Perkins New 1000 Series Instruction manual

i
Perkins New 1000 Series
Models AJ to AS and YG to YK
WORKSHOP MANUAL
4 and 6 cylinder diesel engines for industrial and
agricultural applications
Publication TPD 1350E, Issue 4.
© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in December 2001 by Technical Publications.
This document has been printed from SPI². Not for Resale

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
This document has been printed from SPI². Not for Resale

Workshop Manual, TPD 1350E, Issue 4 iii
New 1000 Series
Contents
1 General information
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...1
Engine views . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...2
Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...3
Safety precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...5
Viton seals . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...6
Engine lift equipment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...7
POWERPART recommended consumable products . ... ... ... ... ... ... ... ... ... ... ... ... ...8
2 Specifications
Basic engine data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .11
Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .12
Thread sealant ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .35
Standard torque tensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .36
Specific torque tensions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .37
Compression test data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .40
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iv Workshop Manual, TPD 1350E, Issue 4
New 1000 Series
3 Cylinder head assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41
Rocker cover
Operation 3-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42
Operation 3-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43
Rocker assembly
Operation 3-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44
Operation 3-4 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45
Operation 3-5 To inspect and to correct ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45
Valve tip clearances
Operation 3-6 To check and to adjust (four cylinder engines) ... ... ... ... ... ... ... ... ... ... 46
Operation 3-7 To check and to adjust (six cylinder engines) . ... ... ... ... ... ... ... ... ... ... 47
Valve springs
Operation 3-8 To change the valve springs (with cylinder head fitted) .. ... ... ... ... ... ... 48
Manifolds ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50
Operation 3-9 To remove and to fit an intake manifold .. ... ... ... ... ... ... ... ... ... ... ... ... 50
Operation 3-10 To remove and to fit an exhaust manifold (one-piece) .. ... ... ... ... ... ... 52
Operation 3-11 To remove and to fit an exhaust manifold (three-piece) ... ... ... ... ... ... 54
Cylinder head assembly
Operation 3-12 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 56
Operation 3-13 To fit (engine types AJ to AQ and YG to YK) ... ... ... ... ... ... ... ... ... ... 58
Operation 3-14 To fit (engine types AR and AS) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 61
Valves and valve springs
Operation 3-15 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 64
Operation 3-16 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 65
Operation 3-17 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 66
Valve guides ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 67
Operation 3-18 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 67
Operation 3-19 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 68
Operation 3-20 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 69
Cylinder head
Operation 3-21 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 70
Operation 3-22 To correct a valve seat with a valve seat cutter ... ... ... ... ... ... ... ... ... 71
Operation 3-23 To fit valve seat inserts . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 73
This document has been printed from SPI². Not for Resale

Workshop Manual, TPD 1350E, Issue 4 v
New 1000 Series
4 Piston and connecting rod assemblies
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .75
Big end bearing
Operation 4-1 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .77
Operation 4-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .78
Operation 4-3 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .78
Piston and connecting rod
Operation 4-4 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .79
Operation 4-5 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .80
Operation 4-6 To check the piston height above the cylinder block .. ... ... ... ... ... ... ... .82
Piston rings
Operation 4-7 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .83
Operation 4-8 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .84
Piston and connecting rod assembly
Operation 4-9 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .85
Operation 4-10 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .86
Operation 4-11 To check the length of a connecting rod .. ... ... ... ... ... ... ... ... ... ... ... .87
Piston and piston rings
Operation 4-12 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .88
Connecting rod
Operation 4-13 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .89
Partially finished small end bush
Operation 4-14 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .90
Piston cooling jets
Operation 4-15 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .91
Operation 4-16 To check the jet alignment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .92
5 Crankshaft assembly
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .93
Crankshaft pulley
Operation 5-1 To remove and to fit (four cylinder engines) ... ... ... ... ... ... ... ... ... ... ... .95
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vi Workshop Manual, TPD 1350E, Issue 4
New 1000 Series
Crankshaft pulley and damper
Operation 5-2 To remove (six cylinder engines) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 96
Operation 5-3 To fit (six cylinder engines) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 97
