Page 1 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.
Page 2 This publication is written in Perkins Approved Clear English 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...
Page 3: Table Of Contents
New 1000 Series Contents 1 General information Introduction ..................1 Engine views ..................2 Engine identification .
Page 4 New 1000 Series 3 Cylinder head assembly General description ................41 Rocker cover Operation 3-1 To remove ................ 42 Operation 3-2 To fit ...
Page 5 New 1000 Series 4 Piston and connecting rod assemblies General description ................75 Big end bearing Operation 4-1 To remove ..
Page 6 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 ...
Page 7 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 ..
Page 8 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 .
Page 9 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 ...
Page 10 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 .
Page 11 New 1000 Series Coolant pump - belt driven ..............277 Operation 12-13 To remove ..............277 Operation 12-14 To fit ...
Page 12 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 ...
Page 13: Special Tools
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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Page 15: General Information
General information 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.
Page 16: Engine Views
New 1000 Series Engine views A0378N A0379 Workshop Manual, TPD 1350E, Issue 4 This document has been printed from SPI². Not for Resale...
Page 17: Engine Identification
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.
Page 18 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.
Page 19: Safety Precautions
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. l Only use these engines in the type of application for which they have been designed.
Page 20: Viton Seals
Do 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. l Fit only genuine Perkins parts. Viton seals Some seals used in engines and in components fitted to engines are made of Viton.
Page 21: Engine Lift Equipment
New 1000 Series 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 of the minimum capacity listed below is used: Four cylinder engines...
Page 22: Powerpart Recommended Consumable Products
New 1000 Series POWERPART recommended consumable products Perkins have made available the products recommended below in order to assist in the correct operation, service and maintenance of your engine and your machine. The instructions for the use of each product are given on the outside of each container.
Page 23 New 1000 Series POWERPART Radiator stop leak For the repair of radiator leaks. Part number 21820127. POWERPART Retainer (high strength) To retain components that have an interference fit. Part number 21820638. POWERPART Retainer (oil tolerant) To retain components that have an interference fit, but is in contact with oil. Part number 21820603.
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Page 25: Specifications
New 1000 Series Specifications Basic engine data Number of cylinders: AJ, AK, AM, AP, AQ, AR, AS .................... 4 YG, YH, YJ, YK ...
Page 26: Data And Dimensions
New 1000 Series Data and dimensions Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions which are shown are those which are mainly used in the factory. The information applies to all engines, unless an engine type code is shown.
Page 27 New 1000 Series Inlet and exhaust valves Inlet valves Diameter of valve stem ............8,953/8,975 mm (0.3525/0.3533 in) Clearance in valve guide ............0,025/0,069 mm (0.001/0.0027 in) Maximum permissible clearance in valve guide: - Production limit..
Page 28 New 1000 Series Dimensions of recesses for valve seat inserts Engine types AJ to AQ and YG to YK Inlet A1................. 10,585/10,715 mm (0.4167/0.4219 in) A2...
Page 29 New 1000 Series Valve seat insert tool Inlet (for 45° valves and 30° valves), engine types AJ to AQ and YG to YK A1 ......................1,5 mm (0.06 in) A2 ...
Page 30 New 1000 Series Inlet (45° valves), engine types AR and AS A1......................1,5 mm (0.06 in) A2...
Page 31 New 1000 Series Valve guides and valve springs Valve guides Inside diameter of partially finished guide ........8,600/8,700 mm (0.3386/0.3425 in) Inside diameter of finished guide..........9,000/9,022 mm (0.3543/0.3552 in) Outside diameter: Inlet..
Page 32 New 1000 Series Pistons and piston cooling jets Pistons Type .........."Fastram" combustion bowl inserted top ring groove, graphite skirt Diameter of bore for gudgeon pin ..........39,703/39,709 mm (1.5631/1.5633 in) Height of piston above top face of cylinder block...
Page 33 New 1000 Series Connecting rods and big end bearings Connecting rods Type................. ‘H' section, wedge shape small end Location of cap to connecting rod ...
Page 34 New 1000 Series Crankshaft Diameter of main journals: - Four cylinder engines .............. 76,16/76,18 mm (2.998/2.999 in) - Six cylinder engines............76,159/76,190 mm (2.9984/2.9996 in) Maximum wear and ovality on journals and crank pins .
Page 35 New 1000 Series The finished sizes for crankshaft journals (A) which have been ground undersize are given in the table below: 0,25 mm 0,51 mm 0,76 mm Item (0.010 in) (0.020 in) 0.030 in) 75,905/75,926 mm 75,651/75,672 mm 75,397/75,418 mm (2.9884/2.9892 in)
Page 36 New 1000 Series With the crankshaft on mountings at the front and rear journals, the maximum run-out (total indicator reading) at the journals must not be more than shown below: Journal 4 cylinder crankshafts 6 cylinder crankshafts Mounting Mounting 0,08 mm (0.003 in) 0,10 mm (0.004 in)
Page 37 New 1000 Series Crankshaft thrust washers Type................Steel back, lead bronze bearing material Position ................Each side of centre main bearing Thickness: - Standard ...
Page 38 New 1000 Series Timing case and drive assembly Camshaft Diameter of number 1 journal ........... 50,71/50,74 mm (1.9965/1.9975 in) Diameter of number 2 journal ........... 50,46/50,48 mm (1.9865.1.9875 in) Diameter of number 3 journal: - Four cylinder engines ..
Page 39 New 1000 Series Idler gear and hub Number of teeth......................63 Diameter of bore of gear..
