Perkins 100 Series: 103-06/103-09/103-10

Perama: M25/M30

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 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
SECTION X
T

Perama Supplement ...................................................................................................................... 10-1

SECTION XI
Conversion Formulas ..................................................................................................................... 11-1
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 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

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 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.

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 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.

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 ENGINE DIAGRAMS

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 Engine cross sectional views

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

DESCRIPTION; GENERAL fully floating gudgeon pin (wrist pin) is made of chrome
molybdenum steel alloy hardened by carburizing and
The Perkins 100 Series is a three cylinder four stroke, retained by the conventional circlip method. The
liquid cooled, compression ignition engine, designed connecting rods are machined from high strength forged
for durability, low weight and compactness. The linerless steel. The big end bearings are renewable steel-backed,
cylinder block, three-piece helical gear train and flange copper/lead alloy overlay with tin plating. The small end
mounted fuel injection pump on the engine cam, reduce bearings are a press fit plain bush of tin-backed lead/
frictional power loss, and engine weight. The special bronze.
swirl pre-combustion chamber along with the small
bore multi-cylinder design offers good fuel
consumption, low noise and excellent startability.
Camshaft:
The Perkins 100 Series offers easy maintenance with The camshaft is made of forged steel and is induction
all service items on the right hand side of engine. 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
DESCRIPTION; COMPONENT ASSEMBLY of the camshaft supports the tachometer drive, cam gear,
governor weight cage and governor slider 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 Cylinder Head:
bearings of the tunnel block design, with crankcase The cylinder head is made of high grade copper chrome
walls extending well below the crankshaft centre line cast iron. Lower speed engines have valve seats
for strength and rigidity. The cylinder bores are plateau machined into the cylinder head, higher speed engines
honed for oil retention and extended ring life. The non- incorporate replaceable heat resistant alloy steel valve
machined surfaces are sealed to ensure cleanliness. 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.
Crankshaft:
The crankshaft is a chrome-molybdenum steel forging, The valves are operated by cold drawn seamless tube
fully machined, static and dynamically balanced with pushrods with hardened steel ball and forged cup ends.
integral counterweights. All bearing surfaces are Flat based tappets are made from case carburized
induction hardened. The axial location is by thrust chrome molybdenum steel operating in machined bores
washers at number four main bearing. The four main in the cylinder block. The rocker shaft is an induction
journals run in replaceable steel-backed cast copper/ hardened hollow steel tube. Valve clearances are
lead alloy bearings. The front of the crankshaft is keyed. adjusted by hardened ball ended screws and locknuts.

Pistons and Connecting Rods: Rocker Cover:

Pistons are cast from high silicon aluminium alloy and The cover is made of cast aluminium with an integral air
are heat treated for low weight with high strength and intake, oil filler and crankcase breather. It is located in
good thermal conductivity. The piston is fitted with three position by rocker pillar studs and secured by cap nuts.
rings; two cast iron, chrome-faced compression rings
and one steel, chrome-faced controlled oil ring. The

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 Gear Train: Lubricating System:
The gear train consists of three helical gears; the A trochoid lobe type oil pump located in the centre of
crankshaft gear, located by a woodruff key. The idler the idler gear sends lubricating oil to the main oil galley
gear houses the lube oil pump and the cam gear via a relief valve through a spin-on bypass oil filter to the
incorporates the governor weight cage. main oil galley. The rockers are pressure fed via an
externally mounted oil pipe, from the main oil gallery to
the cylinder head.

Fuel System:
A flange mounted, Bosch type fuel injection pump is Cooling System:
mounted in the cylinder block and operated by lobes A belt driven centrifugal water pump circulates coolant
machined on the engine cam. The fuel lift pump is via the internal water passages. The coolant is radiator-
located on the right-hand side of the cylinder block and cooled and temperature controlled by a conventional
also operated by the engine camshaft. thermostat.

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 SECTION II
General Engine Data

103-06 103-09 103-10

Type ....................................................................................... Vertical in-line 3 Cyl.
4 Stroke naturally aspirated
Basic Thread and Size ....................................................... Metric
Bore ................................................................................ 64mm (2.52") 72mm (2.83") 75mm (2.95")
Stroke ............................................................................. 64mm (2.52") 72mm (2.83") 72mm (2.83")
Combustion System ............................................................ I.D.I. Special Swirl
Compression Ratio ............................................................. 23.5:1 24:1 23:1
Swept Volume ............................................................... 0.617 (37.65 3,,) 0.879 (53.643") 0.954 (58.213,,)
Firing Order ........................................................................... 1-2-3
Rotation .............................................................................. Anti-clockwise viewed from flywheel
Injection Pump ................................................................... Flange mounted, Bosch type plunger and barrel
Injectors .............................................................................. Bosch type throttle
Injector Setting .................................................................... Working Setting
Kilograms/sq. cm (kg/cm2) 115-125 125-130
Atmospheres (atm) ....................................................... 111-121 121-126
Pounds per sq. inch (PSI) ............................................ 1636-1778 1778-1850
Governor ................................................................................ Mechanical all speed
Cooling System ..................................................................... Liquid with water pump and radiator 1.
Industrial Cooling System Capacity (less radiator) .... 3 litre 1.7 litre 1.7 litre
Perama M25/M30 Cooling System Capacity ..................... 4.0 litre 4.0 litre
Thermostat Operating Temperature .................................... 71c82 °
Lubricating System .............................................................
Pressure feed with Trochoid pump 3.0
Lubricating Oil Capacity (including filter) ............................
litres 3.8 litres 3.8 litres (
Perama M25/M30 4.3 litres)
Oil Pressure Relief ................................................................ 42-71 PSI
Oil Pressure Switch ........................................................... 4.3 PSI
Electrical System
Starter ......................................................................... 12V
Alternator .................................................................... 12V
Battery 12V ................................................................. 45AH min 70AHmin 70 AH min.
Weight, Bare Engine (Industrial) ......................................... 64 kg 83 kg
Height ............................................................................ 489mm 539.6mm
Length F/F .................................................................... 442mm 489.6mm
Width ................................................................................ 390mm 410mm
Min. Idle Speeds 103-06/103.09/10 .................................... 800 revs/min
Perama M25/M30 ................................... 1000 revs/min
Hurth HBW 50 Reverse Gearbox Oil Capacity ............... 0.30 litres
HBW 100 Gearbox Oil Capacity ................................ 0.35 litres

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 Recommended Engine Fluids
Coolant ............................................................................ 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)
Fuel 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 Recommended SAE viscosity grades

Specifications
ow
Engine type API CC/SE API CD/SE 5W20
MIL-L-46152 MIL -L-2104C ( - -L t 0W3o
r --~~ I5W40
CCMC D1 CCMC D2
Naturally aspirated 20W50
• (1)

(1) Not recommended during the first 20/50hours of operation i 40

-30
-22
-20
_4
0
32
10
50
20
68
30
86
40
104
I
Ambient temperature

NB: Ensure correct fluids are used and oil and coolant are filled SLOWLY and to the correct 50°C
122°F

quantities. Hurth Gearbox Oil: Automatic transmission fluid ATF Type `A'.

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 SECTION III
Dismantling Sequence
Alternator Rocker Cover
A. Remove alternator and adjusting bracket. A. Remove breather hose. Loosen and remove
three cap nuts with washers. Lift rocker cover
assembly.

Rocker cover

PB004

Remove Cooling Fan and Pulley

Fuel Injection Pipe

A. Loosen fuel pipe nuts from fuel injection pump
and injectors. Remove pipes as an assembly.
B. Remove spring clamp and fuel return hose.
Atomizer Assembly
E0005
A. Loosen and remove three securing nuts.
Remove leak-off rail. Remove three aluminium
washers and discard. Remove atomizers.
Contact Switches
Rocker Assembly
A. Remove water and oil sender units.
A Loosen and remove three nuts, lock
Water Pump Assembly washers and flat washers from rocker pillar
A. Loosen securing bolts and remove water pump stud. Lift rocker assembly.

assembly and set plate. B. Remove push rods, and valve stem caps.

Rocker arm assembly

PB005 PB007

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 External Oil Pipe Fuel Lift Pump
A. Loosen and remove two banjo bolts at cylinder A. Loosen two cap screws and lift from its bore;
block main oil galley and cylinder head remove joint.
assembly.
B. Remove clamp from fuel injection pump.

PB011
PB008

Cylinder Head Assembly

Fuel Injection Pump Assembly
A. Loosen cylinder head bolts starting from the
centre, in a circular pattern using several A. Remove two bolts and nuts securing fuel injec-
steps of equal torque. Remove head. tion pump to cylinder block. Slowly lift and posi-
tion fuel injection pump until access to link snap
pin is gained.
B. Remove snap pin and remove link from control
rack. Remove fuel injection pump and shim
pack.
NOTE: Injection timing is determined by the
shim pack between fuel injection pump flange
and cylinder block mounting face. The thickness
and number of shims should be checked and
recorded to aid re-assembly.

PB009

Tappets
A. Pull tappets from the machined bores in cylinder
block.

P8012

PB010

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 Crank Pulley Plate Camshaft
A. Loosen pulley nut and remove pulley.

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

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 Connecting Rod and Piston Remove Oil Seal
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.

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

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 SECTION IV
Disassembly, inspection, fits and
clearances of component assemblies
Rocker Arm Assembly Standard Clearance Allowable limit
- Disassembly
0.032-0.068mm 0.2mm
A. Remove the bolt at the rocker arm shaft end. (.001-.026") (.008")
B. Pull out the pin located in No. 1 cylinder rocker
arm bracket.
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 C. Wear on valve stem contact face of the rocker
beyond allowable limit, replace. arm.

Check the face for step wear or score. Slight

wear may be corrected using an oil stone.

Standard dimension Allowable limit

11.65-11.67mm ( 11.57mm (
.459-.460") 456 ) 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 PB028
rocker arm shaft. If the clearance is excessive,
replace.

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 - Inspection and Correction A. Intake valve 103-09/10/Perama M25/M30

Cylinder head Standard diameter Allowable limit

With a straight edge and a thickness gauge, 6.955-6.97mm 6 89mm
check for warping of the cylinder head lower (.274") (271 )
face.

Intake valve 103-06

Standard diameter Allowable limit

5.960-5.975mm 5.9mm (
(.2346-.2352") .2323)

Exhaust valve 103-09/10/Perama M25/M30

Standard diameter Allowable limit

6.94-6.95mm 6.84mm
(.274") (.269)

PB029

Exhaust valve 103-06

Standard diameter Allowable limit
5.940-5.955mm 5.9mm (
(.2339-2344") .2323)

PB030

Check six positions (A to F lines, as shown) for

warping. If found to be warped excessively,
correct with a surface grinder.

PB031

Standard value Allowable limit

c. Thickness of valve head
0.05mm or less 0.12mm
(.002") (.005") If valve head thickness is less than allowable
limit, replace valve.

B. Valve guide and valve stem Standard thickness Allowable limit

a. Check the valve stem for excessive wear or 0.925-1.075mm ( 0.5mm
damage. If found to be excessively .036"-.042") (.020)
damaged, replace.

b. Check valve stem diameters at positions I, II

and III with a micrometer. If the diameter is
less than allowable limit, replace.

Thickness
t
4
PB127

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 d. Valve to valve-guide clearance 150"
Check the clearance between the valve and
valve guide. If the clearance exceeds the
allowable limit, replace.

Intake valve
Contacting
Standard clearance Allowable limit
width
0.025-0.052mm more than 0.2mm (
(.001-.002") .008")

Exhaust valve
1068
Standard clearance Allowable limit

0.045-0.072mm more than 0.25mm

b. Recess of valve seat
(.0018-.0028") (.010") If the recess is more than allowable limit,
replace the valve seat (if fitted).

103-09/10/Perama M25/M30

Standard recess Allowable limit

0.85-1.15mm ( 1 8mm
.034-.045") ( 071 ')

Depth

Clearance

1067 1069

C. Valve seat 103 06

a. Valve seat contact width Standard recess Allowable limit
If the contact width of the valve seat is more 0.70-0.90mm (. 1.8mm
than allowable width, check wear condition 0276-.0354") (.071')
of the valve guide first.
Using the seat cutters of 15° 45° and 75°
correct the seat.
Replacement of valve seat insert (where
fitted):
103-09/10/Perama M25/M30 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
Standard width Allowable limit the valve seat insert by light tapping (
1.7-2.1 mm (. 2.5mm ensuring the head is not damaged).
(098 ) Or 2. Machine the insert out taking care not
067-.082")
to damage the head.
Clean up the insert bore and fit new insert
using a press (1,000 to 1,500kgf) and a suit-
103-06
able smooth surface tool. To assist process,
Standard width Allowable limit chill the valve seat insert with liquid nitrogen
etc or heat the head to between 60 and
1.59-1.80mm (. 2 5mm
100°C.
0626-.0709") (098)

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 c. Lapping of contact face of the valve seat Squareness
Correct valve seat contact using a valve
lapper and lapping compound.
When using a new cylinder head, obtain

4~
correct seat contact width and seat recess
using the seat cutter. Then, carry out lapping.

