AGCO Perkins 1100 Series User manual

ENGINE
SERVICE MANUAL
Perkins®
1100 Series 6-Cylinder Diesel Engine
R1310

CALIFORNIA
Proposition 65 Warning
WARNING: Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other repro-
ductive harm.
WARNING: Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of California to cause
cancer, birth defects, and other reproductive harm. Wash hands after
handling.
TO OUR CUSTOMER:
Congratulations on your selection of an AGCO® Product. We believe
you have exercised excellent judgment in the purchase of your
AGCO® machine. We are most appreciative of your patronage.
Your Dealer has performed the pre-delivery service on your new
machine.
He will discuss with you the operating and maintenance instructions
given in this manual, and instruct you in the proper and varied applica-
tions of this machine. Call on him at any time when you have a
question or need equipment related to the use of your machine.
We recommend that you carefully read this entire manual before
operating the unit. Also, time spent in becoming fully acquainted with
it’s performance features, adjustments, and maintenance schedules
will be repaid in a long and satisfactory life of the product.
This equipment is covered by a written warranty which will be
provided to you by your AGCO® Dealer at time of purchase.
AGCO
®
reserves the right to make changes or add improvements to its products at any time without incurring
any obligation to make such changes to products manufactured previously.
AGCO
®
, or its dealers, accept no
responsibility for variations which may be evident in the actual specifications of its products and the statements
and descriptions contained in this publication.
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ii
Perkins Approved Clear English
This publication is written in
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
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Workshop Manual, TPD 1476E, Issue 1 iii
1100 Series model VK
Contents
1 General information
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...1
Engine views (side mounted turbo) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...2
Engine views (top mounted turbo) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...3
Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...4
Safety precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...5
Engine lift equipment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...7
Viton seals . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...8
POWERPART recommended consumable products . ... ... ... ... ... ... ... ... ... ... ... ... ...9
2 Specifications
Basic engine data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .13
Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .14
Thread sealant ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .32
Standard torque values ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .33
Specific torque values .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .34
Compression test data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .40
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iv Workshop Manual, TPD 1476E, Issue 1
1100 Series model VK
3 Cylinder head assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41
Rocker cover
Operation 3-1 To remove and fit the rocker cover . ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42
Rocker assembly
Operation 3-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43
Operation 3-3 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44
Operation 3-4 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44
Valve tip clearances
Operation 3-5 To check and to adjust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45
Valve springs
Operation 3-6 To change the valve springs (with cylinder head fitted) .. ... ... ... ... ... ... 47
Manifolds ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49
Operation 3-7 To remove and to fit an intake manifold .. ... ... ... ... ... ... ... ... ... ... ... ... 49
Operation 3-8 To remove and to fit an exhaust manifold (two-piece) ... ... ... ... ... ... ... 51
Operation 3-9 To remove and to fit an exhaust manifold (three-piece) . ... ... ... ... ... ... 54
Cylinder head assembly
Operation 3-10 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 56
Operation 3-11 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 58
Valves and valve springs
Operation 3-12 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 62
Operation 3-13 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 63
Operation 3-14 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 64
Valve guides
Operation 3-15 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 65
Operation 3-16 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 66
Operation 3-17 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 67
Cylinder head
Operation 3-18 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 69
Operation 3-19 To correct a valve seat with a valve seat cutter ... ... ... ... ... ... ... ... ... 70
Operation 3-20 To fit valve seat inserts . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 72
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Workshop Manual, TPD 1476E, Issue 1 v
1100 Series model VK
4 Piston and connecting rod assemblies
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .73
Big end bearing
Operation 4-1 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .75
Operation 4-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .76
Operation 4-3 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .76
Piston and connecting rod
Operation 4-4 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .77
Operation 4-5 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .78
Operation 4-6 To check the piston height above the cylinder block .. ... ... ... ... ... ... ... .80
Piston rings
Operation 4-7 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .81
Operation 4-8 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .81
Piston and connecting rod assembly
Operation 4-9 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .82
Operation 4-10 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .83
Operation 4-11 To check the length of a connecting rod .. ... ... ... ... ... ... ... ... ... ... ... .84
Piston and piston rings
Operation 4-12 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .85
Connecting rod
Operation 4-13 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .86
Partially finished small end bush
Operation 4-14 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .87
Piston cooling jets
Operation 4-15 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .88
Operation 4-16 To check the jet alignment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .88
5 Crankshaft assembly
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .89
Crankshaft pulley
Operation 5-1 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .90
Operation 5-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .91
Crankshaft vibration damper
Operation 5-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .92
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vi Workshop Manual, TPD 1476E, Issue 1
1100 Series model VK
Rear end oil seal assembly
Operation 5-4 To remove and to fit the rear end oil seal assembly ... ... ... ... ... ... ... ... 93
Operation 5-5 To remove and to fit a crankshaft palm wear sleeve .. ... ... ... ... ... ... ... 97
Thrust washers
Operation 5-6 To check crankshaft end-float . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 98
Operation 5-7 To remove (with the crankshaft in position) ... ... ... ... ... ... ... ... ... ... ... 99
Operation 5-8 To fit (with the crankshaft in position) . ... ... ... ... ... ... ... ... ... ... ... ... .. 100
Main bearings
Operation 5-9 To remove (with the crankshaft in position) ... ... ... ... ... ... ... ... ... ... .. 101
Operation 5-10 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 102
Operation 5-11 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 102
Crankshaft
Operation 5-12 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 103
Operation 5-13 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 104
Operation 5-14 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 106
Crankshaft timing ring
Operation 5-15 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 107
Operation 5-16 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 108
6 Timing case and drive assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 109
Timing case cover
Operation 6-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 110
Operation 6-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 111
Front oil seal
Operation 6-3 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 113
Operation 6-4 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 114
Operation 6-5 To remove and to fit a crankshaft pulley wear sleeve . ... ... ... ... ... ... .. 116
