Complete workshop repair & service manual with electrical wiring diagrams for Perkins 700 Series (Models UA, UB, UC) 4 Cylinder Naturally Aspirated & Turbocharged Diesel Engines. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Perkins 700 Series Diesel Engines (704 - 26, 704 - 30 UB, 704 - 30T) service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

User’s Handbook for 700 Series (Models UA, UB, UC) 4 Cylinder Naturally Aspirated & Turbocharged Diesel Engines for Industrial, Agricultural & Fork Lift Truck Applications (TPD1336E8).pdf
Workshop Manual for 700 Series (Models UA, UB, UC) 4 Cylinder Naturally Aspirated & Turbocharged Diesel Engines (TPD1392E3).pdf

EXCERPT:
"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:"
"• Ensure that the components have cooled."
"• Use Neoprene gloves and discard the gloves safely after use."
"• Wash the area with calcium hydroxide solution and then with clean water."
"• Disposal 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:"
"• Do 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."
"• Leave the engine to cool for at least one hour and disconnect the battery connections before cleaning."
"• Do not wash any part of the fuel injection pump (FIP), cold start device, electrical shut off solenoid (ESOS) or electrical connectors."
"• Ensure 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."
…

Perkins 700 Series...1
  Models UA, UB and UC...1
  Workshop MANUAL...1
    Four cylinder naturally aspirated and turbocharged diesel engines...1
    Chapters...2
    1 General information...2
    2 Specifications...2
    3 Cylinder head assembly...2
    4 Piston and connecting rod assemblies...2
    5 Crankshaft assembly...2
    6 Timing case and drive assembly...2
    7 Cylinder block assembly...2
    8 Engine timing...2
    9 Aspiration system...2
    10 Lubrication system...2
    11 Fuel system...2
    12 Cooling system...2
    13 Flywheel and housing...2
    14 Electrical equipment...2
    15 Auxiliary equipment...2
    16 Special tools...2
  Contents...3
    1 General information...3
    2 Specifications...3
    3 Cylinder head assembly...4
Rocker cover...4
Rocker assembly (latest engines)...4
Rocker assembly (earlier engines)...4
Rocker shaft (latest engines)...4
Rocker shaft (earlier engines)...4
Valve tip clearance...4
Valve springs (with cylinder head fitted)...4
Exhaust / induction manifolds and gasket...4
Cylinder head setscrews...4
Cylinder head gasket...4
Valve and valve springs...4
Valve stem...4
Valve depth...4
Valve guides...4
Valve seats...5
Valve seat insert...5
Cylinder head...5
  4 Piston and connecting rod assemblies...5
Big end bearing and cap...5
Piston and connecting rod...5
Piston and piston rings...5
Piston rings...5
Connecting rod...5
Small end bush...5
Piston height above the cylinder block...5
Piston cooling jets (UC engines)...5
  5 Crankshaft assembly...6
Crankshaft pulley...6
Rear oil seal...6
Thrust washers and crankshaft end-float...6
Thrust washers...6
Main bearing caps (with crankshaft in position)...6
Main bearings...6
Main bearing caps (front and rear)...6
Crankshaft...6
Wear sleeve...6
  6 Timing case and drive assembly...7
Tamper proof screws...7
Timing case...7
Gear teeth meshing...7
Front oil seal...7
Idler gear...7
Idler gear bushes...7
Idler gear hub...7
Camshaft assembly for the fuel injection pump...7
Camshaft assembly and tappets for the valves...7
Camshaft assembly for the valves...7
Crankshaft gear...7
Backplate...7
  7 Cylinder block assembly...8
Cylinder block bores...8
Camshaft bores...8
  8 Engine timing...8
Valve timing...8
Fuel injection pump timing...8
  9 Aspiration system...8
Turbocharger...8
Impeller and compressor casing...8
Engine breather assembly...8
  10 Lubrication system...9
Oil filter canister...9
Engine lubricating oil...9
Filter head and oil cooler...9
Aluminium sump...9
Steel sump...9
Oil strainer and suction pipe...9
Lubricating oil pump...9
Relief valve...9
  11 Fuel system...9
Fuel filter element...9
Atomiser fault...9
High pressure fuel pipes...9
Leak off rail...9
Atomisers...9
Fuel lift pump...10
Fuel injection pump...10
Governor weight assembly...10
