Perkins 700 Series Instruction Manual

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700 Series
Users Handbook
Workshop Manual
Perkins 700 Series
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How to use this manual
Perkins 700 Series
User's Handbook
Models UA, UB and UC
4 Cylinder naturally aspirated and turbocharged
diesel engines for industrial, agricultural and fork
lift truck applications
Publication TPD 1336E Issue 6
This publication is written for worldwide use. In territories where legal requirements govern engine smoke, emission, noise,
safety factors, etc., then all instructions, data and dimensions given must be applied in such a way that, after servicing
(preventive maintenance) or repairing the engine, it does not contravene the local regulations when in use.
The information is correct at time of print.
Published in May 1999 by Technical Publications, Hawtal Whiting Engineering Ltd.

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700 Series
Section 1
2
General information
Introduction
The Perkins 700 Series engines are some of the
latest developments from Perkins Engines Company
Limited,aworldleaderinthedesignandmanufacture
of high performance diesel engines.
The current range of engines includes the naturally
aspirated and turbocharged versions of the 704-30
direct injection, water cooled diesel engines. These
engines are designed for industrial and agricultural
applications. Also in the range there is the naturally
aspirated 704-26 indirect injection, water cooled
diesel engine. This engine is designed for fork lift
truck applications.
These engines conform to Stage 1 off-highway
emissions to C1-8 mode cycle.
More than sixty years of diesel production
experience, together with the latest technology, have
been applied to the manufacture of your engine to
give you reliable and economic power.
Note: To ensure that you use the relevant
information for your specific engine type, refer to
"Engine identification" on page 7.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible
danger to the person.
Caution: This indicates that there is a possible
danger to the engine.
Note: Is used where the information is important, but
there is not a danger.

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700 Series
3
Contents
1 General information
Title page … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 1
Introduction … … … … … … … … … … … … … … … … … … … … … … … … … … … … 2
Contents … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 3
How to care for your engine … … … … … … … … … … … … … … … … … … … … … … 5
Safety precautions… … … … … … … … … … … … … … … … … … … … … … … … … …6
Engine identification … … … … … … … … … … … … … … … … … … … … … … … … …7
Perkins companies … … … … … … … … … … … … … … … … … … … … … … … … …8
2 Engine views
Introduction … … … … … … … … … … … … … … … … … … … … … … … … … … … …9
Location of engine parts… … … … … … … … … … … … … … … … … … … … … … … …9
3 Operation Instructions
How to start the engine … … … … … … … … … … … … … … … … … … … … … … … 13
How to start a cold engine in cold conditions … … … … … … … … … … … … … … … … 14
How to start a cold engine in temperate conditions … … … … … … … …… … … … … … 15
How to stop the engine … … … … … … … … … … … … … … … … … … … … … … … 15
Adjustment of engine speed range … … … … … … … … … … … … … … … … … … … 16
Engine operation at idle speed … … … … … … … … … … … … … … … … … … … … … 16
Running in … … … … … … … … … … … … … … … … … … … … … … … … … … … … 16
Altitude … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 16
Angle of tilt … … … … … … … … … … … … … … … … … … … … … … … … … … … … 16
4 Preventive maintenance
Preventive maintenance periods … … … … … … … … … … … … … … … … … … … … 17
Schedules … … … … … … … … … … … … … … … … … … … … … … … … … … … … 18
How to drain the cooling system  … … … … … … … … … … … … … … … … … … … … 19
How to check the specific gravity of the coolant … … … … … … … … … … … … … … 20
How to check the drive belt … … … … … … … … … … … … … … … … … … … … … … 21
How to adjust the belt tension … … … … … … … … … … … … … … … … … … … … …  21
How to renew the element / canister of the fuel filter  … … … … … … … … … … … … … 22
Atomiser fault … … … … … … … … … … … … … … … … … … … … … … … … … … … 23
How to renew an atomiser - UA & UC engines… … … … … … … … … … … … … … … … 23
How to renew an atomiser - UB engines … … … … … … … … … … … … … … … … … … 24
How to eliminate air from the fuel system … … … … … … … … … … … … … … … … … 26
How to renew the lubricating oil … … … … … … … … … … … … … … … … … … … … 27
How to renew the canister of the lubricating oil filter … … … … … … … … … … … … … 28
How to renew the engine breather assembly - UA & UB Engines … … … … … … … … … 29
Air filter and restriction indicator … … … … … … … … … … … … … … … … … … … … 30
How to set the valve tip clearances … … … … … … … … … … … … … … … … … … … 31