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 Cap (not fitted on 103-06)

Insert

w. PB036

D. Valve spring
Visually inspect the valve spring for damage.
Position the valve spring on a flat surface and
check the squareness of it using a square, as
shown in the illustration. If it exceeds allowable limit,
replace the spring.
Using a spring tester, check spring force and
free length.

Replace if found to be beyond allowable limit. 103-

09/10/Perama M25/M30

Standard Allowable
value limit
- Reassembly
Reassemble the parts in the reverse order of
Squareness (mm) (1.2).047" (2.0).079"
disassembly.
Free length (mm) (35)1.378" (33.5)1.319" NOTE: When assembling the valve spring,
retainer and collets, take care not to damage
Spring force (kg) (8.1) 17.91bf (7)15.4 lbf the valve guide seal.
(when compressed Cylinder block
to 30.4mm 1.197") - Inspection and Correction A.
Cylinder block top face
Inspect the cylinder block top face for cracks,
damage and warping in the same way as for
103-06 the cylinder head.
Standard Allowable If outside limit, replace cylinder block.
value limit

Squareness (mm) (1.0).039" (1.2).047"

Free length (mm) (33)1.299" (31.5)1.240"

Spring force (kg) (6.9)15.21bf (6.0)13.21bf

(when compressed
to 28.3mm) Standard value Allowable limit

Less than 0.05mm ( 0.12mm (

.002") 005')

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 B. Cylinder bore
a. Visually inspect cylinder bore. There should
First re-bore
be no scoring, rust or corrosion. 0.5mm
b. Measure the cylinder bore at the upper, (.02")
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 New standard bore Allowabl limit
corresponds to the piston oil ring when the e
piston is at the B.D.C. (about 100mm from 64.5-64.519mm 64.7mm
top face). (2.5394-2.5401 ") (2.5472")
Check the bore using a cylinder gauge.

Second re-bore
0.5mm
(.02")

New standard bore Allowable limit

65-65.019mm 65.2mm
(2.5591-2.5598") (2.5669")

Replace
PG044 the
block

c. If the bore is found to be outside allowable

limit, re-bore to the oversize dimension as
shown. Bore spec 103-09/Perama M25

Grinding stone size: 100L x 4W Standard bore Allowable limit

Speed: 162 rpm
Feed (shaft direction): 13 m/min 71.99-72.005mm 72.2mm
Gauge pressure: (2.8342-2.8348") (2.8425")
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 I

First re-bore
0.5mm
(.0196")
Bore spec 103-06

Standard bore Allowable limit

64-64.019m m (2. 64 2mm (

5197-2.5204") 25276
)

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 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
Second re-bore
block
0.5mm
(.0196")

Piston and piston rings

- Disassembly
New standard bore Allowable limit
A. Remove piston rings using a piston ring tool.
72.99-73.005mm
73.2mm B. Remove the circlip and extract the gudgeon pin.
(2.8736-2.8742") (2.8818")

Replace
the
block

Bore spec 103-10/Perama M30

Standard bore Allowable limit
75-75.019mm (2. 75.2mm (
9527-2.9534") 2.9606')

PB040

Inspection
First re-bore A. Piston
0.5mm a. If outer surface of the piston is excessively
(.0196") 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.
New standard bore Allowable limit Calculate the clearance between the
cylinder and piston. If this clearance is more
75.5-75.519mm (2. 75.7mm than allowable, or piston diameter is less
9724-2.9731 ") (2.9803 ) than allowable limit, replace the piston.

Second 103-09 Piston/Perama M25

re-bore Standard clearance Allowable limit

0.5mm
(.0196") 0.0525-0.0825mm 0.25mm
(.0021-.0033") (.0098")

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 Standard diameter Allowable limit Standard diameter Allowable limit

71.9225-71.9375mm 71.7mm 74.9425-74.9575mm 74 7mm (2.

(2.8316-2.8322") (2.8228")
(2.950-2.951 ") 9409 )

Piston Part Largerdiameter

c. Oversized piston
When the cylinder is oversized, ensure
that oversized piston is used.
size number of piston skirt
Standard 115317382 74.9425-74.9575mm
(2.950-2.951 ")
Piston Part Larger diameter 0.5mm 115317386 75.4425-75.4575mm
size number of piston skirt oversize (2.970-2.9706")
Standard 115317560 71.9225-71.9375mm 1.0mm 115317389 75.9425-75.9575mm
(2.8316-2.8322") oversize (2.9898-2.9904")

0.5mm 115317564 72.4225-72.4375mm

oversize (2.8513-2.8519")

1.0mm 115317567 72.9225-72.9375mm

103-06 Piston
oversize (2.8710-2.8716")
Standard clearance Allowable limit

0.038-0.072mm 0 25mm (
(.0015-.0028") .010)

Standard diameter Allowable limit

(Piston)

63.948-63.963mm 63 7mm (
(2.5176-2.5182") 2 5079")

Piston size Largerdiameter

of piston skirt

Standard 63.948-63.963mm
PB041
(2.5176-2.5182")
0.5mm 64.448-64.463mm
oversize (2.5373-2.5379")
1.0mm 64.948-64.963mm
oversize (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.
PB042

103-10 Piston/Perama M30

Standard clearance Allowable limit Standard Allowable limit
clearance
0.0425-0.0665mm 0.25mm -0.004-+0.004mm 0.02mm
(.0017-.0026") (.0098")
(.00015±.00015") (00078 )

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 B. Piston ring d. Oversize piston ring 103-06
a. If the piston ring is worn or damaged, replace If the cylinder is oversized, oversize piston
it. ring set should be employed.
b. Piston ring gap
Insert the rings into the cylinder at right angle to
the cylinder bore and measure the gaps
Piston ring size Partcode number
with a thickness gauge. If the gap is more
than the allowable limit, replace. S.TD. 115107260
O.S. 0.5mm (.02") 115107263
0. S. 1.0mm (0.4") 115107265
103-09/10/Perama M25/M30

Standard gap Allowable limit

No. 1 0.15-0.27mm 1.0mm e. Oversize piston ring - 103-09/Perama M25

ring (.0059-.0106") (.039") If the cylinder is oversized, oversize piston
ring set should be used.
No.2 0.12-0.24mm 1.0mm
(.0047-.009") (.039")

Oil 0.2-0.35mm 1.0mm

ring (.0078-.0137") (.039") Piston ring size Part No.

Standard 115107191
0.5mm oversize (.019") 115107194
103-06 GAP
1.0mm oversize (0.39") 115107196
Standard gap Allowable limit

No. 1 0.13-0.25mm 1.0mm

ring (.005-.010") (.039")
f. Oversize piston ring - 103-10/Perama M30
No.2 0.10-.22mm 1.0mm If the cylinder is oversized, oversize piston
(.004-.009") (.039") ring set should be used.
Oil 0.10-0.30mm 1.0mm
ring (.004-.012") (.039")

Piston ring size Part No.

Standard 115107201
c. Measure the clearance between the piston
ring groove and ring. If the clearance 0.5mm oversize (.019") 115107204
exceeds the allowable limit, replace the ring. 1.0mm oversize (.039") 115107206

Standard Allowable
clearance limit g. Mounting position of the piston ring
Confirm that the piston ring is set as shown
in the illustration 1077.
No. 1 0.06-0.1 mm 0.25mm
ring (.002-.0039") (.0098")
No.2 0.05-0.09mm 0.25mm
ring (.0019-.0035") (.0098")
Oil 0.02-0.06mm 0.15mm
ring (.0007-.002") (.0059")

O Piston ring
Piston End
gap

1076 Expander connecting part 1077

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 C. Gudgeon pin B. Clearance between small end bush and the
Check the outside diameter of the gudgeon pin. gudgeon pin.
If it is less than the allowable limit, replace. Measure the inside diameter of the connecting
rod small end bush.
If the clearance exceeds the allowable limit.
103-09/10/Perama M25/M30 replace.

Standard OD Allowable limit

20.998-21.002mm 20.98mm 103-09/10/Perama M25/M30

(.8266-.8268") (.8259')
Standard clearance Allowable limit
0.008-0.023mm 0.08mm
(.0003-.0009") (.003")
103-06 Gudgeon pin
Standard OD Allowable limit
18.998-19.002mm 18.98mm
103-06 Clearance
(.7480-.7481") (.7472")
Standard Allowable limit
clearance
0.013-0.028mm 0.08mm
(.0005-.0011") (.0031")
Connecting Rod
- Inspection
A. Distortion or damage. C. Play between the connecting rod and the
Check the connecting rod for distortion between crankshaft.
the large
with and smallrod
a connecting ends of theIfconnecting
aligner. rod
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 Allowable
value limit Standard play Allowable limit
Distortion Less than
0.1-0.3mm (. 0.7mm (
(for 100mm) 0.08mm 0.2mm 0039-.0118") 0275 )
(3.937) (.003) (.0078)
Parallel Less than
(for 100mm) 0 05mm ( 015mm
D. Oil clearance
(3.937") 0019) (0059 )
I 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.

1. Gauge 1078
2. Gudgeon pin
3. Distortion
4. Flat surface of the aligner
5. Pin

PB04
6

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 Bearing Holder Bearing Journal Part No. Crankshaft

- Disassembly and Inspection A. size No. center journal

diameter
Centre bearing
a. Remove the bearing holder, and check it for No.1 198517330* 42.964-42.975
peeling, melting, stepped wear and other S.TD. No.2 198517340 (1.6915-1.6919")
damage. If it is excessively damaged, No. 3 198517101 45.964-45.975
replace.
198517110 (1.8096-1.8100")
b. Using the plastigauge, measure the oil clear-
ance between the crankshaft centre journal No. 1 198517334' 42.714-42.725
and the bearing. U.S0.25 No.2 198517344 (1.6817-1.6821")
If the oil clearance is more than the allowable (.010") No.3 198517105* 45.714-45.725
limit, replace the bearing. Or, grind the
198517114 (1.7998-1.8002")
crankshaft centre journal, and use under-
sized bearing (Refer to "Crankshaft"). No. 1 198517337* 42.464-42.475
U.S 0.50 No.2 198517347 (1.6718-1.6722")
(.020") No.3 198517108* 45.464-45.475
198517117 (1.7899-1.7904")
103-09/10/Perama M25/M30 Upper bearing
Standard oil clearance Allowable limit

0.039-0.092mm 0 2mm (
(.0015-.0036") 0078)
No 3 No. 2 No. 1

Bearing Bearing Crankshaft

size Number centrejournal

diameter (mm)
Standard 198517101' 45.964-45.975mm Front
198517110 (1,8096-1.8100")
0.25mm 198517105* 45.714-45.725mm
U.S. 198517114 (1.7997-1.8001") PB049
(.0098")
0.50mm 198517108* 45.464-45.475mm B. Thrust clearance 103-06
Check the thrust clearance for wear, poor contact,
U.S. 198517117 (1.7899-1.7903")
burning or other defects.
(.0196")
N.B. No thrust washers are fitted.
Upper bearing
Standard clearance Allowable limit
0.1 to 0.3mm 0.5mm
103-06 Holder
(.004-012") (.020")
Bearing
Journal Standard oil Allowable limit
No. clearance
Thrust washers. 103-09/10/Perama M25/M30
No. 1, 2 0.035-0.088 0.2
Check the thrust washer for wear, poor contact,
(.0014-.0035") (.008") burning or other defects. Defective washers
No.3 0.039-0.092 0.2 must be replaced.
(.0015-.0036") (.008")

Standard Thickness Allowable limit

1.95-2.0mm (. 1 8mm (
0767-.0787") 0708 )

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 Assemble the connecting rod and connecting 103-06
rod cap, and tighten to the specified torque (3.0- Bearing Crankshaftpin Part No.
3.5kgf.m) (21.7-25.31bf.ft) - 103-09/10/Perama size O.D. dimension (mm)
M25/M30, (2.1-2.6kgf.m) (15.2-18.81bf.ft) - 103-
06
S.TD. 34.964-34.975mm 198517310
NOTE: Never rotate the connecting rod.
(1.3765-1.3770")
Remove the connecting rod cap. Measure the
oil clearance with the scale printed on the gauge 0.25mm 34.714-34.725mm 198517314
bag. U. S. (1.3667-1.3671")
NOTE: Measure the widest area. (.010")
0.50mm 34.464-34.475mm 198517317
U. S. (1.3568-1.3573")
(.020")

- 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 Allowable limit
0.035-0.083mm 0.2mm (.
(.001-.003") 0078)

103-06
Standard clearance Allowable limit Arrow mark or 'F' (103-06)
0.031-0.079m m ( 0.2mm (.
.0012-.0031 ") 0078)

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

D. Replace the piston ring on the piston. Position
size O.D. dimension (mm)
scribe mark uppermost.
Standard 198517130 38.964-38.975mm E. When the connecting rod or piston/gudgeon pin
(1.5340-1.5344") has been replaced, difference in weight of the
assembly (connecting rod plus piston rings)
0.25mm 198517134 38.714-38.725mm should not exceed 10 grams between cylinders.
U.S. (1.5241-1.5246")
(.0098")
0.50mm 198517137 38.464-38.475mm
U. S. (1.5143-1.5147")
(.0196")

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 - Reassembly 103-09/10/Perama M25/M30
A. Reassemble the bearing holder, centre bearing Standard oil clearance Allowable limit
and thrust washer as follows:
a. Face the chamfered part of the bearing 0.039-0.106mm 0.2mm
holder toward front. Install the bearing holder (.0015-.0041") (.0078")
which has reference bit at the centre. Then
install the bearing holder on which the thrust 103-06
washer is to be mounted at the flywheel side ( 0.035-0.102mm 0.2mm
where fitted). (.0014-.0040") (.0078")
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: (2.5-
3.0 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.