Idler gear and hub
Operation 6-6 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 117
Operation 6-7 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 118
Idler gear and hub for the compressor ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 119
Operation 6-8 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 119
Operation 6-9 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 120
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Workshop Manual, TPD 1476E, Issue 1 vii
1100 Series model VK
Fuel pump gear . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...121
Operation 6-10 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...121
Operation 6-11 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...123
Camshaft gear
Operation 6-12 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...125
Crankshaft gear
Operation 6-13 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...126
Timing case
Operation 6-14 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...127
Operation 6-15 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...128
Camshaft and tappets
Operation 6-16 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...130
Operation 6-17 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...131
7 Cylinder block assembly
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...133
Cylinder block
Operation 7-1 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...134
Operation 7-2 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...135
Operation 7-3 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...136
Operation 7-4 To remove and to fit a new type ‘D’ plug to the tappet chamber ... ... ...137
Cylinder liner
Operation 7-5 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...139
Operation 7-6 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...140
Operation 7-7 To fit a service liner ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...142
Operation 7-8 To fit a partially finished liner .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...145
8 Engine timing
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...149
Engine timing
Operation 8-1 Method 1 - To set number 1 piston to TDC on the compression stroke .151
Operation 8-2 Method 2 - To set number 1 piston to TDC on the compression stroke .152
Operation 8-3 To set number 1 piston to 4° after TDC on the compression stroke .. ...153
Operation 8-4 To check the valve timing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...155
Operation 8-5 To check the timing of the fuel injection pump ... ... ... ... ... ... ... ... ... ...156
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viii Workshop Manual, TPD 1476E, Issue 1
1100 Series model VK
9 Aspiration system
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 157
Turbocharger
Operation 9-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 159
Operation 9-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 160
Operation 9-3 To clean the impeller and the compressor casing .. ... ... ... ... ... ... ... .. 161
Operation 9-4 To check the operation of the waste-gate ... ... ... ... ... ... ... ... ... ... ... .. 162
Turbocharger faults ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 163
List of possible causes . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 164
Exhaust elbow
Operation 9-5 To remove and fit an exhaust elbow ... ... ... ... ... ... ... ... ... ... ... ... ... .. 165
Closed Circuit Breather System
Operation 9-6 To remove and fit the breather assembly ... ... ... ... ... ... ... ... ... ... ... .. 166
Operation 9-7 To remove and fit the closed circuit drain valve .. ... ... ... ... ... ... ... ... .. 168
10 Lubrication system
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 169
Lubrication system flow diagram ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 170
Lubrication system flow diagram for the compressor ... ... ... ... ... ... ... ... ... ... ... .. 171
Filter canister
Operation 10-1 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 172
Filter head
Operation 10-2 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 173
High position filter canister
Operation 10-3 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 174
High position oil filter head and adaptor plate
Operation 10-4 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 175
High position filter head by-pass valve
Operation 10-5 To dismantle and assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 177
Filter head oil test valve ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 178
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Workshop Manual, TPD 1476E, Issue 1 ix
1100 Series model VK
Sump
Operation 10-6 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...179
Operation 10-7 To fit an aluminium sump . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...180
Operation 10-8 To fit a cast iron sump .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...182
Dipstick tube
Operation 10-9 To remove and fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...184
Oil strainer and suction pipe
Operation 10-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...185
Operation 10-11 To inspect and to correct ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...185
Lubricating oil pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...186
Operation 10-12 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...186
Operation 10-13 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...187
Operation 10-14 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...188
Lubricating oil pump idler gear shaft .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...189
Operation 10-15 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...189
Operation 10-16 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...191
Relief valve
Operation 10-17 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...192
Operation 10-18 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...193
Operation 10-19 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...193
Flexible oil pipes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...194
Operation 10-20 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...194
Operation 10-21 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...195
Operation 10-22 To Inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...195
11 Fuel system
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...197
Typical fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...198
Fuel filter
Operation 11-1 To renew the fuel filter canister ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...200
Atomisers .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...201
Operation 11-2 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...202
Operation 11-3 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...203
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xWorkshop Manual, TPD 1476E, Issue 1
1100 Series model VK
Fuel lift pump
Operation 11-4 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 205
Operation 11-5 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 206
Operation 11-6 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 207
Operation 11-7 To test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 208
Bosch fuel injection pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 209
Operation 11-8 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 210
Operation 11-9 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 212
Air in the fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 215
Operation 11-10 To eliminate air from the fuel system .. ... ... ... ... ... ... ... ... ... ... ... .. 215
12 Cooling system
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 219
Thermostat
Operation 12-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 220
Operation 12-2 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 221
Operation 12-3 To test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 222
Thermostat housing
Operation 12-4 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 222
Coolant pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 223
Operation 12-5 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 223
Operation 12-6 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 224
Operation 12-7 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 226
Operation 12-8 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 229
Fan
Operation 12-9 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 234
Fan drive
Operation 12-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 235
Lubricating oil cooler ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 236
Operation 12-11 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 236
Operation 12-12 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 237
Operation 12-13 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 238

