to the crankshaft angle (BTDC)
103-06 (KB lists)
103-09/10/Perama M25/M30 (KC, KD lists)
Crankshaft angle (BTDC)
Position mm (inch)
Crankshaft angle (BTDC)
Position mm (inch)
25
3.937 (.1550")
15
1.615 (.0636")
27
4.573 (.1800")
17
5.251 (.2067")
19
24
26
28
29
3.636 (.1431 ")
4.250 (.1673")
4.906 (.1931 ")
14
1.409 (.0555")
16
1.836 (.0723")
18
2.317 (.0912")
2.069 (.0815")
2.577 (.1015")
30
5.605 (.2224")
20
32
6.341 (.2496")
22
3.438 (.1353")
24
4.075 (.1604")
31
5.965 (.2348")
21
23
25
26
27
2.851 (.1122")
3.138 (.1235")
3.750 (.1476")
4.413 (.1737")
4.763 (.1875")
5.125 (.2018")
103-09/M25
Changing the shims thickness by 0.1 mm will
change the timing approximately one degree.
Adding shims decreases the angle while
subtracting shims increases the angle.
Injection timing adjusting shim
0.2
Thickness (mm)
F
0.55-0.75 .
0216-.0295"
Part Number
131437320
0.5
131437340
Measurement (mm)
131437330
0.45-0.75 .
0177-.0295'
NOTE: When the shim is not needed, assemble by
coating using liquid sealant.
Measurement (mm)
NOTE: Delivery holder tightening torques:
(103-06) 3.5-3.9kgf.m (25-281bf/ft).
Feed Pump
A. Insert using securing bolts.
Tappet
A. Coat the tappet with oil, and assemble.
Cylinder Head
A. Set the piston to the top dead center, measure the
amount of protrusion above the cylinder block with
depth gauge or dial gauge.
Tightened
thickness
Gasket No.
103-06
Tightened
10
(.0295-.0335)
Oil Filter
A. Coat the mounting face with a thin film of oil, and hand
tighten.
Gasket No.
103-10
1111471
0.75-0.85
(103-09/10/Perama M25/M30)4.0-4.5kgf.m
(29-331bf/ft).
Tightened
thickness
111147280
103-06
Assemble the delivery valve (IN).
Gasket No.
103-09
111147250
103-10/M30
131437310
0.3
0.4
Measurement (mm)
t=1.3
t=1.3
thickness
t=1.3
NOTE: Last four digits of code numbers are stamped
on the head gasket. Install the head gasket with code
numbers at top.
C. Tighten the cylinder head in 3-step procedures, in the
order shown in the illustration. Finally tighten with
specified torque.
Specified torque:
5.0 to 5.3kgf.m (36 to 381bf/ft) 103-09/10/Perama M25/
M30.
3.5 to 4.Okgf.m (25 to 291bf/ft) 103-06.
1z
/11
O
/0\J
04
13
O/~
01
03
0
~ X7
02
14
106
12
E0098
PB099
NOTE: Take measurement by pressing the piston lightly.
Measure the protrusions for three cylinders. And, use
the highest reading as a reference.
B. Ensure the cylinder head gasket meets the tolerance
levels.
NOTE: Spring pin is used for positioning.
Coat threads of bolts with grease based with molybdenum disulphide.
Oil Pipe
Eyebolt tightening torque:
1.0 to 1.3kgf.m (7.2 to 9.41bf/ft).
PB103
PB101
Cap, Push Rod and Rocker Arm Assembly
A. Install the cap on the end of valve stem.
B. Install the push rod and rocker arm assembly.
Rocker arm assembly tightening torque:
2.0 to 2.5kgf.m (14.5 to 18.11bf/ft).
Cylinder Head Cover
A. Evenly tighten the cylinder head cover. Ensure
gasket remains in location
Cylinder head cover tightening torque:
1.0 to 1.2kgf.m (7 to 91bf/ft)
Water Pump Assembly and Radiator Hose
Liquid Packing Water
(siliconpump
RTVassembly.
type)
PB102
Valve Clearance Adjustment
A. Loosen the nut and adjust the clearance of both
the intake and exhaust valves to 0.2mm (.0078")
with the adjust screw.
NOTE: Adjust when the engine is cold. Set the
No. 1 cylinder to the top dead center, and adjust
the clearances of intake/exhaust valves of No.
1 cylinder and exhaust valve of No. 2 cylinder.
Then, turn the crankshaft counter-clockwise by
240° (viewed from the front) to adjust clearance
of intake valve of No. 2 cylinder and intake/
exhaust valves of No. 3 cylinder.
J
Glow Plug and Connector
Glow plug tightening torque: 1.5
to 2.Okgf.m (11 to 14.51bf/ft).
E0004-1
Radiator Hose
Mano-Contact
Mano-contact tightening torque:
1.5 to 2.Okgf.m (11 to 14.51bf/ft).
Nozzle/Holder Assembly
A. Install new cap and gasket securely ref. PB038.
Install the nozzle and holder assembly with
socket for the nozzle holder. Install the return
pipe.
Nozzle/holder tightening torque:
8 to 8.5kgf.m (58 to 621bf/ft) 103-09/10/Perama
M25/M30.
6 to 7kgf.m (43 to 511bf/ft) 103-06.
PB105
Return Pipe and Injection Pipe
A. After installing the return pipe, mount injection
pipes.
Injection pipe tightening torque:
2.0 to 2.5kgf.m (14.5 to 181bf/ft).
Alternator Assembly
A. Install the assembly. Check belt groove alignment.
V Belt, Fan Pulley and Cooling Fan
A. After mounting the fan pulley and cooling fan,
install the V belt.
B. Depress the belt at the center between
crankshaft pulley and the alternator pulley,
finger force of approximately 1 kg, (.51bf/ft).
fan belt tension should be adjusted such
the deflection becomes 5mm (.2") upon
above check.
Cooling fan tightening torque: 0.9
to 1.3kgf.m (6.5 to 9.51bf/ft).
the
with
The
that
the
PB106
SECTION VI
Electrical Systems
Alternator
N.B. (Perama M25/M30 Lucas A127 - see
Section 10).
- Specification and Performance
103-09/10/Perama
M25/M30G P9150
Type
Direction of rotation
Clockwise
(Viewed from pulley)
Speed
1300-6000rpm
Charging capacity
15-16.5A at 14V
at 5000rpm
Minimum charging
speed
Less than 1600rpm
(at 13V)
Regulator
RS5101
Part number
Q 40
w
C
0
30
6 20
D
10
z0
Revolution N(
185046160
103-06
Type
Direction of rotation
Speed
Charging capacity
Minimum charging
speed
Regulator
PB118
18
FM
16
E
B
14
12
OC"
Upper limit
Lower limit
10
8
6
4
2
0
1
E0103
23
4
Speed(rpm)
5 6 x 103
PB119
rpm)
Part number
GP8146
Clockwise
(Viewed from pulley)
1600-5600rpm
14-15Aat14V
at 5200rpm
RS5101
185046160
- Construction
The alternator consists of the stator (armature
coil and coil plate) and the flywheel which
contain ferrite magnets.
Regulator
RS5101
Alternator
Blue
Re
d
G
een
Blac
k
e
12V _
Battery
Load
Charge
lamp
PB121
Inspection
A. Connect an ammeter and a voltmeter as shown (
PB121) and check the relation of the charging
current with the terminal voltage.
1. Flywheel complete
2. Stator complete 3.
Plate
4. Ball bearing
103/06 Tests:
Relation between charge
current and battery
terminal voltage
(at alternator 5200rpm)
E0104
Normal
1 More than 14A at 14V
2 14A-0.5A at 14-15V
Abnormal
Cause
voltage more than 15V
regulator
More than 14A at battery
Charge current OA
Flowing charge current
but low battery voltage
Alternator Performance of unit alone
No load voltage (between
blue and blue) tester
reading at operation (
about 5200rpm)
Tester
continuity
Between
blue and
blue of
lead wire
Insulation resistance (
between a lead wire and
coil plate)
Improper operation of
Defective alternator or
regulator or improper
connection
Defective battery
(overdischarge)
Normal
Abnormal
Cause
Continuity observed
Continuity not observed
Disconnected coil
More than 3MSI
Less than 3Mf I
Improper coil insulation
More than AC 28V
Less than AC28V AC OV
Demagnetized flywheel,
disconnected coil or
wiring harness
103-09/10 Tests:
Relation between charge
current and battery
terminal voltage
(at alternator 5000rpm)
Normal
1. More than 15A at 14V
2. 15A-0.5A at 14-15V
Alternator Performance of unit alone
Normal
No load voltage (between
blue and blue) tester reading
at operation (about
5000rpm)
Tester
continuity
Between
blue and
blue of
lead wire
Insulation resistance (
between a lead wire and coil
plate)
More than AC 30V
Abnormal
Cause
voltage more than 15V
regulator
More than 15A at battery
Improper operation of
Charge current OA
Defective alternator or
Flowing charge current
but low battery voltage
Defective battery
(overdischarge)
Abnormal
Cause
Less than AC30V AC OV
regulator or improper
connection
Demagnetized flywheel,
disconnected coil or
wiring harness
Continuity observed
Continuity not observed
Disconnected coil
More than 3Mtt
Less than 3Mohm
Improper coil insulation
B. Inspection of Flywheel
Turn the flywheel by hand. If 12-time resistance due
to magnetic force is experienced in one turn, and
turns relatively smoothly, there is no trouble in the
flywheel.