Speed control lever assembly...10
Fuel injection pump linkage...10
  12 Cooling system...10
Coolant...10
Thermostat...10
Fan...10
Coolant pump...10
Oil cooler...10
  13 Flywheel and housing...11
Flywheel...11
Starter ring...11
Flywheel housing...11
  14 Electrical equipment...11
Drive belt...11
Alternator...11
Glowplugs (starting aid)...11
Starter motor...11
Electrical stop solenoid...11
  15 Auxiliary equipment...11
Power take-off assembly...11
  16 Special tools...11
General information...13
  Introduction...13
  Engine views - Naturally aspirated engine...15
  Engine views - Turbocharged engine...16
  Engine I.D. location...17
  Safety precautions...18
  Viton seals...20
  Safety cautions when an engine is cleaned...20
  Engine lift equipment...21
  POWERPART consumable products...22
Specifications...25
  Basic engine data...25
    (1) Minimum pressure at maximum engine speed and normal engine temperature...25
    (2) Engine weight may alter with final specification...25
  Data and dimensions...26
  Cylinder head assembly...26
  Inlet and exhaust valves...27
  Valve springs, tappets, and rocker levers...28
  Dimensions of a recess for a valve seat insert...29
  Dimensions for a valve seat insert tool...30
  Pistons and connecting rods...32
  Crankshaft...34
  Timing case and drive assembly...35
  Cylinder block...36
  Timing data...38
  Lubrication system...39
  Fuel system...40
    (1) For original atomisers...40
    (2) For atomisers that have been overhauled (e.g. fitted with new springs)...40
  Cooling system...40
  Electrical equipment...41
  Auxiliary equipment...41
  Thread sealant...42
  Recommended torque tensions...43
  Compression test data...45
    1 Ensure that the valve tip clearances are set correctly...45
    2 Remove the atomisers...45
    3 Fit a suitable gauge into the hole in the cylinder head for the atomiser...45
    4 Disconnect the stop solenoid or put the stop control in the no-fuel position. Operate the start....45
    5 Repeat for each cylinder...45
Cylinder head assembly...47
  Rocker cover...47
    To remove and to fit Operation 3-1...47
  Rocker assembly (latest engines)...48
    To remove and to fit Operation 3-2...48
      1 Release the two setscrews on each bracket starting from the outer brackets and move in toward t....48
      2 Release the nuts on each bracket starting from the outer brackets and move in toward the centre...48
      3 Remove the upper brackets, remove the rocker assembly. Note that the hollow dowel fits into the....48
      1 Fit the rocker shaft, ensure that the hollow pin in the rocker shaft locates in the hole in the....49
      2 Put the caps in position on the rocker shaft. Ensure that each cap is correctly matched with it....49
      3 Tighten the setscrews starting with the inner setscrews and moving outwards...49
  Rocker assembly (earlier engines)...50
    To remove and to fit Operation 3-3...50
      1 Release the eight setscrews for the brackets of the rocker shaft. Release gradually and evenly ....50
      2 Remove the nuts and lift off the rocker assembly...50
      1 Before the rocker assembly is fitted, ensure that the oil holes and are free of dirt...51
      2 Check that the push rods fit correctly in the sockets of the tappets...51
      3 Fit the fasteners finger tight...51
      4 Tighten gradually and evenly, the inner nuts and then the outer nuts to 22 Nm (16 lbf ft) 2,2 k....51
      5 Tighten gradually and evenly, the eight setscrews to 9 Nm (7 lbf ft) 0,9 kgf m...51
      6 Adjust the valve tip clearances...51
  Rocker shaft (latest engines)...52
    To dismantle, to inspect and to assemble Operation 3-4...52
  Rocker shaft (earlier engines)...53
    To dismantle, to inspect and to assemble Operation 3-5...53
  Valve tip clearance...54
    To check Operation 3-6...54
  Valve springs (with cylinder head fitted)...55
    To remove and to fit Operation 3-7...55
  Exhaust / induction manifolds and gasket...56
    To remove and to fit Operation 3-8...56
  Cylinder head setscrews...57
    To remove and to fit Operation 3-9...57
  Cylinder head gasket...58
    To remove and to fit Operation 3-10...58