Workshop Manual, TPD 1476E, Issue 1 xi
1100 Series model VK
13 Flywheel and housing
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...239
Flywheel
Operation 13-1 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...239
Ring gear
Operation 13-2 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...240
Flywheel housing
Operation 13-3 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...241
14 Electrical equipment
Alternators . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...243
Operation 14-1 To check the drive belts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...244
Operation 14-2 To adjust drive belt tension .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...244
Operation 14-3 To remove and to fit the drive belts .. ... ... ... ... ... ... ... ... ... ... ... ... ...244
Operation 14-4 To remove and to fit the alternator ... ... ... ... ... ... ... ... ... ... ... ... ... ...245
Operation 14-5 To maintain ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...245
Operation 14-6 Fault diagnosis for the alternator .. ... ... ... ... ... ... ... ... ... ... ... ... ... ...246
Starter motors ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...248
Operation 14-7 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...248
Operation 14-8 To maintain the brush gear and the commutator . ... ... ... ... ... ... ... ...249
Operation 14-9 To test on the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...249
Starting aid ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...250
Operation 14-10 To remove and to fit a fuelled starting aid .. ... ... ... ... ... ... ... ... ... ...250
Operation 14-11 To check the fuelled starting aid . ... ... ... ... ... ... ... ... ... ... ... ... ... ...251
Electronic components ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...252
Operation 14-12 To remove and to fit the Engine Control Module (ECM) ... ... ... ... ...254
Operation 14-13 To remove and to fit the Voltage Load Protection Module (VLPM) ...256
Operation 14-14 To program a new ECM . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...257
Operation 14-15 To remove and to fit the engine speed and timing sensor . ... ... ... ...258
Operation 14-16 To remove and to fit a pressure sensor .. ... ... ... ... ... ... ... ... ... ... ...259
Operation 14-17 To remove and to fit a temperature sensor ... ... ... ... ... ... ... ... ... ...261
Wiring harness .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...263
Operation 14-18 To repair a sensor connector . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...265
Operation 14-19 To repair a Diagnostic, an ECM, or a MIC connector . ... ... ... ... ... ...268
Operation 14-20 To connect a new wire or connector to the wiring harness ... ... ... ...270