If noise is heard during rotation, the bearing is
defective. Replace the bearing.
If the flywheel turns without any resistance, the
magnetic force is too weak.
The magnet should be replaced with new.
- Disassembly
When the alternator is defective or the flywheel turns
abnormally, disassemble the alternator as explained
below.
A. Remove the dust cap (6) using a screw driver.
B. Hold the pulley side jaw of the flywheel complete (1)
with a vice, loosen the nut (7).
C. Pull out the spring washer (8) and washer (9).
D. Pull out the flywheel complete (1). If it is hard to
remove, tap the M10 threads with a plastic
hammer.
1. Flywheel complete
2. Plate complete 3.
Coil plate 4. Stator
complete 5. Bearing 6.
Dust cap 7. Nut
14
8. Spring washer
9.
Washer
10. Coupler
11. Clamp 12.
Screw
13.
Screw
14.
Collar
E. Disconnect the coupler (10) terminal stopper from
the plate complete.
F Loosen the M4 screw (12) and remove the clamp.
G. Remove the M4 screw (13).
H. Pull out the stator complete (4) from the coil plate
(3).
I. Position the coil plate (3) rear side on a surface
plate, and insert a rod having diameter of
approximately 24mm. Then push the bearing
with a press to remove. (Replace the front
bearing as a flywheel complete).
NOTE: NEVER CLAMP the flywheel body with
any vice.
J. Rotate the bearing manually to confirm that it
rotates without noise.
- Reassembly
A. Reassemble the alternator in the reverse of order
of its disassembly, paying attention to the
following precautions.
a. When installing the bearing, place the bearing
housing side of the coil plate (3) on the flat
plate. Then press the bearing from rear side of
the coil plate using a rod of 31 mm diameter. (
Apply a rod on the outer face of the bearing.
)
b. Tighten the nut (7) with the torque of 2.5 to
3.Okgf.m.
c. Clamp the flywheel complete.
d. Never suspend the alternator from a lead wire.
Regulator
- Specification
Type
RS5101
Weight
Approx. 250 gram
Part No.
185516060
Applicable battery
Charging lamp
Applicable alternator
Adjusted voltage
12V
12V less than 3.4W
No-load voltage of less
than 70V
Output current of less
than 16A
14.5+0.5V
Inspection
A. Adjusted voltage
Refer to "Inspection of Alternator".
B. Unit inspection of regulator
With circuit tester, carry out the inspection as
shown in the separate table.
E0107
RS5101 Tester Checking table.
Tester (+) terminal
Tester (-) termina
Blue
Blue
OFF
Yellow
ON
Blue
Red
Green
Black
Blue
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
Colour of cable
Red
Yellow
Green
Black
ON
OFF
OFF
OFF
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
NOTE: Set the tester at high resistance range.
'ON' denotes the fluctuation of the tester needle
while 'OFF' denotes no fluctuation of the
needle.
If the above results are attained, the tester is in
good condition. However, even when the above
test results are obtained, there may be the case
that the regulator is not able to function correctly
due to deterioration. Please take care of the
deterioration.
B. Magnetic switch
The magnetic switch operates the plunger in
the switch and engages the pinion via the shift
lever. It opens and closes the points to start and
stop the starting motor.
C. Pinion
The pinion transmits the rotation of the motor to
the engine. The pinion is provided with an
overriding clutch to interrupt the power from the
engine when the engine starts.
The overriding clutch composes of a rotor and
clutch outer. The rotor is always pushed by the
roller spring and the clutch outer is tapered
where the roller is housed. When the rotor
rotates in a direction that the roller enters the
wider part, the pinion and clutch outer turn
idly, but, when the roller rotates in the narrower
part, the roller works as a key to transmit the
rotation.
Precaution Upon Handling
A. As large current flows through the regulator
generating heat, the regulator must be
positioned to the specified location.
B. Securely install the regulator so that bottom face
of the regulator is in full contact with the heat
radiating plate or to the body.
C. Never remove the battery wiring during machine
operation. If removed, damage of the safety
monitor, etc. will occur.
- Operation and Performance A.
Put on the starting switch
B. Electric current flows to the magnetic switch,
a shunt coil and series coil, the plunger is
attracted and the shift lever pushes out the
pinion.
Charge Lamp
Load
Head Lampp etc.)
C. The pinion is engaged with the ring gear.
D. The contactor comes in contact, current flows to
the starting motor, and the motor rotates to start
the engine.
a. When the teeth of the pinion and ring gear run
against each other, the pinion sleeve spring is
compressed and plunger moves.
Condense,
E0109
Starter motor
- Structure b. The contactor comes in contact, current The starting motor consists of a motor, magnetic flows
directly from the battery to the motor switch, pinion and other component parts. to rotate the armature
and the pinion
A. Motor
engages with the ring gear.
A DC series motor is used for this model, which
provides large starting torque.
c. The pinion engages with the ring gear
completely to turn the ring gear.
Starter Motor Specifications
Model
S114-381
Model
S114.381
RatedTime
(sec.)
30
Output
(kw)
Weight
(kg)
1.2
5.9
Revolution
direction
(viewed from
the pinion side)
Clockwise
Non-loading
Pinion
pushing
voltage (V)
Terminal
voltage (V)
Current (A)
8 or less
12
60 or less
Clutch
system
Overrunning
Engaging
system
Magnetic shift
Loading
Revolution
speed (rpm)
6000
or more
N.B. Model M003T32589 has output 0.7kw 12V and is Series wound.
Terminal
voltage (V)
Current (A)
Torque
(kg-m)
5
540 or less
1.6 or more
E. Engine starts.
F After the engine starts, return switch to run
mode.
G. The magnetic switch loses attracting force, the
pinion returns by the return spring with the shift
lever and disengaged, and the motor stops.
B. Remove the dust cover and take out the E ring
and thrust washer, where fitted. Remove the
rear cover and brush holder.
Ii
-
C. Remove the bush assembly and yoke.
PB108
Connecting diagram. Handling Method
A. Fix the gear case firmly to the engine side so that it
is not affected by the large impact when the
motor starts.
Standard gap between the pinion and ring gear
is 3-5mm.
Use a wire of specified thickness and tighten it
firmly. Insufficient tightening causes larger
contact resistance and makes starting difficult.
D. Remove the shift lever and armature.
PB109
B. Precautions for starting
a. Ensure battery is charging. Insufficient
charging will make starting more difficult.
b. After the engine has started, turn switch to
run mode.
c. When it is difficult to start the engine by the
starting switch, turning it frequently will
decrease the battery electricity. In such a
case, turn off the switch once and then keep
it on for about 10 seconds. Repeat this procedure several times.
d. Never turn on the starting switch while the
engine is operating.
- Disassembly and Reassembly (Typical)
A. Remove the solenoid (magnetic switch).
PB110
E. Remove the pinion, as shown by first removing
the snap ring ref PB111. Re-assembly by using
puller as shown in PB112.
Inspection and Service A.
Armature
PB112
H. Reassembly should be made in the reverse order of
disassembling after inspecting as described in the
paragraph of "Inspection and service". After
assembling, check thrust gap for armature is 0.5mm
maximum and then check and adjust the dimension,
[.
Check and adjust the dimension, c
The distance for which the pinion is pushed out by
the magnetic switch is called the dimension c
Measure the dimension [before installing the
motor.
a. Connect the (+) and (-) terminals of the battery
to the S terminal of the magnetic switch.
NOTE: Use a 12V battery. Never short circuit (
contact) (+) and (-).
b. The pinion is inserted up to the pinion stopper.
c. As shown in PB114, push the pinion to the
arrow direction by finger so that there is no play
and measure the dimension i. i = 0.2-1.5mm (
1.2kw motor) and 0.5 to 2.0mm on 0.7kw motor.
Loosen the adjusting nut and adjust by the
adjusting screw, or shims where fitted.
a. Short-circuit test of the coil
Use a growler tester for the test.
Place the armature core in a growler tester and,
applying an iron piece, turn the armature.
Vibration of the iron piece indicates short-circuit.
Then replace the armature.
b. Check the insulation between commutator and
shaft. If continuity is indicated, it shows poor
insulation. Then replace the coil. Proper
measurement with a circuit tester is impossible.