Operation 5-4 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 98
Rear oil seal assembly .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 99
Operation 5-5 To remove and to fit (one-piece assembly) . ... ... ... ... ... ... ... ... ... ... ... 99
Operation 5-6 To remove and to fit (two-piece assembly) . ... ... ... ... ... ... ... ... ... ... .. 102
Operation 5-7 To renew the rear end oil seal (two-piece assembly) ... ... ... ... ... ... .. 103
Operation 5-8 To remove and to fit a wear sleeve . ... ... ... ... ... ... ... ... ... ... ... ... ... .. 104
Thrust washers
Operation 5-9 To check crankshaft end-float . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 105
Operation 5-10 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 106
Operation 5-11 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 107
Main bearings
Operation 5-12 To remove (with the crankshaft in position) .. ... ... ... ... ... ... ... ... ... .. 108
Operation 5-13 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 109
Operation 5-14 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 109
Crankshaft
Operation 5-15 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 110
Operation 5-16 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 111
Operation 5-17 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 113
Balancer unit
Operation 5-18 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 114
Operation 5-19 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 115
Operation 5-20 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 117
Operation 5-21 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 120
Operation 5-22 To remove and to fit the needle roller bearings for the drive shaft ... .. 121
Operation 5-23 To remove and to fit the bushes for the balance weights . ... ... ... ... .. 122
6 Timing case and drive assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 123
Timing case cover
Operation 6-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 124
Operation 6-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 125
Front oil seal
Operation 6-3 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 127
Operation 6-4 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 128
Operation 6-5 To remove and to fit a wear sleeve . ... ... ... ... ... ... ... ... ... ... ... ... ... .. 130
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Workshop Manual, TPD 1350E, Issue 4 vii
New 1000 Series
Idler gear and hub
Operation 6-6 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...131
Operation 6-7 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...133
Idler gear and hub for the compressor
Operation 6-8 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...135
Operation 6-9 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...136
Fuel pump gear . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...137
Operation 6-10 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...137
Operation 6-11 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...139
Camshaft gear
Operation 6-12 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...141
Crankshaft gear
Operation 6-13 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...142
Timing case
Operation 6-14 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...143
Operation 6-15 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...144
Camshaft and tappets
Operation 6-16 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...146
Operation 6-17 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...147
7 Cylinder block assembly
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...149
Cylinder block
Operation 7-1 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...150
Operation 7-2 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...151
Operation 7-3 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...152
Operation 7-4 To remove and to fit a new type ‘D’ plug to the tappet chamber ... ... ...153
Cylinder liner
Operation 7-5 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...155
Operation 7-6 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...156
Operation 7-7 To fit a service liner ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...158
Operation 7-8 To fit a partially finished liner .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...161
Cylinder bore, engine types AR and AS
Operation 7-9 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...164
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viii Workshop Manual, TPD 1350E, Issue 4
New 1000 Series
8 Engine timing
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 165
Engine timing
Operation 8-1 To set number 1 piston to TDC on the compression stroke ... ... ... ... .. 167
Operation 8-2 Another method to set number 1 piston to TDC . ... ... ... ... ... ... ... ... .. 168
Operation 8-3 To check the valve timing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 169
Operation 8-4 To check the timing of the fuel injection pump ... ... ... ... ... ... ... ... ... .. 170
9 Aspiration system
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 171
Turbocharger
Operation 9-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 173
Operation 9-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 174
Operation 9-3 To clean the impeller and the compressor casing .. ... ... ... ... ... ... ... .. 176
Operation 9-4 To remove and to fit the actuator assembly of the waste-gate unit ... .. 177
Operation 9-5 To check and adjust the operation of the waste-gate . ... ... ... ... ... ... .. 178
Turbocharger faults ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 179
List of possible causes . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 180
Open engine breather ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 181
Operation 9-6 To clean and to renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 181
Operation 9-7 To Inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 183
Closed engine breather . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 184
Operation 9-8 To renew the breather valve assembly ... ... ... ... ... ... ... ... ... ... ... ... .. 185