  Valve and valve springs...59
    To remove and to fit Operation 3-11...59
  Valve stem...60
    To inspect Operation 3-12...60
  Valve depth...61
    To check Operation 3-13...61
  Valve guides...62
    To check Operation 3-14...62
    To remove and to fit Operation 3-15...63
  Valve seats...64
    To correct Operation 3-16...64
      1 Fit the pilot in the valve guide and tighten the pilot...64
      2 Select the relevant cutter. Set the blades of the cutters to the diameter of the valve seat to ....64
      3 Carefully rotate the cutter in a clockwise direction. Remove only the minimum material to ensur....64
      4 When the seat is cut, remove the cutter and the pilot. Remove any debris from the area of the v....64
      5 Fit the valve and lightly lap the valve and the seat...64
      6 Check that the valve depth is within limits given in the relevant Data and dimensions for "Inle....64
  Valve seat insert...65
    To fit Operation 3-17...65
      1 Remove the valve guide and clean the bore into that the guide is to be fitted...65
      2 Fit new valve guides, see Operation 3-15...65
      3 The internal bore of the finished reamed or machined valve guide must be used as a pilot to mac....65
      4 Measure the depth of the recess in two places 90 apart. The correct depths are:...65
      5 If the depth of the recess has been reduced, surface grind the bottom face of the insert by an ....65
      6 If the insert has been surface ground, ensure that the outer edge of the back face of the inser....65
      7 With the bore of the valve guide used as a pilot, and with the rear face of the insert towards ....65
      8 Ensure that when fitted, the bottom face of the insert is in contact with the bottom of the rec....65
      9 Cut the valve seat at 45 (an included angle of 90) for all valves, see Operation 3-16...65
  Cylinder head...66
    To check the distortion of the lower face Operation 3-18...66
      1 Inspect the cylinder head for signs of gas or coolant leakage...66
      2 Remove the valve springs and the valves, see Operation 3-11...66
      3 Clean the face of the cylinder head and the passages for coolant and for lubricating oil...66
      4 Test the cylinder head for leaks at the pressure given in the relevant Data and dimensions for ....66
      5 When the cylinder head is thoroughly clean, check it for cracks. Check carefully the areas arou....66
      6 The bottom face of the cylinder head for only UA and UC engines can be machined if, there is di....66
      7 Use a straight edge and feeler gauges to check the cylinder head for distortion, refer to the r....66
      8 Check the valve seats for wear and for damage...66
      9 Where there is little damage, the valve and valve seat can be lapped. When the valve seats are ....66
      10 More badly damaged valve seats can be corrected by use of the cutter tool, see Operation 3-16,....66
Piston and connecting rod assemblies...67
  Big end bearing and cap...67
    To remove and to fit the early type Operation 4-1...67
    To remove and to fit the latest type (fractured split connecting rods) Operation 4-2...68
  Piston and connecting rod...70
    To dismantle and to assemble the early type Operation 4-3...70
    To fit the early type Operation 4-4...72
    To dismantle and to assemble the latest type (fractured split connecting rods) Operation 4-5...73
    To fit the latest type (fractured split connecting rods) Operation 4-6...75
  Piston and piston rings...76
    To remove and to fit Operation 4-7...76
    To inspect Operation 4-8...77
      1 Fit new piston rings in the grooves in the piston and check for wear of the grooves with feeler....77
      2 Compare the piston ring clearance in the groove to that given for new components in the relevan....77
      3 Renew the piston, if the grooves are worn too much...77
  Piston rings...78
    To inspect Operation 4-9...78
  Connecting rod...79
    To check for bend and to inspect Operation 4-10...79
    To check length and to inspect Operation 4-11...82
  Small end bush...84
    To remove and to fit Operation 4-12...84
  Piston height above the cylinder block...85
    To check Operation 4-13...85