Be sure to use a 500 V megger for checking. If
the test result is more than 1 Mil, it is
acceptable.
c. Inspection of the surface of commutator
The part of the commutator surface where
the brush is sliding in contact can be distinguished clearly. If the sliding area is rough,
grind with sand paper of No. 500 or 600. If the
indication of a dial gauge exceeds 0.5mm (.002")
, correct with a lathe.
d. Insulator of the commutator
Measure the depth of the insulator of the
commutator, and correct as indicated in
PG144 if the result is 0.2mm (.008") or less.
Chamfered 0,5 to ,
8mm
Unacceptable
Pinion
\ Stop ring
bracket
Front /
PB114
d. Check operation of magnetic switch and change
adjusting plate if necessary.
PG144
e. Shaft bend
Measure the bend of the shaft with a dial
gauge. Holding the center of the armature
shaft ends, measure the run-out of the center
bearing metal. Turn the armature quietly and
read the value indicated by the dial gauge
pointer. Real bend is 1/ 2 of the reading.
Allowable bend limit: 0.08mm (.003")
B. Field Coil
PINION CLEARANCE
Acceptable
a. Check the field coil for disconnection using a
tester. Inspect the continuity between terminals
connected with a brush of the field coil. If no
continuity is indicated on the tester, it shows
disconnection. Then replace the field coil with
new one.
b. Check the continuity between the field coil
and yoke with a tester. Inspect the continuity
between either terminal of the field coil and
yoke. Continuity shows insufficient insulation. Then replace the coil.
D. Magnetic switch
a. Check the shunt coil for disconnection.
Inspect the continuity between the magnetic
switch S terminal and coil case (metal part).
If continuity is not indicated, it shows disconnection. Then replace the switch with new
one.
C. Movement of the brush
a. Check movement of the brush. When the
brush does not move smoothly, check the
bend of the brush holder and stain on the
- Troubleshooting
sliding surface of the brush holder, correct
A. The pinion does not move when the starting
and clean.
switch is on.
b. Check the insulation between the brush
B. Check the series coil for disconnection. Inspect
holder (0 side) and holder base ((Dside...
the continuity between the magnetic switch S
earth). If continuity is indicated, it shows
terminal and M terminal. If no continuity is indiinsufficient insulation.
cated, it shows disconnection. Then replace the
Then replace the brush with new one.
coil.
c. Allowable wear limit of the brush is:
C. Pinion
1.2kw motor 12mm (New 16mm) 0.
a. Check the pinion teeth for wear and other
7kw motor 11.5mm (New 17mm)
damages. Replace faulty pinion.
d. Measurement of the tension of the brush
b. Check the pinion for smooth sliding. If
spring.
scratches or burr is found on the pinion
metal, replace the pinion.
Standard tension is 1.6kg to 2.0kg.
c.
If
the clutch freewheels in both directions or
Set the brush spring and pull up with a spring
seizes when spun by hand, replace. Do not
balance and measure the load when the
clean in solvent.
brush is raised up.
Replace a faulty spring with new one. Service
limit: 1.2kw motor 1.4kg: 0.7kw motor 0.9kg.
Position
Cause
Wiring
Disconnection, loosened terminals of the battery and switch
Starting motor
Pinion-engaged screw part of the armature shaft is tucked and the
pinion does not move.
Starting switch
Magnetic switch
Insufficient contact. No current flows.
I Repair and retighten
Irregular movement of the magnetic switch plunger, disconnection
or short circuit.
(2) Pinion is engaged, motor rotates, but the engine does not start.
Positio
n
Starting motor
Faulty overruning clutch
Cause
(3) Pinion is engaged with the ring gear but starting motor does not start.
Position
Remedy
Cause
Repair the contact
area or replace
Replace
Repair or replace
Remedy
Replace
Remedy
Wiring
Disconnection of the wire connecting the battery and magnetic switch
Replace, retighten
Starting motor
Insufficient engagement of the pinion and ring gear
Replace
Magnetic switch
(solenoid)
or insufficient fastening of the wire connecting the earth, magnetic
switch and motor terminal.
Incorrect installation
Worn out brush, faulty contact of the brush spring
Stained commutator
Faulty armature and field coil
Insufficient connection of the field coil and brush
Insufficient contact of the contactor
Rough contact surface of the contactor
or replace
the wire
Reinstall
Replace
Correct
Repair or replace
Retighten
Replace
Replace
(4) The motor rotates at full speed before the pinion engages with the ring gear.
Position
Starting motor
Fatigued pinion sleeve spring
Cause
Remedy
Replace
(5) After the engine starts, the motor does not stop when the starting switch is off.
Position
Starting switch
Magnetic switch
Cause
Faulty switch
Remedy
Replace
Faulty magnetic switch (solenoid)
Glow Plug
A sheathed type glow plus is employed and
provides excellent starting.
- Specification
Part No. 185366060
Current
Rated voltage
10.5V
Replace
B. Short circuit
The glow plug is of a simple structure and short
circuit is rarely caused. However, if the central
electrode, body, sheath, etc. come in contact,
wiring of preheating circuit is burnt during starting.
Correction: Remove the connector and measure
the resistance of each plug terminal and earth
with a tester. The tester reading should be 1.6 ± 0.
161)
Resistance of 0 indicates short circuit.
6.9A
Thermoswitch
- Specifications
Part No.
385720100
Type
TB-121A
Switching temperature
101 to 109°C (Off to
On)
95°C and higher
Operating load
1 Heat wire
2 Sheath
3 Asbestos
4 Body
- Structure
5 Nut
6 Magnesium oxide powder
7 Insulation bush
8 Core
ON
Fig 2124
Coiled thin heat wire is placed in the sintered
magnesium oxide powder enclosed by stainless
sheath. One end of the heat wire is welded to the
sheath end and the other end to the central
electrode. By setting the starter switch to the
position of Heat (H), the heat wire preheats the air
in the combustion chamber.
- Troubleshooting
Switching off
temperature
12V-3W
A. Disconnection of the heat wire.
The glow plug operates even when any one of the
heat wires is disconnected because it is
connected in parallel. However, when disconnected, preheating time of the glow signal is
extremely extended.
Check/Remove the connector and check the
continuity between each plug terminal and body
earth. If continuity is not observed, it shows
disconnection. Then replace the heat wire.
95°C
101°C
Oil Pressure Switch
109°C
PB123
Part No. 185246060
Oil pressure switch operating range:
0.2 to 0.4kg/cm2 (2.8-5.7 psi)
A. The oil pressure switch is a warning device to
inform low engine lubricating oil pressure. When oil
pressure becomes less than specified the
warning light is activated. This pressure switch
houses a diaphragm and contact points.
WIRING DIAGRAMS
-
Perama
- 103-06, 103-09, 103-10 15 amp alternator 103-09, 103-10 35 amp alternator
Wiring Diagram (103-06, 103-09, 103-10)
Wiring Diagram Maximum Circuit Resistance
Resistance of battery cables 1, 2 & 3 not to exceed 0.0018 ohm
Circuit
Cable No.
Alternator
Charging
4
7, 8, 9, 13
Starting
Motor
Solenoid
Glowplugs
(via glow signal)
4
5
6
4, 5, 10,11, 12
Circuit
current
Maximum
circuit
resistance
15 amp
0.0333 ohm
15.75 amp
0.04 ohm
27 amp
0.0185 ohm
Maximum
circuit
volt drop
0.5 volt
0.63 volt
0.5 volt
Remarks
See glow plugs circuit
See glow plugs circuit
See glow plugs circuit
Wiring Diagram (103-09, 103-10)
Wiring Diagram Maximum Circuit Resistance
Resistance of battery cables 1, 2 & 3 not to exceed 0.0018 ohm
Circuit
Alternator
Charging
Starting
Motor
Solenoid
Glow plugs
(via glow signal)
Cable No.
Circuit
current
Maximum
circuit
resistance
7
35 amp
0.0143 ohm
5
6
15.75 amp
0.04 ohm
4
4, 5, 8, 9, 10
27 amp
0.0185 ohm
Maximum
circuit
volt drop
0.5 volt
0.63 volt
0.5 volt
Remarks
See glow plugs circuit
See glow plugs circuit
See glow plugs circuit
A. ENGINE DOES NOT START
SECTION VII
Trouble Shooting
CAUSE
Faulty key switch and or stop solenoid ..................................
Insufficient charging or complete discharging of
the battery ................................................................................
Lack of fuel .................................................................................
Air mixed in the fuel system ......................................................
Clogged fuel filter .....................................................................
Irregular and faulty fuel supply
(Injection pump trouble) ..........................................................
Glow plug not heated .............................................................
Improper viscosity of the lubricating oil ...................................
Clogged air cleaner ....................................................................
No compression .........................................................................
Broken fusible link .......................................................................
REMEDY
Correct the connection and contact.
Charge.
Supply fuel.
Bleed the air.
Replace.
Repair in an authorized service shop.
Breakage of the glow plug: replace.
Inspect and replace.
Clean.