xii Workshop Manual, TPD 1476E, Issue 1
1100 Series model VK
15 Auxiliary equipment
Compressor ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 271
Operation 15-1 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 272
Operation 15-2 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 273
Operation 15-3 To remove the reed valves ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 275
Operation 15-4 To fit the reed valves . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 276
Operation 15-5 To remove the top unloader valve ... ... ... ... ... ... ... ... ... ... ... ... ... .. 277
Operation 15-6 To fit the top unloader valve .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 278
Operation 15-7 To remove the crankshaft / connecting rod / piston / piston rings . ... .. 279
Operation 15-8 To fit the crankshaft / connecting rod / piston / piston rings .. ... ... ... .. 280
Power steering pump
Operation 15-9 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 282
Adaptor for a hydraulic pump or a steering pump
Operation 15-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 283
Operation 15-11 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 284
Operation 15-12 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 285
Exhauster
Operation 15-13 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 286
16 Special tools
List of special tools .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 288

Workshop Manual, TPD 1476E, Issue 1 1
1
1100 Series model VK
General information 1
Introduction
This Workshop Manual has been written to provide assistance in the service and overhaul of the Perkins 1100
Series six cylinder, (model VK) engines. For overhaul procedures the assumption is made that the engine is
removed from the application. The engine conforms with USA (EPA/CARB) tier 2 and EC stage 2 emissions
legislation for agricultural and industrial applications.
Most of the general information which is included in the relevant User’s Handbook has not been repeated in
this workshop manual and the two publications should be used together.
When reference is made to the "left" or "right" side of the engine, this is as seen from the flywheel end of the
engine.
Special tools have been made available, for a list of these, see 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 under "POWERPART recommended
consumable products" on page 9. Reference to the relevant consumable products is also made at the
beginning of each operation.
Data and dimensions are included in Chapter 2, Specifications.
Read and remember the "Safety precautions" on page 5. They are given for your protection and must be used
at all times.
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.

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2Workshop Manual, TPD 1476E, Issue 1
1100 Series model VK
Engine views (side mounted turbo)
A
R1310
B
R1311

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Workshop Manual, TPD 1476E, Issue 1 3
1100 Series model VK
Engine views (top mounted turbo)
A
R1312/1
R1313
B

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4Workshop Manual, TPD 1476E, Issue 1
1100 Series model VK
Engine identification
The Perkins 1100 Series engines have been designed for agricultural, industrial and construction applications.
Model VK are all turbocharged engines.
The correct identification of the engine is by the full engine number.
The engine number is stamped on a label which is fastened to the left side (A2) of the cylinder block. An
example of an engine number is:
VKU090001H
If you need parts, service or information for your engine, you must give the complete engine number to your
Perkins distributor. If there is a number in the area of the label marked TPL No, then this number must also be
given to your Perkins distributor.
Other identification labels fitted to the engine include:
An emissions legislation label (A3) fitted either to the right side of the engine between the fuel lift pump and
the flywheel housing, or to the left side of the engine to the rear of the fuel injection pump.
A label (A1) with the fuel injection pump part number attached to the fuel injection pump.
If a short engine has been fitted in service, two engine serial numbers and a TPL number are stamped on the
engine serial number label (B3).
The engine serial number plate (B) contains the following information:
lTPL number (1).
lType (2).
lSerial number (3).
lList number (4).
R1398
B
LIST No SERIAL No TYPE
TPL No
ENGLAND
Perkins
4 3 2
1
2
1
A
A0043/3
3