      1 Put the piston height tool on the face of the cylinder block and rotate the dial of the gauge t....85
      2 Rotate the crankshaft until the piston is just before top dead centre (TDC)...85
      3 Carefully put the tool over the top of the piston with the plunger of the gauge in contact with....85
  Piston cooling jets (UC engines)...86
    To remove, and to fit Operation 4-14...86
    To check the jet alignment Operation 4-15...87
      1 Put the gauge on the ring dowels (B3) in the cylinder block. The words “Front Top” must be towa....87
      2 For early type jets carefully insert a 1,2 mm (0.047 in) diameter rod into each jet, they must ....87
      3 When the rods (B1) are inserted into the jets, they must protrude through the holes (B2) in the....87
      4 If they do not, bend each effected jet carefully until the end of the rod does protrude through....87
      5 Remove gauge and the rods...87
Crankshaft assembly...89
  Crankshaft pulley...89
    To remove and to fit Operation 5-1...89
    To fit a wear sleeve Operation 5-2...91
  Rear oil seal...92
    To remove Operation 5-3...92
    To fit Operation 5-4...93
  Thrust washers and crankshaft end-float...94
    To inspect Operation 5-5...94
  Thrust washers...95
    To remove and to fit Operation 5-6...95
  Main bearing caps (with crankshaft in position)...96
    To remove and to fit Operation 5-7...96
  Main bearings...97
    To inspect Operation 5-8...97
  Main bearing caps (front and rear)...98
    To remove Operation 5-9...98
    To fit Operation 5-10...99
  Crankshaft...100
    To remove Operation 5-11...100
    To fit Operation 5-12...101
    To inspect and to overhaul Operation 5-13...102
  Wear sleeve...104
    To fit (early) Operation 5-14...104
      1 Remove the crankshaft, see Operation 5-11...104
      2 Fit the wear sleeve, in accordance with the manufacturer's instructions, supplied with the slee....104
    To fit (latest) Operation 5-15...105
      1 Fit the wear sleeve, in accordance with the manufacturer's instructions, supplied with the slee....105
Timing case and drive assembly...107
  Tamper proof screws...107
    To remove and to fit Operation 6-1...107
      1 Use a suitable hacksaw to cut through the cap (A5/B3) and the lock nut (A2) at the groove (B1)....107
      2 Fit a new sealing washer and a new lock nut from the service kit. Make the adjustment and tight....107
      3 Fit the new retainer ring (A3) to the lock nut...107
      4 Fit the rubber plug (A4) into the end of the lock nut...107
      5 Put the cap onto the lock nut and carefully press the cap on by hand. Ensure that the cap is he....107
      1 Remove the plastic tamper proof cap (C2) from the maximum speed adjustment with a suitable lever...108
      2 Make the adjustment and fit a new cap, part number 2648A119. The cap is pressed onto the lock n....108
  Timing case...109
    To remove and to fit Operation 6-2...109
    To renew Operation 6-3...111
  Gear teeth meshing...112
    To check backlash Operation 6-4...112
  Front oil seal...113
    To remove and to fit Operation 6-5...113
  Idler gear...114
    To remove Operation 6-6...114
  Idler gear bushes...115
    To remove and to fit Operation 6-7...115
  Idler gear hub...116
    To remove and to fit Operation 6-8...116
  Camshaft assembly for the fuel injection pump...117
    To remove and to fit Operation 6-9...117
      1 Release the setscrew for the plate that retains the camshaft bearing...117
      2 Rotate the plate 180 and tighten the setscrew. This will hold the plate away from the bearing...117
  Camshaft assembly and tappets for the valves...118
    To remove and to fit Operation 6-10...118
  Camshaft assembly for the valves...119
    To remove and to fit Operation 6-11...119
  Crankshaft gear...120
    To remove and to fit Operation 6-12...120
      1 To fit the gear, it will be necessary to heat the gear before it will fit onto the crankshaft...120
      2 Heat the gear gradually to not more than 300 C (572 F). Do not use a flame as this can cause ....120
      3 Fit the gear with the timing marks towards the front...120
  Backplate...121
