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Perkins New 1000 Series Repair Manual

Perkins New 1000 Series
370 pages
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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

Table of Contents

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Perkins New 1000 Series Specifications

General IconGeneral
Engine TypeDiesel
Cylinder ArrangementInline
Number of Cylinders4 or 6
Cooling SystemLiquid Cooled
AspirationTurbocharged

Summary

General Information

Safety Precautions

Essential safety guidelines for operating and maintaining the engine.

Engine Lift Equipment

Guidelines and recommendations for safely lifting engine components.

Specifications

Basic Engine Data

Key technical data for Perkins 1000 Series engines, including cylinder count and bore.

Data and Dimensions

Detailed specifications and measurements for cylinder head components.

Standard Torque Tensions

Standard torque values for common fasteners like setscrews, nuts, and pipe unions.

Specific Torque Tensions

Component-specific torque settings for engine assembly and disassembly.

Cylinder Head Assembly

Rocker Assembly

Procedures for removing, fitting, dismantling, and inspecting the rocker assembly.

Valve Tip Clearances

Instructions for checking and adjusting valve tip clearances for 4-cylinder engines.

Cylinder Head Assembly Procedures

Procedures for removing and fitting the cylinder head assembly.

Valves and Valve Springs

Procedures for removing, fitting, and inspecting valves and valve springs.

Cylinder Head Inspection and Correction

Methods for inspecting and correcting the cylinder head for distortion and wear.

Piston and Connecting Rod Assemblies

Big End Bearings

Procedures for removing and fitting big end bearings.

Piston and Connecting Rod

Procedures for removing and fitting pistons and connecting rods.

Crankshaft Assembly

Rear Oil Seal Assembly

Procedures for removing and fitting one-piece and two-piece rear oil seal assemblies.

Main Bearings

Procedures for removing and fitting main bearings with the crankshaft in position.

Crankshaft

Procedures for removing and fitting the crankshaft.

Timing Case and Drive Assembly

Fuel Pump Gear

Procedures for removing and fitting the fuel pump gear.

Timing Case

Procedures for removing and fitting the timing case.

Cylinder Block Assembly

Cylinder Block Procedures

Procedures for dismantling and assembling the cylinder block.

Engine Timing

Setting Number 1 Piston to TDC

Methods for setting the number 1 piston to Top Dead Center on the compression stroke.

Fuel Injection Pump Timing

Procedure for checking the timing of the fuel injection pump.

Aspiration System

Turbocharger

Procedures for removing and fitting the turbocharger.

Turbocharger Faults

Chart to assist in diagnosing common turbocharger faults.

Lubrication System

Lubricating Oil Pump

Procedures for removing and fitting the lubricating oil pump.

Fuel System

Fuel Filter Element

Procedures for renewing fuel filter elements (separate and canister types).

Air in the Fuel System

Procedure for eliminating air from the fuel system.

Flywheel and Housing

Flywheel

Procedures for removing and fitting the flywheel.

Special Tools

List of Special Tools

Catalog of specialized tools required for engine service and repair.

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