Perkins UA Instruction manual

i
Perkins 700 Series
Models UA, UB and UC
WORKSHOP MANUAL
Four cylinder naturally aspirated and turbocharged
diesel engines
Publication TPD 1392E, Issue 3.
© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in February 2002 by Technical Publications.
Perkins Engines Company Limited, Peterborough PE1 5NA, England.
This document has been printed from SPI². Not for Resale

ii
Chapters
1 General information
2 Specifications
3 Cylinder head assembly
4 Piston and connecting rod assemblies
5 Crankshaft assembly
6 Timing case and drive assembly
7 Cylinder block assembly
8 Engine timing
9 Aspiration system
10 Lubrication system
11 Fuel system
12 Cooling system
13 Flywheel and housing
14 Electrical equipment
15 Auxiliary equipment
16 Special tools
The following pages contain a detailed table of contents.
Perkins Approved Clear English
This publication is written in
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Workshop Manual, TPD 1392E, issue 3 iii
700 Series
Contents
1 General information
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...1
Engine views - Naturally aspirated engine . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...3
Engine views - Turbocharged engine . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...4
Engine I.D. location ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...5
Safety precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...6
Viton seals . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...8
Engine lift equipment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...9
POWERPART consumable products .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .10
2 Specifications
Basic engine data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .13
Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .14
Thread sealant ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .30
Recommended torque tensions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .31
Compression test data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .34
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iv Workshop Manual, TPD 1392E, issue 3
700 Series
3 Cylinder head assembly
Rocker cover
Operation 3-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35
Rocker assembly (latest engines)
Operation 3-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36
Rocker assembly (earlier engines)
Operation 3-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38
Rocker shaft (latest engines)
Operation 3-4 To dismantle, to inspect and to assemble ... ... ... ... ... ... ... ... ... ... ... ... 40
Rocker shaft (earlier engines)
Operation 3-5 To dismantle, to inspect and to assemble ... ... ... ... ... ... ... ... ... ... ... ... 41
Valve tip clearance
Operation 3-6 To check . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42
Valve springs (with cylinder head fitted)
Operation 3-7 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43
Exhaust / induction manifolds and gasket
Operation 3-8 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44
Cylinder head setscrews
Operation 3-9 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45
Cylinder head gasket
Operation 3-10 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 46
Valve and valve springs
Operation 3-11 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47
Valve stem
Operation 3-12 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 48
Valve depth
Operation 3-13 To check ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49
Valve guides
Operation 3-14 To check ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50
Operation 3-15 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 51
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Workshop Manual, TPD 1392E, issue 3 v
700 Series
Valve seats
Operation 3-16 To correct . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .52
Valve seat insert
Operation 3-17 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .53
Cylinder head
Operation 3-18 To check the distortion of the lower face .. ... ... ... ... ... ... ... ... ... ... ... .54
4 Piston and connecting rod assemblies
Big end bearing and cap
Operation 4-1 To remove and to fit the early type . ... ... ... ... ... ... ... ... ... ... ... ... ... ... .55
Operation 4-2 To remove and to fit the latest type (fractured split connecting rods) . ... .56
Piston and connecting rod
Operation 4-3 To dismantle and to assemble the early type . ... ... ... ... ... ... ... ... ... ... .58
Operation 4-4 To fit the early type . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .60
Operation 4-5 To dismantle and to assemble the latest type (fractured split connecting
rods) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .61
Operation 4-6 To fit the latest type (fractured split connecting rods) . ... ... ... ... ... ... ... .63
Piston and piston rings
Operation 4-7 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .64
Operation 4-8 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .65
Piston rings
Operation 4-9 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .66
Connecting rod
Operation 4-10 To check for bend and to inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... .67
Operation 4-11 To check length and to inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .70
Small end bush
Operation 4-12 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .72
Piston height above the cylinder block
Operation 4-13 To check ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .73
Piston cooling jets (UC engines)
Operation 4-14 To remove, and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .74
Operation 4-15 To check the jet alignment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .75
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vi Workshop Manual, TPD 1392E, issue 3
700 Series
5 Crankshaft assembly
Crankshaft pulley
Operation 5-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 77
Operation 5-2 To fit a wear sleeve . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79
Rear oil seal
Operation 5-3 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 80
Operation 5-4 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 81
Thrust washers and crankshaft end-float
Operation 5-5 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 82
Thrust washers
Operation 5-6 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 83
Main bearing caps (with crankshaft in position)
Operation 5-7 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 84
Main bearings
Operation 5-8 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 85
Main bearing caps (front and rear)
Operation 5-9 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 86
Operation 5-10 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 87
Crankshaft
Operation 5-11 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 88
Operation 5-12 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 89
Operation 5-13 To inspect and to overhaul ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 90
Wear sleeve
Operation 5-14 To fit (early) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 92
Operation 5-15 To fit (latest) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 93
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Workshop Manual, TPD 1392E, issue 3 vii
700 Series
6 Timing case and drive assembly
Tamper proof screws
Operation 6-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .95
Timing case
Operation 6-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .97
Operation 6-3 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .99