PB052

-T i groove
Notch

Crankshaft Bearing (bush) -

Inspection
A. Check the bearing (bush) for peeling, melting, PB053
seizure or poor contact. If found to be defective,
replace.
B. Using cylinder gauge and micrometer, measure D. If the oil clearance exceeds the allowable limit,
the oil clearance between the bearing (bush) replace the bearing (bush). Or, grind the
and the crankshaft journal. crankshaft journal. In this case, use undersize
C. Measure inside diameters at positions 1 and 2 bearing (bush).
(1085). At each position, measure in both direc- E. When replacing the crankshaft journal (bush),
tions A and B as shown. The oil clearance can use a press to install.
be obtained by subtracting this value from the
maximum crankshaft journal diameter.
Crankshaft journal (bush)

103-09/10/Perama M25/M30
Size Cord number Outside diameter

Standard 198517080 45.964-45.975mm

(1.8096-1.8100")
0.25mm 198517084 45.714-45.725mm
U. S. (1.7997-1.8001 ')
(.0098")
0.50mm 198517087 45.464-45.475mm
U. S. (1.7899-1.7903")
1085
(0196")

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 F After grinding the crankshaft journal, check the
oil clearance.

Crankshaft journal (bush) 103-06

Bush Bush code No. Crankshaft journal
size O.D. finished size (o)
S.TD. 198517300 42.964-42.975mm
(1.6915-1.6919")
U.S.O. 25 198517304 42.714-42.725mm
(.010") (1.6817-1.6821") Perama M25/M30 103-
U.S.O. 50 198517307 42.464-42.475mm 09/10 103-06

(.020") (1.6718-1.6722") 9mm (13.5mm

8mm-.t..- 13mm

After grinding the crankshaft journal, confirm

that correct oil clearance.

How To Replace Bush

1. Removal of bush Cylinder I
Remove the bush from the housing (Cylinder block i > Front side
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 Align
to correct depth by using Bush Driving
Tool, adjusting the oil hole and direction I PB129
of bush as per attached PB129 and
following sequence. Crankshaft
Inspection
(1) Press in the bush to cylinder block from A. Crankshaft deflection
engine front side. Support the crankshaft with V-block. Position a
Note: dial gauge on the crankshaft centre journal, and
Must not press in the bush to cylinder block turn the crankshaft gradually by one full turn.
from the opposite side. The correct pressing If the gauge reading is more than allowable
side is chamfered etc, to allow smooth limit, correction or replacement of the crankshaft
operation. is needed.

(2) ( Align oil hole of the housing and bush.

install the bush confirming the mark and oil
3) Standard deflection Allowable limit
groove (hole).
0.03mm or less (. 0.06mm
0011") (.0023')
(4) Lubricate at outer surface of the bush.
(5) Press in the bushing to the housing until

2.3correct
Confirmdepth
afterby using Bush Driving Tool.
installation
Confirm the alignment of oil hole of the
housing and the bush, also check inner
diameter is within tolerance.

PB054

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 B. Oil Seal contact face and oil hole 103-09/10/Perama M25/M30
Check the oil seal contact face for damage Shaft diameter of crankshaft pin
or wear.
Standard Allowable
Check oil holes for clogging. diameter limit
C. Crankshaft journal and pin for stepped wear.
Standard 38.964- 38.90mm
Take four measurements (AA and BB
38.975mm
diameters at positions "1" and "2"). If the
(1.5340- (1.531 ")
maximum difference between the
1.5344")
measurements is more than allowable limit,
correction is required. 0.25mm U.S. 38.714- 38.65mm
38.725mm
1
(1.5241- (1.5216")
1.5246")

0.50mm U.S. 38.464- 38.40mm*

38.475mm
(1.5143- (1.5118")
1.5147")

If the diameter is less than this value, the

crankshaft must be replaced with new.

103-06
Crankshaft journal shaft diam. (o)

Cross Section of Assy'd std. value Repair req. value

Pin and Journal 42.964-42.975 42.90
No. 1
No.2 (1.6915-1.6919") (1.689")
Standard
No.3 45.948-45.959 45.90
(1.8090-1.8094") (1.807")

U.S. 0.25 No. 1 42.714-42.725 42.65

(.01") No.2 (1.6817-1.6821") (1.679"
No.3 45.698-45.709 45.65
(1.7991-1.7996") (1.797")

U.S. 0.50 No. 1 42.464-42.475 42.40*

A (0.02") No.2 (1.6718-1.6722") (1.669")

Allowable difference (stepped wear) No.3 45.448-45.459 45.40*

(1.7893-1.7897") (1.787")
0.05mm (.0019")
LranKsnan pin aiameier to) iu s-uo 1
2

When measured diameter is less than the

allowable limit, correct by grinding and use
undersize bearings and bush.
O.D. finished size Repair req. valu
103-09/10/Perama M25/M30
34.964.34.975 34.90
Shaft diameter of crankshaft journal Standard (1.3765-1.3770") (1.374")
Standard Allowable
U.S. 0.25 34.714-34.725 34.65
diameter limit
(.01") (1.3667-1.3671") (1.364")
Standard 45.964- 45.9mm
U.S. 0.50 34.464-34.475 34.40*
45.975mm (1.3568-1.3573")
(.02") (1.354"
(1.8096- (1.807")
1.8100") * Replace crankshaft if U.S. 0.50 is exceeded.
0.25mm U.S. 45.714- 45.65mm
45.725mm
(1.7997- (1.797")
1.8001 ")
0.50mm U.S. 45.464- (45.40mm*
45.475mm
(1.7899- (1.787"*)
1.7903"')

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 NOTE: When grinding the crankshaft, work with 103-09/10/Perama M25/M30
the following specifications: (A) Cam height (intake and exhaust cams)

Standard value Allowable limit

26.445-26.5mm 26.1 mm
(1.041-1.043") (1.0275")

103-06
Standard value
I Allowable limit
26.565-26.62mm 26 1mm (1.
(1.0459-1.0480") 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.

103-09/10/Perama M25/M30
Flywheel and Ring gear - (B) Height of cam for injection pump
Inspection Standard height I Allowable limit
A. Check the ring gear. If it is excessively damaged or 33.94-34.06mm ( 33 8mm
worn, replace it. 1.336") (1341 )

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. 103-06

Standard height Allowable limit

34.48-34.52mm ( 34.3mm (
1.3575-1.3591 ") 1 3504")

(C) Height of cam for fuel feed pump -

All engines

Standard height Allowable limit

27.9-28.0mm ( 27.0mm
1.098-1.102") (1.06)

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.

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 C. Camshaft gear and bearing assembly: Oil Pump
3 - Disassembly
6 A. Remove the snap ring.
5 B. Take out collar spring and shim.
8 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
1. Snap ring 6. Rotor
PB061
order illustrated in 1090. 2. Collar 7. Spring
3. Spring 8. Idle gear
Timing Gear - 4. Shim 9. Thrustwasher
Inspection 5. Oil pump cover
A. Check the timing gears for wear and damage on
the contact area. Replace if any defect is found. - Inspection
B. Measure the back-lash of gears with a thickness A. Check oil pump cover, rotor and vane for wear. If
gauge or dial gauge. If the allowable limit is excessively worn or damaged; replace.
exceeded, replace all timing gears. 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.

Standard back-lash Allowable limit - Reassembly

A. Reassemble the oil pump in reverse order of
0.08mm 0.25mm disassembly.
(.003 ) (.010") 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 103-
09/ 10/Perama M25/M30, and 0.02 to 0.15mm (.
0008 to .0059") for 103-06. Allowable limit 0.
25mm (.0098").

PB060

1094

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 Oil Filter - Inspection
- Construction and Function
Thermostat
This engine employs a cartridge type filter. A. Replace the thermostat if the valve opens at ambient
Pressurized oil from the oil pump enters from (A); temperature.
and is filtered by a fuli flow filter, before discharge B. Place the thermostat into water. Raise the water
through (B). temperature gradually and inspect the valve
When the full flow filter is clogged, the safety opening temperature and valve lift. (Standard
valve opens to bypass the oil. 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 103 06

Type Wax pellet Wax pellet
type type

Temperature when 69 to 73°C 75°C

starting to open

Temperature when 82°C 90°C

fully open

Valve lift (when the 8.0mm 6mm

water temperature
is 82°C
- 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
- 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.

PB066

Water Pump
A. Check for cracks, wear, leaks, bearing roughness or
damage. If defective replace assembly.

- Reassembly
103-06 PB064 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.

3
103-06 PB065

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 103-09/10/Perama M25/M30 Feed
Fuel Pre-filter pum
tank p

Injection Injection Fuel

nozzle pump filter

0,
PB068

Inspection

tim
m 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
Radiator 103-06/103-09/10 with grease to aid assembly.
A pressure type radiator cap is employed to B. Coat the mounting face of the element with
obtain higher cooling efficiency. When the grease, and install it hand tight. (All types).
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. ( Feed Pump Assembly -
shown by white arrow). Disassembly
When coolant temperature falls coolant pres- A. Before disassembly see section A, B, C of
sure may become less than atmospheric pres- Inspection and then note reference marks on
sure. As this may fracture the radiator, the the diaphragm cap, top body assembly and
vacuum relief valve opens at 0.04 to 0.05kg/cm2 ( bottom body as shown in the figure.
2.9lb/ft to 3.6lb/ft) to protect the radiator. (black
arrow).
N.B. Perama M25/M30 pressure cap is 0.5kg/
cm2

Inspection
PB069
A. Check the radiator for water leaks. If water
leaks, repair or replace the radiator. B. Remove the bolt to remove the cap and top body
B. Check radiator fins for clogging by mud and/or assembly.
other foreign matter. If clogged, clean the fins.
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
Top body assembly Cap
needle is returned to the tank through the over-
flow pipe. PB07
0

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 C. Remove the diaphragm from the bottom body, B. Drain all fuel in the feed pump.
Check condition of the top body as follows. Draw air
and turn the piston to align the bottom body C
from IN side with vacuum and put air into
groove with the pin hole.

D. Remove the pin from the piston. OUT side. If air stops in both cases, the body
NOTE: Pay attention to the inner spring. is normal.

\0 LIT

~.
5

IN

Piston

Bottom body
PB074
PB07 D. Confirm that the diaphragm has no damage, such
1 as cracks.
E. Take out the piston, spring and diaphragm from the
bottom body.

Bottom body

Piston

PB075

Diaphragm - Reassembly
A. Reassemble the feed pump in the reverse order of
its disassembly.

PB072
Governor

- Inspection
A. Before disassembling the feed pump, confirm that the - Construction/Function
piston and bottom body are not seized.