10 Lubrication system
General description - four cylinder engine lubrication system ... ... ... ... ... ... ... .. 187
General description - Six cylinder engine lubrication system . ... ... ... ... ... ... ... .. 188
Filter canister
Operation 10-1 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 191
Filter head
Operation 10-2 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 192
Sump
Operation 10-3 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 193
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Workshop Manual, TPD 1350E, Issue 4 ix
New 1000 Series
Oil strainer and suction pipe
Operation 10-4 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...194
Operation 10-5 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...195
Lubricating oil pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...196
Operation 10-6 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...196
Operation 10-7 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...197
Operation 10-8 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...198
Lubricating oil pump idler gear shaft .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...199
Operation 10-9 To remove (six cylinder engines) . ... ... ... ... ... ... ... ... ... ... ... ... ... ...199
Operation 10-10 To fit (six cylinder engines) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...201
Operation 10-11 To remove and to fit (four cylinder engines) ... ... ... ... ... ... ... ... ... ...202
Relief valve
Operation 10-12 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...203
Operation 10-13 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...204
Operation 10-14 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...204
Flexible oil pipes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...205
Operation 10-15 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...205
Operation 10-16 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...206
Operation 10-17 To Inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...207
11 Fuel system
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...209
Cold start advance unit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...212
Typical fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...215
Fuel filters .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...216
Fuel filter element
Operation 11-1 To renew - separate element type ... ... ... ... ... ... ... ... ... ... ... ... ... ...217
Operation 11-2 To renew - canister type ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...218
Operation 11-3 To renew - quick release canister type . ... ... ... ... ... ... ... ... ... ... ... ...219
Atomisers .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...220
Operation 11-4 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...221
Operation 11-5 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...222
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xWorkshop Manual, TPD 1350E, Issue 4
New 1000 Series
Fuel lift pump
Operation 11-6 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 224
Operation 11-7 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 225
Operation 11-8 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 226
Operation 11-9 To test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 227
Bosch fuel injection pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 228
Operation 11-10 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 230
Operation 11-11 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 232
Operation 11-12 To adjust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 234
Lucas/Delphi DP 200 Series fuel injection pump ... ... ... ... ... ... ... ... ... ... ... ... ... .. 235
Operation 11-13 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 237
Operation 11-14 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 239
Operation 11-15 To adjust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 242
Operation 11-16 Electrical shut off solenoid (ESOS) . ... ... ... ... ... ... ... ... ... ... ... ... .. 243
Stanadyne fuel injection pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 245
Operation 11-17 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 248
Operation 11-18 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 249
Operation 11-19 To adjust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 251
Air in the fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 254
Operation 11-20 To eliminate air from the fuel system .. ... ... ... ... ... ... ... ... ... ... ... .. 254
12 Cooling system
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 257
Thermostats
Operation 12-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 258
Operation 12-2 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 259
Operation 12-3 To test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 260
Coolant pump - early gear driven pumps ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 261
Operation 12-4 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 261
Operation 12-5 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 262
Operation 12-6 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 263
Operation 12-7 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 264
Operation 12-8 To remove and to fit a pressed steel cover (early coolant pumps) ... .. 267
Coolant pump - latest gear driven pumps ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 268
Operation 12-9 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 268
Operation 12-10 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 269
Operation 12-11 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 270
Operation 12-12 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 273
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Workshop Manual, TPD 1350E, Issue 4 xi
New 1000 Series
Coolant pump - belt driven .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...277
Operation 12-13 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...277
Operation 12-14 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...279