Page 40 Cylinder liner specifications Caution: Specialist training and equipment is needed to machine the finish of a partially finished liner. For further information contact your nearest Perkins Distributor. Partially finished liner Interference fit of liner in parent bore ..........0,025/0,076 mm (0.003/0.001 in) Inside diameter of partially machined liner.
Page 41 Note: Two oversize pistons are available in service:- 0,5 mm (0.020 in) and 1,0 mm (0.040 in). Caution: Specialist training and equipment is needed to machine the cylinder bore. For further information contact your nearest Perkins Distributor. Preliminary bore Final size of standard bore before it is honed......102,873/102,924 mm (4.0501/4.0521 in) First oversize of bore before it is honed ..
Page 42 New 1000 Series Turbocharger The make and type of turbocharger fitted is marked on the turbocharger identification plate; as a general guide the make and type of turbocharger fitted are as follows: 4 Cylinder engines ................... . Garrett T20 6 Cylinder engines .
Page 43 New 1000 Series Lubrication system Oil filter Type..................Full flow, screw-on type canister Pressure to open by-pass valve in filter...
Page 44 New 1000 Series Oil pressure relief valve (standard) Diameter of bore for plunger ............18,24/18,27 mm (0.718/0.719 in) Outside diameter of plunger............18,16/18,18 mm (0.715/0.716 in) Clearance of plunger in bore..
Page 45 New 1000 Series Atomiser service setting The code letters are stamped on the side of the atomiser body just below the connection for the nut of the high pressure pipe. Set and reset pressure Code Holder Nozzle (lbf/in 2645A308 2645A624...
Page 46 New 1000 Series Cooling system Coolant pump, early gear driven pump Type ......................Centrifugal Outside diameter of shaft...
Page 47 New 1000 Series Thermostat Type: - Single ................. Wax element, by-pass blanking - Twin..................Wax element, by-pass blanking Nominal temperature "Start to open"...
Page 48 New 1000 Series Electrical equipment Alternators Note: The information which follows is general and can change with specific applications. Make and type ......Lucas/Delphi, AC5RS / Magneti Marelli, A127 / Bosch KI and Bosch NI Rating: - Lucas/Delphi AC5RS ...
Page 49: Thread Sealant
New 1000 Series Thread sealant When setscrews or studs are fitted into holes which are tapped through the cylinder block, a suitable sealant must be used to prevent leakage. Micro encapsulated anaerobic sealant (M.E.A.S) fasteners have been introduced instead of jointing compounds or other sealants when the fasteners are fitted in through holes into oil or coolant passages.
Page 50: Standard Torque Tensions
New 1000 Series Standard torque tensions Most of the torque tensions on the engine are standard. Special torque tensions are listed in the separate special torque tables. The standard torque tensions listed in the tables below can be used when a special torque is not necessary.
Page 51: Specific Torque Tensions
New 1000 Series Specific torque tensions The torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted. Special torques for setscrews and nuts Torque Thread Description size lbf ft kgf m Cylinder head assembly...
Page 52 New 1000 Series Torque Thread Description size lbf ft kgf m Cylinder block Setscrews, fitted instead of piston cooling jet(s) 3/8 UNF Fuel system Nuts, high-pressure fuel pipes Bolt banjo, leak-off connection Gland nut, atomiser body Setscrews, for the gear of the fuel injection pump...
Page 53 New 1000 Series Torque Thread Description size lbf ft kgf m Electrical equipment Nut, alternator pulley: - CAV AC5RA and AC5RS 5/8 UNF - Thin nut A127, and motorola pulley, 22 mm A/F - Thick nut A127, and motorola pulley, 24 mm A/F...
Page 54: Compression Test Data
New 1000 Series Compression test data Tests have shown that many factors affect compression pressures. Battery and starter motor condition, ambient conditions and the type of gauge used can give a wide variation of results for a given engine. It is not possible to give accurate data for compression pressure, but tests have shown that the results should...
Page 55: Cylinder Head Assembly
New 1000 Series Cylinder head assembly General description In a diesel engine there is little carbon deposit and for this reason the number of hours run is no indication of when to overhaul a cylinder head assembly. The factors which indicate when an overhaul is necessary are how easily the engine starts and its general performance.
Page 56: Rocker Cover
New 1000 Series Rocker cover To remove Operation 3-1 Note: Engines are supplied with rocker covers (A or B) made of a plastic material or aluminum. 1 Disconnect the breather pipe. 2 Remove the cap nuts and rubber seal (A1 or B1) from the top of the rocker cover and remove the heat shield, if one is fitted.
Page 57: Operation 3-2 To Fit
New 1000 Series To fit Operation 3-2 Note: Reflective heat shields fitted to plastic rocker covers must be kept clean and free from dust, oil or paint. If the surface of the heat shield is not shiny, the rocker cover protected by the heat shield could be damaged.
Page 58: Rocker Assembly
New 1000 Series Rocker assembly To remove and to fit Operation 3-3 To remove 1 Remove the rocker cover, see Operation 3-1. 2 Release evenly and gradually the fasteners of the rocker shaft brackets; begin with the end brackets and move toward the centre.
Page 59: Operation 3-4 To Dismantle And To Assemble
New 1000 Series To dismantle and to assemble Operation 3-4 To dismantle 1 Remove the clips from both ends of the rocker shaft. Ensure that the ends of the rocker shaft are not damaged. Release the location screw (A1) for the oil supply connection.
Page 60: Valve Tip Clearances
New 1000 Series Valve tip clearances To check and to adjust (four cylinder engines) Operation 3-6 Notes: l The valve tip clearance is measured between the top of the valve stem and the rocker lever (A). With the engine hot or cold, the correct clearances are 0,20 mm (0.008 in) for the inlet valves and 0,45 mm (0.018 in) for the exhaust valves.