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Workshop Manual, TPD 1476E, Issue 1 5
1100 Series model VK
Safety precautions
These safety precautions are important. You must refer also to the local regulations in the country of use.
Some items only refer to specific applications.
lOnly use these engines in the type of application for which they have been designed.
lDo not change the specification of the engine.
lDo not smoke when you put fuel in the tank.
lClean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
lDo not put fuel in the tank while the engine runs (unless it is absolutely necessary).
lDo not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training;
even then extreme care must be used to prevent injury).
lDo not make adjustments that you do not understand.
lEnsure that the engine does not run in a location where it can cause a concentration of toxic emissions.
lOther persons must be kept at a safe distance while the engine or auxiliary equipment is in operation.
lDo not permit loose clothing or long hair near moving parts.
lKeep away from moving parts during engine operation.
Warning! Some moving parts cannot be seen clearly while the engine runs.
lDo not operate the engine if a safety guard has been removed.
lDo not remove the filler cap or any component of the cooling system while the engine is hot and while the
coolant is under pressure, because dangerous hot coolant can be discharged.
lDo not allow sparks or fire near the batteries (especially when the batteries are on charge) because the
gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially
to the eyes.
lDisconnect the battery terminals before a repair is made to the electrical system.
lOnly one person must control the engine.
lEnsure that the engine is operated only from the control panel or from the operators position.
lIf your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
lDiesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons.
Protect your hands with gloves or a special solution to protect the skin.
lDo not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets of clothing.
lDiscard used lubricating oil in a safe place to prevent contamination.
lEnsure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is
started.
lUse extreme care if emergency repairs must be made in adverse conditions.
lThe combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes, see "Viton seals" on page 8 for safety precautions.
lRead and use the instructions relevant to lift equipment, see "Engine lift equipment" on page 7.
lAlways use a safety cage to protect the operator when a component is to be pressure tested in a container
of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to
be pressure tested.
lDo not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
lTurbochargers operate at high speed and at high temperatures. Keep fingers, tools and items away from
the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.

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6Workshop Manual, TPD 1476E, Issue 1
1100 Series model VK
lDo not clean an engine while it runs. If cold cleaning fluids are applied to a hot engine, certain components
on the engine may be damaged.
lFit only genuine Perkins parts, failure to do so may damage the engine and effect the warranty.
lTo prevent damage to the ECM. If the engine or the equipment that the engine is fitted to is to be painted
by an Electro-painting process, the engine must be suitably earthed to the equipment and the equipment
suitably earthed to ground.

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Workshop Manual, TPD 1476E, Issue 1 7
1100 Series model VK
Engine lift equipment
The maximum weight of the engine without coolant, lubricant or a gearbox fitted will vary for different
applications. It is recommended that lift equipment with a minimum capacity of 600 kg (1320 lbs) is used.
Before the engine is lifted:
lAlways use lift equipment of the approved type and of the correct capacity to lift the engine. It is
recommended that lift equipment of the type shown in (A) is used, to provide a vertical lift directly above
the engine lift brackets (A1). Never use a single lift bracket to raise an engine.
lCheck the engine lift brackets for damage and that they are secure before the engine is lifted. The torque
for the setscrews for the engine lift brackets is 44 Nm (33 lbf ft) 4,5 kgf m.
lTo prevent damage to the rocker cover, ensure that there is clearance between the hooks and the rocker
cover.
lUse lift equipment or obtain assistance to lift heavy engine components such as the cylinder block, cylinder
head, flywheel housing, crankshaft and flywheel.
A
A0044
1