    To remove and to fit Operation 6-13...121
Cylinder block assembly...123
  Cylinder block bores...123
    To inspect Operation 7-1...123
  Camshaft bores...124
    To renew Operation 7-2...124
Engine timing...127
  To set approximately number 1 piston to TDC on the compression stroke...127
    1 Remove the spring clip and the spacer from the front of the rocker shaft. Release the fasteners....128
    2 Release the tappet adjustment screw and remove the front rocker lever. Tighten the fasteners of....128
    3 Remove the valve spring and the cap from the front valve with the valve spring compressor and t....128
    4 Allow the valve to be held by the top of the piston. Fasten a dial test indicator with its plun....128
    5 Rotate slowly, the crankshaft counter-clockwise 45. Then slowly rotate the crankshaft clockwis....128
  Valve timing...129
    To check Operation 8-1...129
  Fuel injection pump timing...130
    To check Operation 8-2...130
      1 Connect a suitable clean tank, with a capacity of approximately 0,75 litres (1.32 pints) and a ....132
      2 Connect a swan neck pipe to the delivery valve holder for number one cylinder. Put a suitable c....132
      3 Add 0,5 litres (0.9 pints) of clean fuel to the container...132
      4 Open the valve...132
      5 Turn the crankshaft slowly in a clockwise direction (C1), until the flow of fuel from the swan ....132
      6 If it is necessary to adjust the timing, remove the pump and fit a shim of the correct thicknes....133
      7 To retard the timing; fit a thicker shim. To advance the timing; fit a thinner shim...133
      8 The timing will change approximately 1 for each 0,10 mm (0.004 in) of shim thickness...133
      9 If the shim has to be changed, it will be necessary to repeat procedure...133
      10 When the timing is correct, remove the swan neck pipe and the tank assembly...133
      11 Remove the delivery valve holder from the pump...133
      12 Tighten the holder to the specified torque...133
Aspiration system...135
  Turbocharger...135
    To remove and to fit Operation 9-1...135
  Impeller and compressor casing...136
    To clean Operation 9-2...136
      1 Release the clip and remove the hose from the compressor inlet. Release the clips and push the ....136
      2 Make a reference mark on the compressor casing (A1) and on the bearing housing (A2) to ensure c....136
      3 Release the circlip. It may be necessary to remove the turbocharger if access to the circlip is....136
      4 Remove carefully the compressor casing from the turbocharger. If the casing is tight, lightly h....136
      5 Put the compressor casing in a suitable container that contains a non-caustic solution. Allow t....136
      6 Clean the impeller with a soft brush...136
      7 Push carefully the compressor impeller towards the bearing housing and turn the impeller by han....136
      8 Fit the circlip loosely to the bearing housing...137
      9 Ensure that the flat face of the circlip is toward the compressor casing. Fit the casing to the....137
      10 Fit the hoses to the compressor inlet and tighten the clip. Slide the hose along the cross ove....137
      11 Tighten the clips...137
  Engine breather assembly...138
    To renew (UA and UB engines) Operation 9-3...138
    To renew (Early UC engines) Operation 9-4...139
    To renew (Latest UC engines) Operation 9-5...140
      1 Release the hose clips (A4) and (A6) and remove the hoses...140
      2 Release two setscrews (A5)...140
      3 Release the hose clip (A7) then pull the breather assembly out of the pipe (A8)...140
      4 Remove the breather valve (A2)...140
      5 Clean the inside of the pipes and the breather adaptor with a proprietry cleaning fluid and dry....140
      6 Fit the new breather valve (A2) if required...141
      7 Fit the metal bracket (A9) and the two setscrews (if removed) and gradually and evenly tighten...141
      8 Push the adaptor (A3) together with the hose (A7) onto the pipe (A8). Tighten the hose clip...141
      9 Fit the hose in the correct position and tighten the hose clip (A6)...141
      10 Fit the hose in the correct position and tighten the hose clip (A4)...141