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4
Contents
5 Engine Fluids
Fuel specification … … … … … … … … … … … … … … … … … … … … … … … … … … 33
Lubricating oil specification … … … … … … … … … … … … … … … … … … … … … … 34
Coolant specification … … … … … … … … … … … … … … … … … … … … … … … … 35
6 Fault diagnosis
Problems and possible causes … … … … … … … … … … … … … … … … … … … … … 36
List of possible causes … … … … … … … … … … … … … … … … … … … … … … … … 37
7 Engine preservation
Introduction … … … … … … … … … … … … … … … … … … … … … … … … … … … … 38
Procedure… … … … … … … … … … … … … … … … … … … … … … … … … … … … … 38
8 Parts and service
Introduction … … … … … … … … … … … … … … … … … … … … … … … … … … … … 40
Service literature … … … … … … … … … … … … … … … … … … … … … … … … … … 40
Training … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 40
POWERPART Recommended consumable products … … … … … … … … … … … … … 40
9 General data
Engine … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 42

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700 Series
Section 1
5
General information
How to care for your engine
Caution: Do not clean an engine while it
runs. If cold cleaning fluids are applied to a hot
engine, certain components on the engine may be
damaged.
This handbook has been written to assist you to
maintain and operate your engine correctly.
To obtain the best performance and the longest life
from your engine, you must ensure that the
maintenance operations are done at the intervals
indicated in "Preventive maintenance". If the engine
works in a very dusty environment or other adverse
conditions, certain maintenance intervals will have to
be reduced. Renew the filter canister and lubricating
oil regularly in order to ensure that the inside of your
engine remains clean.
Ensure that all adjustments and repairs are done by
personnel who have had the correct training. Perkins
distributorshave this type of personnelavailable.You
can also obtain parts and service from your Perkins
distributor, enquire at one of the Perkins companies
listed on page 8.
The terms "left side" and "right side" apply when the
engine is seen from the flywheel end.
Warning! Read the "Safety precautions" and
remember them. They are given for your protection
and must be applied at all times.

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700 Series
Section 1
6
General information
Safety precautions
These safety precautions are important. You must
referalsotothelocalregulationsin the countryofuse.
Some items only apply to specific applications.
• Always refer to the text of this handbook for
specific warnings and cautions.
• Only use these engines in the type of application
for which they have been designed.
• Do not change the specification of the engine.
• Do not make adjustments that you do not
understand.
• Do not smoke when you put fuel in the tank.
• Clean away fuel which has been spilt. Material
which has been contaminated by fuel must be
moved to a safe place.
•Do not put fuel in the tank while the engine runs
(unless it is absolutely necessary).
•Do not clean, add lubricating oil, or adjust the
engine while it runs (unless you have had the
correct training; even then extreme caution must
be used to prevent injury).
•Ensure that the engine does not run in a location
where it can cause a concentration of toxic
emissions.
•Other persons must be kept at a safe distance
while the engine, auxiliary equipment is in
operation.
•Do not permit loose clothing or long hair near
moving parts.
Warning! Keep away from moving parts during
engine operation. Warning! Some moving parts
cannot be seen clearly while the engine runs.
•Do not operate the engine if a safety guard has
been removed.
•Do not remove the filler cap or any component of
the cooling system while the engine is hot and
while the coolant is under pressure, because
dangerous hot coolant can be discharged.
•Do not allow sparks or fire near the batteries
(especially when the batteries are on charge)
because the gases from the electrolyte are highly
flammable. The battery fluid is dangerous to the
skin and especially to the eyes.
•Disconnect the battery terminals before a repair is
made to the electrical system.
•Only one person must control the engine.
•Ensure that the engine is operated only from the
control panel or from the operator's position.
•If your skin comes into contact with high-pressure
fuel, obtain medical assistance immediately.
•Diesel fuel and lubricating oil (especially used
lubricating oil) can damage the skin of certain
persons. Protect your hands with gloves or a
special solution to protect the skin.
•Do not wear clothing which is contaminated by
lubricating oil. Do not put material which is
contaminated with oil into the pockets.
•Discard used lubricating oil and coolant in
accordance with local regulations to prevent
contamination.
•Ensure that the control lever of the transmission
drive is in the "out-of-drive" position before the
engine is started.
•The combustible material of some components of
the engine (for example certain seals) can
becomeextremelydangerousifitisburned.Never
allow this burnt material to come into contact with
the skin or with the eyes.
•Always use a safety cage to protect the operator
when a component is to be pressure tested in a
container of water. Fit safety wires to secure the
plugs which seal the hose connections of a
component which is to be pressure tested.
•Do not allow compressed air to contact your skin.
If compressed air enters your skin, obtain medical
help immediately.
•Turbochargers operate at high speed and at high
temperatures.Keepfingers,toolsanddebrisaway
from the inlet and outlet ports of the turbocharger
and prevent contact with hot surfaces.
•Some components are not waterproof and should
not be washed with a high-pressure water jet or
steam.
•Fit only genuine Perkins parts.