Operation 12-15 To remove high position pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...281
Operation 12-16 To fit high position pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...283
Operation 12-17 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...285
Operation 12-18 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...286
Fan
Operation 12-19 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...289
Fan drive (engines with gear driven coolant pumps)
Operation 12-20 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...290
Lubricating oil cooler
Operation 12-21 To remove (four cylinder turbocharged engines) ... ... ... ... ... ... ... ...291
Operation 12-22 To fit (four cylinder turbocharged engines) . ... ... ... ... ... ... ... ... ... ...292
Operation 12-23 To dismantle and to assemble (four cylinder engines) ... ... ... ... ... ...293
Operation 12-24 To remove (six cylinder turbocharged engines) . ... ... ... ... ... ... ... ...294
Operation 12-25 To fit (six cylinder turbocharged engines) .. ... ... ... ... ... ... ... ... ... ...296
Operation 12-26 To dismantle and to assemble (six cylinder engines) . ... ... ... ... ... ...298
Operation 12-27 To remove and to fit (canister type) ... ... ... ... ... ... ... ... ... ... ... ... ...300
Operation 12-28 To remove and to fit cooler bypass valve ... ... ... ... ... ... ... ... ... ... ...300
Intercoolers ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...301
Horizontally mounted intercooler
Operation 12-29 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...302
Operation 12-30 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...304
Vertically mounted intercooler
Operation 12-31 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...306
Operation 12-32 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...307
Operation 12-33 To clean and to inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...309
13 Flywheel and housing
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...311
Flywheel
Operation 13-1 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...311
Ring gear
Operation 13-2 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...312
Flywheel housing
Operation 13-3 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...313
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xii Workshop Manual, TPD 1350E, Issue 4
New 1000 Series
14 Electrical equipment
Alternators . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 315
Operation 14-1 To check the drive belts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 316
Operation 14-2 To adjust drive belt tension ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 317
Operation 14-3 To remove and to fit the drive belts ... ... ... ... ... ... ... ... ... ... ... ... ... .. 318
Operation 14-4 To remove and to fit the alternator ... ... ... ... ... ... ... ... ... ... ... ... ... .. 319
Operation 14-5 To maintain ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 319
Operation 14-6 Fault diagnosis .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 320
Starter motors ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 322
Operation 14-7 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 323
Operation 14-8 To maintain the brush gear and the commutator .. ... ... ... ... ... ... ... .. 324
Operation 14-9 To test on the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 324
Operation 14-10 Fault diagnosis ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 325
Starting aids ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 326
Operation 14-11 To remove and to fit a fuelled starting aid ... ... ... ... ... ... ... ... ... ... .. 326
Operation 14-12 To remove and to fit a twin-fuelled starting aid ... ... ... ... ... ... ... ... .. 327
Operation 14-13 To check the fuelled starting aid . ... ... ... ... ... ... ... ... ... ... ... ... ... .. 328
Operation 14-14 To remove and to fit a port heater ... ... ... ... ... ... ... ... ... ... ... ... ... .. 328
15 Auxiliary equipment
Bendix Compressor
Operation 15-1 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 330
Operation 15-2 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 331
Knorr-Bremse compressor
Operation 15-3 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 333
Operation 15-4 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 334
Operation 15-5 To remove the reed valves ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 336
Operation 15-6 To fit the reed valves . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 337
Operation 15-7 To remove the top unloader valve ... ... ... ... ... ... ... ... ... ... ... ... ... .. 338
Operation 15-8 To fit the top unloader valve .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 339
Operation 15-9 To remove the crankshaft / connecting rod / piston / piston rings . ... .. 340
Operation 15-10 To fit the crankshaft / connecting rod / piston / piston rings ... ... ... .. 341
Power steering pump
Operation 15-11 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 343
Adaptor for a hydraulic pump or a steering pump with a splined drive
Operation 15-12 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 344
Operation 15-13 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 345
Operation 15-14 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 346
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Workshop Manual, TPD 1350E, Issue 4 xiii
New 1000 Series
Exhauster
Operation 15-15 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...347
16 Special tools
List of special tools . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...350
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Workshop Manual, TPD 1350E, Issue 4 1
1
New 1000 Series
General information 1
Introduction
This Workshop Manual has been written to provide assistance in the service and overhaul of Perkins New
1000 Series engines. For overhaul procedures the assumption is made that the engine is removed from the
application. The engine conforms with USA (EPA/CARB) stage 1 and EEC stage 1 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.
