1100 Series

92 Issue 1

Servicing the Outlet Check Plugs

July 2010

This engine news article applies to six and four cylinder engines, models PJ, PK, NH and NJ.
If the engine turns over but the engine does not start, refer to Operation and Maintenance Manual, Fuel
System - Prime and Troubleshooting, Engine Cranks but Will Not Start.
If the engine will not start, new service parts are available.
The new service parts are the following components:
Plug (Perkins part number 3346A013)
Pin (Perkins part number 2116A401)
Spring (Perkins part number 3174A032).
These parts are required for the installation procedure. If both check plugs require replacement, then a quantity
of two of each component is required.

Removal Procedure
Warning! Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may
cause personal injury or death.
Cautions:
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised
personnel that have the correct training. Refer to Systems Operation, Testing and Adjusting, Cleanliness
of Fuel System Components for detailed information on the standards of cleanliness that must be observed
during ALL work on the fuel system.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance,
testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before
opening any compartment or disassembling any component containing fluids. Dispose of all fluids
according to local regulations and mandates.
Note: Put identification marks on all hoses and all plastic tube assemblies for installation purposes. Plug all
plastic tube assemblies. This helps to prevent fluid loss and this helps to keep contaminants from entering the
system. Ensure that cap kit (Perkins kit number U5MK1124) is used.
1 Turn the fuel supply to the off position.
2 Turn the battery disconnect switch to the off position.
Note: Perkins recommends the use of a clean sheet placed under the fuel injection pump. The clean sheet will
assist in the prevention of the components falling onto the ground below the application.

Engine News - 1100 Series 92 Issue 1

July 2010

2
1

3
4
5

3 Remove one outlet check plug (A2) from fuel injection pump (A1). Remove the plug, the spring (B5) and the
outlet check valve (B4).
4 Clean the components with alcohol or contact cleaner. Inspect the components for wear or damage. If there
is damage to the radius surface of the outlet check valve, replace with a new outlet check valve.
5 Flush out the head of the fuel injection pump (A1) with clean alcohol or contact cleaner. Inspect the head of
the fuel injection pump for damage or debris on the seat area (B3).
6 Use a cotton swab with alcohol or contact cleaner applied, swab threads in counterclockwise direction. This
will remove debris from the threads.
Note: Caution is required to prevent pushing debris into the internal passages. Do not use a clockwise
direction to clean debris from threads as debris could be pushed into the fuel injection pump.

Installation Procedure
Warning! Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may
cause personal injury or death.
Cautions:
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorised
personnel that have the correct training. Refer to Systems Operation, Testing and Adjusting, Cleanliness
of Fuel System Components for detailed information on the standards of cleanliness that must be observed
during ALL work on the fuel system.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance,
testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before
opening any compartment or disassembling any component containing fluids. Dispose of all fluids
according to local regulations and mandates.
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
1 Crank the engine until fuel comes out of one of the plug orifices, free of air.

Engine News - 1100 Series 92 Issue 1

July 2010

2
1

3
4
5

2 Replace the plug, spring (B5) and valve (B4). Tighten the plug finger tight.
3 Crank the engine again until the fuel comes out the outlet check plug orifice, free of air.
4 Tighten the outlet check plug (A2) finger tight. Tighten the outlet check plug (A2) to a torque of 40 Nm (30
lbf/ft) 4 kgf m.
5 Repeat steps 3 to 6 of the removal procedure for the other outlet check plug. Repeat steps 1 to 4 of the
installation procedure for the other outlet check plug.
6 Turn the battery disconnect switch to the on position.
7 Turn the fuel supply to the on position.
8 Remove the air from the fuel system. Refer to Operation and Maintenance Manual, Fuel System - Prime
for the correct procedure.
9 Start the engine. Refer to Operation and Maintenance Manual, Starting the Engine for the correct
procedure. Check for fuel leaks.
Note: The threads can retain a small amount of fluid that will seep out during the early hours of operation and
could be confused with a leak.
End
Perkins Confidential Yellow. Issued by Perkins Engines Company Ltd, Peterborough PE1 5NA, England. Proprietary information of
Perkins Engines Company Ltd 2010, all rights reserved. The information is correct at the time of print. This Engine News article is for
technical information only and cannot be used as a basis for any claim including but not limited to warranty.
To enable the distribution lists for engine news articles to be maintained, If you currently receive engine news articles, but no
longer require them, please contact Terry Bell by email at bell_terry_c@perkins.com