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700 Series
Section 1
7
General information
Engine identification
704-30 engine - identification letters UA
704-30T engine - identification letters UC
704-26 engine - identification letters UB
The engine number is stamped on the left side of the
cylinder block (A1), behind the high pressure pump.
The engine number is stamped on a plate on the right
side of the cylinder block.
An example of an engine number is
UA80862U123456F
UA Type code letters
8086 Build list number
U Built in the UK
123456 Engine serial number
F Year of manufacture
If you need parts, service or information for your
engine,youmustgivethecompleteenginenumberto
your Perkins distributor.

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700 Series
Section 1
8
General information
Perkins companies
Australia
Perkins Engines Australia Pty. Ltd,
Suite 4, 13A Main Street,
Mornington 3931, Victoria, Australia.
Telephone: [phone]
Telex: Perkoil AA30816
Fax: [phone]
France
Moteurs Perkins S.A.,
"Parc des reflets",
165 Avenue du Bois de la Pie,
95700 Roissy Charles de Gaulle, France.
Telephone: [phone]
Fax: [phone]
Germany
Perkins Motoren GmbH,
Saalaeckerstrasse 4,
63801 Kleinostheim,
Germany.
Telephone: [phone]
Fax: [phone]
Italy
Motori Perkins S.p.A.,
Via Socrate 8,
22070 Casnate con Bernate (Como), Italy.
Telephone: [phone]/564625
Fax: [phone]
Japan
Perkins Engines (Japan) K.K.,
Reinanzaka Building, 5th Floor,
14-2 Akasaka, 1-chome, Minato-ku,
Tokyo 107, Japan.
Telephone: [phone]
Telex: Perkoil J2424823
Fax: [phone]
Singapore
Perkins Engines (Far East) pte Ltd
Tuas Avenue 13
Singapore 638999
Telephone: [phone]
Fax: [phone]
United Kingdom
Perkins Engines Company Ltd,
Eastfield, Peterborough PE1 5NA,
England.
Telephone: [phone]
Telex: 32501 Perken G
Fax: [phone]
United States of America
Perkins International - North America,
26200 Town Center Drive,
Suite 280,
Novi, Michigan 48375
USA
Telephone: [phone]
Fax: [phone]
Perkins Engines Latin America Inc,
Suite 620,
999, Ponce de Leon Boulevard,
Coral Gables,
Florida 33134, U.S.A.
Telephone: [phone]
Telex: 32501 Perken G
Fax: [phone]
In addition to the above companies, there are
Perkins distributors in most countries. Perkins
Engines Company Limited., Peterborough or one
of the above companies can provide details.

