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Perkins 700 Series User Handbook
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05/99
Printed in England
© Propriety information of Perkins Engines Company Limited, all rights reserved
700 Series
Users Handbook
Workshop Manual
Perkins 700 Series
Interactive CD
Introduction.
Whilst you are in this page, you have the choice of either navigating to
the Users Handbook or the Workshop Manual, by simply selecting the
title of your choice.
2
Table of Contents
Table of Contents
4
Default Chapter
2
How to Use this Manual
2
1 General Information
3
Introduction
3
Table of Contents
4
Contents
5
How to Care for Your Engine
6
Safety Precautions
7
Engine Identification
8
Perkins Companies
9
2 Engine Views Introduction
10
Location of Engine Parts
10
3 Operation Instructions
14
How to Start the Engine
14
How to Start a Cold Engine in Cold Conditions
15
How to Start a Cold Engine in Temperate Conditions
16
How to Stop the Engine
16
Adjustment of Engine Speed Range
17
Engine Operation at Idle Speed
17
Running in
17
Altitude
17
Angle of Tilt
17
4 Preventive Maintenance
18
Preventive Maintenance Periods
18
Schedules
19
How to Drain the Cooling System
20
How to Check the Specific Gravity of the Coolant
21
How to Check the Drive Belt
22
How to Adjust the Belt Tension
22
How to Renew the Element / Canister of the Fuel Filter
23
Atomiser Fault
24
How to Renew an Atomiser - UA & UC Engines
24
How to Renew an Atomiser - UB Engines
25
How to Eliminate Air from the Fuel System
27
How to Renew the Lubricating Oil
28
How to Renew the Canister of the Lubricating Oil Filter
29
How to Renew the Engine Breather Assembly - UA & UB Engines
30
How to Set the Valve Tip Clearances
32
5 Engine Fluids
34
Fuel Specification
34
Lubricating Oil Specification
35
Coolant Specification
36
6 Fault Diagnosis
37
Problems and Possible Causes
37
List of Possible Causes
38
7 Engine Preservation
39
Introduction
39
Procedure
39
8 Parts and Service
41
Introduction
41
Service Literature
41
Training
41
POWERPART Recommended Consumable Products
41
9 General Data
43
Engine
43
Table of Contents
48
General Information
52
Safety
52
General Safety Precautions
52
Viton Seals
54
Engine Identification
57
Engine Views
58
Compression Test Data
60
Specifications
61
Basic Engine Data
61
Recommended Torque Tensions
62
Data and Dimensions
64
Cylinder Head Assembly
78
Rocker Assembly - to Remove and to Fit
79
Rocker Shaft - to Dismantle, to Inspect and to Assemble
81
Valve Tip Clearance - to Check
83
Valve Springs (with Cylinder Head Fitted) - to Remove and to Fit
84
Exhaust / Induction Manifolds and Gaskets - to Remove and to Fit
85
Cylinder Head Setscrews - to Remove and to Fit
86
Cylinder Head Gasket - to Remove and to Fit
87
Valve and Valve Springs - to Remove and to Fit
88
Valve Stem - to Inspect
89
Valve Depth - to Check
90
Valve Guides Clearance - to Check
91
Valve Guides - to Remove and to Fit
92
Valve Seats - to Correct
93
Valve Seat Inserts - to Fit
94
Cylinder Head - to Check the Distortion of the Lower Face
95
Big End Bearing and Cap - to Remove and to Fit
96
Connecting Rod Assembly
96
Piston and Connecting Rod - to Dismantle and to Assemble
97
Piston and Piston Ring - to Inspect
99
Piston and Connecting Rod - to Fit
101
2. Connecting Rod to Check
103
Small End Bush - to Remove and to Fit
104
Crankshaft Assembly
107
Crankshaft Pulley - to Remove and to Fit
107
Crankshaft Pulley - to Fit a Wear Sleeve
108
Rear Oil Seal - to Remove
109
Rear Oil Seal - to Fit
110
Thrust Washer and Crankshaft End Float - to Inspect
111
Thrust Washers - to Remove and to Fit
112
Main Bearings - to Inspect
114
Main Bearing Caps (Front and Rear) - to Remove
115
Crankshaft - to Remove
117
Crankshaft - to Fit
118
Crankshaft - to Inspect and to Overhaul
119
Wearsleeve - to Fit
120
Timing Case and Drive Assembly
121
Tamper Proof Screws
121
Timing Case - to Remove
122
Timing Case - to Fit
124
Timing Case - to Renew
125
Front Oil Seal - to Remove and to Fit
126
Idler Gear Bushes- to Remove and to Fit
128
Idler Gear Hub - to Remove and to Fit
129
Camshaft Assembly for the Fuel Injection Pump - to Remove and to Fit
130
Camshaft Assembly and Tappets for the Valves - to Remove and to Fit
131
Camshaft Assembly for the Valves - to Remove and to Fit
132
Crankshaft Gear -To Remove and to Fit
133
Cylinder Block Assembly
135
Cylinder Block Bores - to Inspect
135
Camshaft Bush - to Renew
136
Engine Timing
137
To Set Accurately Number 1 Piston to TDC on the Compression Stroke
137
To Check the Valve Timing
139
Turbocharger
144
Turbocharger - to Remove and to Fit
144
To Clean the Impeller and the Compressor Casing
145
Engine Breather Assembly - to Renew
146
Lubrication System
147
Oil Filter Canister - to Renew
147
Engine Lubrication Oil - to Renew
148
Sump - to Remove and to Fit
150
Lubricating Oil Pump - to Inspect
153
Fuel System
155
Fuel Filter Element - to Renew
155
Atomiser Fault - to Inspect
156
High Pressure Fuel Pipes - to Remove and to Fit
157
Leak-Off Rail - to Remove and to Fit
158
Atomisers - to Remove and to Fit
159
Fuel Lift Pump - to Remove and to Fit
160
Fuel Lift Pump - to Test
161
Fuel Injection Pump - to Remove and to Fit
162
To Eliminate Air from the Fuel System
164
Governor Weight Assembly - to Remove and to Fit
165
Fuel Injection Pump Linkage - to Remove and to Fit
169
Fuel Injection Pump Linkage - to Renew
170
To Record the Maximum Fuel Position of the Fuel Control Rack
171
Cooling System
178
To Drain and to Fill
178
Thermostat - to Remove and to Fit
179
Thermostat - to Test
180
Coolant Pump - to Remove and to Fit
182
Flywheel and Flywheel Housing
184
Flywheel - to Remove and to Fit
184
Flywheel - to Inspect
185
Flywheel Housing- to Remove and to Fit
187
Electrical Equipment
188
Drive Belt - to Remove and to Fit
188
Alternator - to Remove and to Fit
189
Glow Plugs (Starting Aid)- to Remove and to Fit
190
Glow Plugs (Starting Aid)- to Check
191
Starter Motor - to Remove, to Fit and to Test
192
Electrical Stop Solenoid - to Remove and to Fit
193
Power Take-Off Assembly - to Remove and to Fit
194
Auxiliary Equipment
194
Power Take-Off Assembly - to Dismantle and to Assemble
195
Special Tools
196
List of Special Tools
196
Other manuals for Perkins 700 Series
Workshop Manual
206 pages
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Perkins 700 Series Specifications
General
Engine Type
Diesel
Number of Cylinders
4
Cooling System
Liquid Cooled
Aspiration
Turbocharged
Emissions Compliance
Tier 3/Stage IIIA
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