Repair in a service shop.
Replace.
B. IRREGULAR RUNNING OF THE ENGINE
CAUSE
Air mixed in the fuel system .....................................................
Uneven fuel injection (Troubled fuel injection pump) .............
Clogged fuel filter .......................................................................
Defective governor ..................................................................
Engine itself defective ................................................................
REMEDY
Bleed the air.
Repair at authorized shop.
Replace.
Check and correct.
Repair in a service shop.
C. ENGINE STOPS DURING OPERATION
CAUSE
Lack of fuel in the fuel tank ......................................................
Clogged fuel filter ........................................................................
Air mixed in the fuel system .....................................................
Faulty function of the engine ......................................................
REMEDY
Supply fuel and bleed air.
Replace.
Bleed the air.
Repair in a service shop.
D. OVERHEAT OF THE ENGINE
CAUSE
Lack of cooling water ..................................................................
Loosened or slipping fan belt ...................................................
Damaged fan belt ......................................................................
Clogged radiator .........................................................................
Clogged radiator fin ....................................................................
Dust or scale clogged in the cooling water passage ............
Faulty function of the thermostat .............................................
Lack of lubricating oil ..................................................................
Overloading ................................................................................
REMEDY
Supply water. Inspect leakage and correct.
Remove oil, dust, etc. and tighten.
Replace.
Flush the radiator.
Clean.
Flush the system.
Inspect or replace thermostat.
Add oil.
Decrease the load.
E. GAS (WHITE OR BLUE) SMOKE
CAUSE
Excess engine oil ........................................................................
Too low viscosity of the engine oil ..............................................
Faulty injection timing .................................................................
REMEDY
Inspect and correct the level.
Inspect and replace the oil to correct one.
Too late: correct.
REMEDY
Inspect and replace to correct grade.
Inspect and adjust (in a service shop).
Repair in a service shop.
Reduce the load.
REMEDY
ct the tension.
Repl
ace.
ct and correct.
i r.
ace.
CAUSE
Unsuitable fuel .........................................................................
Excess injection ...........................................................................
Faulty function of the engine .....................................................
Overloading ................................................................................
Clogged air cleaner ....................................................................
F DARK GREY SMOKE G.
FAULTY CHARGING
REMEDY
ct and tighten.
Clea ge the battery.
n.
it in a service shop.
Repl
ace.
CAUSE
Loosened fan belt ..................................................................................
Correct
Faulty wiring
........................................................................................
Broken
lamp bulb
........................................................................
Replace the bulb.
Inspect
Broken wire between battery to the lamp .............................
Correct it.
Faulty battery ..........................................................................................
Repair
Worn out alternator brush .....................................................................
Replace
J. Broken
OIL PRESSURE
LAMP NOT TURNED OFF
fuse ............................................................................................
Replace
CAUSE
REMEDY
CAUSE
REMEDY
Lack of engine oil ........................................................................
in the MOTOR
pressure switch
H.Trouble
STARTER
DOES(mano-contact)
NOT RUN .............
Supply oil up to the specified level.
Replace the switch.
Inspect and retighten.
Replace with new one.
Oil leakage from the lubricating system ..................................
Clogged oil filter ..........................................................................
CAUSE
Short-circuit between oil pressure lamp
or disconnected
wiring ........................................................ Repair.
andLoosened
mano-contact
............................................................................
Inspect
Dropped voltage of the battery ........................................................... Char
Damaged starter motor .........................................................................
Repaair
Broken fusible link .............................................................................
Replace
SECTION VIII
Service Standards
103-09, 103-10, Perama M25, M30
Unless otherwise stated 103-09 is equivalent to Perama M25
103-10 is equivalent to Perama M30
Inspection
items
CYLINDER HEAD
Standard
Dimensio
n
Bore
Type 103-10
Bore
Distortion of upper face of cylinder
block
PISTON 103-09
Skirt diameter (longer diameter)
Clearance to cylinder
Inside diameter of piston pin
Piston pin hole-to-pin clearance
PISTON 103-10
Skirt diameter (longer diameter)
Clearance to cylinder
Inside diameter of piston pin
Piston pin hole-to-pin clearance
PISTON RING 103-09
Piston ring gap:
No. 1 ring
No. 2 ring
Oil ring
ENGINE
more than 30
(425 psi)
CYLINDER BLOCK
Type 103-09
Standard
Value
72
(2.835")
75
(2.952")
72 (2.835")
21 (826 )
75 (2.952")
21 (.826")
To Be
Repaire
d
less than 25
(355 psi)
less than 0.05
more than 0.12
0.85-1.15
(.034-.045")
1.8
(.045")
1.7-2.1
(.067-.083")
5.25-5.75kgf.m
38-421bf/ft
2.5
(.098")
Dry type (single
piece)
71.99-72.005
(2.834-2.835")
Dry type (single
piece)
75-75.019
(2.95-2.954")
less than 0.05
(.002")
Allowable
Limit
Engine 200rpm
Valve seat angle
45"
Coat threads with
molybdenum bisul
fulde based grease.
72.2
(2.843")
73.2
(2.88")
Oversize (0.5, 1.0)
(.020/.040")
75.2
(2.960")
0.12
(.005")
76.2
(3.0")
Oversize (0.5, 1.0)
(.020/.040")
71.9325-71.9475 (2.832-2.833")
71.7 (2.823")
0.0425-0.0725 (.0017-.0029")
0.25 (.009")
-0.004-+0.004 (-.0001 -± 0001 )
0 02 ( 0007')
74.9425-74.9575 (2.950-2.951 ")
74.7 (2.941 ")
0.0425-0.0665 (.0017-.0026")
0.25 (.009")
-0.004-+0.004 (.0001-±.0001 ")
0.02 (.0007")
20.998-21.002 (.8267-8268")
20.998-21.002 (.8266-.8268")
0.15-0.27
(.0059-.010")
0.12-0.24
(.004-.010")
0.2-0.35
(.007-.013")
Remarks
1.0
(.039")
Oversize (0.5, 1.0)
(.020/.040")
20'C
Oversize (0.5, 1.0)
(.020/.040")
20°C
Standard
Inspection items
PISTON RING 103-09 (Continued)
Dimension
Piston ring groove-to-ring clearance
No. 1 ring
Oil ring
No. 1 ring
No. 2 ring
Oil ring
PISTON RING 103-10
2
(.079")
1.5
(.059")
4
(.157")
Piston ring gap:
No. 1 ring
Piston ring groove-to-ring clearance
No. 1 ring
Oil ring
Oil ring
CONNECTING ROD
Twist between small and large end
holes (per 100mm)
2
(.079")
1.5
(.060")
4
(.157")
Straightness at 100mm between small
and large end hole
Front-to-rear clearance between
connecting rod and crank pin
Connecting rod bearing-to-crank pin
clearance
Crush height of large end bearing
Connecting rod bearing
(inner diameter x width)
Connecting rod bolt torque kg-m
39 x 17.5
(1.535")
Weight difference with piston gram
Crush height of small end bush
CRANKSHAFT
Diameter of journal
Diameter of pin
Limit
0.15
(.006)
1.97-1.99
(.077-.078")
1.47-1.49
(.058-.059")
3.97-3.99
(.156-.157")
1.97-1.99
(.078-.078")
1.47-1.49
(.058-.059")
3.97-3.99
(.156-.157")
less than 0.08
(.003")
less than 0.05
(.002")
0.1-0.3
(.004-.011")
0.035-0.083
(.001-.003")
0.006-0.046
(.0002-.0018")
Remarks
0.25
(.009")
Oversize (0.5, 1.0)
(.020/.040")
1.0
(.039")
0.06-0.1
(.002-.003")
0.05-0.09
(.002-.0035")
0.02-0.06
(.0007-.002")
No. 2 ring
No. 2 ring
Allowable
(.0059-.012")
0.15-0.35
(.0059-.014")
Oil ring
No. 1 ring
To Be
Repaired
0.2-0.35
(.007-.013")
0.15-0.30
No. 2 ring
Ring width
Value
0.06-0.1
(.002-.003")
0.05-0.09
(.002-.0035")
0.02-0.06
(.0007-.002")
No. 2 ring
Ring width
Standard
0.25
0.15
(.009")
(.006")
Oversize (0.5, 1.0)
(.020/.040")
0.2
(.0007")
0.15
(.006")
0.7
(.0027")
0.2
(.0007")
Oil clearance
Crush height
3.0-3.5
(22-251b/ft)
less than 10
0.034-0.095
(.001-.0037")
46
(1.81")
39
(1.54")
45.964-45.975
1.8096-1.810")
38.964-38.975
(1.534-1.535")
45.9
(1.807"
38.9
(1.532")
Undersize
.0.25,0.0)
(010-.020")
Same to above
Inspection items
CRANKSHAFT (Continued)
Roughness, main journal and crank pin
Crankshaft deflection
Standard
Dimension
Standard
Value
1.6Z
Axial play of crankshaft
Thickness of thrust washer
O.D. x I.D. of bush (journal metal)
Crush height of bush (journal metal)
Clearance between crankshaft and
journal (bush)
I.D. x O.D. of center bearing
Clearance between crankshaft journal
and center bearing
Tightening allowance of center bearing
2.0
(.080")
46 x 50
(1.811-1.969")
46 x 50
(1.811-1.969")
less than 0.03
(less than.001")
0.05-0.3
(.002-.012")
1.95-2.0
(.076-.080")
VALVE
Diameter of intake valve stem
Diameter of exhaust valve stem
Clearance between valve I Inlet
stem and valve guide
Exhaust
Valve clearance (Intake/exhaust)
more than 0.06
(more than .002"
)
0.5
1.8
0.074-0.130
(.003-.005")
0.039-0.106
(.0015-.004")
0.2
0.039-0.092
(.0015-.004")
0.008-0.048
(.0003-.0018")
0.2
6.955-6.97
(.2738-.2744")
6.94-6.95
(.273-.274")
0.03-0.06
(.001 -.002")
0.05-0.75
(.002-.003")
1
0.2
(.008")
8.1
(3.6lb/ft)
35 (1.4")
Spring strength (at 30.4mm
compressed length) kg
Free length
Inlet valve Open-before l.u.u. 1i timing CloseAfter B.D.C. 43° Exhaust valve Open-Before B.D.C.