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700 Series
Section 2
9
Engine Views
Engine views
Introduction
Perkins engines are built for specific applications and the views which follow do not necessarily match your
engine specification.
Location of engine parts
Front and left side view of a UA or a UB engine (A)
1 Front lift bracket
2 Return connection from the heater
3 Thermostat housing
4 Outlet connection for the coolant
5 Coolant pump pulley
6 Alternator
7 Drive belt
8 Crankshaft pulley
9 Engine breather
10 Rear lift bracket
11 Exhaust manifold
12 Filler cap for the lubricating oil
13 Outlet connection for the heater
14 Starter motor

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Section 2
10
Engine Views
Rear and right side view of a UA or a UB engine (A)
15 Rocker cover
16 Atomiser
17 Glow plug
18 Fuel filter
19 Engine identification number
20 Flywheel housing
21 Flywheel
22 Canister for the lubricating oil filter
23 Air inlet connection
24 Induction manifold
25 Inlet connection for the coolant
26 Fuel injection pump
27 Stop control solenoid
28 Speed control
29 Lubricating oil dipstick
30 Fuel lift pump
31 Sump for the engine lubricating oil

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Section 2
11
Engine Views
Front and left side view of a UC engine (A)
1 Front lift bracket
2 Fan
3 Thermostat housing
4 Outlet connection for the coolant
5 Coolant pump pulley
6 Alternator
7 Drive belt
8 Crankshaft pulley
9 Cross-over pipe
10 Turbocharger
11 Exhaust manifold
12 Filler cap for the lubricating oil
13 Starter motor
14 Drain plug for the lubricating oil
A
1
2
3
4
6
5
7
11
10
12
13
14
9
8

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Section 2
12
Engine Views
Rear and right side view of a UC engine (A)
15 Rear lift bracket
16 Atomiser
17 Glow plug
18 Induction manifold
19 Engine breather
20 Lubricating oil dipstick
21 Flywheel housing
22 Flywheel
23 Lubricating oil sump
24 Fuel injection pump
25 Stop control solenoid
26 Engine speed control
27 Fuel lift pump
28 Lubricating oil cooler
29 Lubricating oil filter canister
30 Fuel filter canister
A
15
17
19
21
22
23
20
16
18
24
26
25
27
29
28
30

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700 Series
Section 3
13
Operation Instructions
How to start the engine
Warning! Ether type fuels must not be used in 700
Series engines.
Use only this procedure to start the engine; it has
been designed to protect the engine and the
environment.
Several factors affect engine start, for example:
•The power of the batteries
•The performance of the starter motor
•The viscosity of the lubricating oil
•The installation of a cold start system.
Diesel engines need a cold starting aid if they are to
start in cold conditions. The 700 Series engines are
equippedwith glow plugs.Theseelectricallyoperated
plugs are fitted into the combustion chamber of each
cylinder. The use of these glow plugs is only
necessary in cold conditions.
These engines can be fitted with an "automatic
control system" to operate the glow plugs before and
after the engine has started. This system is designed
tohelptheenginerunevenlyandreducesmokewhen
the engine is first started in cold temperatures. The
period of time that the glow plugs will operate has
been set automatically according to ambient
temperatures.
Before the engine is started the operator should
understand fully the reason for the controls and their
use.
Before the engine is started:
1 Check that there is enough coolant and, if
necessary, add the correct coolant, see section 4 of
this handbook.
2 Check that there is enough lubricating oil in the
sump and, if necessary, add lubricating oil, see
section4ofthishandbook.Ensurethatthelubricating
oil is of the correct grade for the ambient conditions.
3 Fill the fuel tank with fuel of the correct
specification.
4 Check the air filter and its connections.
5 Ensure that all of the electrical connections are
tight.
Notes:
•See section 5 of this handbook for the correct
engine fluids.
•The procedures to start the engine may vary
according to the application. If possible, consult
the User's Handbook for the application.
Cautions:
•Do not operate the engine at high speeds without
a load.
•If the engine has not run for several weeks, see
"Caution" on page 39.