Link 0

PB073 PB076

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 A. A mechanical all speed governor is used. It is bolt limits the movement of the arm and has
housed in the gear case. been adjusted and sealed at the factory.
A flyweight assembly is mounted on the C. Max. fuel and start spring.
camshaft. The movement of the flyweight is
These are built into the cylinder block, to regu-
transmitted to the injection pump control rack
late fuel injection at high speed. Regulation of
by way of the slider, control lever and link. A
fuel injection in the middle speed range is by
spring which is hooked to the arm and tension
torque spring to realize higher torque.
lever regulates the movement of the flyweight.
A start spring is placed between the gear case
By changing the set angle of the governor lever,
and link. This spring automatically functions to
tension on this spring is changed. Thus, the
increase fuel during the start mode.
engine speed can be regulated by the governor
An idling spring at the gear case stabilizes
lever.
engine idling speed.
B. Maximum speed set bolt. The max. fuel has been adjusted at the factory
and sealed.
Set bolt is mounted on the cylinder block. This

Nozzle and Holder -

Specification
Item Perama M25/M30/103-09/103-10 103-06

Part code 131406330 131406340

Assembly number 093500-3320 093500-2240
Nozzle holder 093100-3320 093100-2240
(ND-KCA46SD332)
Nozzle 093400-1460 093400-5010
(ND-DN4SDND146) (ND-4PDI)
Nozzle type Throttle type Throttle type
Needle valve diameter 6mm 3.5mm
Pintle diameter 1mm
Valve opening pressure 115-125kg/cm2 (111-121 ats) 115-125kg/cm2
Spraying angle 4° 4°

Construction/Function - Disassembly/Inspection
A. Place the nozzle holder (body) in a vice and turn
A. The nozzle has been machined to inject fuel,
the nozzle nut to disassemble.
which is pressure-fed from the injection pump
NOTE: Care should be taken so that the needle
to the combustion chamber. Fuel is pressure-fed
valve does not fall when the nozzle is removed.
from the oil hole of the nozzle holder to the
B. Wash the nozzle body and needle valve and
nozzle body and sprayed from the nozzle
inspect the nozzle for seizure, sticking and fuel
compressing the spring when the pressure
leakage on the seat surface. If fuel leakage is
exceeds the specified value. Some fuel lubri-
detected, replace the nozzle.
cates and cools the nozzle and nozzle body, and
C. Inspect the upper and lower contact surfaces of
returns via the return pipe.
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.
Full opening

6
Valve closed Valve open (main jet)

M
,
qL7111
11Y

11
17

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 Reassembly/Adjustment Air Cleaner
A. Before fitting a new nozzle assembly, soak it in - Construction/Function
heated light oil (50°-60°C) to remove anti-corro- The 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
tighten with a nozzle nut. A. At every 100-200 hours of operation, take out the
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.
7. Finally, leave to dry.
C. When operating the machine in dusty environ-
5. 6. ment, increase service frequency.
4.
3.
D. At every sixth cleaning or every year, replace the
2. element.
1. Gasket
2 Nozzle nut
. Tightening
torque 8 - 10
kgf.m
E. After cleanina the element, put a light inside
3. Nozzle element, and check it the
for cracks, holes or wear.

1118 4. Spacer If damage is found or the gasket is broken,

replace the element.
5. Rod Do not install the element until completely dry.
6. Spring F
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.

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Downloaded from www.Manualslib.com manuals search engine
 SECTION V
Reassembly
Precautions Before Assembling 103-06
A. Wash parts before assembling. (Especially, oil
Standard play Allowable limit
gallery, bearings, pistons and cylinder bores
should be washed thoroughly.) 0.1-0.3mm ( 0.5mm
B. Apply new oil to sliding and rotating surfaces of .004-.012") (.020")
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.
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.
PB08
3

Rear Oil Seal

A. This is a pressfit, retained by the back plate.

PB082 PB084

Back Plate
C. Measure crankshaft end float.
A. Coat the area around the M10 threaded holes
with liquid packing solvent based sealant and
103-09/10/Perama M25/M30 fix the back plate with bolts.
Standard play Allowable limit Back plate tightening torque:
4.7 to 5.5kgf.m (34 to 401bf/ft) 103-09/10/

0.05-0.3mm 0.5mm
(.002-.012") (.020") Perama M25/M30.
1.3 to 1.7kgf.m (9 to 121bf/ft) 103-06.

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 103-06

PB087
PB085

Flywheel NOTE: Install pistons from front in ascending

order.
A. Fit the flywheel, note location of the spring pin. D. Tighten the connecting rod cap to specified
Flywheel tightening torque: torque.
6.0 to 7.Okgf.m (43 to 501bf/ft) 103-09/10/ Perama Connecting rod tightening torque:
M25/M30. 3.0 to 3.5kgf.m (22 to 251bf/ft) 103-09/10/
7.0 to 8.Okgf.m (51 to 581bf/ft) 103-06. 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.

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 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.

PB092
Thrust washer

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 posi-
tion. 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.

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 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

Adjusting the Fuel Injection Timing

Normally this procedure provides correct injec-
tion timing. However, when new injection pump,
camshaft assembly, or cylinder block is used,
fuel injection timing should be adjusted as
1
1 explained below.
I A. Reassemble the injection pump according to the
procedures above. Use the shim of 0.5mm thick-
ness.
Crankshaft Pulley B. Remove the delivery valve holder at the front side (
A. Align the key way and key on the crankshaft radiator side) of the injection pump.
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.

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 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 Degrees Crank BTDC

Injection
PB097 X Y Timing
Z
KC30233, 34 20 18 18 17.5-19.5
C. Pull out the delivery valve (IN), and reinstall the
KD 30245, 46
spring and delivery valve holder.
KC30229, 30, 35, 23 22 22 21.5-23.5
36
KD30241, 42, 47,
48
KC30225, 26, 27, 24 23 23 22-24
28, 31, 32
KD30237, 38, 39,
40, 43, 44
KB30221, 22 28 25 27 24.5-26.5
KB30216, 17, 18, 29 26 28 25.5-27.5
23,70
KB30219, 20, 24, 30 27 29 26.5-28.5
71
i
-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)
24 3.636 (.1431 ") 14 1.409 (.0555")
25 3.937 (.1550") 15 1.615 (.0636")
26 4.250 (.1673") 16 1.836 (.0723")
27 4.573 (.1800") 17 2.069 (.0815")
28 4.906 (.1931 ") 18 2.317 (.0912")
29 5.251 (.2067") 19 2.577 (.1015")
30 5.605 (.2224") 20 2.851 (.1122")
31 5.965 (.2348") 21 3.138 (.1235")
32 6.341 (.2496") 22 3.438 (.1353")
23 3.750 (.1476")
24 4.075 (.1604")
25 4.413 (.1737")
26 4.763 (.1875")
27 5.125 (.2018")

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 Changing the shims thickness by 0.1 mm will 103-09/M25
change the timing approximately one degree.
Measurement (mm) Gasket No. Tightened
Adding shims decreases the angle while 103-09 thickness
subtracting shims increases the angle.
0.55-0.75 . 111147250 t=1.3
0216-.0295"
Injection timing adjusting shim
Thickness (mm) Part Number
103-10/M30
0.2 131437310
Measurement (mm) Gasket No. Tightened
0.3 131437320
103-10 thickness
0.4 131437330
0.45-0.75 . 111147280 t=1.3
0.5 131437340 0177-.0295'

NOTE: When the shim is not needed, assemble by 103-06

coating using liquid sealant.
Measurement (mm) Gasket No. Tightened
F Assemble the delivery valve (IN).
103-06 thickness
NOTE: Delivery holder tightening torques: 1111471 t=1.3
(103-06) 3.5-3.9kgf.m (25-281bf/ft). 0.75-0.85
(.0295-.0335) 10
(103-09/10/Perama M25/M30)4.0-4.5kgf.m
(29-331bf/ft).
Oil Filter
A. Coat the mounting face with a thin film of oil, and hand NOTE: Last four digits of code numbers are stamped
tighten. on the head gasket. Install the head gasket with code
Feed Pump numbers at top.
C. Tighten the cylinder head in 3-step procedures, in the
A. Insert using securing bolts.
order shown in the illustration. Finally tighten with
Tappet specified torque.
A. Coat the tappet with oil, and assemble. Specified torque:
5.0 to 5.3kgf.m (36 to 381bf/ft) 103-09/10/Perama M25/
Cylinder Head
M30.
A. Set the piston to the top dead center, measure the
3.5 to 4.Okgf.m (25 to 291bf/ft) 103-06.
amount of protrusion above the cylinder block with
depth gauge or dial gauge.

1z /11 13
O O/~

/0\J
01 03 0
~ X7

04 02 106

14 12

E0098

NOTE: Spring pin is used for positioning.

Coat threads of bolts with grease based with molyb-
denum disulphide.
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.

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 Oil Pipe
Eyebolt tightening torque:
1.0 to 1.3kgf.m (7.2 to 9.41bf/ft).

PB103

Cylinder Head Cover

A. Evenly tighten the cylinder head cover. Ensure
gasket remains in location
Cylinder head cover tightening torque:
PB101 1.0 to 1.2kgf.m (7 to 91bf/ft)

Cap, Push Rod and Rocker Arm Assembly

A. Install the cap on the end of valve stem. Water Pump Assembly and Radiator Hose
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).

Liquid Packing Water

(siliconpump
Glow Plug and Connector
RTVassembly.
type) J E0004-1
Radiator Hose

Glow plug tightening torque: 1.5

PB102 to 2.Okgf.m (11 to 14.51bf/ft).

Valve Clearance Adjustment Mano-Contact

A. Loosen the nut and adjust the clearance of both Mano-contact tightening torque:
the intake and exhaust valves to 0.2mm (.0078") 1.5 to 2.Okgf.m (11 to 14.51bf/ft).
with the adjust screw. Nozzle/Holder Assembly
NOTE: Adjust when the engine is cold. Set the
A. Install new cap and gasket securely ref. PB038.
No. 1 cylinder to the top dead center, and adjust
Install the nozzle and holder assembly with
the clearances of intake/exhaust valves of No.
socket for the nozzle holder. Install the return
1 cylinder and exhaust valve of No. 2 cylinder.
pipe.
Then, turn the crankshaft counter-clockwise by
240° (viewed from the front) to adjust clearance Nozzle/holder tightening torque:
of intake valve of No. 2 cylinder and intake/ 8 to 8.5kgf.m (58 to 621bf/ft) 103-09/10/Perama
exhaust valves of No. 3 cylinder. M25/M30.
6 to 7kgf.m (43 to 511bf/ft) 103-06.

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 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 align-
ment.

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 the
crankshaft pulley and the alternator pulley, with
finger force of approximately 1 kg, (.51bf/ft). The
fan belt tension should be adjusted such that
the deflection becomes 5mm (.2") upon the
above check.
Cooling fan tightening torque: 0.9
to 1.3kgf.m (6.5 to 9.51bf/ft).

PB106

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 SECTION VI
Electrical Systems

Alternator
N.B. (Perama M25/M30 Lucas A127 - see
Section 10).

- Specification and Performance

103-09/10/Perama
Type M25/M30G P9150

Direction of rotation Clockwise Q 40

(Viewed from pulley)
w
Speed 1300-6000rpm C D30
6 20
Charging capacity 15-16.5A at 14V
at 5000rpm 0 10
Minimum charging Less than 1600rpm
speed (at 13V)
z0
Regulator RS5101
Part number 185046160 Revolution N(
PB119
rpm)

103-06
Type GP8146

Direction of rotation Clockwise

(Viewed from pulley)

Speed 1600-5600rpm
Charging capacity 14-15Aat14V
at 5200rpm

Minimum charging
speed

Regulator RS5101
Part number 185046160
PB118

18
Upper limit

FM
16 Lower limit - Construction
E OC"
The alternator consists of the stator (armature
14 B coil and coil plate) and the flywheel which
contain ferrite magnets.
12

10

0 1 23 4 5 6 x 103
Speed(rpm)
E0103 search engine
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 e
Regulator Re
RS5101 d
Alternator
G 12V _
een Battery
Blue Blac Load
k
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 E0104

103/06 Tests:
Normal Abnormal Cause

Relation between charge 1 More than 14A at 14V More than 14A at battery Improper operation of
current and battery voltage more than 15V regulator
terminal voltage
(at alternator 5200rpm) Charge current OA Defective alternator or
2 14A-0.5A at 14-15V
regulator or improper
connection

Flowing charge current Defective battery

but low battery voltage (overdischarge)

Alternator Performance of unit alone

Normal Abnormal Cause
No load voltage (between More than AC 28V Less than AC28V AC OV Demagnetized flywheel,
blue and blue) tester disconnected coil or
reading at operation ( wiring harness
about 5200rpm)

Tester Between Continuity observed Continuity not observed Disconnected coil

continuity blue and
blue of
lead wire

Insulation resistance ( More than 3MSI Less than 3Mf I Improper coil insulation
between a lead wire and
coil plate)

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 103-09/10 Tests:
Normal Abnormal Cause

Relation between charge 1. More than 15A at 14V More than 15A at battery Improper operation of
current and battery voltage more than 15V regulator
terminal voltage
(at alternator 5000rpm) Charge current OA Defective alternator or
2. 15A-0.5A at 14-15V
regulator or improper
connection

Flowing charge current Defective battery

but low battery voltage (overdischarge)

Alternator Performance of unit alone

Normal Abnormal Cause

No load voltage (between More than AC 30V Less than AC30V AC OV Demagnetized flywheel,
blue and blue) tester reading disconnected coil or
at operation (about wiring harness
5000rpm)
Tester Between
Continuity observed Continuity not observed Disconnected coil
continuity blue and
blue of
lead wire
Insulation resistance (
between a lead wire and coil
More than 3Mtt Less than 3Mohm Improper coil insulation
plate)

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 14

abnormally, disassemble the alternator as explained 1. Flywheel complete 8. Spring washer

below. 2. Plate complete 3. 9. Washer
A. Remove the dust cap (6) using a screw driver. Coil plate 4. Stator 10. Coupler
B. Hold the pulley side jaw of the flywheel complete (1) complete 5. Bearing 6. 11. Clamp 12.
with a vice, loosen the nut (7). Dust cap 7. Nut Screw 13.
Screw 14.
C. Pull out the spring washer (8) and washer (9). Collar
D. Pull out the flywheel complete (1). If it is hard to
remove, tap the M10 threads with a plastic
hammer.