43° timing
Close-AfterTD.C.
13°
PUSH ROD
Outer diameter
Allowable
Limit
Remarks
(.020")
(.070")
(.009")
(.009")
Under size (0.25, 0.5)
(.010-.020")
Oil clearance
Under size (0.25, 0.5)
(.010-.020")
Oil clearance
Crush height
VALVE SYSTEM
CAMSHAFT
Overall length
To Be
Repaired
157
(6.18")
6.3
(.248")
156.8-157.2
(6.173-6.189")
6.89
(.271 ")
6.84
(2.69")
more than 0.2
(more than .007")
more than 0.25
(more than.010")
0.5
(.020")
7
(3.21b/ft)
33.5 (1.3")
When cold
Inspection items
Standard
Standard
11.66
(.460")
11.65-11.668
(.459-.4594")
0.032-0.068
(.001-.002")
11.57
(.456")
0.2
(.008")
0.2-0.4
(1.45-2.891b/ft)
3-5
(43-71)
0.01-0.15
(.0004-.006")
0.1-0.15
(.004-.006")
0.25
(.010")
0.2
(1.45")
Dimension
ROCKER ARM
Wear, rocker arm shaft
Clearance between rocker arm and
shaft
OIL PUMP
Oil pressure switch operating pressure
(kg/cm2)
Relief pressure (kg/cm2) psi.
Value
To Be
Repaired
LUBRICATION SYSTEM
0.3
(2.17lb/ft)
Tip clearance (rotor-to-vane)
Side clearance (rotor-to-cover)
FUEL SYSTEM
Allowable
Limit
Remarks
Oil clearance
INJECTION PUMP KC30225, KC30226, KC30227, KC30228, KC30231, KC30232, KD30237, KD30238, KD30239, KD30240, KD30243, KD30244
Type
Diameter of plunger
Stroke of plunger
Injection timing
131017310
Before T D. C.
Type
Diameter of plunger
Injection timing
131017290
6mm
Piston movement
before TD.C.
Type
Diameterof plunger
Injection timing
5.5mm
18°
2.317mm
(.0912")
KC30230, KC30235. KC30236, KD30241, KD30242, KD30247, KD30248
Before T D.C.
131017350
6mm
Piston movement
before T D. C.
Type
Injection pressure kg/cm2
Angle of injection direction
COOLING
Thermostat open temperature (°C)
5.5mm
22°
3.438mm
(.1353")
INJECTION NOZZLE
Cooling method
23'
3.750mm
(.1476")
KC30234, KD30245, KD30246
Before T D. C.
INJECTION PUMP KC30229,
Stroke of plunger
5.0mm
Piston movement
before T D. C.
INJECTION PUMP KC30233,
Stroke of plunger
6mm
120
(116ats)
4°
131406330
125-130
(121-130ats)
COOLING SYSTEM
Water cooled forced circulation
71
69.5-72.5
103.09
103.10
Inspection items
COOLING (Continued)
Thermostat full-open temperature (°C)
Pump discharge (lit/min)
(at 2600rpm engine speed at cold)
STARTER MOTOR
Type
No. of teeth of pinion gear
Shifting method of pinion
Wear of commutator diameter
Stepped wear of commutator
Standard
Dimension
Spring force of brush (kg)
ALTERNATOR
Allowable
Limit
40
ELECTRICAL SYSTEM
S114-381
9
43(1.7")
185086321
Magnetic
0.05 (.002")
16
(.630")
1.6
(.7271b)
Type
GP9150
Bend of rotor shaft
REGULATOR
Type
Regulating voltage
To Be
Repaire
d
82
Bending allowance of armature shaft
Length of brush
Standard
Value
14.5
0.4 (.015")
0.08 or more
(.003")
0.07
(.003")
RS510
1
14-15
40(1.6")
12
(.472")
1.4
(.6361b)
185046160
185516060
Remark
s
103-06 Service Standards
103-06
Inspection items
Standard
Dimension
CYLINDER HEAD
Standard
Value
ENGINE
more than 30
(426.6)
less than 0.05
(.002")
Type
CYLINDER
BLOCK
Bore
Distortion of upper face of cylinder
block
PISTON
Skirt diameter (longer diameter)
Clearance to cylinder
Inside diameter of piston pin
Piston pin hole-to-pin clearance
PISTON PIN
Outer diameter of pin
Small end bush-to-pin clearance
PISTON RING
Piston ring gap:
No. 1 ring
No. 2 ring
Oil ring
To Be
Repaired
less than 25
(355.5)
1.8
(.0709")
1.59-1.80
(.0626-.0709")
3.5-4.0
(25.3-28.9)
2.5
(.098")
64.2
(2.5276")
0.12
(.0047")
Remarks
Engine 200rpm
more than 0.12
(.0047")
0.70-0.90
(.0256-.0354")
Dry type (single piece)
64
64.00-64.019
(2.52")
(2.5197-2.5204")
less than 0.05
(.002")
Allowable
Limit
Valve seat angle
45°
Coat threads with
molybdenum bisul
fulde based grease.
