This is the Perkins workshop manual for the Prima, Prima Marine, and 500 Series four cylinder diesel engines, publication TPD 01921273. It covers Prima units built for vehicle use, Prima Marine engines for boats (the naturally aspirated Prima M50 and the turbocharged M80T), and 500 Series engines for agricultural and industrial machines, both naturally aspirated and turbocharged.
The 130 page manual runs through the full engine: cylinder head and valve gear, pistons and connecting rods, crankshaft, timing case and belt, cylinder block, aspiration and turbocharger, lubrication, fuel system, cooling with its raw water circuit, flywheel housing and the marine reverse gearbox, plus electrical equipment with wiring diagrams.
Use it to trace a fault, set tappet clearances, renew oil seals and the timing belt, or carry out a full rebuild. Specifications and recommended torque tensions are gathered up front so the wear limits and settings are easy to find.
What's Inside This Perkins Prima, Prima Marine, Prima M50, Prima M80T Manual
| System | Pages | Key Topics |
|---|---|---|
| Perkins Workshop Manual | 1 | |
| Amendment Status | 2-3 | Number, Date |
| General Information | 4-8 | Introduction, Engine Identification, Safety Precautions, Asbestos Joints |
| Specifications | 9-25 | Basic Engine Data, Recommended Torque Tensions |
| Cylinder Head Assembly | 26-38 | General Description, Camshaft Cover, Tappet Clearances, Front Oil Seal of Camshaft, Camshaft, Valves and Valve Springs, Valve Guides |
| Piston and Connecting Rod Assemblies | 39-47 | Big End Bearing (Remove and to Fit, Inspect), Piston and Connecting Rod Assembly (to Remove and to Fit), Piston Rings (to Remove and to Fit), Piston and Rings (to Inspect) |
| Crankshaft Assembly | 48-57 | Crankshaft Pulley (to Remove and to Fit), Front Oil Seal (to Renew), Rear Oil Seal (Renew, Remove and to Fit the Separate Oil Seal Housing) |
| Timing Case and Drive Assembly | 58-66 | Timing Case Cover (to Remove and to Fit), Timing Belt (Check the Belt Condition and Tension, Adjust the Belt Tension, Remove and to Fit) |
| Cylinder Block Assembly | 67-70 | Cylinder Block (Dismantle and to Assemble, Inspect, Correct a Glazed Bore), To Dismantle and to Assemble, To Inspect, To Correct a Glazed Bore |
| Engine Timing | 71-74 | General Description |
| Aspiration System | 75-78 | Induction and Exhaust Manifolds (to Remove and to Fit), Turbocharger (to Remove and to Fit, Waste-Gate Unit) |
| Lubrication System | 79-85 | Filter Canister (to Renew), Filter Head (to Remove and to Fit), Lubricating Oil Sump (to Remove and to Fit) |
| Fuel System | 86-94 | General Description, Fuel Filter Canister, Lift Pump, Fuel Injection Pump |
| Cooling System | 95-105 | Coolant Circuit (Drain, Fill), Raw Water Circuit (to Drain), Thermostat (Remove and to Fit, Test), Water Pump (to Remove and to Fit) |
| Flywheel, Flywheel Housing and Marine Reverse Gearbox | 106-110 | Flywheel (to Remove and to Fit), Ring Gear (to Remove and to Fit), Flywheel Housing or Backplate (to Remove and to Fit), Reverse Gearbox for Marine Engines (to Remove and to Fit) |
| Electrical Equipment | 111-122 | Alternators, Starter Motors, Starting Aid, Wiring Diagrams (Precautions, Drive Belt, Alternator, Starter Motor, Glow Plugs, Marine Engines) |
| Auxiliary Equipment | 123-124 | Exhauster (Remove and to Fit, Test), To Remove and to Fit, To Test |
| List of Special Tools | 125-130 | Tension Gauge, Drive Belt, Alternator, Valve Seat Cutters, Adjustable Pilot, Remover/Replacer, Oil Seals, Camshaft |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Cylinder head setscrews torque (first stage) | 50 Nm (37 lbf ft) 5,1 kgf m | p. 34 |
| Cylinder head setscrews torque (second stage) | 100 Nm (74 lbf ft) 10,2 kgf m | p. 34 |
| Valve guide inside diameter (reamed in position) | 7,450/7,463 mm (0.2933/0.2938 in) | p. 16 |
| Valve guide interference fit in cylinder head | 0,04/0,08 mm (0.0016/0.0031 in) | p. 16 |
| Top ring width | 1,978/1,990 mm (0.0778/0.0783 in) | p. 18 |
| Second ring width | 1,73/1,74 mm (0.068/0.069 in) | p. 18 |
| Cylinder bore diameter | 84,442/84,469 mm (3.3245/3.3256 in) | p. 21 |
| Maximum permissible wear in bore | 0,15 mm (0.006 in) | p. 21 |
| Maximum resistance of battery cables 1 and 2 | 0.0017 ohms | p. 121 |
| Cylinder bore maximum wear before rebuild | 0,15 mm (0.006 in) | p. 70 |
| Cylinder bore oversize machining diameter | 0,50 mm (0.0197 in) | p. 70 |
| Nominal bore | 84,5 mm (3.33 in) | p. 11 |