Where the information applies only to certain engine types, this is indicated in the text.
The details of some operations will be different according to the type of fuel injection pump which is fitted. The
specific pump type used can be found by reference to the manufacturer’s identification plate on the pump body.
Generally, the type of pump fitted is as shown below.
lLucas/Delphi - DP200 Series
lBosch - EPVE
lStanadyne - DB4.
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 on page 8. Reference to the relevant
consumable products is also made at the beginning of each operation, where relevant.
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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1
2Workshop Manual, TPD 1350E, Issue 4
New 1000 Series
Engine views
A0378N
A0379
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1
Workshop Manual, TPD 1350E, Issue 4 3
New 1000 Series
Engine identification
The Perkins New 1000 Series engines have been designed for industrial and agricultural applications. There
are both four and six cylinder engines, each of which will have three basic engine types, naturally aspirated,
turbocharged and turbocharged with an intercooler.
In this workshop manual, the different engine types are indicated by their code letters. These are the first two
letters of the engine number as indicated below:
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:
AK80920*U510256B*
The components of the engine number are as follows:
AK80920*U510256B*
Continued
AJ Four cylinder, naturally aspirated
AK Four cylinder, turbocharged
AM Four cylinder, turbocharged and intercooled
AP Four cylinder, naturally aspirated, belt driven coolant pump
AQ Four cylinder, turbocharged, belt driven coolant pump
AR Four cylinder, naturally aspirated, 103 mm cylinder bore
AS Four cylinder, naturally aspirated, belt driven coolant pump, 103 mm cylinder bore
YG Six cylinder, naturally aspirated
YH Six cylinder, turbocharged
YJ Six cylinder, charge cooled, air to air
YK Six cylinder, turbocharged and intercooled
AK Model code number
80920 Build list number
U Built in the UK
510256 Engine serial number
B Year of manufacture
21
3
A
A0043
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1
4Workshop Manual, TPD 1350E, Issue 4
New 1000 Series
Date letters for engines start from the 1st of January each year. To comply with the new emissions legislation
that engines built before 1st April 1999 can be clearly identified from those built after this date, a new letter has
been used from the 1st of April 1999. The date letters used are as follows:
From the 1st of January 1999 to the 31st of March 1999 the date letter is E.
From the 1st of April 1999 to the 31st of January 1999 the date letter is F.
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 to the side of the cylinder block.
A label (A1) with the fuel injection pump part numbers.
If a short engine has been fitted in service two engine serial numbers and a TPL number are stamped on the
engine serial number pad (B3).
Examples of the serial numbers are shown in (B).
If parts for the short engine are needed in service, use the serial number (B4). If parts which were moved from
the original engine to the short engine are needed, use the serial number (B1) and the TPL number (B2).
21
3
A
A0043
4
1
23
B
A0045
AK80920*U510256B*
AJ39770 TPL No212
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Workshop Manual, TPD 1350E, Issue 4 5
New 1000 Series
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 6 for safety precautions.
lRead and use the instructions relevant to lift equipment, see "Engine lift equipment" on page 7.Continued
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1
6Workshop Manual, TPD 1350E, Issue 4
New 1000 Series
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.
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.
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 which 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 which have been burnt, ensure that the precautions
which follow are used:
lEnsure that the components have cooled
lUse neoprene gloves and discard the gloves safely after use
lWash the area with calcium hydroxide solution and then with clean water
lDisposal of components and gloves which 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.
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