TD 500

@Perkins Technical Data Document

Sheet 1 of 6

Issue No. 2
General Machining Standards Date 04.Oct.02

Alterations incorporated :- 02P123, 02P166

General Notes :
This Technical Data (TD) Document provides the detailed requirements for which there is
insufficient space on the component drawing.
The requirements of an individual TD may be altered by the addition of a specific note on the
drawing. In this case the additional note shall override the requirements stated in the TD.
Any changes to the structure or content of this TD must be actioned by means of a Design
Change (DC), approved by the owner.

Owned by : Authorised by : Date:

M. E. Spinks Authorised by Design Change DCP 02P166 03.Oct.2002

Technical
Standards
Team

PURPOSE

To define the general machining requirements for component features which are not
specifically noted on the component drawing.

CONTENTS

1. SCOPE
2. SURFACE TEXTURE
3. TOLERANCES
4. REFERENCES

APPENDICES
APPENDIX ‘A’ – TOLERANCES FOR DRILLED HOLE DIAMETERS.

Perkins Engines Company Limited 2002

Perkins Confidential : Green

 TD 500
@Perkins Technical Data Document
Sheet 2 of 6

Issue No. 2
General Machining Standards Date 04.Oct.02

1. SCOPE

Affects all component drawings where machining is required.

2. SURFACE TEXTURE

Surface texture notation to be evaluated in accordance with BS ISO 1302:1992 and

BS ISO 4287:1997.

3. TOLERANCES

3.1. Features With Undefined Tolerances.

3.1.1. Dimensions which relate to a machined surface, but which are not toleranced
shall be within ±0,4 mm.

3.1.2. Drilled hole positions, which are not toleranced, shall be within Ø0,4 mm of
true position. Non-critically positioned (where alignment of components is not
affected) holes and tappings in bosses of sumps and inlet manifolds (drain,
dipstick, heater etc.) shall be positioned within Ø 2,0 mm of true position.

3.2. Drilled Hole

For size tolerances refer to Appendix’A’

3.3. Tapped Holes

3.3.1. The depth of the drilled hole specified should be regarded as the maximum
depth and the depth of thread specified should be regarded as the minimum
full thread depth.

3.3.2. The diameter of the drilled hole specified shall be in accordance with
BS 1157, and the depth shall be indicated in square brackets. The drilled and
tapped hole shall be specified on the drawing as follows :-

Example (1) M8 x 1,25 x 20 [25]

Where M8 is the thread size.
1,25 is the thread pitch.
20 is the minimum tapping depth
[25] is the maximum drilling depth.

Example (2) M8 x 1,25 x 20

Would indicate that the drilled hole is a through hole, but the
tapped hole is depth limited.

Example (3) M8 x 1,25

Would indicate that both drilled and tapped holes are through
holes.

Perkins Engines Company Limited 2002

Perkins Confidential : Green

 TD 500
@Perkins Technical Data Document
Sheet 3 of 6

Issue No. 2
General Machining Standards Date 04.Oct.02

3.3.3. Thread tolerances will be in accordance with :-

Metric to BS 3643 class 6g/6H
Unified to BS 1580 class 2A/2B
Pipe to BS 2779 tolerance B

3.3.4. ISO metric threads to be manufactured to ISO 898-1 in grade 8,8 unless
otherwise quoted. Surface integrity and standard requirements to ISO
6157-1. Special requirements to ISO 6157-3.

3.3.5. Through hole tappings into water, oil and internal air passages shall have a
lead-in chamfer of 1,6 x 45° applied to prevent stripping of sealant coatings
(i.e. MEAS) from the inserted hardware.

3.4. Geometrical Tolerances

Tolerances, which are defined within a framed rectangle, are described as

“Geometrical Tolerances” and shall be evaluated in accordance with the
requirements of BS ISO 1101:1983.

3.5. Form Tolerances

The following form tolerances shall be effective for all relevant surfaces that are not
already controlled by tolerances defined on the component drawing.

3.5.1. Flatness
0,025 mm

Surface shall lie within two parallel

planes 0,025 mm apart per 100 mm
100 mm span in any direction.
The flatness tolerance quoted will depend on the application, on the rigidity of
the component, the material used, thickness of gasket (if any), and without
qualification will be the permitted maximum error in the free state. It is
acceptable to quote flatness tolerances in both free state and clamped
condition.

Perkins Engines Company Limited 2002

Perkins Confidential : Green

 TD 500
@Perkins Technical Data Document
Sheet 4 of 6

Issue No. 2
General Machining Standards Date 04.Oct.02

3.5.2. Squareness / angularity (excluding holes)

Face shall be within a tolerance zone

0,05 mm 0,05mm wide per 100mm span at the
required angle to the datum plane.
100 mm Note; faces at 90 degree angle are the
normal and are usually unspecified.
required Note; chamfers are considered to be
angle angled faces less than 5mm long and
will be controlled within +/- 5 degrees.

3.5.3. Squareness and angularity of holes

Centreline of the hole is

25mm permitted to depart from
the required alignment by
0,05mm per 25mm depth
of hole.
0,05mm
3.5.4. Parallelism

tolerance X/2 If the total tolerance of

the interface dimension
is 'X', then the upper and
tolerance X lower faces shall each lie
between two parallel
planes 'X/2' apart.
tolerance X/2 Up to a maximum of 0,2mm

Perkins Engines Company Limited 2002

Perkins Confidential : Green

 TD 500
@Perkins Technical Data Document
Sheet 5 of 6

Issue No. 2
General Machining Standards Date 04.Oct.02

3.5.5. Shaft runout

tolerance 'Y'

tolerance 'X'

The tolerance on the runout

of one diameter to another
diameter shall lie within a
cylindrical tolerance band
equal to half of the total of the
two tolerances involved. runout tolerance to be (X + Y)/2

3.5.6. Symmetry
0,2 mm
=

Feature shall lie

within two parallel
planes 0,2 mm apart.
=

0,2 mm

3.6. Finishing

All processing residues (oil, swarf, etc.) shall be removed from components. All
processing burrs shall be removed.

3.7. Identity Symbols

Components shall only be marked in accordance with TD 520.

Perkins Engines Company Limited 2002

Perkins Confidential : Green

 TD 500
@Perkins Technical Data Document
Sheet 6 of 6

Issue No. 2
General Machining Standards Date 04.Oct.02

4. REFERENCES

ISO 1302 ................ Surface texture indication method

ISO 4287 ................ Surface texture profile method
ISO 898-1 ............... ISO metric thread manufacture
ISO 6157-1 ............. ISO metric thread surface integrity and standard requirements
ISO 6157-3 ............. ISO metric thread special requirements
ISO 1101 ................ Geometrical tolerance method
BS 1157 ................. Drilled hole diameter recommendations
BS 3643 ................. Metric threads
BS 1580 ................. Unified threads
BS 2779 ................. Pipe threads
TD 520 ................... Component Identification

APPENDIX ‘A’ – Tolerances for drilled hole diameters.

25
24
23
22
21
20
Nominal Hole Size 'Y' (mm)

19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0.13 0.15 0.17 0.19 0.21 0.23 0.25

Hole Tolerance Upper Limit 'X' (mm)

The hole upper tolerance can be calculated from the formula

Y-1 Where Y = the nominal hole size
X= + 0,13 and X = the upper tolerance limit
200
Minimum diameter shall be nominal -0,075mm.
Above 25mm diameter, the upper limit shall remain constant at +0,25mm.
Inch hole sizes shall be pro rata with the metric graph values for oversize and
nominal –0.003” for minimum diameter.

Perkins Engines Company Limited 2002

Perkins Confidential : Green