Page 61: Operation 3-7 To Check And To Adjust (Six Cylinder Engines)
New 1000 Series To check and to adjust (six cylinder engines) Operation 3-7 Notes: l The valve tip clearance is measured between the top of the valve stem and the rocker lever (A). With the engine hot or cold, the correct clearances are 0,20 mm (0.008 in) for the inlet valves and 0,45 mm (0.018 in) for the exhaust valves.
Page 62: Valve Springs
New 1000 Series Valve springs To change the valve springs (with cylinder head fitted) Operation 3-8 Special requirements Special tools Description Part number Description Part number Valve spring compressor 21825666 Setscrew adaptor used with 21825666 21825932 Stud adaptor used with 21825666 21825931 Note: Steps 1 to 12 refer to a change of valve springs for a single cylinder.
Page 63 New 1000 Series 9 Fit the valve spring caps. Caution: Ensure that the valve spring is compressed squarely or damage can occur to the valve stem. 10 Fit the valve spring compressor, compress the valve spring and fit the collets. Remove the valve spring compressor.
Page 64: Manifolds
New 1000 Series Manifolds Introduction The exhaust manifolds fitted to these engines have large clearance holes for the setscrews. It is important that these manifolds are fitted correctly. A new three-piece exhaust manifold has been introduced for some turbocharged six cylinder engines with side mounted turbochargers.
Page 65 New 1000 Series To fit Caution: Do not scratch or damage the flange faces of the intake manifold. Notes: l New setscrews have sealant applied by the manufacturer to the first 13,0 mm (0.50 in) of the threads. If the setscrews are to be used again, clean the old sealant from the male and female threads and apply new sealant POWERPART Threadlock and nutlock to the setscrews.
Page 66: Operation 3-10 To Remove And To Fit An Exhaust Manifold (One-Piece)
Only use the approved setscrews as they are made of a material to withstand high temperatures. l Do not fasten brackets, that are not approved by Perkins, to the exhaust manifold as the manifold could be damaged when it becomes hot.
Page 67 New 1000 Series 1 If fitting a new manifold, ensure that the ferrules are fitted correctly. On four cylinder engines with a top exit port (A1), the ferrules are in positions 3 and 6. Those with a side exit port (A2), the ferrules are in positions 2 and 5.
Page 68: Operation 3-11 To Remove And To Fit An Exhaust Manifold (Three-Piece)
Only use the approved setscrews as they are made of a material to withstand high temperatures. l Do not fasten brackets, that are not approved by Perkins, to the exhaust manifold as the manifold could be damaged when it becomes hot.
Page 69 New 1000 Series Note: If a side mounted turbocharger support bracket (B2) is fitted, fit the two longer setscrews (B1). 5 Fit the remaining setscrews and tighten them finger tight. 6 Remove the guide studs and fit the remaining setscrews.
Page 70: Cylinder Head Assembly
New 1000 Series Cylinder head assembly To remove Operation 3-12 1 Drain the cooling system. 2 Disconnect the battery terminals. 3 For engines fitted with turbochargers: Disconnect all connections to the turbocharger and remove the turbocharger, see Operation 9-1. 4 Remove the intake manifold, see Operation 3-9.
Page 71 New 1000 Series 11 Release the clip of the coolant by-pass hose at the cylinder head. Release the setscrews and remove the coolant by-pass connection and the hose. 12 Disconnect the coolant temperature sender unit. 13 Four cylinder engines: Remove the oil cooler if it is integral with the cylinder block, see Operation 12-21.
Page 72: Operation 3-13 To Fit (Engine Types Aj To Aq And Yg To Yk)
New 1000 Series To fit (engine types AJ to AQ and YG to YK) Operation 3-13 Special requirements Special tools Description Part number Angle gauge, to tighten cylinder head 21825607 setscrews Note: See Operation 3-14 for AR and AS engine types 1 Clean the bottom face of the cylinder head and the top face of the cylinder block.
Page 73 New 1000 Series 7 Tighten the setscrews, in the correct sequence, a further part of a turn according to the length of the setscrews (refer to Operation 3-12 illustrations A or B). Short setscrews (S) must be turned a further 150° (2.5 flats).
Page 74 New 1000 Series 20 For engines fitted with turbochargers: Fit the turbocharger, see Operation 9-2. 21 Fit the fuel pipe between the fuel filter and the fuel lift pump. 22 Fill the cooling system. 23 Connect the battery. 24 Eliminate air from the fuel system, see Operation 11-20.
Page 75: Operation 3-14 To Fit (Engine Types Ar And As)
New 1000 Series To fit (engine types AR and AS) Operation 3-14 Special requirements Special tools Description Part number Angle gauge, to tighten cylinder head 21825607 setscrews Note: See Operation 3-13 for AJ to AQ and YG to YK engine types.
Page 76 New 1000 Series 9 Tighten the M10 setscrews, in the correct sequence, a further part of a turn according to the length of the setscrews, see (C) and (D). Short setscrews (S) must be turned a further 120° (2 flats). Medium length setscrews (M) must be turned a further 120°...
Page 77 New 1000 Series 10 Put the push rods in position. Ensure that the end of each push rod fits correctly in the tappet socket. 11 Fit the rocker assembly, see Operation 3-3. 12 Set the valve tip clearances, see Operation 3-6 for four cylinder engines or Operation 3-7 for six cylinder engines.
Page 78: Valves And Valve Springs
New 1000 Series Valves and valve springs To remove Operation 3-15 Special requirements Special tools Description Part number Description Part number Valve spring compressor 21825666 Setscrew adaptor used with 21825666 21825932 Stud adaptor used with 21825666 21825931 Warning! Wear eye protection during this operation.