65.2
(2.5669")
Over size (0.5, 1.0)
(.02,.04")
63.7
(2.5079")
0.25
(.010")
Oversize (0.5, 1.0)
(.02,.04")
20°C
MAIN REVOLVING SYSTEM
64
(2.52")
19
(.748")
19
(.748")
63.948-63.963
(2.5176-2.5182")
0.038-0.072
(.0015-.0028")
18.998-19.002
(.7480-.7481 ")
-0.004-+0.004
(-.00016-+.00016")
18.998-19.002
(.7480-.7481")
0.02
(.0008")
0.013-0.028
(.0005-.0011")
0.08
(.0031 ")
0.13-0.25
(.0051-0.01 ")
0.10-0.22
(.004-0.009")
0.10-0.30
(.004-.012")
1.0
(.04")
Oil clearance
Inspection items
PISTON RING (Continued)
Standard
Dimension
Piston ring groove-to-ring clearance
No 1 ring
Oil ring
No. 2 ring
Oil ring
CONNECTING ROD
1.5
(.059")
1.5
(.059")
3
(.118")
Twist between small and large end
holes (per 100mm)
35 x 14.5
(1.378 x o-s71 1
Weight difference with piston gram
Crush height of small end bush
CRANKSHAFT
Diameter of journal
No. 1, 2
No. 3
Diameter of pin
Roughness, main journal and crank pin
Crankshaft deflection
Axial play of crankshaft
Repaired
Allowable
Limit
less than 0.05
(.002")
0.1-0.3
(.004-.012")
0.031-0.079
(.0012-.0031 ")
-0.01-+0.03
(-.0004-+.0012")
0.15
(.006")
Oversize (0.5, 1.0)
(.020,.04")
0.2
(.008")
0.15
(.006")
0.7
(.028")
0.2
(.008")
2.1-2.6
(15.2-18.8lbs/ft)
less than 10
-0.013-+0.05
(-.0005-+.002")
43
(1.693")
46
(1.811")
35
(1.378")
1.6Z
Oil clearance
300kg
(661.4lbs)
300kg
(661.4lbs)
42.964-42.975
(1.6915-1.6919")
45.948-45.959
(1.8089-1.8094")
34.964-34.975
(1.3765-1.3770")
less than 0.03
(.0012")
0.1-0.3
(.004-.012")
Remarks
0.25
(.010")
1.47-1.49
(.0579-.0587")
1.47-1.49
(.0579-.0587")
2.97-2.99
(.1169-.1177")
less than 0.08
(.00315")
Straightness at 100mm between small
and large end hole
Front-to-rear clearance between
connecting rod and crank pin
Connecting rod metal-to-crank pin
clearance
Crush height of large end bearing
Connecting rod bearing
(inner diameter x width)
Connecting rod bolt torque kg.m
Value
To Be
0.06-0.1
(.0024-.004")
0.05-0.09
(.0020-.0035")
0.02-0.06
i (.0008-.0024")
No. 2 ring
Ring width
No. 1 ring
Standard
(1.689")
45.9
(1.807")
34.9
(1.374")
more than 0.06
(.0024")
0.5
(.020")
Under size (0.25,0.5)
(.01,.02")
Same to above
Inspection items
CRANKSHAFT (Continued)
O.D x I.D- of bush (journal metal)
Crush height of bush (journal metal)
Clearance between crankshaft and
journal metal (bush)
O. D. x I. D. of center bearing
Clearance between crankshaft journal
and center bearing
Crush height of center bearing
Crush height of center bearing
CAMSHAFT
Standard
Dimension
47 x 43
(1.85 x 1.69")
47 x 43
(1.85 x 1.69")
43
(1.693")
46
(1.811")
For intake/exhaust
Diameter of intake valve stem
Diameter of exhaust valve stem
Inlet
Exhaust
Thickness of valve
PB127
1.0
(.04")
-
T-Valve clearance (intake/exhaust)
Valve
spring
Spring strength (at 28.3mm
compressed length) kg
Free length
Squareness
PB128
y
X---
0.2
(.008")
0.035-0.088
(.0014-.0035")
+0.015-+0.055
(+.0006 ..+0022")
0.2
(.008")
0-+0.055
(0-+.0022")
VALVE SYSTEM
6.9
(.008")
(15.211 bs)
33
(1.299")
less than 1.0
(.04")
Under size (0.25, 0.5)
(.01,.02")
500kg
(1102.3lbs)
Oil clearance
Undersize (0.25, 0.5)
(.01, 0.2")
Oil clearance
300kg
(661.4lbs)
300kg
(661.4lbs)
34.3
(1.389")
27.0
(1.063")
0.25
(.010")
5.960-5.975
(.2346-.2352")
5.940-5.955
(.2339-.2344")
0.025-0.052
(.001 -.002")
0.045-0.072
(.0018-.0028")
0.925-1.075
(.0364-.0423")
0.2
Remarks
26.1
(1.028")
27.9-28.0
(1.0984-1.1024")
0.08
(.0031 ")
VALVE
Allowable
Limit
0.05-0.09
(.002-.0035")
0.035-0.088
(.0014-.0035")
34.48-34.52
(1.3575-1.3591")
For feed pump
PB126
Backlash of cam gear
Clearance between valve
stem and alve guide
To Be
Repaired
26.565-26.620
(1.0459-1.0480")
For injection pump
Height
of cam
Standard
Value
5.9
5.9
(.2323")
(.2323")
more than 0.2
(.008")
more than 0.25
(.010")
0.5
(.020")
0.5
(.020")
When cold
6.0
(13.2Ibs)
31.5
(1.240")
i1.2
(.05")
Inspection items
VALVE (Continued)
Standard
Dimension
Inlet valve
timing
Open-BeforeTD.C.
Close-After B.D.C.
43°
timing
Close-AfterTD.C.
13°
Exhaust valve
PUSH ROD
Open-Before B.D.C.
Overall length
Outer diameter
ROCKER ARM
Wear, rocker arm shaft
Clearance between rocker arm and
shaft
Lubrication oil capacity (lit)
Tip clearance (rotor-to-vane)
Type
Diameter of plunger
Stroke of plunger
146
(5.748")
6.3
(.248")
145.6-146.4
(5.732-5.764")
11.66
(.459")
11.65-11.67
(.4587-.4594")
0.032-0.068
(.0013-.0027")
LUBRICATION SYSTEM
0.3
(4.27)
Injection timing
Piston movement
beforeTD.C.
11.57
(.4555")
0.2
(.008")
0.2-0.4
(2.844-5.688)
3-5
(42.66-71.1)
3.0
0.02-0.15
(.0008-.006")
0.1-0.15
(.004-_006")
FUEL SYSTEM
131017390
4.5
(.177")
BeforeTD.C.
Allowable
Limit
Remarks
43°
Side clearance (rotor-to-cover)
INJECTION PUMP
To Be
Repaired
13°
OIL PUMP
Oil pressure switch operating pressure
(kg/cm2) (psi)
Relief pressure (kg/cm2) (psi)
Standard
Value
6
27.0-29.0°
4.573-5.251
(.1800-.2067')
0.25
(.010")
0.2
(.008")
Oil clearance
Inspection items
INJECTION NOZZLE
Type
Injection pressure kg/cm2 (psi)
Angle of injection direction
COOLING
(tooling method
Thermostat open temperature ('C)
Thermostat full-open temperature ('C)
Pump discharge (lit/min)
(at 2500rpm engine speed at cold)
STARTER MOTOR
Type
No. of teeth of pinion gear
Shifting method of pinion
Wear of commutator diameter
Stepped wear of commutator
Standard
Dimension
Spring force of brush (kg) (Ibs)
ALTERNATOR
Type
Bend of rotor shaft
REGULATOR
Type
Regulating voltage
To Be
Value
Repaired
Allowable
Limit
093500-2240 (Part No. 131406340
120
115-125
(1706)
(1635.3-1777.5)
4°
COOLING SYSTEM
Water cooled, forced circulation
75
73.5-76.5
90
40
ELECTRICAL SYSTEM
M003T32589 (Part No. 185086370)
8
Magnetic
32
(1.26")
Bending allowance of armature shaft
Length of brush
Standard
17
(.63")
1.95
(4.3)
0.05
(.002")
1.66-2.24
(3.66-4.94)
GP8146 (Part No. 185046210)
RS5101 (Part No. 185516060)
14.5
0.4
(.016")
0.08 or more
(.003")
14-15
0.07 (.
0028")
31
(1.22")
11.5
(.45")
0.9
(1.98)
Remarks
SECTION IX
Recommended Torque
Tensions for 103-06, 103-09, 103-10,
Perama M25, M30
Tensions kgf m (lbf ft)
COMPONENT
Bearing holder bolts .................................................
Rear plate bolts .........................................................
Flywheel bolts ...........................................................
Connecting rod nuts .................................................
Suctionfilter bolts ......................................................
Sump bolts ................................................................
Crankshaft pulley nut ................................................
Cylinder head bolts ...................................................
Injection pump bolts .................................................
Injection pump nut ..................................................
Rocker arm nuts .....................................................
Head cover nuts ......................................................
Cooling fan bolts .....................................................
Oil pipe banjo bolts ...................................................
Oil pan drain bolt .....................................................
Injection nozzle .......................................................
Injection pipe ...........................................................
Thermo switch ........................................................
Oil pressure switch ..................................................
Glow plug ...................................................................
Solenoid ..................................................................
Relief valve .................................................................
Smokeset nut (max fuel) ...........................................
Adjusting screw nuts ..................................................
Other engines
2.5-3.0 (19-22)
4.7-5.5 (34-40)
6.0-7.0 (43-51)
3.0-3.5 (22-25)
0.9-1.3 (7-9)
0.9-1.3 (7-9)
12-13 (87-94)
5.0-5.3 (36-38) oiled
0.9-1.3 (7-9)
0.9-1.3 (7-9)
2.0-2.5 (15-19)
1.0-1.2 (7-9)
0.9-1.3 (7-9)
1.0-1.3 (7-9)
3.0-4.0 (22-29)
8.0-8.5 (58-62)
2.0-2.5 (15-19)
2.5-3.0 (19-22)
1.5-2.0(11-15)
1.5-2.0(11-15)
1.5-2.0(11-15)
6.0-7.0 (44-51)
2.0-2.5 (15-19)
1.3-1.7 (7-12)
103-06
2.0-2.5 (14-18)
1.3-1.7 (9-12)
7.0-8.0 (51-58)
2.1-2.6 (15-19)
0.9-1.3 (7-9)
0.9-1.3 (7-9)
9-10 (65-72)
3.5-4 (25-29)
0.9-1.3 (7-9)
0.9-1.3 (7-9)
2.0-2.5 (15-19)
1.0-1.2 (7-9)
0.9-1.3 (7-9)
1.0-1.3 (7-9)
3.0-4.0 (22-29)
6-7(43-51)
2.0-2.5 (15-19)
2.5-3.0 (19-22)
1.5-2.0(11-15)
1.5-2.0(11-15)
1.5-2.0(11-15)
6.0-7.0 (44-51)
2.0-2.5 (15-19)
1.3-1.7 (7-12)
SECTION X
Perama Extra Service Items M25/M30
Hurth Gearbox
Lubrication of Jabsco Water Pump
Heat Exchanger Tube Stack Engine
Preservation Lucas A127 - 55 amp
Alternator
How to check the amount of lubricating oil in the
Hurth reverse gearbox
1 Release and remove the dipstick from the top of
the reverse gearbox (A).