Gear teeth meshing
Operation 6-4 To check backlash .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...100
Front oil seal
Operation 6-5 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...101
Idler gear
Operation 6-6 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...102
Idler gear bushes
Operation 6-7 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...103
Idler gear hub
Operation 6-8 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...104
Camshaft assembly for the fuel injection pump
Operation 6-9 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...105
Camshaft assembly and tappets for the valves
Operation 6-10 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...106
Camshaft assembly for the valves
Operation 6-11 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...107
Crankshaft gear
Operation 6-12 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...108
Backplate
Operation 6-13 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...109
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viii Workshop Manual, TPD 1392E, issue 3
700 Series
7 Cylinder block assembly
Cylinder block bores
Operation 7-1 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 111
Camshaft bores
Operation 7-2 To renew . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 112
8 Engine timing
To set approximately number 1 piston to TDC on the compression stroke ... ... .. 115
Valve timing
Operation 8-1 To check . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 117
Fuel injection pump timing
Operation 8-2 To check . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 118
9 Aspiration system
Turbocharger
Operation 9-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 123
Impeller and compressor casing
Operation 9-2 To clean .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 124
Engine breather assembly
Operation 9-3 To renew (UA and UB engines) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 126
Operation 9-4 To renew (Early UC engines) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 127
Operation 9-5 To renew (Latest UC engines) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 128
Operation 9-6 To remove and to fit the breather deflectors ... ... ... ... ... ... ... ... ... ... .. 130
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Workshop Manual, TPD 1392E, issue 3 ix
700 Series
10 Lubrication system
Oil filter canister
Operation 10-1 To renew .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...131
Engine lubricating oil
Operation 10-2 To renew .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...132
Filter head and oil cooler
Operation 10-3 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...133
Aluminium sump
Operation 10-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...134
Steel sump
Operation 10-5 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...135
Oil strainer and suction pipe
Operation 10-6 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...136
Lubricating oil pump
Operation 10-7 To renew .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...137
Operation 10-8 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...138
Relief valve
Operation 10-9 To remove, to fit and to renew .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...139
11 Fuel system
Fuel filter element
Operation 11-1 To renew .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...141
Atomiser fault
Operation 11-2 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...143
High pressure fuel pipes
Operation 11-3 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...144
Leak off rail
Operation 11-4 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...145
Atomisers
Operation 11-5 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...146
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xWorkshop Manual, TPD 1392E, issue 3
700 Series
Fuel lift pump
Operation 11-6 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 148
Operation 11-7 To test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 149
Fuel injection pump
Operation 11-8 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 150
Operation 11-9 To eliminate air from the fuel system ... ... ... ... ... ... ... ... ... ... ... ... .. 152
Governor weight assembly
Operation 11-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 153
Speed control lever assembly
Operation 11-11 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 154
Operation 11-12 To renew . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 155
To change a plain bush to a threaded bush ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 156
Fuel injection pump linkage
Operation 11-13 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 157
Operation 11-14 To renew . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 158
To record the maximum fuel position of the fuel control rack .. ... ... ... ... ... ... ... .. 159
How to use the reference setting for maximum fuel .. ... ... ... ... ... ... ... ... ... ... ... .. 164
12 Cooling system
Coolant
Operation 12-1 To drain and to fill . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 167
Thermostat
Operation 12-2 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 168
Operation 12-3 To test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 169
Fan
Operation 12-4 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 170
Coolant pump
Operation 12-5 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 171
Oil cooler
Operation 12-6 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 172
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Workshop Manual, TPD 1392E, issue 3 xi
700 Series
13 Flywheel and housing
Flywheel
Operation 13-1 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...173
Operation 13-2 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...174
Starter ring
Operation 13-3 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...175
Flywheel housing
Operation 13-4 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...176
14 Electrical equipment
Drive belt
Operation 14-1 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...177
Alternator
Operation 14-2 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...178
Glowplugs (starting aid)
Operation 14-3 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...179
Operation 14-4 To check ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...183
Starter motor
Operation 14-5 To remove, to fit and to test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...184
Electrical stop solenoid
Operation 14-6 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...185
15 Auxiliary equipment
Power take-off assembly
Operation 15-1 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...187
Operation 15-2 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...188
16 Special tools
Special tools list ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...189
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Workshop Manual, TPD 1392E, issue 3 1
1
700 Series
General information 1
Introduction
This Workshop Manual has been written for Perkins Technicians working at distributors to provide assistance
in the service and overhaul of Perkins 700 Series engines. It has been compiled for use in conjunction with
normal workshop practice and information contained in current service bulletins. Mention of certain accepted
practices therefore, has been purposely omitted in order to avoid repetition. For overhaul procedures the
assumption is made that the engine is removed from the application.