Page 79: Operation 3-16 To Fit
New 1000 Series To fit Operation 3-16 Special requirements Special tools Description Part number Description Part number Valve spring compressor 21825666 Setscrew adaptor used with 21825666 21825932 Stud adaptor used with 21825666 21825931 Warning! Wear eye protection during this operation.
Page 80: Operation 3-17 To Inspect And To Correct
New 1000 Series To inspect and to correct Operation 3-17 Special requirements Special tools Description Part number Description Part number Gauge, valve depth 21825496 Dial gauge for use with 21825496 21825617 1 Check the depth of the valves below the face of the cylinder head before the valve springs are removed.
Page 81: Valve Guides
New 1000 Series Valve guides Note: Later engines have an improved exhaust valve guide (B1), with a groove (B2) to retain the valve seal (B3). To inspect Operation 3-18 To check the valve guides for wear: The maximum permissible clearance (A5) with a valve lift of 15,0 mm (0.6 in), between the valve stem and the bore of the guide is 0,100 mm (0.008 in) for inlet valves and 0,121 mm...
Page 82: Operation 3-19 To Remove
New 1000 Series To remove Operation 3-19 Special requirements Special tools Description Part number Description Part number Valve guide remover and replacer 21825478 Adaptor used with 21825478 27610019 1 Fit the adaptor (A4) into the remover/replacer tool (A3). 2 With the adaptor fitted to the tool, put the spacer (A5) in position on the tool. Pass the adaptor through the valve guide (A6) and put the spacer and tool in position on the valve seat.
Page 83: Operation 3-20 To Fit
New 1000 Series To fit Operation 3-20 Special requirements Special tools Description Part number Description Part number Distance piece, inlet guide, used with Valve guide remover and replacer 21825478 21825482 21825478, and 27610019 Adaptor used with 21825478, Distance piece, exhaust guide, used...
Page 84: Operation 3-21 To Inspect And To Correct
New 1000 Series Cylinder head To inspect and to correct Operation 3-21 1 Remove the cylinder head assembly, see Operation 3-12. 2 Remove the thermostat housing. 3 Inspect the cylinder head for signs of gas or coolant leakage. 4 Remove the valve springs and the valves, see Operation 3-15.
Page 85: Operation 3-22 To Correct A Valve Seat With A Valve Seat Cutter
New 1000 Series To correct a valve seat with a valve seat cutter Operation 3-22 Special requirements Special tools Description Part number Cutter (31° or 46°) for inlet and exhaust 27610030 valve seats and valve guide reamer Caution: Valves must not be lapped.
Page 86 New 1000 Series Caution: Ensure that the valve seat cutter is not allowed to fall on to the seat as this can damage the blades. 3 Fit the reamer/cutter assembly into the valve guide. Carefully turn the handle in a clockwise direction (B4) and gradually move the reamer into the valve guide until the valve guide is reamed to the finished size.
Page 87: Operation 3-23 To Fit Valve Seat Inserts
New 1000 Series To fit valve seat inserts Operation 3-23 1 Remove the valve guide and clean the bore into which the guide is to be fitted. 2 Fit new partially finished valve guides, see Operation 3-19. 3 With the bore of the new partially finished valve guide used as a pilot, machine the recess in the cylinder head to the correct dimensions, refer to the Data and dimensions for "Dimensions of recesses for valve seat...
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Page 89: Piston And Connecting Rod Assemblies
General description The pistons used in the New 1000 Series engines have a "Fastram" combustion chamber in the top of the piston (A). The piston (B) for engine types AR and AS has two recesses in the top face for the valves. The combustion chamber is designed to give an efficient mix of fuel and air.
Page 90 Connecting rod parts kits are also available with the small end bush fitted and machined to obtain the correct connecting rod grade. For further information refer to your nearest Perkins distributor. Notes: l If the crankshaft or the cylinder block is to be renewed, it may be necessary to change the grade of the connecting rods, see Operation 4-11.
Page 91: Big End Bearing
New 1000 Series Big end bearing To remove Operation 4-1 Notes: l There are location thimbles (B1) fitted to the latest bolts used with connecting rods that have serrated faces. l The location thimbles are used in the factory to prevent movement of the bolts when the nuts for the big end cap are tightened by automatic equipment.
Page 92: Operation 4-2 To Fit
New 1000 Series To fit Operation 4-2 1 Clean the bearing faces of the connecting rod and the crank pin. 2 Ensure that the protrusion for the location dowels is 3,0/4,5 mm (0.12/0.18 in) above the cap faces. Clean the complete bearing and lubricate the bearing surface and the crank pin with clean engine lubricating oil.
Page 93: Piston And Connecting Rod
New 1000 Series Piston and connecting rod To remove Operation 4-4 1 Drain the lubricating oil and the cooling system. 2 Remove the cylinder head assembly, see Operation 3-12. 3 Remove all carbon from the top of the bores of the cylinder liners.
Page 94: Operation 4-5 To Fit
New 1000 Series To fit Operation 4-5 Special requirements Special tools Description Part number Piston replacer tool 21855615 1 Ensure that the piston, the cylinder bore, the crank pin and the big end of the connecting rod are clean. Lubricate the piston and the cylinder liner with clean engine lubricating oil.
Page 95 New 1000 Series 9 Check the piston height above the top face of the cylinder block, see Operation 4-6. 10 Fit the lubricating oil strainer and suction pipe, see Operation 10-4, or the balancer unit, see Operation 5- 11 Fit the lubricating oil sump, see Operation 10-3.