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 E. Disconnect the coupler (10) terminal stopper from - Reassembly
the plate complete. A. Reassemble the alternator in the reverse of order
F Loosen the M4 screw (12) and remove the clamp. of its disassembly, paying attention to the
G. Remove the M4 screw (13). following precautions.
H. Pull out the stator complete (4) from the coil plate
(3). 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
I. Position the coil plate (3) rear side on a surface the coil plate using a rod of 31 mm diameter. (
plate, and insert a rod having diameter of Apply a rod on the outer face of the bearing.
approximately 24mm. Then push the bearing )
with a press to remove. (Replace the front b. Tighten the nut (7) with the torque of 2.5 to
bearing as a flywheel complete). 3.Okgf.m.
NOTE: NEVER CLAMP the flywheel body with
c. Clamp the flywheel complete.
any vice.
J. Rotate the bearing manually to confirm that it d. Never suspend the alternator from a lead wire.
rotates without noise.

Regulator
- Specification

Type RS5101
Part No. 185516060
Weight Approx. 250 gram
Applicable battery 12V
Charging lamp 12V less than 3.4W
Applicable alternator No-load voltage of less
than 70V
Output current of less
than 16A

Adjusted voltage 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
E0107
shown in the separate table.

RS5101 Tester Checking table.

Tester (+) terminal Colour of cable
Tester (-) termina Blue Blue Red Yellow Green Black
Blue OFF ON OFF OFF OFF
Blue OFF ON OFF OFF OFF
Red OFF OFF OFF OFF OFF
Yellow ON ON ON OFF ON
Green OFF OFF OFF OFF OFF
Black OFF OFF OFF OFF OFF

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 NOTE: Set the tester at high resistance range. B. Magnetic switch
'ON' denotes the fluctuation of the tester needle The magnetic switch operates the plunger in
while 'OFF' denotes no fluctuation of the the switch and engages the pinion via the shift
needle. lever. It opens and closes the points to start and
If the above results are attained, the tester is in stop the starting motor.
good condition. However, even when the above C. Pinion
test results are obtained, there may be the case
The pinion transmits the rotation of the motor to
that the regulator is not able to function correctly
the engine. The pinion is provided with an
due to deterioration. Please take care of the
overriding clutch to interrupt the power from the
deterioration.
engine when the engine starts.
The overriding clutch composes of a rotor and
clutch outer. The rotor is always pushed by the
Precaution Upon Handling roller spring and the clutch outer is tapered
A. As large current flows through the regulator where the roller is housed. When the rotor
generating heat, the regulator must be rotates in a direction that the roller enters the
positioned to the specified location. wider part, the pinion and clutch outer turn
B. Securely install the regulator so that bottom face idly, but, when the roller rotates in the narrower
of the regulator is in full contact with the heat part, the roller works as a key to transmit the
radiating plate or to the body. rotation.
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.
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.
Charge Lamp Load Condense, a. When the teeth of the pinion and ring gear run
against each other, the pinion sleeve spring is
Head Lampp etc.)

E0109 compressed and plunger moves.

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 c. The pinion engages with the ring gear
provides large starting torque. completely to turn the ring gear.

Starter Motor Specifications

Revolution
Model RatedTime Output Weight direction Clutch Engaging
(sec.) (kw) (kg) (viewed from system system
the pinion side)

S114-381 30 1.2 5.9 Clockwise Overrunning Magnetic shift

Non-loading Loading
Pinion
Model pushing Terminal Revolution Terminal Torque
voltage (V) voltage (V) Current (A) speed (rpm) voltage (V) Current (A) (kg-m)
6000
S114.381 8 or less 12 60 or less or more 5 540 or less 1.6 or more

N.B. Model M003T32589 has output 0.7kw 12V and is Series wound.

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 E. Engine starts. B. Remove the dust cover and take out the E ring
F After the engine starts, return switch to run and thrust washer, where fitted. Remove the
mode. rear cover and brush holder.
G. The magnetic switch loses attracting force, the
pinion returns by the return spring with the shift
lever and disengaged, and the motor stops.

-Ii

PB108

C. Remove the bush assembly and yoke.

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. PB109
Use a wire of specified thickness and tighten it
firmly. Insufficient tightening causes larger D. Remove the shift lever and armature.
contact resistance and makes starting difficult.
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 proce-
dure several times.

PB110
d. Never turn on the starting switch while the
engine is operating. E. Remove the pinion, as shown by first removing
the snap ring ref PB111. Re-assembly by using
- Disassembly and Reassembly (Typical) puller as shown in PB112.
A. Remove the solenoid (magnetic switch).

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 Inspection and Service A.
Armature
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.
PB112 c. Inspection of the surface of commutator
The part of the commutator surface where
H. Reassembly should be made in the reverse order of the brush is sliding in contact can be distin-
disassembling after inspecting as described in the guished clearly. If the sliding area is rough,
paragraph of "Inspection and service". After grind with sand paper of No. 500 or 600. If the
assembling, check thrust gap for armature is 0.5mm indication of a dial gauge exceeds 0.5mm (.002")
maximum and then check and adjust the dimension, , correct with a lathe.
[. d. Insulator of the commutator
Check and adjust the dimension, c Measure the depth of the insulator of the
The distance for which the pinion is pushed out by commutator, and correct as indicated in
the magnetic switch is called the dimension c PG144 if the result is 0.2mm (.008") or less.
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.

Chamfered 0,5 to ,
8mm

Unacceptable Acceptable
PG144
Pinion

\ Stop ring

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
Front / bearing metal. Turn the armature quietly and
bracket 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
a. Check the field coil for disconnection using a
PINION CLEARANCE
tester. Inspect the continuity between terminals
PB114 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
d. Check operation of magnetic switch and change new one.
adjusting plate if necessary.

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 b. Check the continuity between the field coil D. Magnetic switch
and yoke with a tester. Inspect the continuity a. Check the shunt coil for disconnection.
between either terminal of the field coil and Inspect the continuity between the magnetic
yoke. Continuity shows insufficient insula- switch S terminal and coil case (metal part).
tion. Then replace the coil. If continuity is not indicated, it shows discon-
C. Movement of the brush nection. Then replace the switch with new
one.
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
holder (0 side) and holder base ((Dside...
B. Check the series coil for disconnection. Inspect
the continuity between the magnetic switch S
earth). If continuity is indicated, it shows terminal and M terminal. If no continuity is indi-
insufficient 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.
7kw motor 11.5mm (New 17mm) a. Check the pinion teeth for wear and other
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
Standard tension is 1.6kg to 2.0kg. metal, replace the pinion.
Set the brush spring and pull up with a spring c. If the clutch freewheels in both directions or
balance and measure the load when the seizes when spun by hand, replace. Do not
brush is raised up. clean in solvent.
Replace a faulty spring with new one. Service
limit: 1.2kw motor 1.4kg: 0.7kw motor 0.9kg.

Position Cause Remedy

Wiring Disconnection, loosened terminals of the battery and switch I Repair and retighten
Starting switch Insufficient contact. No current flows. Repair the contact
area or replace
Starting motor Pinion-engaged screw part of the armature shaft is tucked and the Replace
pinion does not move.
Magnetic switch Irregular movement of the magnetic switch plunger, disconnection Repair or replace
or short circuit.

(2) Pinion is engaged, motor rotates, but the engine does not start.

Positio Cause Remedy

n
Starting motor Faulty overruning clutch Replace

(3) Pinion is engaged with the ring gear but starting motor does not start.

Position Cause Remedy

Wiring Disconnection of the wire connecting the battery and magnetic switch Replace, retighten
or insufficient fastening of the wire connecting the earth, magnetic or replace
switch and motor terminal. the wire
Starting motor Insufficient engagement of the pinion and ring gear Replace
Incorrect installation Reinstall
Worn out brush, faulty contact of the brush spring Replace
Stained commutator Correct
Faulty armature and field coil Repair or replace
Insufficient connection of the field coil and brush Retighten
Magnetic switch Insufficient contact of the contactor Replace
(solenoid) Rough contact surface of the contactor Replace

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 (4) The motor rotates at full speed before the pinion engages with the ring gear.

Position Cause Remedy

Starting motor Fatigued pinion sleeve spring Replace

(5) After the engine starts, the motor does not stop when the starting switch is off.

Position Cause Remedy

Starting switch Faulty switch Replace

Magnetic switch Faulty magnetic switch (solenoid) Replace

Glow Plug B. Short circuit

A sheathed type glow plus is employed and The glow plug is of a simple structure and short
provides excellent starting. circuit is rarely caused. However, if the central
electrode, body, sheath, etc. come in contact,
- Specification
wiring of preheating circuit is burnt during starting.
Part No. 185366060 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.
Rated voltage Current
161)
10.5V 6.9A Resistance of 0 indicates short circuit.

Thermoswitch
- Specifications

Part No. 385720100

Type TB-121A

Operating load 12V-3W

Switching temperature 101 to 109°C (Off to

On)
1 Heat wire 5 Nut Switching off 95°C and higher
2 Sheath 6 Magnesium oxide powder temperature
3 Asbestos 7 Insulation bush

ON
4 Body 8 Core
Fig 2-
124
- Structure

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 95°C 101°C 109°C
in the combustion chamber.
PB123

- Troubleshooting Oil Pressure Switch

A. Disconnection of the heat wire. Part No. 185246060
The glow plug operates even when any one of the
heat wires is disconnected because it is Oil pressure switch operating range:
connected in parallel. However, when discon-
0.2 to 0.4kg/cm2 (2.8-5.7 psi)
nected, preheating time of the glow signal is
extremely extended.
Check/Remove the connector and check the
A. The oil pressure switch is a warning device to
continuity between each plug terminal and body
inform low engine lubricating oil pressure. When oil
earth. If continuity is not observed, it shows
pressure becomes less than specified the
disconnection. Then replace the heat wire.
warning light is activated. This pressure switch
houses a diaphragm and contact points.

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 WIRING DIAGRAMS

- Perama

- 103-06, 103-09, 103-10 15 amp alternator -

103-09, 103-10 35 amp alternator

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 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. Circuit Maximum Maximum Remarks

current circuit circuit
resistance volt drop

Alternator 4 0.5 volt See glow plugs circuit

Charging 7, 8, 9, 13 15 amp 0.0333 ohm
Starting 4 See glow plugs circuit
Motor 5 See glow plugs circuit
0.63 volt
Solenoid 6
15.75 amp 0.04 ohm
Glowplugs 4, 5, 10,11, 12 27 amp 0.0185 ohm 0.5 volt
(via glow signal)

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 Wiring Diagram (103-09, 103-10)

Wiring Diagram Maximum Circuit Resistance

Resistance of battery cables 1, 2 & 3 not to exceed 0.0018 ohm

Cable No. Circuit Maximum Maximum Remarks

Circuit
current circuit circuit
resistance volt drop

Alternator 0.5 volt See glow plugs circuit

Charging 7 35 amp 0.0143 ohm

Starting 4 See glow plugs circuit

Motor 5 0.63 volt See glow plugs circuit
Solenoid 6 15.75 amp 0.04 ohm

Glow plugs 4, 5, 8, 9, 10 27 amp 0.0185 ohm 0.5 volt

(via glow signal)

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 SECTION VII
Trouble Shooting
A. ENGINE DOES NOT START
CAUSE REMEDY
Faulty key switch and or stop solenoid .................................. Correct the connection and contact.
Insufficient charging or complete discharging of
the battery ................................................................................ Charge.
Lack of fuel ................................................................................. Supply fuel.
Air mixed in the fuel system ...................................................... Bleed the air.
Clogged fuel filter ..................................................................... Replace.
Irregular and faulty fuel supply
(Injection pump trouble) .......................................................... Repair in an authorized service shop.
Glow plug not heated ............................................................. Breakage of the glow plug: replace.
Improper viscosity of the lubricating oil ................................... Inspect and replace.
Clogged air cleaner .................................................................... Clean.
No compression ......................................................................... Repair in a service shop.
Broken fusible link ....................................................................... Replace.

B. IRREGULAR RUNNING OF THE ENGINE

CAUSE REMEDY
Air mixed in the fuel system ..................................................... Bleed the air.
Uneven fuel injection (Troubled fuel injection pump) ............. Repair at authorized shop.
Clogged fuel filter ....................................................................... Replace.
Defective governor .................................................................. Check and correct.
Engine itself defective ................................................................ Repair in a service shop.

C. ENGINE STOPS DURING OPERATION

CAUSE REMEDY
Lack of fuel in the fuel tank ...................................................... Supply fuel and bleed air.
Clogged fuel filter ........................................................................ Replace.
Air mixed in the fuel system ..................................................... Bleed the air.
Faulty function of the engine ...................................................... Repair in a service shop.