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700 Series
Section 3
14
Operation Instructions
How to start a cold engine in cold
conditions
Warning! Ether type fuels must not be used in 700
Series engines.
Note: Use this method when the cylinder head
temperatures are below 0oC (32oF).
1 Adjust the engine speed control to the maximum
speed position.
2 If a combined heat/start switch (A) is used:
Move the start key to the "H" position (A) for a period
of ten seconds. Move the start key to the "HS"
position (A) to engage the starter motor. When the
engine starts, release the start key to the "H" position
(A) and hold in this position. As the engine speed
begins to increase, quickly reduce the engine speed.
When the engine runs evenly, adjust the speed
control to get an even idle speed.
If separate heat and start switches are used: Actuate
the glow plugs for a period of ten seconds. Engage
the starter motor with the glow plugs still actuated.
When the engine starts, release the starter switch. As
the engine speed begins to increase, quickly reduce
the engine speed and continue to actuate the glow
plugs until the engine runs evenly and then adjust the
speed control to get an even idle speed.
3 Iftheenginedoes not start in 15 seconds, movethe
combined heat/start key to the "R" position (A) for 30
seconds or release the separate switches for 30
seconds. Then repeat the start procedure.
For engines fitted with automatic glow plug
control
1 Adjust the engine speed control to the maximum
speed position.
2 Move the start key to the "R" position (B ). A light
will be illuminated to indicate glow plug operation.
When the light is switched off (automatically), move
the start key to the "S" position (B) to engage the
starter motor. When the engine starts, release the
start key to the "R" position (B). As the engine speed
begins to increase, quickly reduce the engine speed.
At this point, the glow plugs will continue to operate
for a short period of time.
Note: The amount of time will vary according to the
ambient temperature.
Caution: Always ensure that the engine and starter
motor are stationary before the starter motor is
engaged again.
3 Iftheenginedoes not start in 15 seconds, movethe
start key to the "O" position (B) and repeat
paragraphs 1 and 2.
When the engine runs evenly, adjust the speed
control to get an even idle speed.

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700 Series
Section 3
15
Operation Instructions
How to start a cold engine in temperate
conditions
1 Adjust the engine speed control to the maximum
speed position.
2 Move the start key to the "HS" position (A) to
engage the starter motor. When the engine starts,
releasethe start key to the"R" position. Asthe engine
speed begins to increase, quickly reduce the engine
speed.Thenadjust the engine speed controltogetan
even idle speed.
3 Iftheenginedoes not start in 15 seconds, movethe
start key to the "R" position and hold it there for 30
seconds. Then engage the starter motor again for a
maximum period of 15 seconds. If the engine still
does not start, use the start procedure for cold
conditions.
How to stop the engine
Note: If the engine has operated at normal operating
temperature for a long period of time, run the engine
at idle speed for 30 seconds before the engine is
stopped. This will allow heat from the large ferrous
components to pass into the lubricating oil and the
engine coolant.
Move the engine start key to the "OFF" position.

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700 Series
Section 3
16
Operation Instructions
Adjustment of engine speed range
These engines conform with USA (EPA/CARB) stage
1 and EEC stage 1 emissions legislation for
agricultural and industrial applications.
The idle or maximum speed settings must not be
changed by the engine operator, because this can
damage the engine or the transmission.
Specialist equipment, which is available at your
Perkins Distributor, is needed to adjust the idle or
maximum speed settings. The warranty of the engine
can be affected if the seals on the fuel injection pump
are broken during the warranty period by a person
who is not approved by Perkins.
Engine operation at idle speed
Do not operate the engine for prolonged periods at
idlespeed as thiscould have anadverse affecton the
engine performance or damage the engine.
Running-in
Cautions:
•Do not operate the engine at high speeds without
a load.
•Do not overload the engine.
A gradual running-in of a new engine or an exchange
engine is not necessary. Prolonged operation at light
loads during the early life of the engine can cause
lubricating oil to enter the exhaust system. Maximum
load can be applied to a new engine as soon as the
engineisputintoserviceandthecoolanttemperature
has reached a minimum of 60 oC (140 oF).
The engine will benefit if the load is applied as soon
as possible after the engine is put into service.
Altitude
The engine will run correctly up to an altitude of 600m
(2,000 ft). If the engine is to run at an altitude above
this,an increase insmokemaybe seen; thisisnormal
for a naturally aspirated engine. Turbocharged
engines can run correctly up to an altitude of 3000m
(10 000 ft). Contact your Perkins distributor if
adjustments are necessary.
Angle of tilt
Caution: Do not operate the engine an angle of tilt
greater than 30o. This is especially important for
turbocharged engines. If there is doubt, contact the
Perkins Service Department. If the approved angle is
exceeded, an excess of lubricating oil could enter the
breather valve. This could cause the engine speed to
increase rapidly without control.