Note: With effect from engine number U------U806626D, a requirement of emissions legislation is that access
to adjustments that affect the engine’s exhaust emissions is limited to personnel approved by Perkins Engines
Company Limited. These adjustments are on the timing case, therefore, only Perkins approved personnel
should remove and fit the timing case. If there is doubt, contact your nearest Perkins Dealer/Distributor for
advice. Any claim including but not limited to warranty will not be acceptable to Perkins Engines Company
Limited if it can be seen that an adjustment has been made by a person not approved by Perkins.
How to use this manual
This manual is illustration and text based and is divided into 16 chapters. The illustrations and text in each
chapterfollowthesequence for the completedisassemblyofaparticularassemblyorcomponent.Reassembly
is achieved by using the illustrations in reverse order from the rear of the chapter. Reference to renewing joints
has been omitted, it being understood that this will be carried out when applicable. Similarly, it is understood
that in reassembly and inspection, all parts are to be thoroughly cleaned and lubricated, and where present,
burrs and scale are to be removed. Any open ports of high precision components, e.g. fuel injection equipment
exposed by dismantling, must be blanked off until reassembly, to prevent the ingress of debris.
When fitting setscrews into "through" holes into the interior of the engine, the threads should be cleaned and
fitted with a suitable sealant. Throughout this manual, whenever the "left" or "right" of the engine is referred to,
it is that side of the engine when viewed from the flywheel end.
Special tools have been made available and a list of these is given in Chapter 16, Special tools. Reference to
the relevant special tools is also made at the beginning of each operation, where relevant.
POWERPART recommended consumable products are listed on page 10. Reference to the relevant
consumable products is also made at the beginning of each operation.
Data and dimensions are provided as an integral part of each operation and also in Chapter 2, Specifications.
Always use the full engine number to order new parts.
Read and remember the "Safety precautions" on page 6. They are given for your protection and must
be used at all times.
Note: Most of the information included in the User’s Handbook (Chapters 1 to 6), has not been repeated in
this Workshop Manual. The two publications should be used together.
The engines referred to in this manual are the UA (3,0 litre - direct injection), the UB (2,6 litre - indirect injection)
and the UC (3,0 litre - turbocharged direct injection).
The engines conform to Stage 1 off-highway emissions to C1-8 mode cycle ref. ISO 8178 part 4.
Continued
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2Workshop Manual, TPD 1392E, issue 3
700 Series
The 3,0 litre versions are, water cooled, naturally aspirated or turbocharged, four cylinder diesel engine with
direct injection. They have been specifically designed for industrial and agricultural applications. The 2,6 litre
version, is a water cooled, naturally aspirated, four cylinder diesel engine with indirect injection. It has been
specifically designed for fork-lift truck applications. Where the information applies to only one engine type, this
will be indicated in the text and/or illustration by use of the particular code letters.
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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Workshop Manual, TPD 1392E, issue 3 3
700 Series
Engine views - Naturally aspirated engine
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4Workshop Manual, TPD 1392E, issue 3
700 Series
Engine views - Turbocharged engine
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Workshop Manual, TPD 1392E, issue 3 5
700 Series
Engine I.D. location
The engine number is stamped on a label (A1) that is located on the right rear side of the engine. It consists
of the following:
Abbreviations and codes
Engine build list numbering system.
The engine parts list numbering system is defined as follows:
Code I Engine type code
Code II Engine build list number
Build list number is dependent upon specification.