D. OVERHEAT OF THE ENGINE

CAUSE REMEDY
Lack of cooling water .................................................................. Supply water. Inspect leakage and correct.
Loosened or slipping fan belt ................................................... Remove oil, dust, etc. and tighten.
Damaged fan belt ...................................................................... Replace.
Clogged radiator ......................................................................... Flush the radiator.
Clogged radiator fin .................................................................... Clean.
Dust or scale clogged in the cooling water passage ............ Flush the system.
Faulty function of the thermostat ............................................. Inspect or replace thermostat.
Lack of lubricating oil .................................................................. Add oil.
Overloading ................................................................................ Decrease the load.

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 E. GAS (WHITE OR BLUE) SMOKE
CAUSE REMEDY
Excess engine oil ........................................................................ Inspect and correct the level.
Too low viscosity of the engine oil .............................................. Inspect and replace the oil to correct one.
Faulty injection timing ................................................................. 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.
ct and correct.
i r.
ace.
Repl
ace.
CAUSE
Unsuitable fuel .........................................................................
Excess injection ...........................................................................
Faulty function of the engine .....................................................
Overloading ................................................................................
REMEDY
Clogged air cleaner .................................................................... ct and tighten.
Clea ge the battery.
n. it in a service shop.
Repl
ace.
F DARK GREY SMOKE G.
FAULTY CHARGING
CAUSE
Loosened fan belt ..................................................................................
Correct
CAUSE REMEDY
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
Lack of engine oil ........................................................................ Supply oil up to the specified level.
H.Trouble
STARTERin the MOTOR DOES(mano-contact)
pressure switch NOT RUN ............. Replace the switch.
Oil leakage from the lubricating system .................................. Inspect and retighten.
Clogged oil filter .......................................................................... Replace with new one.
Short-circuit between oil pressure lamp
CAUSE
andLoosened or disconnected
mano-contact wiring ........................................................ Repair.
............................................................................
Inspect
Dropped voltage of the battery ........................................................... Char
Damaged starter motor .........................................................................
Repaair
Broken fusible link .............................................................................
Replace
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 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 Standard Standard To Be Allowable Remarks

Dimensio Value Repaire Limit
items n d
ENGINE
CYLINDER HEAD more than 30 less than 25 Engine 200rpm
(425 psi) (355 psi)

less than 0.05 more than 0.12

0.85-1.15 1.8 Valve seat angle

(.034-.045") (.045") 45"

1.7-2.1 2.5
(.067-.083") (.098")
5.25-5.75kgf.m Coat threads with
38-421bf/ft molybdenum bisul
fulde based grease.
CYLINDER BLOCK
Type 103-09 Dry type (single
piece)
Bore 72 71.99-72.005 72.2 73.2 Oversize (0.5, 1.0)
(2.835") (2.834-2.835") (2.843") (2.88") (.020/.040")
Type 103-10 Dry type (single
Bore 75 piece)
75-75.019 75.2 76.2 Oversize (0.5, 1.0)
(2.952") (2.95-2.954") (2.960") (3.0") (.020/.040")
Distortion of upper face of cylinder less than 0.05 0.12
block (.002") (.005")

PISTON 103-09
Skirt diameter (longer diameter) 72 (2.835") 71.9325-71.9475 (2.832-2.833") 71.7 (2.823") Oversize (0.5, 1.0)
(.020/.040")
Clearance to cylinder 0.0425-0.0725 (.0017-.0029") 0.25 (.009") 20'C
Inside diameter of piston pin 21 (826 ) 20.998-21.002 (.8267-8268")
Piston pin hole-to-pin clearance -0.004-+0.004 (-.0001 -± 0001 ) 0 02 ( 0007')
PISTON 103-10
Skirt diameter (longer diameter) 75 (2.952") 74.9425-74.9575 (2.950-2.951 ") 74.7 (2.941 ") Oversize (0.5, 1.0)
(.020/.040")
Clearance to cylinder 0.0425-0.0665 (.0017-.0026") 0.25 (.009") 20°C
Inside diameter of piston pin 21 (.826") 20.998-21.002 (.8266-.8268")
Piston pin hole-to-pin clearance -0.004-+0.004 (.0001-±.0001 ") 0.02 (.0007")
PISTON RING 103-09
Piston ring gap:
No. 1 ring 0.15-0.27
(.0059-.010")
No. 2 ring 0.12-0.24 1.0
(.004-.010") (.039")
Oil ring 0.2-0.35
(.007-.013")

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 Inspection items Standard Standard To Be Allowable
Dimension Value Repaired Limit Remarks
PISTON RING 103-09 (Continued)
Piston ring groove-to-ring clearance
No. 1 ring 0.06-0.1 0.25
(.002-.003") (.009")
No. 2 ring 0.05-0.09
(.002-.0035")
Oil ring 0.02-0.06 0.15
(.0007-.002") (.006)
Ring width
No. 1 ring 2 1.97-1.99
(.079") (.077-.078")
No. 2 ring 1.5 1.47-1.49 Oversize (0.5, 1.0)
(.059") (.058-.059") (.020/.040")
Oil ring 4 3.97-3.99
(.157") (.156-.157")
PISTON RING 103-10
Piston ring gap:
No. 1 ring 0.2-0.35
(.007-.013")
No. 2 ring 0.15-0.30 1.0

(.0059-.012") (.039")
Oil ring 0.15-0.35
(.0059-.014")
Piston ring groove-to-ring clearance
No. 1 ring 0.06-0.1 0.25
(.002-.003") (.009")
No. 2 ring 0.05-0.09
(.002-.0035")
Oil ring 0.02-0.06 0.15
(.0007-.002") (.006")
Ring width
No. 1 ring 2 1.97-1.99
(.079") (.078-.078")
No. 2 ring 1.5 1.47-1.49 Oversize (0.5, 1.0)
(.060") (.058-.059") (.020/.040")
Oil ring 4 3.97-3.99
CONNECTING ROD (.157") (.156-.157")
Twist between small and large end less than 0.08 0.2
holes (per 100mm) (.003") (.0007")
Straightness at 100mm between small less than 0.05 0.15
and large end hole (.002") (.006")
Front-to-rear clearance between 0.1-0.3 0.7
connecting rod and crank pin (.004-.011") (.0027")
Connecting rod bearing-to-crank pin 0.035-0.083 0.2 Oil clearance
clearance (.001-.003") (.0007")
Crush height of large end bearing 0.006-0.046 Crush height
(.0002-.0018")
Connecting rod bearing 39 x 17.5
(inner diameter x width) (1.535")
Connecting rod bolt torque kg-m 3.0-3.5
(22-251b/ft)
Weight difference with piston gram less than 10
Crush height of small end bush 0.034-0.095
(.001-.0037")
CRANKSHAFT
Diameter of journal 46 45.964-45.975 45.9 Undersize

(1.81") .0.25,0.0)
1.8096-1.810") (1.807"
(010-.020")
Diameter of pin 39 38.964-38.975 38.9 Same to above
(1.54") (1.534-1.535") (1.532")

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 Standard Standard To Be Allowable Remarks
Inspection items Dimension Value Repaired Limit

CRANKSHAFT (Continued)
Roughness, main journal and crank pin 1.6Z
Crankshaft deflection less than 0.03 more than 0.06
(less than.001") (more than .002"
Axial play of crankshaft 0.05-0.3 ) 0.5
(.002-.012") (.020")
Thickness of thrust washer 2.0 1.95-2.0 1.8
(.080") (.076-.080") (.070")
O.D. x I.D. of bush (journal metal) 46 x 50 Under size (0.25, 0.5)
(1.811-1.969") (.010-.020")
Crush height of bush (journal metal) 0.074-0.130
(.003-.005")
Clearance between crankshaft and 0.039-0.106 0.2 Oil clearance
journal (bush) (.0015-.004") (.009")
I.D. x O.D. of center bearing 46 x 50 Under size (0.25, 0.5)
(1.811-1.969") (.010-.020")
Clearance between crankshaft journal 0.039-0.092 0.2 Oil clearance
and center bearing (.0015-.004") (.009")
Tightening allowance of center bearing 0.008-0.048 Crush height
(.0003-.0018")
VALVE SYSTEM
CAMSHAFT

VALVE
Diameter of intake valve stem 6.955-6.97
1 6.89
(.2738-.2744") (.271 ")
Diameter of exhaust valve stem 6.94-6.95 6.84
(.273-.274") (2.69")
Clearance between valve I Inlet 0.03-0.06 more than 0.2
(.001 -.002") (more than .007")
stem and valve guide
Exhaust 0.05-0.75 more than 0.25
(.002-.003") (more than.010")

Valve clearance (Intake/exhaust) 0.2 0.5 When cold

(.008") (.020")
Spring strength (at 30.4mm 8.1 7
compressed length) kg (3.6lb/ft) (3.21b/ft)
Free length 35 (1.4") 33.5 (1.3")

Inlet valve Open-before l.u.u. 1i timing Close-

After B.D.C. 43° Exhaust valve Open-Before B.D.C.
43° timing Close-AfterTD.C. 13°
PUSH ROD

Overall length 157 156.8-157.2

(6.18") (6.173-6.189")
Outer diameter 6.3
(.248")

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 Inspection items Standard Standard To Be Allowable
Dimension Value Repaired Limit Remarks
ROCKER ARM
Wear, rocker arm shaft 11.66 11.65-11.668 11.57
(.460") (.459-.4594") (.456")
Clearance between rocker arm and 0.032-0.068 0.2 Oil clearance
shaft (.001-.002") (.008")
LUBRICATION SYSTEM
OIL PUMP
Oil pressure switch operating pressure 0.3 0.2-0.4
(kg/cm2) (2.17lb/ft) (1.45-2.891b/ft)
Relief pressure (kg/cm2) psi. 3-5
(43-71)
Tip clearance (rotor-to-vane) 0.01-0.15 0.25
(.0004-.006") (.010")
Side clearance (rotor-to-cover) 0.1-0.15 0.2
(.004-.006") (1.45")
FUEL SYSTEM
INJECTION PUMP KC30225, KC30226, KC30227, KC30228, KC30231, KC30232, KD30237, KD30238, KD30239, KD30240, KD30243, KD30244
Type 131017310
Diameter of plunger 5.0mm
Stroke of plunger 6mm
Before T D. C. 23'
Injection timing Piston movement 3.750mm
before T D. C. (.1476")
INJECTION PUMP KC30233, KC30234, KD30245, KD30246
Type 131017290
Diameter of plunger 5.5mm
Stroke of plunger 6mm
Before T D. C. 18°
Injection timing Piston movement 2.317mm
before TD.C. (.0912")
INJECTION PUMP KC30229, KC30230, KC30235. KC30236, KD30241, KD30242, KD30247, KD30248
Type 131017350
Diameterof plunger 5.5mm
Stroke of plunger 6mm
Before T D.C. 22°
Injection timing Piston movement 3.438mm
before T D. C. (.1353")
INJECTION NOZZLE
Type 131406330
Injection pressure kg/cm2 120 125-130
(116ats) (121-130ats) 103.09
Angle of injection direction 4° 103.10
COOLING SYSTEM
COOLING
Cooling method Water cooled forced circulation
Thermostat open temperature (°C) 71 69.5-72.5

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 Standard Standard To Be Allowable Remark
Inspection items Limit
Dimension Value Repaire s
d
COOLING (Continued)
Thermostat full-open temperature (°C) 82
Pump discharge (lit/min) 40
(at 2600rpm engine speed at cold)
ELECTRICAL SYSTEM
STARTER MOTOR
Type S114-381 185086321
No. of teeth of pinion gear 9
Shifting method of pinion Magnetic
Wear of commutator diameter 43(1.7") 40(1.6")
Stepped wear of commutator 0.05 (.002") 0.4 (.015")
Bending allowance of armature shaft 0.08 or more
(.003")
Length of brush 16 12
(.630") (.472")
Spring force of brush (kg) 1.6 1.4
(.7271b) (.6361b)
ALTERNATOR
Type GP9150 185046160
Bend of rotor shaft 0.07
(.003")
REGULATOR
Type RS510 185516060
Regulating voltage 14.5 1
14-15

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 103-06 Service Standards

103-06
Inspection items Standard Standard To Be Allowable
Dimension Value Repaired Limit Remarks

ENGINE
CYLINDER HEAD
more than 30 less than 25
(426.6) (355.5) Engine 200rpm
less than 0.05 more than 0.12
(.002") (.0047")

0.70-0.90 1.8
(.0256-.0354") (.0709")
Valve seat angle
45°

1.59-1.80 2.5
(.0626-.0709") (.098")
3.5-4.0 Coat threads with
(25.3-28.9) molybdenum bisul
fulde based grease.