2 Clean the dipstick and insert it into its position
but do not engage the thread.
3 Remove the dipstick and check that the
lubricating oil level is up to the groove (Al) in
the dipstick. If necessary, add automatic transmission fluid, ATF type "A", through the dipstick
hole to the correct level. Do not add too much oil.
4 Ensure that the sealing ring (A2) for the dipstick is
not damaged. Fit the sealing ring and the
dipstick to the reverse gearbox.
/a
1 Ensure that the seacock is closed.
2 Disconnect the hose connections at the pump.
3 Remove the four setscrews which fasten the
pump to its drive housing. Remove the pump.
4 Clean and inspect for wear the drive components
of the pump. Renew the drive adaptor and/or the
pump, if necessary.
`
400-000*044
40-0001
I
1
1
How to check/lubricate the impeller and the drive of
the raw water pump
Attention: Do not loosen the drive housing of
the raw water pump. The alignment of this
housing has been carefully adjusted with a
special alignment tool.
5 Release the six screws which fasten the end
plate of the raw water pump and remove the
plate.
6 Inspect the rubber impeller for excessive wear or
for damage and renew it, if necessary. To remove
the impeller, remove the rubber end cap and then
pull the impeller from the shaft. Apply Marfak
2HD grease to the blades of the new impeller
and fit the impeller into the housing with the
blades bent anticlockwise (A). Fit the rubber
end cap.
7 Clean the contact surfaces of the pump body and
the end plate. Apply jointing compound to a
new joint and fit it to the body with the wide area
of the joint over the eccentric plate (Al) in the
body. Fit the end plate and tighten the end
plate screws.
8 Apply a high melting point grease (for example
Shell Alvania R2) to the drive housing and to the
drive components.
9 Fit the pump to its adaptor plate with a new joint
between the pump and the plate. Tighten the
four pump setscrews.
10 Connect the hose connections at the pump.
11 If necessary, open the seacock. How to clean the
tube stack of the heat exchanger
If there are hard deposits or debris in the tubes, the
best method to clean them is to use a noncaustic solution which is approved by the
manufacturer.
If the deposits or the debris are soft, the tubes
can be cleaned with a steel rod pushed through
the tubes in the opposite direction to the water
flow. Ensure that the rod does not damage the
tubes.
To obtain access to the tube stack
1 Drain the circuits of the cooling system.
2 Loosen the support clips of the outlet pipe of the
heat exchanger and disconnect the pipe from the
front end cap of the heat exchanger.
3 Loosen the clips of the neoprene end caps and
remove the caps. The tubes can now be
checked for restriction and cleaned, if necessary.
4 Ensure that there is an equal protrusion of the
tube stack through each end of the housing
before the end caps are fitted.
Engine Preservation
The recommendations indicated below are
designed to prevent damage to the engine when it
is withdrawn from service for a prolonged
period. Use these procedures after the engine
is withdrawn from service. The instructions for
the use of POWERPART products are given on
the outside of each container.
Procedure
1 Completely clean the outside of the engine.
2 When a preservative fuel is to be used, drain the
fuel system and fill it with the preservative fuel.
POWERPART Lay-Up 1 can be added to the
normal fuel to change it to a preservative fuel.
If preservative fuel is not used, the system can
be completely filled with normal fuel but the fuel
must be drained and discarded at the end of the
storage period together with the fuel filter
canister.
3 Operate the engine until it is warm. Then correct
leakages of fuel, lubricating oil or air. Stop the
engine and drain the lubricating oil from the
sump.
4 Renew the canister of the lubricating oil filter.
5 Fill the sump to the full mark with new and clean
lubricating oil and add POWERPART Lay-Up 2
to the oil to protect the engine against corrosion. If
POWERPART Lay-Up 2 is not available, use a
correct preservative fluid instead of the
lubricating oil. If a preservative fluid is used, this
must be drained and the lubricating oil sump
must be filled to the correct level with normal
lubricating oil at the end of the storage period.
6 Drain the coolant circuit. In order to protect the
cooling system against corrosion, it is necessary to fill it with a coolant that has a corrosion
inhibitor. If protection against frost is necessary, use
an antifreeze mixture. If protection against frost
is not necessary, use water with an approved
mixture of corrosion inhibitor.
7 Operate the engine for a short period in order to
circulate the lubricating oil and the coolant in the
engine.
8 Close the seacock and drain the raw water cooling
system. If a lubricating oil cooler is fitted to the
Hurth reverse gearbox and protection against
frost is necessary, disconnect the top hose at the
cooler and inject 50ml (0.1 UK pint) of undiluted
antifreeze into the cooler.
9 Remove the end plate from the raw water pump and
lubricate the impeller and the inside of the pump
with Marfak 2HD grease or glycerine. If
necessary, glycerine can be put in the inlet
connection of the pump but the engine must be
turned to circulate the glycerine through the
pump.
Attention: The raw water pump must never run
in a dry condition because this can damage the
impeller blades.
10 Remove the atomisers and spray POWERPART
Lay-Up 2 into each cylinder bore. If this is not
available, clean engine lubricating oil will give
a degree of protection. Spray into the cylinder
bores 140m1 (0.25 pint) of lubricating oil divided
evenly between the cylinders.
11 Slowly turn the crankshaft one revolution and
then fit the atomisers, complete with new seat
washers.
12 Remove the air filter or the induction cap. Spray
POWERPART Lay-Up 2 into the induction
manifold. Seal the manifold with waterproof
tape.
13 Remove the exhaust pipe. Spray POWERPART
Lay-Up 2 into the exhaust manifold. Seal the
manifold with water proof tape.
14 Disconnect the battery. Then put the battery into safe
kerosene or a special fluid used for this purpose.
storage in a fully charged condition. Before the
Ensure that the fluid does not enter the cover of
battery is put into storage, protect its terminals
the alternator.
against corrosion. POWERPART Lay-Up 3 can
3 Ensure that air can pass easily over the casing to
be used on the terminals.
to keep it cool.
15 Seal the vent pipe of the fuel tank or the fuel filler Fault diagnosis
cap with waterproof tape.
The alternator is so designed that a flow of
16 Remove the alternator drive belt and put it into
current indicated by no light at the warning light or a
storage.
reading shown on an ammeter is enough
17 In order to prevent corrosion, spray the engine
indication that the system is in correct operation. If
with POWERPART Lay-Up 3. Do not spray the
the system is in correct operation, no open
area inside the alternator cooling fan.
circuit, voltage or current output checks need to
18 If the transmission is not to be used for at least a
be done on the installation unless:
year, fill the Hurth gearbox completely with its
• The warning light does not show when the alternormal lubricating oil. This will have to be
nator is stationary and the switch is in the "on"
drained and the normal amount of new
position or it shows a light when the alternator
lubricating oil added when the engine is
is in operation.
returned to service.
Attention: After a period in storage, but before
• No charge current is shown on the ammeter.
the engine is started, operate the starter motor
• The battery is discharged.
with the stop button pressed or with the engine
• The battery is hotter than normal which is an
stop control in the "stop" position until oil presindication of loss of voltage control.
sure is indicated. Oil pressure is indicated when the
If one or more of the above symptoms occur, the
low pressure warning light is extinguished.
procedure indicated below should be
If the engine protection is done correctly
applied.
according to the above recommendations, no
1 Ensure that the battery is in a fully charged
corrosion damage will normally occur. Perkins
condition.
are not responsible for damage which may
2 Connect a moving-coil voltmeter of good quality,
occur when an engine is in storage after a period in
with a range of 0-50 volts, across the positive
service.
and negative terminals of the alternator. If an
Alternator A127 - 55 amp ammeter is not fitted in the electrical circuit, fit
a moving-coil ammeter of good quality, with a
To remove and to fit
range of 0-100 ampere, in the wire between the
• remove
alternator and the positive terminal of the
battery.
1 Disconnect the electrical connection.
3 Turn the warning light switch to the "on" position (
2 Loosen the pivot fasteners of the alternator and the
main switch on instrument panel) when the
fasteners of the adjustment link.
warning light should be illuminated.
3 Release all the belt tension and remove the belt.
4 Switch on a 10-15 ampere load, for example,
4 Remove the adjustment link from the alternator
lights, fans, etc..
and remove the pivot bolt(s). Make a note of the
5 Start the engine and operate it at a fast idle speed
position of the washers and distance pieces to
when either the warning light should be
ensure that they are fitted correctly. Remove the
extinguished or the ammeter indicates a small
alternator.
change in the current in relationship to the
engine speed.
