Perkins 700 series ub four cylinder diesel engine service repair 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

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

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)
Rocker assembly (earlier engines)
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)
Exhaust / induction manifolds and gasket
Cylinder head setscrews
Cylinder head gasket
Operation 3-10 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 46
Valve and valve springs
Valve stem
Operation 3-12 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 48
Valve depth
Operation 3-13 To check ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49
Valve guides

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

vi Workshop Manual, TPD 1392E, issue 3
700 Series
5 Crankshaft assembly
Crankshaft pulley
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
Main bearing caps (with crankshaft in position)
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

Workshop Manual, TPD 1392E, issue 3 vii
700 Series
6 Timing case and drive assembly
Tamper proof screws
Timing case
Operation 6-3 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 99
Gear teeth meshing
Operation 6-4 To check backlash .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 100
Front oil seal
Idler gear
Operation 6-6 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 102
Idler gear bushes
Idler gear hub
Camshaft assembly for the fuel injection pump
Camshaft assembly and tappets for the valves
Operation 6-10 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 106
Camshaft assembly for the valves
Crankshaft gear
Backplate

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

Workshop Manual, TPD 1392E, issue 3 ix
700 Series
10 Lubrication system
Oil filter canister
Operation 10-1 To renew .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 131
Engine lubricating oil
Filter head and oil cooler
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
Lubricating oil pump
Relief valve
Operation 10-9 To remove, to fit and to renew .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 139
11 Fuel system
Fuel filter element
Atomiser fault
High pressure fuel pipes
Leak off rail
Atomisers

x Workshop 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 11-9 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 11-12 To renew . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 155
To change a plain bush to a threaded bush ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 156
Fuel injection pump linkage
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 12-3 To test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 169
Fan
Coolant pump
Oil cooler

Workshop Manual, TPD 1392E, issue 3 xi
700 Series
13 Flywheel and housing
Flywheel
Starter ring
Flywheel housing
14 Electrical equipment
Drive belt
Alternator
Glowplugs (starting aid)
Starter motor
Operation 14-5 To remove, to fit and to test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 184
Electrical stop solenoid
15 Auxiliary equipment
Power take-off assembly
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
chapter follow the sequence for the complete disassembly of a particular assembly or component. 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

1
2 Workshop 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.

1
700 Series
Engine views - Naturally aspirated engine

1
4 Workshop Manual, TPD 1392E, issue 3
700 Series
Engine views - Turbocharged engine

1
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
1

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Perkins 700 series ub four cylinder diesel engine service repair manual