      11 Fit the two setscrews (A5) and gradually and evenly tighten...141
    To remove and to fit the breather deflectors Operation 9-6...142
      1 Remove the fuel injection pump, see Operation 11-8...142
      2 Remove the threaded adaptor (A4)...142
      3 Remove the deflector (A1) from inside the housing for the fuel injection pump...142
      1 Fit a new “O” ring (A3) to the threaded adaptor (A4)...142
      2 Ensure that the machined face (A2) or the unmachined face is clean and free from oil and grease...142
      3 Insert the deflector (A1) into the housing for the fuel injection pump, ensure that the square ....142
      4 Fit the threaded adaptor (A4) into the deflector (A1) and tighten to:...142
      5 Fit the fuel injection pump, see Operation 11-8...142
Lubrication system...143
  Oil filter canister...143
    To renew Operation 10-1...143
  Engine lubricating oil...144
    To renew Operation 10-2...144
  Filter head and oil cooler...145
    To remove and to fit Operation 10-3...145
      1 Release the setscrew and remove the filter head from the cylinder block...145
      2 Discard the "O" rings (A1) on the setscrew and the "O" ring (A2) on the filter head. Fit the fi....145
      3 Fit new "O" rings to the setscrew and tighten the setscrew to the torques shown...145
  Aluminium sump...146
    To remove and to fit Operation 10-4...146
  Steel sump...147
    To remove and to fit Operation 10-5...147
      1 Drain the sump of oil...147
      2 Remove the setscrews that fasten the sump to the cylinder block and to the timing case, remove ....147
      3 Wash the sump with a suitable cleaning fluid, ensure that all the cleaning fluid is removed...147
      4 Thoroughly clean the flange face of the sump, the cylinder block and the timing case mating fac....147
      1 Place the new joint on the flange face (A1) of the sump, with the black face towards the cylind....147
      2 Fit the sump onto the cylinder block. Fit a setscrew on each side of the sump to ensure it is i....147
      3 Gradually and evenly tighten all the setscrews...147
      4 Fill the sump with approved lubricating to the correct level, see Operation 10-2...147
  Oil strainer and suction pipe...148
    To remove and to fit Operation 10-6...148
  Lubricating oil pump...149
    To renew Operation 10-7...149
    To inspect Operation 10-8...150
  Relief valve...151
    To remove, to fit and to renew Operation 10-9...151
Fuel system...153
  Fuel filter element...153
    To renew Operation 11-1...153
  Atomiser fault...155
    To inspect Operation 11-2...155
  High pressure fuel pipes...156
    To remove and to fit Operation 11-3...156
  Leak off rail...157
    To remove and to fit Operation 11-4...157
  Atomisers...158
    To remove and to fit Operation 11-5...158
  Fuel lift pump...160
    To remove and to fit Operation 11-6...160
    To test Operation 11-7...161
      1 Disconnect the fuel outlet pipe from the fuel lift pump. Fit a 0-70 kPa (0-10 lbf/in2) 0-0,7 kg....161
      2 Release the connection at the gauge and operate the priming lever of the lift pump to eliminate....161
      3 Operate the starter motor for 10 seconds with the engine stop control in the stop position or w....161
      4 Remove the gauge and connect the outlet pipe to the lift pump. Release the vent screw on the fu....161
      5 Connect the engine stop solenoid...161
  Fuel injection pump...162
    To remove and to fit Operation 11-8...162
      1 Release the union nuts of the high-pressure pipes from the atomisers and fuel injection pump an....162
      2 Remove the support bracket / blanking plate from the side of the cylinder block...162
      3 Record the position of the four setscrews, because on some earlier engines, they are of differe....162
    To eliminate air from the fuel system Operation 11-9...164
      1 Loosen the vent plug (A1) on the side of the fuel injection pump...164
      2 Operate the priming lever (A2) until fuel, free from air, comes from the vent point. Tighten th....164
      3 Turn the start key to the "ON" position...164
      4 Operate the starter motor for intervals of 15 seconds until the engine starts. It is important ....164