Page 96: Operation 4-6 To Check The Piston Height Above The Cylinder Block
New 1000 Series To check the piston height above the cylinder block Operation 4-6 Special requirements Special tools Description Part number Description Part number Piston height and valve depth gauge 21825496 Dial gauge for use with 21825496 21825617 Caution: If the correct piston height above the cylinder block is not obtained, damage to the engine can occur.
Page 97: Piston Rings
New 1000 Series Piston rings To remove Operation 4-7 Note: The pistons have two compression rings and an oil control ring. All the piston rings are above the gudgeon pin. To ensure that the correct type is obtained always use the engine identification number to order new parts.
Page 98: Operation 4-8 To Fit
New 1000 Series To fit Operation 4-8 Use a suitable piston ring expander to fit the piston rings. Caution: Only expand the ring gaps enough to ensure that the ends of the rings do not damage the piston when the ring is put into position.
Page 99: Piston And Connecting Rod Assembly
New 1000 Series Piston and connecting rod assembly To dismantle Operation 4-9 Caution: The pistons and connecting rods are matched to the relevant cylinder. Note the position of each connecting rod and piston for correct assembly. 1 Remove the piston rings, see Operation 4-7.
Page 100: Operation 4-10 To Assemble
New 1000 Series To assemble Operation 4-10 1 Clean the bore of the small end bush and lubricate it with clean engine lubricating oil. 2 Fit a new circlip in the circlip groove of one of the gudgeon pin bosses. Ensure that it fits correctly in the groove.
Page 101: Operation 4-11 To Check The Length Of A Connecting Rod
New 1000 Series To check the length of a connecting rod Operation 4-11 A partially finished small end bush, which can be fitted to the original connecting rod and machined to obtain the correct length grade is available, see Operation 4-14. Specialist equipment and personnel with the correct training are needed to machine the partially finished small end bush.
Page 102: Piston And Piston Rings
New 1000 Series Piston and piston rings To inspect Operation 4-12 1 Check the piston for wear and other damage. 2 Check that the piston rings are free to move in their grooves and that the rings are not broken.
Page 103: Connecting Rod
New 1000 Series Connecting rod To inspect Operation 4-13 1 Check the small end bush for wear or for other damage and renew it, if necessary. Note: Connecting rod kits are available with a new small-end bush fitted and finished to the correct grade, see Operation 4-11 to identify the correct connecting rod grade.
Page 104: Partially Finished Small End Bush
Caution: Do not use a reamer, specialist equipment and personnel with the correct training are needed to machine the partially finished small end bush. For further information refer to your nearest Perkins distributor. 4 Machine the partially finished bush. To obtain the correct connecting rod grade, see Operation 4-11, and the Data and dimensions for "Connecting rods and big end bearings"...
Page 105: Piston Cooling Jets
New 1000 Series Piston cooling jets To remove and to fit Operation 4-15 To remove Release the valve assembly and remove the piston cooling jet assembly (A). Notes: l The crankshaft is removed in (A) to show clearly the piston cooling jet.
Page 106: Operation 4-16 To Check The Jet Alignment
New 1000 Series To check the jet alignment Operation 4-16 Insert a 1,70 mm (0.067 in) diameter rod, of suitable length, into the jet. If a suitable rod is not available, reduce the end of a thicker rod to 1,70 mm (0.067 in) diameter for a length of 16,00 mm (0.630 in). When the rod is inserted into the jet it must extend out of the top of the cylinder within the area shown in (A).
Page 107: Crankshaft Assembly
New 1000 Series Crankshaft assembly General description The crankshaft is a chrome-molybdenum forging which has five main journals for four cylinder engines and seven main journals for six cylinder engines. End-float is controlled by thrust washers on both sides of the centre main bearing.
Page 108 New 1000 Series Six cylinder engines have a viscous damper (C2) which is fastened to the front or rear face of the pulley (C1). All of the dampers are designed for the suppression of torsional vibrations in the engine crankshaft.
Page 109: Crankshaft Pulley
New 1000 Series Crankshaft pulley To remove and to fit (four cylinder engines) Operation 5-1 To remove 1 Remove the drive belt(s), see Operation 14-3. 2 Release the three setscrews (A2) which hold the pulley and remove the setscrews, the thrust block (A1) and the pulley (A3).
Page 110: Crankshaft Pulley And Damper
New 1000 Series Crankshaft pulley and damper To remove (six cylinder engines) Operation 5-2 Caution: A viscous damper (A1) should be renewed if there is impact damage to the outer casing or if there is leakage of the viscous fluid from the cover plate. Check for damage in the area around the holes for the damper fasteners.
Page 111: Operation 5-3 To Fit (Six Cylinder Engines)
New 1000 Series To fit (six cylinder engines) Operation 5-3 Special requirements Consumable products Description Part number POWERPART Retainer (oil tolerant) 21820603 1 If the damper is fitted to the rear face of the pulley, fit the damper to the pulley with its inner flange against the rear face of the pulley.
Page 112: Operation 5-4 To Inspect
New 1000 Series To inspect Operation 5-4 1 When an integral pulley and damper (A) is fitted, the assembly should be renewed if: l The rubber insert (A1) between the hub and the outer ring is split l The rubber insert is damaged by oil or solvents l There is movement of the pulley or outer ring on the hub.
Page 113: Rear Oil Seal Assembly
New 1000 Series Rear oil seal assembly Introduction Early engines have a two-piece rear end oil seal assembly, the oil seal can be renewed and fitted to different depths in the housing to allow for wear on the crankshaft palm, see Operation 5-7.
Page 114 New 1000 Series To fit 1 Ensure that all parts and surfaces of the engine block are clean and free from oil, grease and dirt. 2 Place the new rear assembly onto the crankshaft palm, push the seal on until the seal housing contacts the cylinder block face.
