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New 1000 Series
Perkins New 1000 Series Repair Manual
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Perkins New 1000 Series
Models AJ to AS and
YG to YK
WORKSHOP MANUAL
4 and 6 cylinder dies
el engines for industrial and
agricultural applications
Public
ation TP
D 1350E, Is
sue 4.
© Proprie
tary
informat
ion of P
erkin
s Eng
ines C
ompany
Limi
ted, all r
ights r
eserve
d.
The info
rmation
is cor
rect at th
e time of p
rint.
Publis
hed in
Decemb
er 2001 b
y Tech
nical
Public
ations.
This document has been printed from SPI². Not for Resale
2
Table of Contents
Default Chapter
3
Table of Contents
3
Special Tools
13
1 General Information
15
Introduction
15
Engine Views
16
Engine Identification
17
Safety Precautions
19
Viton Seals
20
Engine Lift Equipment
21
POWERPART Recommended Consumable Products
22
2 Specifications
25
Basic Engine Data
25
Data and Dimensions
26
Thread Sealant
49
Standard Torque Tensions
50
Specific Torque Tensions
51
Compression Test Data
54
3 Cylinder Head Assembly
55
General Description
55
Rocker Cover
56
Operation 3-1 to Remove
56
Operation 3-2 to Fit
57
Rocker Assembly
58
Operation 3-3 to Remove and to Fit
58
Operation 3-4 to Dismantle and to Assemble
59
Operation 3-5 to Inspect and to Correct
59
Valve Tip Clearances
60
Operation 3-6 to Check and to Adjust (Four Cylinder Engines)
60
Operation 3-7 to Check and to Adjust (Six Cylinder Engines)
61
Valve Springs
62
Operation 3-8 to Change the Valve Springs (with Cylinder Head Fitted)
62
Manifolds
64
Operation 3-9 to Remove and to Fit an Intake Manifold
64
Operation 3-10 to Remove and to Fit an Exhaust Manifold (One-Piece)
66
Operation 3-11 to Remove and to Fit an Exhaust Manifold (Three-Piece)
68
Cylinder Head Assembly
70
Operation 3-12 to Remove
70
Operation 3-13 to Fit (Engine Types AJ to AQ and YG to YK)
72
Operation 3-14 to Fit (Engine Types AR and AS)
75
Valves and Valve Springs
78
Operation 3-15 to Remove
78
Operation 3-16 to Fit
79
Operation 3-17 to Inspect and to Correct
80
Valve Guides
81
Operation 3-18 to Inspect
81
Operation 3-19 to Remove
82
Operation 3-20 to Fit
83
Operation 3-21 to Inspect and to Correct
84
Operation 3-22 to Correct a Valve Seat with a Valve Seat Cutter
85
Operation 3-23 to Fit Valve Seat Inserts
87
4 Piston and Connecting Rod Assemblies
89
General Description
89
Big End Bearing
91
Operation 4-1 to Remove
91
Operation 4-2 to Fit
92
Operation 4-3 to Inspect
92
Piston and Connecting Rod
93
Operation 4-4 to Remove
93
Operation 4-5 to Fit
94
Operation 4-6 to Check the Piston Height above the Cylinder Block
96
Piston Rings
97
Operation 4-7 to Remove
97
Operation 4-8 to Fit
98
Piston and Connecting Rod Assembly
99
Operation 4-9 to Dismantle
99
Operation 4-10 to Assemble
100
Operation 4-11 to Check the Length of a Connecting Rod
101
Piston and Piston Rings
102
Operation 4-12 to Inspect
102
Connecting Rod
103
Operation 4-13 to Inspect
103
Partially Finished Small End Bush
104
Operation 4-14 to Remove and to Fit
104
Piston Cooling Jets
105
Operation 4-15 to Remove and to Fit
105
Operation 4-16 to Check the Jet Alignment
106
5 Crankshaft Assembly
107
General Description
107
Crankshaft Pulley
109
Crankshaft Pulley and Damper
110
Operation 5-3 to Fit (Six Cylinder Engines)
111
Operation 5-4 to Inspect
112
Rear Oil Seal Assembly
113
Operation 5-5 to Remove and to Fit (One-Piece Assembly)
113
Operation 5-6 to Remove and to Fit (Two-Piece Assembly)
116
Operation 5-7 to Renew the Rear End Oil Seal (Two-Piece Assembly)
117
Operation 5-8 to Remove and to Fit a Wear Sleeve
118
Thrust Washers
119
Operation 5-9 to Check Crankshaft End-Float
119
Operation 5-10 to Remove
120
Operation 5-11 to Fit
121
Main Bearings
122
Operation 5-12 to Remove (with the Crankshaft in Position)
122
Operation 5-13 to Fit
123
Operation 5-14 to Inspect
123
Crankshaft
124
Operation 5-15 to Remove
124
Operation 5-16 to Fit
125
Operation 5-17 to Inspect
127
Balancer Unit
128
Operation 5-18 to Remove and to Fit
128
Operation 5-19 to Dismantle
129
Operation 5-20 to Assemble
131
Operation 5-21 to Inspect
134
Operation 5-22 to Remove and to Fit the Needle Roller Bearings for the Drive Shaft
135
Operation 5-23 to Remove and to Fit the Bushes for the Balance Weights
136
6 Timing Case and Drive Assembly
137
General Description
137
Timing Case Cover
138
Operation 6-2 to Fit
139
Front Oil Seal
141
Operation 6-4 to Fit
142
Idler Gear and Hub
145
Operation 6-6 to Remove
145
Operation 6-7 to Fit
147
Idler Gear and Hub for the Compressor
149
Operation 6-9 to Fit