      5 If the engine runs correctly for a short time and then stops or runs roughly, check for air in ....164
  Governor weight assembly...165
    To remove and to fit Operation 11-10...165
  Speed control lever assembly...166
    To remove and to fit Operation 11-11...166
    To renew Operation 11-12...167
  To change a plain bush to a threaded bush...168
    1 Use a suitable extractor (M10) to remove the plain bush from the timing case (A1)...168
    2 Cut an M16 X 1 mm thread in the parent bore for the bush (A2)...168
    3 Fit the threaded bush (A3)...168
  Fuel injection pump linkage...169
    To remove and to fit Operation 11-13...169
      (1) See Operation 11-14...169
    To renew Operation 11-14...170
      (1) Use POWERPART Retainer (oil tolerant) on ONLY the first two threads...170
  To record the maximum fuel position of the fuel control rack...171
    1 Remove the 'D' plug from the timing case (A)...171
    2 Remove the access plate from the cylinder block (B)...171
    3 Put the clamp into the timing case such that the end of the clamp points downwards (C)...171
    4 When the end of the clamp is entered far into the timing case, rotate the tool counter-clockwis....172
    5 Tighten the adjustment screw, finger tight, to hold together the two levers...172
    6 To ensure that the tool has held both the levers, move the tool backwards and forwards. The peg....172
    7 Remove the spring (F1) and then the spring (F2) from the peg...172
    8 Remove the fuel injection pump (G)...173
    9 Remove the shim from the fuel pump housing...173
    10 Remove the stud from the fuel pump housing (H)...173
    11 Clean the flange face of the fuel pump housing...173
    12 Put the tool into position on the two dowels in the fuel pump housing; the adjustment rod of t....173
    13 Put the peg on the end of the adjustment rod into the hole in the control link. Fit the retain....174
    14 Push the clamping tool towards the timing case, rotate the adjustment knob counter-clockwise s....174
    15 Ensure that the setting ring is not in contact with the locking ring, refer to illustration (M....174
    16 When the feeler gauge fit between the setting plate and the setting ring is correct, keep pres....175
    17 Remove the tool from the engine and ensure that the setting and locking rings are not disturbed...175
  How to use the reference setting for maximum fuel...176
    1 Check that the adjustment screw for the maximum fuel adjustment protrudes approximately 25 mm (....176
    2 Put the tool into position on the two dowels in the fuel pump housing; the adjustment rod of th....176
    3 Put the peg on the end of the adjustment rod into the hole in the control link. Fit the spring ....176
    4 Put the setting plate into position, between the rear face of the tool and the setting ring, an....176
    5 Release the lock nut of the maximum fuel adjustment and rotate the adjustment screw clockwise u....177
    6 Fit the cap nut to the adjustment screw. The latest engines have a tamper proof cap, see Operat....177
    7 Remove the setting plate. Carefully rotate the adjustment knob clockwise approximately 1/4 turn....177
    8 Remove clamp from the timing case...177
    9 Apply Liquid gasket to the side faces of a new "D" plug and fit the "D" plug...177
    10 Ensure that the flange face of the fuel pump housing is clean and fit the shim (G1) for the fu....177
Cooling system...179
  To drain and to fill Operation 12-1...179
    1 Remove the filler cap of the cooling system...179
    2 Drain the cooling system of coolant, then flush the cooling system with POWERPART Easy Flush...179
    1 Fill the engine cooling system with antifreeze to the correct level, at a rate no faster than s....179
    2 Fit the filler cap of the cooling system...179
    3 Operate the engine at medium speed range for thirty seconds...179
    4 Stop the engine. When the engine has stopped any trapped air is eliminated automatically throug....179
    5 Check the coolant level and if necessary fill again to the correct level...179
  Thermostat...180