Page 115 New 1000 Series Alignment tool The alignment tool is not currently available and must be manufactured locally to the following specifications: 1 Outer surface (D1) to be knurled 2 All sharp edges to be removed 3 All dimensions in millimetres 4 To be made from material EN 32, harden 0.5 mm deep.
Page 116: Operation 5-6 To Remove And To Fit (Two-Piece Assembly)
New 1000 Series To remove and to fit (two-piece assembly) Operation 5-6 Special requirements Special tools Consumable products Description Part number Description Part number POWERPART Threadlock and 21820117 nutlock Crankshaft rear oil seal adaptor 21825540 POWERPART Silicone rubber 1861108 sealant To remove 1 Remove the drive components from the rear end of the engine.
Page 117: Operation 5-7 To Renew The Rear End Oil Seal (Two-Piece Assembly)
New 1000 Series To renew the rear end oil seal (two-piece assembly) Operation 5-7 Special requirements Special tools Description Part number Replacer tool for rear oil seal 21825540 Note: The oil seal of the one-piece rear end oil seal assembly cannot be renewed, the complete assembly must be renewed, see Operation 5-5.
Page 118: Operation 5-8 To Remove And To Fit A Wear Sleeve
New 1000 Series To remove and to fit a wear sleeve Operation 5-8 To remove 1 Remove the rear end oil seal, see Operation 5-5, or Operation 5-6. 2 With a sharp tool mark a deep line along the length of the sleeve.
Page 119: Thrust Washers
New 1000 Series Thrust washers To check crankshaft end-float Operation 5-9 The axial movement of the crankshaft is controlled by thrust washers fitted both sides of the centre main bearing (A). The end-float can be checked with a feeler gauge between a thrust washer and the crankshaft (B), or with a dial test indicator on one end of the crankshaft to check the movement (C).
Page 120: Operation 5-10 To Remove
New 1000 Series To remove Operation 5-10 1 Drain the lubricating oil and remove the lubricating oil sump, see Operation 10-3. 2 If necessary, remove the balancer unit, see Operation 5-18. 3 If necessary, remove the lubricating oil strainer and suction pipe, see Operation 10-4.
Page 121: Operation 5-11 To Fit
New 1000 Series To fit Operation 5-11 1 Lubricate the thrust washers with clean engine lubricating oil. 2 Slide the upper halves of the thrust washers into their recesses in the cylinder block. Ensure that the sides of the thrust washers that have the grooves (A1) are against the crankshaft.
Page 122: Main Bearings
New 1000 Series Main bearings To remove (with the crankshaft in position) Operation 5-12 Notes: l If the rear main bearing is to be removed with the crankshaft in position, the flywheel, the flywheel housing, the rear oil seal housing and the bridge piece will have to be removed.
Page 123: Operation 5-13 To Fit
New 1000 Series To fit Operation 5-13 1 Clean the upper half of the shell bearing and lubricate the bearing surface with clean engine lubricating oil. Caution: Only the upper half of the bearing has lubrication holes and must be fitted to the cylinder block.
Page 124: Crankshaft
New 1000 Series Crankshaft To remove Operation 5-15 Note: If the crankshaft is to be renewed, it may be necessary to change the grade of the connecting rods, see Operation 4-11. This will occur if the correct piston height above the block face cannot be maintained with the original piston and connecting rod assemblies, see Operation 4-6.
Page 125: Operation 5-16 To Fit
New 1000 Series To fit Operation 5-16 Special requirements Consumable products Description Part number POWERPART Silicone rubber 1861108 sealant 1 Ensure that all lubricating oil passages are clean and free from restriction. 2 Clean the main bearing housings and the upper half of the bearings. Fit the shell bearings with the location tags fitted correctly in their recesses.
Page 126 New 1000 Series 11 Fit the connecting rod caps, see Operation 4-2. Rotate the crankshaft two turns to ensure free movement. 12 On four cylinder engines, if necessary, fit the balancer unit, see Operation 5-18. If a balancer unit is not...
Page 127: Operation 5-17 To Inspect
New 1000 Series To inspect Operation 5-17 Check the crankshaft for wear and other damage. The maximum permissible wear and ovality on the crankshaft journals and crank pins is 0,04 mm (0.0016 in). The main journals and the crank pins of some standard size crank shafts can be machined to 0,25mm (0.010 in), 0,50mm (0.020 in) or 0,75 mm (0.030 in) undersize on diameter, refer to the Data and dimensions for...
Page 128: Balancer Unit
New 1000 Series Balancer unit To remove and to fit Operation 5-18 To remove 1 Drain the lubricating oil from the sump and remove the sump, see Operation 10-3. Warning! The weight of the unit is approximately 25 kg (55 lb).
Page 129: Operation 5-19 To Dismantle
New 1000 Series To dismantle Operation 5-19 1 Remove the balance weight cover (A8). 2 Release the setscrew and remove the idler gear assembly (A1). Keep the components together as an assembly to protect the needle roller bearing. 3 Prevent movement of the drive shaft (A2) and loosen the nut (A4) of the drive gear for the balance weights (A3).
Page 130 New 1000 Series 5 Release the setscrews and remove the oil transfer plate and joint from the rear of the balancer unit. Make a note of the position of the direction arrows on the outside of the transfer plate (B or C) to ensure that it can be assembled correctly.
Page 131: Operation 5-20 To Assemble
New 1000 Series To assemble Operation 5-20 Special requirements Consumable products Description Part number POWERPART Threadlock and 21820117 nutlock 1 Ensure that the location spigot (A8) on the rear face of the lubricating oil pump is clean. Clean the contact faces of the lubricating oil pump and the balancer frame.