150
Fuel Pump Gear
151
Operation 6-10 to Remove
151
Operation 6-11 to Fit
153
Camshaft Gear
155
Operation 6-12 to Remove and to Fit
155
Crankshaft Gear
156
Operation 6-13 to Remove and to Fit
156
Timing Case
157
Operation 6-14 to Remove
157
Operation 6-15 to Fit
158
Camshaft and Tappets
160
Operation 6-16 to Remove
160
Operation 6-17 to Fit
161
7 Cylinder Block Assembly
163
General Description
163
Cylinder Block
164
Operation 7-2 to Assemble
165
Operation 7-3 to Inspect
166
Operation 7-4 to Remove and to Fit a New Type 'D' Plug to the Tappet Chamber
167
Cylinder Liner
169
Operation 7-6 to Remove
170
Operation 7-7 to Fit a Service Liner
172
Operation 7-8 to Fit a Partially Finished Liner
175
Cylinder Bore, Engine Types AR and as
178
8 Engine Timing
179
General Description
179
Operation 8-1 to Set Number 1 Piston to TDC on the Compression Stroke
181
Operation 8-2 Another Method to Set Number 1 Piston to TDC
182
Operation 8-3 to Check the Valve Timing
183
Operation 8-4 to Check the Timing of the Fuel Injection Pump
184
9 Aspiration System
185
General Description
185
Turbocharger
187
Operation 9-1 to Remove
187
Operation 9-2 to Fit
188
Operation 9-3 to Clean the Impeller and the Compressor Casing
190
Operation 9-4 to Remove and to Fit the Actuator Assembly of the Waste-Gate Unit
191
Operation 9-5 to Check and Adjust the Operation of the Waste-Gate
192
Turbocharger Faults
193
List of Possible Causes
194
Open Engine Breather
195
Operation 9-6 to Clean and to Renew
195
Operation 9-7 to Inspect
197
Closed Engine Breather
198
Operation 9-8 to Renew the Breather Valve Assembly
199
10 Lubrication System
201
General Description - Four Cylinder Engine Lubrication System
201
General Description - Six Cylinder Engine Lubrication System
202
Filter Canister
205
Filter Head
206
Operation 10-2 to Remove and to Fit
206
Sump
207
Operation 10-3 to Remove and to Fit
207
Oil Strainer and Suction Pipe
208
Operation 10-4 to Remove and to Fit
208
Operation 10-5 to Inspect and to Correct
209
Lubricating Oil Pump
210
Operation 10-6 to Remove
210
Operation 10-7 to Fit
211
Operation 10-8 to Inspect
212
Lubricating Oil Pump Idler Gear Shaft
213
Operation 10-9 to Remove (Six Cylinder Engines)
213
Operation 10-10 to Fit (Six Cylinder Engines)
215
Operation 10-11 to Remove and to Fit (Four Cylinder Engines)
216
Relief Valve
217
Operation 10-12 to Remove and to Fit
217
Operation 10-13 to Dismantle and to Assemble
218
Operation 10-14 to Inspect
218
Flexible Oil Pipes
219
Operation 10-15 to Remove
219
Operation 10-16 to Fit
220
Operation 10-17 to Inspect
221
11 Fuel System
223
General Description
223
Cold Start Advance Unit
226
Typical Fuel System
229
Fuel Filters
230
Fuel Filter Element
231
Operation 11-1 to Renew - Separate Element Type
231
Operation 11-2 to Renew - Canister Type
232
Operation 11-3 to Renew - Quick Release Canister Type
233
Atomisers
234
Operation 11-4 to Remove
235
Operation 11-5 to Fit
236
Fuel Lift Pump
238
Operation 11-6 to Remove and to Fit
238
Operation 11-7 to Dismantle
239
Operation 11-8 to Assemble
240
Operation 11-9 to Test
241
Bosch Fuel Injection Pump
242
Operation 11-10 to Remove
244
Operation 11-11 to Fit
246
Operation 11-12 to Adjust
248
Lucas/Delphi DP 200 Series Fuel Injection Pump
249
Operation 11-13 to Remove
251
Operation 11-14 to Fit
253
Operation 11-15 to Adjust
256
Operation 11-16 Electrical Shut off Solenoid (ESOS)
257
Stanadyne Fuel Injection Pump
259
Operation 11-17 to Remove
262
Operation 11-18 to Fit
263
Operation 11-19 to Adjust
265
Air in the Fuel System
268
Operation 11-20 to Eliminate Air from the Fuel System
268
12 Cooling System
271
General Description
271
Thermostats Operation 12-1 to Remove
272
Operation 12-2 to Fit
273
Operation 12-3 to Test
274
Coolant Pump - Early Gear Driven Pumps
275
Operation 12-4 to Remove
275
Operation 12-5 to Fit
276
Operation 12-6 to Dismantle
277
Operation 12-7 to Assemble
278
Operation 12-8 to Remove and to Fit a Pressed Steel Cover (Early Coolant Pumps)
281
Coolant Pump - Latest Gear Driven Pumps
282
Operation 12-9 to Remove
282
Operation 12-10 to Fit
283
Operation 12-11 to Dismantle
284
Operation 12-12 to Assemble
287
Flywheel and Housing
325
Electrical Equipment
329
Auxiliary Equipment
343
Special Tools
363
Fuel Pump Gear
369
4
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Perkins New 1000 Series Specifications
General
Engine Type
Diesel
Cylinder Arrangement
Inline
Number of Cylinders
4 or 6
Cooling System
Liquid Cooled
Aspiration
Turbocharged
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