• fit
6 Increase the engine speed for a moment to near
1 Put the alternator in position and assemble
maximum speed, when the charge current
loosely the pivot fasteners and the adjustment
should be approximately 55 amperes (A127) for a
link and its fasteners. Ensure that the washers
12 volt system.
and the distance pieces are fitted in their correct
7 Operate the alternator at approximately half speed
positions and that the alternator pulley is aligned to
(engine speed approximately 1800 rev/ min) and
the crankshaft pulley within ±2.4mm (3/32in).
remove the electrical load. The voltage should go
2 Fit the drive belt and adjust the drive belt tension.
up to 14 volts for a 12 volt system or 28 volts for
Tighten the fasteners and check the tension
a 24 volt system and then remain constant. At
again.
the same time the current reading should show
3 Connect the electrical connection.
a reduction.
If a fault is found, the alternator should be
• maintain
removed for test by a specialist.
1 Ensure that the drive belt is not worn and that
The regulator is a sealed unit and a repair is not
the belt tension is correct.
possible. If there is a regulator fault, the regulator
2 Keep the alternator clean. To clean the alternator,
must be renewed.
use a material which is damp with
SECTION XI
Conversion Formulas
TIGHTENING TORQUE TABLES
Screw
size
M4
Bolt head
identification
marks as per
grade
4T,4.8
7T, 8T, 8.8
10T,11 T
4T, 4.8
M5
7T, 8T, 8.8
10T, 11T
4T, 4.8
M6
7T 8T, 8.8
10T, 11T
4T, 4.8
M8
7T, 8T, 8.8
Screw
pitch
(mm)
0.7
0.8
1.0
1.25
10T,11 T
4T, 4.8
M10
7T, 8T, 8.8
10T 11T
4T, 4.8
M12
4T, 8T, 8.8
10T, 11T
4T, 4.8
M14
7T, 8T, 8.8
1.5
1.75
2.0
10T, 11T
7T, 8T, 8.8
10T, 11T
4T, 4.8
M18
M20
7T, 8T, 8.8
7T, 8T, 8.8
10T, 11T
15--
torque
(kgf.cm)
21
Screw
pitch
(mm)
2.0
torque
(kgf.cm)
50---
d
0
z
o
m
70
68- 96
50- 70
85- 115
290- 370
450-- 570
550-- 710
380- 480
670- 850
940-1,180
640--- 820
1,060-1,340
1,520-1,880
2,100-2,600
1,160-1,440
2,000-2,400
1,470.1,830
2,450-2,950
3,700-4,500
~~
S45C
SCM435
i
10T
4T
8T
4.8
8.8
i
0010
120- 160
230- 290
;3 S20C
SGD41-D
SWRM12
E
29-- 41
130-- 170
SS41
Y
1.0
1.25
1.25
1.5
1.5
1.5
2,800-3,400
2.5
Tightening
36- 50
880-1,120
2.0
Fine thread
27- 37
1,420-1,780
10T, 11T
4T, 4.8
Tightening
260--- 340
4T, 4.8
M16
Coarse thread
1.5
155- 205
270-- 350
310- 410
290-- 370
500--- 640
590--- 750
440- 560
760- 960
1,010-1,290
710--- 890
1,190-1,510
1,500-1,900
930-1,170
1,600-1,960
2,250-2,750
1,3401,660
2,350-2,850
3,050-3,750
1,750-2,150
2,800-3,400
4,050-4,950
TIGHTENING TORQUE TABLES
Screw
size
M6
M8
M10
M12
M14
M16
M18
M20
-°
SS41
Bolt head
identification
marks as per
Screw
pitch
grade
(mm)
4T, 4.8
7T, 8T, 8.8
1.0
10T 11T
4T, 4.8
7T, 8T, 8.8
4T, 4.8
7T, 8T, 8.8
4T, 4.8
7T, 8T, 8.8
4T, 4.8
7T, 8T, 8.8
4T, 4.8
7T, 8T, 8.8
4T, 4.8
7T, 8T, 8.8
4T, 4.8
7T, 8T, 8.8
S45C
E
M
L
a+
O
4T
m
4.8
8T
8
88
10T
22.6--28.4
55.7-61.5
68.0-85.4
46.3--59.3
76.7-96.9
103-129
63.7-81.0
110--136
268-326
I
0010-1
25.5-33.3
44.1-55.9
53.9-69.6
37.3--47.1
65.7-83.4
92.2-116
62.8-80.4
104-131
139-175
86.3--110
149-184
196-235
177-213
/
28.4-36.3
145-174
106-132
/
12.7-16.7
206-255
203-246
Fine thread
Tightening torque
lbs-ft
N.m
8.3--11.3
152-188
83.9-104
SCM435
\
16.6-21.0
27.5--34.7
2.5
10T, 11T
11.8---15.7
39.8--51.4
2.0
10T, 11T
8.7--11.6
32.6--41.2
2.0
10T, 11T
(mm)
4.9-6.9
18.8-24.6
2.0
10T, 11T
N.m
lbs-ft
3.6-5.1
21.0--26.8
1.75
10T, 11T
Screw
pitch
9.4-12.3
1.5
10T, 11T
Tightening torque
6.1-8.3
1.25
10T 11T
SGD41-D
SWRM12
Coarse thread
114-141
275-333
144-1.79
240-289
363-441
1.0
1.25
1.25
1.5
11.2-14.8
15.2-20.1
19.5-25.3
26.5-34.3
22.4-29.7
21.0--26.8
30.4-40.2
28.4-36.3
36.2-46.3
49.0-62.8
55.0-69.5
74.5-94.1
51.4-64.4
69.6-87.3
42.7-54.3
31.8-40.5
73.1---93.3
86.1--109
109-137
1.5
1.5
1.5
67.3-84.6
116-142
163-199
96.9-120
57.9-73.6
43.2-54.9
99.1--127
117-148
147-186
91.2-115
157-192
221-270
131-163
170-206
230-279
127-156
172-211
221--271
203-246
293-358
299-368
275-333
397-485
CONVERSION TABLES
.0
0
7.233
(9.8)
1
0
.1
.2
0.723
(0.98)
1.45
(1.96)
kgf-m Ibs/ft, (N.m)
.3
2.17
(2.94)
.4
.5
.6
.7
.8
.9
2.89
(3.92)
3.62
(4.9)
4.34
(5.88)
5.06
(6.86)
5.79
(7.84)
6.51
(8.82)
7.96
(10.8)
8.7
(11.8)
9.4
(12.7)
10.1
(13.7)
10.8
(14.7)
11.6
(15.7)
12.3
(16.7)
13.0
(17.6)
13.7
(18.6)
2
14.5
(19.6)
15.2
(20.6)
15.9
(21.6)
16.6
(22.5)
17.4
(23.5)
18.1
(24.5)
18.8
(25.5)
19.5
(26.5)
20.3
(27.4)
20.9
(28.4)
3
21.7
(29.4)
22.4
(30.4)
23.1
(31.4)
23.9
(32.3)
24.6
(33.3)
25.3
(34.3)
26.0
(35.3)
26.8
(36.3)
27.5
(37.2)
28.2
(38.2)
4
28.9
(39.2)
29.7
(40.2)
30.4
(41.2)
31.1
(42.1)
31.8
(43.1)
32.5
(44.1)
33.3
(45.1)
34.0
(46.1)
34.7
(47.0)
35.4
(48.0)
5
36.2
(49.0)
36.9
(50.0)
37.6
(51.0)
38.3
(51.9)
39.1
(52.9)
39.8
(53.9)
40.5
(54.9)
41.2
(55.9)
42.0
(56.8)
42.7
(57.8)
6
43.4
(58.8)
44.1
(59.8)
44.8
(60.8)
45.6
(61.7)
46.3
(62.7)
47.0
(63.7)
47.7
(64.7)
48.5
(65.7)
49.2
(66.6)
49.9
(67.6)
7
50.6
(68.6)
51.4
(69.6)
52.1
(70.6)
52.8
(71.5)
53.5
(72.5)
54.2
(73.5)
55.0
(74.5)
55.7
(75.5)
56.4
(76.4)
57.1
(77.4)
8
57.9
(78.4)
58.6
(79.4)
59.3
(80.4)
60.0
(81.3)
60.8
(82.3) i
61.5
(83.3)
62.2
(84.3)
62.9
(85.3)
63.7
(86.2)
64.4
(87.2)
9
65.1
(88.2)
65.8
(89.2)
66.5
(90.2)
67.3
(91.1)
68.0
(92.1)
68.7
(93.1)
69.4
(94.1)
70.2
(95.1)
70.9
(96.0)
71.6
(97.0)
For example
42.0 lbs-ft
5.8 kgf-m =
1
.1
.2
.3
.4
.5
.6
.7
.8
.9
(
42.0
4
9
1
II
2
3
5
6
7
8
I
(56.8 N.m)
t
+
(56.8)
1mm
-
1m
=0.03937in.
=3.28084ft. 1
kgf-m =7.2331bs-ft 1
kfg-m = 9 . 8 N . m 1 kg/cm
2
=14.22psi.
1kg
=2.204621bs
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