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700 Series
Section 4
17
Preventive Maintenance
Preventive maintenance periods
These preventive maintenance periods apply to
average conditions of operation. Check the periods
given by the manufacturer of the equipment in which
the engine is installed. Use the periods which are
shortest . When the operation of the engine must
conform to the local regulations these periods and
proceduresmay need tobeadaptedto ensure correct
operation of the engine.
It is good preventive maintenance to check for
leakage and loose fasteners at each service.
These maintenance periods apply only to engines
that are operated with fuel and lubricating oil which
conform to the specifications given in this handbook.

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700 Series
Section 4
18
Preventive Maintenance
Schedules
The schedules which follow must be applied at the interval (hours or months) which occur first.
(1) If one is fitted.
(2) By a person who has had the correct training.
(3) Renew the antifreeze every 2 years. If a coolant inhibitor is used instead of antifreeze, it should be
renewed every 6 months.
(4) The oil change interval will change with the sulphur content of the fuel (see the table below and the Fuel
Specification in section 5). The interval to change the canister of the lubricating oil filter is not affected.
(5) UC engines: Renew the engine breather valve every 5000 hours (2). Refer to the workshop manual.
AFirst service at 25/50 hours
BEvery day or every 8 hours
CEvery 250 hours or 6 months
DEvery 500 hours or 12 months
EEvery 1000 hours
FEvery 2000 hours
GEvery 3000 hours
ABCDEFG Operation
Check the amount of coolant
Check the specific gravity of the coolant (2) (3)
Check the tension and the condition of the drive belt
Drain water from the fuel pre-filter (1)
Renew the canister of the fuel filter and renew the fuel strainer
Ensure that the atomisers are checked (always use new clamps - UA and UC
engines) (2)
Ensure that the idle speed is checked and adjusted, if it is necessary (2)
Check the amount of lubricating oil in the sump
Check the lubricating oil pressure at the gauge (1)
Renew the engine lubricating oil - UA and UC engines (4)
Renew the canister of the lubricating oil filter - UA and UC engines
Renew the engine lubricating oil - UB engines (4)
Renew the canister of the lubricating oil filter - UB engines
Clean the air cleaner or empty the dust bowl of the air filter
-extremely dusty conditions
-normal conditions
Clean or renew the air filter element, if this has not been indicated earlier
Ensure that the valve tip clearances of the engine are checked and, if necessary,
adjusted (2)
Check all hoses and connections
Remove and clean the components and the pipe for the engine breather - UA and
UB engines(2)
Ensure that the engine breather is renewed - UA and UB engines (2) (5)
Ensure that the alternator, the starter motor, etc. are checked (2)
Ensure that the glow plugs are checked (2)
Inspect the electrical system (2)

05/99
Printed in England
© Propriety information of Perkins Engines Company Limited, all rights reserved
700 Series
Section 4
19
Preventive Maintenance
How to drain the cooling system
Warnings!
•Donot drain thecoolantwhilethe engine isstillhot
and the system is under pressure because
dangerous hot coolant can be discharged.
•Discard used coolant in a safe place and in
accordance with local regulations
1 Ensure that the machine is on level ground.
2 Remove the filler cap of the cooling system.
3 Remove the drain plug (A1) from the side of the
cylinderblock inorderto draintheengine.Ensurethat
the drain holes are not restricted.
4 Openthetap or remove the drainplugatthebottom
of the radiator in order to drain the radiator. If the
radiator does not have a tap or drain plug, disconnect
the hose at the bottom of the radiator.
5 Flush the system with POWERPART Easy Flush.
6 Fit the drain plugs and the filler cap. Close the
radiator tap or connect the radiator hose.