Page 132 New 1000 Series 6 Put the balancer frame upside down on the bench (B1). Turn the gear of the drive shaft (B3) until the larger of the two outer holes (B2) - in the front face of the drive gear - is in the position shown in (B). Ensure that the drive shaft will not move from this position.
Page 133 New 1000 Series 9 If necessary, press a new bearing (E14) into the idler gear (E12). Lubricate the bearing with clean engine lubricating oil. Fit the hub (E13) into the bearing and fit the thrust washer (E15) onto the rear of the hub. Ensure that the threads of the setscrew are clean and dry.
Page 134: Operation 5-21 To Inspect
New 1000 Series To inspect Operation 5-21 1 Clean all the components before inspection. 2 Check the gear teeth and the splines of the drive shaft for wear or other damage. Renew the drive shaft if necessary. 3 Check the idler gear, needle roller bearing, hub and thrust washer for wear or other damage. Renew the components if necessary.
Page 135: Operation 5-22 To Remove And To Fit The Needle Roller Bearings For The Drive Shaft
New 1000 Series To remove and to fit the needle roller bearings for the drive shaft Operation 5-22 1 Press out the bearings with a suitable adaptor. 2 Clean the parent bores and lubricate them with clean engine lubricating oil.
Page 136: Operation 5-23 To Remove And To Fit The Bushes For The Balance Weights
New 1000 Series To remove and to fit the bushes for the balance weights Operation 5-23 1 Press the bushes out of the balancer frame and the rear cover with a suitable adaptor. 2 Clean the parent bores and lubricate them with clean engine lubricating oil.
Page 137: Timing Case And Drive Assembly
New 1000 Series Timing case and drive assembly General description The timing case (A) is for engines fitted with a gear driven coolant pump. The timing case (B) is for engines fitted with a belt driven coolant pump. The timing case is made of either aluminium or cast iron.
Page 138: Timing Case Cover
New 1000 Series Timing case cover To remove Operation 6-1 1 Remove the fan, see Operation 12-19. 2 Remove the alternator, see Operation 14-4. 3 Remove the crankshaft pulley, see Operation 5-1 or Operation 5-2. 4 Drain the coolant and remove the coolant pump. Gear driven pumps only, see Operation 12-4 or Operation 12-9.
Page 139: Operation 6-2 To Fit
New 1000 Series To fit Operation 6-2 Special requirements Special tools Description Part number Description Part number Centralising tool, (6 cylinder engines) 21825574 Centralising tool, (4 cylinder engines) 21825936 Notes: l When the timing case cover is removed from the engine it is recommended that the oil seal is renewed.
Page 140 New 1000 Series Caution: For engines with gear driven coolant pumps, It is important that the cover of the timing case is centred correctly. If the cover is not centred, the backlash between the fuel pump gear and coolant pump gear could be affected.
Page 141: Front Oil Seal
New 1000 Series Front oil seal To remove Operation 6-3 To remove an oil seal from a timing case cover that is removed from the engine To remove the oil seal from a timing case cover that has been removed from the engine: Use a suitable adaptor or spacer to press the old seal out of the cover.
Page 142: Operation 6-4 To Fit
21825579 Adaptor for use with 21825577 (refer to your nearest Perkins distributor) Note: The seal is fitted to a depth of 10,20/10,70 mm (0.402/0.421 in) from the front face of the oil seal housing to the flat front face of the oil seal. If, in service, there is wear in the seal location area of the crankshaft pulley, oil will continue to leak after a new oil seal is fitted.
Page 143 New 1000 Series To fit an oil seal to a timing case cover that is fitted to the engine 1 Clean the oil seal housing. Inspect the new seal for damage. If a scratch can be seen across the lip of the seal, do not fit the seal.
Page 144 New 1000 Series To remove and to fit a wear sleeve Operation 6-5 To repair a worn crankshaft pulley, a wear sleeve (B) is fitted over the spigot (A1). To remove 1 Remove the crankshaft pulley, see Operation 5-1 or Operation 5-2.
Page 145: Idler Gear And Hub
New 1000 Series Idler gear and hub To remove Operation 6-6 1 Remove the timing case cover, see Operation 6-1. 2 Rotate the crankshaft until the marked teeth of the crankshaft gear and the camshaft gear and the fuel pump gear are all aligned with the marked teeth of the idler gear (A).
Page 146 New 1000 Series 7 For engines that use the idler gear assembly with needle roller bearings; Release the three setscrews, remove the plate of the idler gear (C1). Remove the front thrust washer (C2), the front spacer (C3) and the gear (C4).
Page 147: Operation 6-7 To Fit
New 1000 Series To fit Operation 6-7 1 Use the three idler gear setscrews to ensure the correct position of the idler gear hub (A2) with the lubrication hole (A1) at the top. Push the hub into position and remove the setscrews.
Page 148 New 1000 Series 3 For engines that use the idler gear assembly with needle roller bearings - Inspect the components for wear and other damage and renew them if necessary. Lightly lubricate the components with clean lubricating oil before assembly onto the hub. Fit the hub (D8) as described in step 1. Put the rear spacer (D7) in position on the hub.
Page 149: Idler Gear And Hub For The Compressor
New 1000 Series Idler gear and hub for the compressor To remove Operation 6-8 The compressor is driven directly from the engine timing case and does not have an auxiliary drive assembly. The engine idler gear (A12) drives the compressor gear (A4) through a separate idler gear (A11/B4) fitted onto a hub (A9).