CYLINDER
Type BLOCK Dry type (single piece)
Bore 64 64.00-64.019 64.2 65.2 Over size (0.5, 1.0)
(2.52") (2.5197-2.5204") (2.5276") (2.5669") (.02,.04")
Distortion of upper face of cylinder less than 0.05 0.12
block (.002") (.0047")
MAIN REVOLVING SYSTEM
PISTON
Skirt diameter (longer diameter) 64 63.948-63.963 63.7 Oversize (0.5, 1.0)
(2.52") (2.5176-2.5182") (2.5079") (.02,.04")
Clearance to cylinder 0.038-0.072 0.25 20°C
(.0015-.0028") (.010")
Inside diameter of piston pin 19 18.998-19.002
(.748") (.7480-.7481 ")
Piston pin hole-to-pin clearance -0.004-+0.004 0.02
(-.00016-+.00016") (.0008")
PISTON PIN
Outer diameter of pin 19 18.998-19.002
(.748") (.7480-.7481")
Small end bush-to-pin clearance 0.013-0.028 0.08 Oil clearance
(.0005-.0011") (.0031 ")
PISTON RING
Piston ring gap:
No. 1 ring 0.13-0.25
(.0051-0.01 ")
No. 2 ring 0.10-0.22 1.0
(.004-0.009") (.04")
Oil ring 0.10-0.30
(.004-.012")

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 Standard Standard To Be Allowable
Inspection items Remarks
Dimension Value Repaired Limit
PISTON RING (Continued)
Piston ring groove-to-ring clearance
No 1 ring 0.06-0.1
(.0024-.004") 0.25
No. 2 ring 0.05-0.09 (.010")
(.0020-.0035")
Oil ring 0.02-0.06 0.15
i (.0008-.0024") (.006")
Ring width
No. 1 ring 1.5 1.47-1.49
(.059") (.0579-.0587")
No. 2 ring 1.5 1.47-1.49 Oversize (0.5, 1.0)
(.059") (.0579-.0587") (.020,.04")
Oil ring 3 2.97-2.99
(.118") (.1169-.1177")
CONNECTING ROD
Twist between small and large end less than 0.08 0.2
holes (per 100mm) (.00315") (.008")
Straightness at 100mm between small less than 0.05 0.15
and large end hole (.002") (.006")
Front-to-rear clearance between 0.1-0.3 0.7
connecting rod and crank pin (.004-.012") (.028")
Connecting rod metal-to-crank pin 0.031-0.079 0.2 Oil clearance
clearance (.0012-.0031 ") (.008")
Crush height of large end bearing -0.01-+0.03 300kg
(-.0004-+.0012") (661.4lbs)
Connecting rod bearing 35 x 14.5
(inner diameter x width) (1.378 x o-s71 1

Connecting rod bolt torque kg.m 2.1-2.6

(15.2-18.8lbs/ft)
Weight difference with piston gram less than 10
Crush height of small end bush -0.013-+0.05 300kg
(-.0005-+.002") (661.4lbs)
CRANKSHAFT
No. 1, 2 43 42.964-42.975
Diameter of journal (1.693") (1.6915-1.6919") (1.689") Under size (0.25,0.5)
No. 3 46 45.948-45.959 45.9 (.01,.02")
(1.811") (1.8089-1.8094") (1.807")
Diameter of pin 35 34.964-34.975 34.9 Same to above
(1.378") (1.3765-1.3770") (1.374")
Roughness, main journal and crank pin 1.6Z
Crankshaft deflection less than 0.03 more than 0.06
(.0012") (.0024")
Axial play of crankshaft 0.1-0.3 0.5
(.004-.012") (.020")

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 Standard Standard To Be Allowable
Inspection items Dimension Value Repaired Limit Remarks
CRANKSHAFT (Continued)
O.D x I.D- of bush (journal metal) 47 x 43 Under size (0.25, 0.5)
(1.85 x 1.69") (.01,.02")
Crush height of bush (journal metal) 0.05-0.09 500kg
(.002-.0035") (1102.3lbs)
Clearance between crankshaft and 0.035-0.088 0.2 Oil clearance
journal metal (bush) (.0014-.0035") (.008")
O. D. x I. D. of center bearing 47 x 43 Undersize (0.25, 0.5)
(1.85 x 1.69") (.01, 0.2")
Clearance between crankshaft journal 0.035-0.088 0.2 Oil clearance
and center bearing (.0014-.0035") (.008")
Crush height of center bearing 43 +0.015-+0.055 300kg
(1.693") (+.0006 ..+0022") (661.4lbs)
Crush height of center bearing 46 0-+0.055 300kg
(1.811") (0-+.0022") (661.4lbs)
VALVE SYSTEM
CAMSHAFT
For intake/exhaust 26.565-26.620 26.1
(1.0459-1.0480") (1.028")
For injection pump 34.48-34.52 34.3
Height (1.3575-1.3591") (1.389")
of cam
For feed pump 27.9-28.0 27.0
PB126 (1.0984-1.1024") (1.063")
Backlash of cam gear 0.08 0.25
(.0031 ") (.010")
VALVE
Diameter of intake valve stem 5.960-5.975 5.9
(.2346-.2352") (.2323")
Diameter of exhaust valve stem 5.940-5.955 5.9
(.2339-.2344") (.2323")
Inlet 0.025-0.052 more than 0.2
Clearance between valve (.001 -.002") (.008")
stem and alve guide Exhaust 0.045-0.072 more than 0.25
(.0018-.0028") (.010")
Thickness of valve 1.0 0.925-1.075 0.5
(.04") (.0364-.0423") (.020")

PB127 -
T-Valve clearance (intake/exhaust) 0.2 0.5 When cold
(.008") (.020")
Spring strength (at 28.3mm 6.9 6.0
compressed length) kg (15.211 bs) (13.2Ibs)
Valve Free length 33 31.5
spring (1.299") (1.240")
Squareness y X--- less than 1.0 i1.2

(.04") (.05")

PB128

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 Standard Standard To Be Allowable
Inspection items Dimension Value Repaired Limit Remarks

VALVE (Continued)
Inlet valve Open-BeforeTD.C. 13°
timing Close-After B.D.C. 43°
Exhaust valve Open-Before B.D.C. 43°
timing Close-AfterTD.C. 13°
PUSH ROD
Overall length 146 145.6-146.4
(5.748") (5.732-5.764")
Outer diameter 6.3
(.248")
ROCKER ARM
Wear, rocker arm shaft 11.66 11.65-11.67 11.57
(.459") (.4587-.4594") (.4555")
Clearance between rocker arm and 0.032-0.068 0.2 Oil clearance
shaft (.0013-.0027") (.008")
LUBRICATION SYSTEM
OIL PUMP

Oil pressure switch operating pressure 0.3 0.2-0.4

(kg/cm2) (psi) (4.27) (2.844-5.688)
Relief pressure (kg/cm2) (psi) 3-5
(42.66-71.1)
Lubrication oil capacity (lit) 3.0
Tip clearance (rotor-to-vane) 0.02-0.15 0.25
(.0008-.006") (.010")
Side clearance (rotor-to-cover) 0.1-0.15 0.2
(.004-_006") (.008")
FUEL SYSTEM
INJECTION PUMP
Type 131017390
Diameter of plunger 4.5
(.177")
Stroke of plunger 6
BeforeTD.C. 27.0-29.0°
Injection timing Piston movement 4.573-5.251
beforeTD.C. (.1800-.2067')

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 Inspection items Standard Standard To Be Allowable
Dimension Value Repaired Limit Remarks
INJECTION NOZZLE
Type 093500-2240 (Part No. 131406340
Injection pressure kg/cm2 (psi) 120 115-125
(1706) (1635.3-1777.5)
Angle of injection direction 4°
COOLING SYSTEM
COOLING
(tooling method Water cooled, forced circulation

Thermostat open temperature ('C) 75 73.5-76.5

Thermostat full-open temperature ('C) 90
Pump discharge (lit/min) 40
(at 2500rpm engine speed at cold)
ELECTRICAL SYSTEM
STARTER MOTOR
Type M003T32589 (Part No. 185086370)
No. of teeth of pinion gear 8
Shifting method of pinion Magnetic
Wear of commutator diameter 32 31
(1.26") (1.22")
Stepped wear of commutator 0.05 0.4
(.002") (.016")
Bending allowance of armature shaft 0.08 or more
(.003")
Length of brush 17 11.5
(.63") (.45")
Spring force of brush (kg) (Ibs) 1.95 1.66-2.24 0.9
(4.3) (3.66-4.94) (1.98)
ALTERNATOR
Type GP8146 (Part No. 185046210)
Bend of rotor shaft 0.07 (.
0028")
REGULATOR
Type RS5101 (Part No. 185516060)
Regulating voltage 14.5 14-15

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 SECTION IX
Recommended Torque
Tensions for 103-06, 103-09, 103-10,
Perama M25, M30

Tensions kgf m (lbf ft)

COMPONENT Other engines 103-06

Bearing holder bolts ................................................. 2.5-3.0 (19-22) 2.0-2.5 (14-18)

Rear plate bolts ......................................................... 4.7-5.5 (34-40) 1.3-1.7 (9-12)
Flywheel bolts ........................................................... 6.0-7.0 (43-51) 7.0-8.0 (51-58)
Connecting rod nuts ................................................. 3.0-3.5 (22-25) 2.1-2.6 (15-19)
Suctionfilter bolts ...................................................... 0.9-1.3 (7-9) 0.9-1.3 (7-9)
Sump bolts ................................................................ 0.9-1.3 (7-9) 0.9-1.3 (7-9)

Crankshaft pulley nut ................................................ 12-13 (87-94) 9-10 (65-72)

Cylinder head bolts ................................................... 5.0-5.3 (36-38) oiled 3.5-4 (25-29)
Injection pump bolts ................................................. 0.9-1.3 (7-9) 0.9-1.3 (7-9)
Injection pump nut .................................................. 0.9-1.3 (7-9) 0.9-1.3 (7-9)
Rocker arm nuts ..................................................... 2.0-2.5 (15-19) 2.0-2.5 (15-19)
Head cover nuts ...................................................... 1.0-1.2 (7-9) 1.0-1.2 (7-9)
Cooling fan bolts ..................................................... 0.9-1.3 (7-9) 0.9-1.3 (7-9)
Oil pipe banjo bolts ................................................... 1.0-1.3 (7-9) 1.0-1.3 (7-9)
Oil pan drain bolt ..................................................... 3.0-4.0 (22-29) 3.0-4.0 (22-29)
Injection nozzle ....................................................... 8.0-8.5 (58-62) 6-7(43-51)
Injection pipe ........................................................... 2.0-2.5 (15-19) 2.0-2.5 (15-19)
Thermo switch ........................................................ 2.5-3.0 (19-22) 2.5-3.0 (19-22)
Oil pressure switch .................................................. 1.5-2.0(11-15) 1.5-2.0(11-15)
Glow plug ................................................................... 1.5-2.0(11-15) 1.5-2.0(11-15)
Solenoid .................................................................. 1.5-2.0(11-15) 1.5-2.0(11-15)
Relief valve ................................................................. 6.0-7.0 (44-51) 6.0-7.0 (44-51)
Smokeset nut (max fuel) ........................................... 2.0-2.5 (15-19) 2.0-2.5 (15-19)
Adjusting screw nuts .................................................. 1.3-1.7 (7-12) 1.3-1.7 (7-12)

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 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 1 Ensure that the seacock is closed.
Hurth reverse gearbox 2 Disconnect the hose connections at the pump.
1 Release and remove the dipstick from the top of
3 Remove the four setscrews which fasten the
the reverse gearbox (A).
pump to its drive housing. Remove the pump.
2 Clean the dipstick and insert it into its position
4 Clean and inspect for wear the drive components
but do not engage the thread.
of the pump. Renew the drive adaptor and/or the
3 Remove the dipstick and check that the
pump, if necessary.
lubricating oil level is up to the groove (Al) in
the dipstick. If necessary, add automatic trans-
mission 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
`

400-000*044

40-0001
1
1
5 Release the six screws which fasten the end
I 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
How to check/lubricate the impeller and the drive of and fit the impeller into the housing with the
the raw water pump blades bent anticlockwise (A). Fit the rubber
Attention: Do not loosen the drive housing of end cap.
the raw water pump. The alignment of this
housing has been carefully adjusted with a
special alignment tool.