Code III Country of manufacture
Code IV Engine serial number
The engine serial number is sequential.
Code V Year of Manufacture
Code I II III IV V
Example UA 80862 U 000001 A
Engine Code
704 - 26 UA
704 - 30 UB
704 - 30T UC
Code Country of manufacture
U Made in U.K.
Code Year Code Year
A 1995 F 1/4/1999 - 31/12/1999
B 1996 G 2000
C 1997 H 2001
D 1998 J 2002
E 1/1/1999 - 31/3/1999
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6Workshop Manual, TPD 1392E, issue 3
700 Series
Safety precautions
These safety precautions are important. You must refer also to the local regulations in the country of use.
Some items only refer to specific applications.
lThese safety precautions are important. You must refer also to the local regulations in the country of use.
Some items only apply to specific applications.
lAlways refer to the text of the operations within this workshop manual for specific warnings and cautions.
lOnly use these engines in the type of application for that they have been designed.
lDo not change the specification of the engine.
lDo not smoke when you put fuel in the tank.
lClean away fuel that has been spilt. Material that has been contaminated by fuel must be moved to a safe
place.
lDo not put fuel in the tank while the engine runs (unless it is absolutely necessary).
lDo 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).
lDo not make adjustments that you do not understand.
lEnsure that the engine does not run in a location where it can cause a concentration of toxic emissions.
lOther persons must be kept at a safe distance while the engine, auxiliary equipment is in operation.
lDo not permit loose clothing or long hair near moving parts.
lKeep away from moving parts during engine operation.
Warning! Some moving parts cannot be seen clearly while the engine runs.
lDo not operate the engine if a safety guard has been removed.
lDo 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.
lDo 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.
lDisconnect the battery terminals before a repair is made to the electrical system. Only one person must
control the engine.
lEnsure that the engine is operated only from the control panel or from the operator’s position.
lIf your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
lDiesel 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.
lDo not wear clothing that is contaminated by lubricating oil. Do not put material that is contaminated with
oil into the pockets.
lDiscard used lubricating oil in accordance with local regulations to prevent contamination.
lEnsure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is
started.
lUse extreme care if emergency repairs must be made in adverse conditions.
lThe combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes. Refer to "Viton seals" on page 8.
lRead and use the instructions relevant to "Engine lift equipment" on page 9.
lAlways 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 that seal the hose connections of a component that is to be
pressure tested.
lDo not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately. Continued
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Workshop Manual, TPD 1392E, issue 3 7
700 Series
lTurbochargers operate at high speed and at high temperatures. Keep fingers, tools and items away from
the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.
lDo not wash an engine while it runs or while it is hot. If cold cleaning fluids are applied to a hot engine,
certain components on the engine could be damaged.
lSome components are not waterproof and should not be washed with a high-pressure water jet or steam.
lFit only genuine Perkins parts.
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8Workshop Manual, TPD 1392E, issue 3
700 Series
Viton seals
Some seals used in engines and in components fitted to engines are made of Viton.
Viton is used by many manufacturers and is a safe material under normal conditions of operation. If Viton is
burned, a product of this burnt material is an acid that is extremely dangerous. Never allow this burnt material
to come into contact with the skin or with the eyes.
If it is necessary to come into contact with components that have been burnt, ensure that the precautions that
follow are used:
lEnsure that the components have cooled.
lUse Neoprene gloves and discard the gloves safely after use.
lWash the area with calcium hydroxide solution and then with clean water.
lDisposal of components and gloves that are contaminated must be in accordance with local regulations.
If there is contamination of the skin or eyes wash the affected area with a continuous supply of clean water or
with calcium hydroxide solution for 15 - 60 minutes. Obtain immediate medical attention.
Safety cautions when an engine is cleaned
Care should be taken, when an engine is cleaned with a high pressure cleaning system.
Cautions:
lDo not wash an engine while it runs or while it is hot. If cold cleaning fluids are applied to a hot engine,
certain components on the engine could be damaged.
lLeave the engine to cool for at least one hour and disconnect the battery connections before cleaning.
lDo not wash any part of the fuel injection pump (FIP), cold start device, electrical shut off solenoid (ESOS)
or electrical connectors.
lEnsure that the alternator, starter motor and any other electrical components are shielded and not directly
cleaned by the high pressure cleaning system.
If these cautions are ignored, the engine or certain components could be damaged, fail to operate and also
make the manufacturer’s warranty invalid.
This document has been printed from SPI². Not for Resale