    To remove and to fit Operation 12-2...180
    To test Operation 12-3...181
  Fan...182
    To remove and to fit Operation 12-4...182
  Coolant pump...183
    To remove and to fit Operation 12-5...183
  Oil cooler...184
    To remove and to fit Operation 12-6...184
Flywheel and housing...185
  Flywheel...185
    To remove and to fit Operation 13-1...185
    To inspect Operation 13-2...186
  Starter ring...187
    To remove and to fit Operation 13-3...187
  Flywheel housing...188
    To remove and to fit Operation 13-4...188
Electrical equipment...189
  Drive belt...189
    To remove and to fit Operation 14-1...189
  Alternator...190
    To remove and to fit Operation 14-2...190
  Glowplugs (starting aid)...191
    To remove and to fit Operation 14-3...191
      1 Release the union nuts (B2) of the high-pressure fuel pipes at both ends and remove the pipes...192
      2 Loosen the nuts (B1) on the glow plugs that retain the bus-bar (B3), but do not remove them...192
      3 Slide the bus-bar, part number 3812A017, out from between the nuts and the top of the glow-plug....192
      4 Release the nuts (C1) that retain the glow plugs, but do not remove them...192
      5 Slide the bus-bar (C2), part number 3812A016, out from between the nuts and the tops of the glo....192
      1 Slide the bus-bar (B3) between the nuts (B1) and the top of the glow-plugs. The bus-bar must be....192
      2 Tighten the glow plug nuts of the two outer glow plugs and then the two inner glow plugs to 2 N....192
      3 Fit the high-pressure fuel pipes and tighten the union nuts (B2) to 27 Nm (37 lbf ft) 2,8 kgf m...192
      1 Slide the bus-bar (C2) between the nuts (C1) and the top of the glow-plugs. The bus-bar must be....192
      2 Tighten the glow plug nuts of the two outer glow plugs and then the two inner glow plugs to 2 N....192
    To check Operation 14-4...195
      1 Disconnect the glow plug connection...195
      2 Apply one probe of a multi-meter, that can check continuity, to the terminal of the glow plug a....195
      3 If a multi-meter is not available, connect a 12V test lamp between the positive terminal of the....195
      4 Connect the test lamp between the terminal of the glow plug, that is furthest away from the pow....195
      5 Disconnect the cables at each glow plug...195
      6 Connect the test lamp to the positive terminal of the battery and to the terminal of a glow plu....195
      7 When all of the glow plugs have been checked, connect the cables to the glow plugs...195
      1 Disconnect the power supply cable and the connection cables from the terminals of the glow plugs...195
      2 Connect a 50-0-50 ammeter between the power supply cable and the terminal of a glow plug. Conne....195
      3 Engage the control switch and check the readings of the ammeter and the voltmeter...195
  Starter motor...196
    To remove, to fit and to test Operation 14-5...196
      1 Ensure that the battery is fully charged...196
      2 Turn on the lights and operate the starter switch. If no lights are fitted to the machine, conn....196
      3 If the starter does not operate but the lights keep their power or there is no voltage drop acr....196
      4 Clean the shaft thoroughly with gasolene, or a fluid made especially for the purpose, and apply....196
  Electrical stop solenoid...197
    To remove and to fit Operation 14-6...197
Auxiliary equipment...199
  Power take-off assembly...199
    To remove and to fit Operation 15-1...199
    To dismantle and to assemble Operation 15-2...200
      1 Remove the circlip (A1). Remove the spacer (A2). Press the shaft (A5) out of the ball bearing (....200
      2 Remove the "O" ring (A6). Press the roller bearing (A7) out of the housing...200
      3 Press the cup (A4) out of the front of the drive shaft...200
      1 Press the cup (A4) fully into the drive shaft...200
      2 Press the ball bearing (A3) fully onto the shoulder of the shaft. Fit the spacer (A2). Fit the ....200
      3 Lightly lubricate the recess in the front of the rear housing (A8) and press in the roller bear....200
      4 Renew the "O" ring (A6)...200
Special tools...201
  Special tools list...201