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 7 Clean the contact surfaces of the pump body and 3 Operate the engine until it is warm. Then correct
the end plate. Apply jointing compound to a leakages of fuel, lubricating oil or air. Stop the
new joint and fit it to the body with the wide area engine and drain the lubricating oil from the
of the joint over the eccentric plate (Al) in the sump.
body. Fit the end plate and tighten the end 4 Renew the canister of the lubricating oil filter.
plate screws.
5 Fill the sump to the full mark with new and clean
8 Apply a high melting point grease (for example
lubricating oil and add POWERPART Lay-Up 2
Shell Alvania R2) to the drive housing and to the
to the oil to protect the engine against corrosion. If
drive components.
POWERPART Lay-Up 2 is not available, use a
9 Fit the pump to its adaptor plate with a new joint
correct preservative fluid instead of the
between the pump and the plate. Tighten the
lubricating oil. If a preservative fluid is used, this
four pump setscrews.
must be drained and the lubricating oil sump
10 Connect the hose connections at the pump. must be filled to the correct level with normal
11 If necessary, open the seacock. How to clean the lubricating oil at the end of the storage period.
6 Drain the coolant circuit. In order to protect the
tube stack of the heat exchanger cooling system against corrosion, it is neces-
If there are hard deposits or debris in the tubes, the sary to fill it with a coolant that has a corrosion
best method to clean them is to use a non- inhibitor. If protection against frost is necessary, use
caustic solution which is approved by the an antifreeze mixture. If protection against frost
manufacturer. is not necessary, use water with an approved
If the deposits or the debris are soft, the tubes mixture of corrosion inhibitor.
can be cleaned with a steel rod pushed through 7 Operate the engine for a short period in order to
the tubes in the opposite direction to the water circulate the lubricating oil and the coolant in the
flow. Ensure that the rod does not damage the engine.
tubes. 8 Close the seacock and drain the raw water cooling
system. If a lubricating oil cooler is fitted to the
To obtain access to the tube stack
Hurth reverse gearbox and protection against
1 Drain the circuits of the cooling system. frost is necessary, disconnect the top hose at the
2 Loosen the support clips of the outlet pipe of the cooler and inject 50ml (0.1 UK pint) of undiluted
heat exchanger and disconnect the pipe from the antifreeze into the cooler.
front end cap of the heat exchanger. 9 Remove the end plate from the raw water pump and
3 Loosen the clips of the neoprene end caps and lubricate the impeller and the inside of the pump
remove the caps. The tubes can now be with Marfak 2HD grease or glycerine. If
checked for restriction and cleaned, if necessary. necessary, glycerine can be put in the inlet
4 Ensure that there is an equal protrusion of the connection of the pump but the engine must be
tube stack through each end of the housing turned to circulate the glycerine through the
before the end caps are fitted. pump.
Attention: The raw water pump must never run
Engine Preservation in a dry condition because this can damage the
The recommendations indicated below are impeller blades.
designed to prevent damage to the engine when it 10 Remove the atomisers and spray POWERPART
is withdrawn from service for a prolonged Lay-Up 2 into each cylinder bore. If this is not
period. Use these procedures after the engine available, clean engine lubricating oil will give
is withdrawn from service. The instructions for a degree of protection. Spray into the cylinder
the use of POWERPART products are given on bores 140m1 (0.25 pint) of lubricating oil divided
the outside of each container. evenly between the cylinders.
Procedure 11 Slowly turn the crankshaft one revolution and
then fit the atomisers, complete with new seat
1 Completely clean the outside of the engine. washers.
2 When a preservative fuel is to be used, drain the 12 Remove the air filter or the induction cap. Spray
fuel system and fill it with the preservative fuel. POWERPART Lay-Up 2 into the induction
POWERPART Lay-Up 1 can be added to the manifold. Seal the manifold with waterproof
normal fuel to change it to a preservative fuel. tape.
If preservative fuel is not used, the system can 13 Remove the exhaust pipe. Spray POWERPART
be completely filled with normal fuel but the fuel Lay-Up 2 into the exhaust manifold. Seal the
must be drained and discarded at the end of the manifold with water proof tape.
storage period together with the fuel filter
canister.

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 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 alter-
normal 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
with the stop button pressed or with the engine • The battery is discharged.
stop control in the "stop" position until oil pres- • The battery is hotter than normal which is an
sure is indicated. Oil pressure is indicated when the indication of loss of voltage control.
low pressure warning light is extinguished. If one or more of the above symptoms occur, the
If the engine protection is done correctly procedure indicated below should be
according to the above recommendations, no applied.
corrosion damage will normally occur. Perkins 1 Ensure that the battery is in a fully charged
are not responsible for damage which may condition.
occur when an engine is in storage after a period in 2 Connect a moving-coil voltmeter of good quality,
service. with a range of 0-50 volts, across the positive
and negative terminals of the alternator. If an
Alternator A127 - 55 amp -
ammeter is not fitted in the electrical circuit, fit
To remove and to fit a moving-coil ammeter of good quality, with a
range of 0-100 ampere, in the wire between the
• remove alternator and the positive terminal of the
1 Disconnect the electrical connection. battery.
2 Loosen the pivot fasteners of the alternator and the 3 Turn the warning light switch to the "on" position (
fasteners of the adjustment link. main switch on instrument panel) when the
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
• fit engine speed.
1 Put the alternator in position and assemble 6 Increase the engine speed for a moment to near
loosely the pivot fasteners and the adjustment maximum speed, when the charge current
link and its fasteners. Ensure that the washers should be approximately 55 amperes (A127) for a
and the distance pieces are fitted in their correct 12 volt system.
positions and that the alternator pulley is aligned to 7 Operate the alternator at approximately half speed
the crankshaft pulley within ±2.4mm (3/32in). (engine speed approximately 1800 rev/ min) and
2 Fit the drive belt and adjust the drive belt tension. remove the electrical load. The voltage should go
Tighten the fasteners and check the tension up to 14 volts for a 12 volt system or 28 volts for
again. a 24 volt system and then remain constant. At
the same time the current reading should show
3 Connect the electrical connection.
a reduction.
• maintain If a fault is found, the alternator should be
1 Ensure that the drive belt is not worn and that removed for test by a specialist.
the belt tension is correct. The regulator is a sealed unit and a repair is not
2 Keep the alternator clean. To clean the alternator, possible. If there is a regulator fault, the regulator
use a material which is damp with must be renewed.

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 SECTION XI
Conversion Formulas

TIGHTENING TORQUE TABLES

Coarse thread Fine thread SS41

Bolt head ;3 S20C S45C SCM435
Screw Tightening Screw Tightening
Screw identification SGD41-D
size marks as per pitch torque pitch torque SWRM12
grade (mm) (kgf.cm) (mm) (kgf.cm)
4T,4.8 15-- 21 i
~~ 10T
M4 7T, 8T, 8.8 0.7 27- 37
Y
10T,11 T 36- 50
E i

4T 8T
4T, 4.8 29-- 41
d
7T, 8T, 8.8 0.8 50--- 0
M5 z
70 o
10T, 11T 68- 96 m

4T, 4.8 50- 70 4.8 8.8

M6 7T 8T, 8.8 1.0 85- 115
0010
10T, 11T 120- 160

4T, 4.8 130-- 170 155- 205

M8 7T, 8T, 8.8 1.25 230- 290 1.0 270-- 350

10T,11 T 290- 370 310- 410

4T, 4.8 260--- 340 290-- 370

M10 7T, 8T, 8.8 1.5 450-- 570 1.25 500--- 640

10T 11T 550-- 710 590--- 750

4T, 4.8 380- 480 440- 560

M12 4T, 8T, 8.8 1.75 670- 850 1.25 760- 960

10T, 11T 940-1,180 1,010-1,290

4T, 4.8 640--- 820 710--- 890

M14 7T, 8T, 8.8 2.0 1,060-1,340 1.5 1,190-1,510

10T, 11T 1,420-1,780 1,500-1,900

4T, 4.8 880-1,120 930-1,170

M16 7T, 8T, 8.8 2.0 1,520-1,880 1.5 1,600-1,960

10T, 11T 2,100-2,600 2,250-2,750

4T, 4.8 1,160-1,440 1,3401,660

M18 7T, 8T, 8.8 2.0 2,000-2,400 1.5 2,350-2,850

10T, 11T 2,800-3,400 3,050-3,750

4T, 4.8 1,470.1,830 1,750-2,150

M20 7T, 8T, 8.8 2.5 2,450-2,950 1.5 2,800-3,400

10T, 11T 3,700-4,500 4,050-4,950

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 TIGHTENING TORQUE TABLES
Coarse thread
Fine thread
Bolt head
Screw identification Screw Tightening torque Screw Tightening torque
size marks as per pitch pitch

grade (mm) lbs-ft N.m (mm) lbs-ft N.m

4T, 4.8 3.6-5.1 4.9-6.9
M6 7T, 8T, 8.8 1.0 6.1-8.3 8.3--11.3

10T 11T 8.7--11.6 11.8---15.7

4T, 4.8 9.4-12.3 12.7-16.7 11.2-14.8 15.2-20.1

M8 7T, 8T, 8.8 1.25 16.6-21.0 22.6--28.4 1.0 19.5-25.3 26.5-34.3
10T 11T 21.0--26.8 28.4-36.3 22.4-29.7
30.4-40.2
4T, 4.8 18.8-24.6 25.5-33.3 21.0--26.8 28.4-36.3
M10 7T, 8T, 8.8 1.5 32.6--41.2 44.1-55.9 1.25 36.2-46.3 49.0-62.8
10T, 11T 39.8--51.4 53.9-69.6
42.7-54.3 57.9-73.6
4T, 4.8 27.5--34.7 37.3--47.1 31.8-40.5 43.2-54.9
M12 7T, 8T, 8.8 1.75 55.7-61.5 65.7-83.4 1.25 55.0-69.5 74.5-94.1
10T, 11T 68.0-85.4 92.2-116 73.1---93.3 99.1--127
4T, 4.8 46.3--59.3 62.8-80.4 51.4-64.4 69.6-87.3
M14 7T, 8T, 8.8 2.0 76.7-96.9 104-131 1.5 86.1--109 117-148
10T, 11T 103-129 139-175 109-137 147-186
4T, 4.8 63.7-81.0 86.3--110 67.3-84.6 91.2-115
M16 7T, 8T, 8.8 2.0 110--136 149-184 1.5 116-142 157-192
10T, 11T 152-188 206-255 163-199 221-270

4T, 4.8 83.9-104 114-141 96.9-120 131-163

M18 7T, 8T, 8.8 2.0 145-174 196-235 1.5 170-206 230-279
10T, 11T 203-246 275-333 221--271 299-368
4T, 4.8 106-132 144-1.79 127-156 172-211
M20 7T, 8T, 8.8 2.5 177-213 240-289 1.5 203-246
275-333
10T, 11T 268-326 363-441 293-358
-° SS41 397-485

SGD41-D S45C SCM435

SWRM12

10T
\ /

E /
M 4T 8T

8
L I
a+
O
m

4.8

88
0010-1

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 CONVERSION TABLES

kgf-m Ibs/ft, (N.m)

.0 .1 .2 .3 .4 .5 .6 .7 .8 .9

0.723 1.45 2.17 2.89 3.62 4.34 5.06 5.79 6.51

0 (8.82)
(0.98) (1.96) (2.94) (3.92) (4.9) (5.88) (6.86) (7.84)

1 7.233 7.96 8.7 9.4 10.1 10.8 11.6 12.3 13.0 13.7
(9.8) (10.8) (11.8) (12.7) (13.7) (14.7) (15.7) (16.7) (17.6) (18.6)

2 14.5 15.2 15.9 16.6 17.4 18.1 18.8 19.5 20.3 20.9
(19.6) (20.6) (21.6) (22.5) (23.5) (24.5) (25.5) (26.5) (27.4) (28.4)

3 21.7 22.4 23.1 23.9 24.6 25.3 26.0 26.8 27.5 28.2
(29.4) (30.4) (31.4) (32.3) (33.3) (34.3) (35.3) (36.3) (37.2) (38.2)

4 28.9 29.7 30.4 31.1 31.8 32.5 33.3 34.0 34.7 35.4
(39.2) (40.2) (41.2) (42.1) (43.1) (44.1) (45.1) (46.1) (47.0) (48.0)

5 36.2 36.9 37.6 38.3 39.1 39.8 40.5 41.2 42.0 42.7
(49.0) (50.0) (51.0) (51.9) (52.9) (53.9) (54.9) (55.9) (56.8) (57.8)

6 43.4 44.1 44.8 45.6 46.3 47.0 47.7 48.5 49.2 49.9
(58.8) (59.8) (60.8) (61.7) (62.7) (63.7) (64.7) (65.7) (66.6) (67.6)

56.4 57.1
50.6 51.4 52.1 52.8 53.5 54.2 55.0 55.7
7
(76.4) (77.4)
(68.6) (69.6) (70.6) (71.5) (72.5) (73.5) (74.5) (75.5)

8 57.9 58.6 59.3 60.0 60.8 61.5 62.2 62.9 63.7 64.4
(78.4) (79.4) (80.4) (81.3) (82.3) i (83.3) (84.3) (85.3) (86.2) (87.2)

70.2 70.9 71.6

65.1 65.8 66.5 67.3 68.0 68.7 69.4
9
(95.1) (96.0) (97.0)
(88.2) (89.2) (90.2) (91.1) (92.1) (93.1) (94.1)

0 For example

5.8 kgf-m = 42.0 lbs-ft

I
(56.8 N.m)
t
1
.8 .9
.1 .2 .3 .4 .5 .6 .7
1 (
2
II 1mm =0.03937in.
3
1m =3.28084ft. 1
4 42.0
- kgf-m =7.2331bs-ft 1
+ kfg-m = 9 . 8 N . m 1 kg/cm
5 (56.8) -
6 2 =14.22psi.
7 1kg =2.204621bs
8
9

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