Page 150: Operation 6-9 To Fit
New 1000 Series To fit Operation 6-9 1 Renew the "O" ring (A1). Lightly lubricate the components with clean lubricating oil before they are assembled onto the hub. Check that the four cap screws which secure the idler hub bracket (B2) to the timing case are tightened to the correct torque 35 Nm (26 lbf ft) 3,5 kgf m.
Page 151: Fuel Pump Gear
New 1000 Series Fuel pump gear The fuel injection timing is set with specialist tools in the factory after the engine has been accurately set to TDC, number 1 cylinder on the compression stroke. The fuel pump gear has timing marks (A) which can be used to find the approximate position of TDC on number 1 cylinder compression stroke.
Page 152 A special Torx socket (E3) part number 27610122 is needed to remove and to fit these tamper proof fasteners, refer to your Perkins distributor. All other engine models have four flanged setscrews to secure the gear.
Page 153: Operation 6-11 To Fit
New 1000 Series To fit Operation 6-11 Special requirements Special tools Description Part number Description Part number Bosch fuel injection pump timing pin 27610032 Stanadyne and Lucas/Delphi fuel 27610033 injection pump timing pin Socket Torx drive 27610122 The fuel pump gear will only fit in one position. The gear is fitted with the letters C and M at the front.
Page 154 A special Torx socket (D3) part number 27610122 is needed to remove and to fit these tamper proof fasteners, refer to your Perkins distributor. All other engine models have four flanged setscrews to secure the gear.
Page 155: Camshaft Gear
New 1000 Series Camshaft gear To remove and to fit Operation 6-12 Special requirements Special tools Description Part number Description Part number Gear puller 21825565 Adaptors for use with 21825565 21825930 To remove 1 Remove the timing case cover, see Operation 6-1.
Page 156: Crankshaft Gear
New 1000 Series Crankshaft gear To remove and to fit Operation 6-13 To remove 1 Remove the timing case cover, see Operation 6-1. 2 Rotate the crankshaft until the marked teeth of the crankshaft gear and the camshaft gear are in mesh with the idler gear.
Page 157: Timing Case
New 1000 Series Timing case To remove Operation 6-14 1 Remove the fan, see Operation 12-19. 2 Remove the drive belts, see Operation 14-3. 3 Remove the crankshaft pulley, see Operation 5-1 or Operation 5-2. 4 If necessary, remove the fan drive assembly, see Operation 12-20.
Page 158: Operation 6-15 To Fit
New 1000 Series To fit Operation 6-15 Special requirements Consumable products Description Part number Description Part number POWERPART Threadlock and POWERPART Jointing compound 1861117 21820117 nutlock 1 Ensure that the sump joint is not damaged. If the joint is damaged, remove the sump and fit it with a new joint after the timing case has been fitted.
Page 159 New 1000 Series 8 Fit the camshaft gear, see Operation 6-12 and the idler gear, see Operation 6-7. Ensure that all the timing marks are correctly aligned. 9 Fit the fuel injection pump and the drive gear: l For Bosch fuel injection pumps, see Operation 11-11 l For Lucas/Delphi DP200 Series fuel injection pumps, see Operation 11-14 l For Stanadyne fuel injection pumps, see Operation 11-18.
Page 160: Camshaft And Tappets
New 1000 Series Camshaft and tappets To remove Operation 6-16 1 Drain the lubricating oil and the coolant. 2 Remove the timing case, see Operation 6-14. 3 Remove the rocker cover, see Operation 3-1. 4 Remove the rocker assembly and the push rods, see Operation 3-3.
Page 161: Operation 6-17 To Fit
New 1000 Series To fit Operation 6-17 1 Ensure that all components are clean and are lubricated with clean engine lubricating oil. 2 With the engine upside down, fit the tappets in position. 3 Carefully fit the camshaft. 4 Fit the camshaft thrust washer. Ensure that it is fitted correctly on the hollow dowel (A2).
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Page 163: Cylinder Block Assembly
Data and dimensions for "Cylinder bore specifications (engine types AR and AS)" on page 27. Note: Short engines are also available. Your Perkins distributor has specialist equipment and personnel with the correct training to repair worn cylinder bores. Workshop Manual, TPD 1350E, Issue 4...
Page 164: Cylinder Block
New 1000 Series Cylinder block To dismantle Operation 7-1 Note: If the cylinder block is to be renewed, it may be necessary to change the grade of the connecting rods, see Operation 4-11. This will occur if the correct piston height above the block face cannot be maintained with the original piston and connecting rod assemblies, see Operation 4-6.
Page 165: Operation 7-2 To Assemble
New 1000 Series To assemble Operation 7-2 Special requirements Consumable products Description Part number POWERPART Threadlock and 21820117 nutlock 1 Clean thoroughly the new cylinder block. Ensure that all the oil passages are clean and free from debris. 2 Remove the threaded plugs from the old cylinder block and clean the threads. Seal the threads with POWERPART Threadlock and nutlock, or a similar sealant, and fit the threaded plugs into the new cylinder block.
Page 166: Operation 7-3 To Inspect
New 1000 Series To inspect Operation 7-3 1 Clean the passages for the coolant and for the oil. 2 Check the cylinder block for cracks and for other damage. 3 The top face of the cylinder block must not be machined as this will affect the liner flange depth and the piston height above the top face of the cylinder block.
Page 167: Operation 7-4 To Remove And To Fit A New Type 'D' Plug To The Tappet Chamber
New 1000 Series To remove and to fit a new type ‘D’ plug to the tappet chamber Operation 7-4 Special requirements Consumable products Description Part number POWERPART Pipe sealant 21820122 The new ‘D’ plug (A) has baffle plates (A1) attached to the rear of the ‘D’ plug. When fitted to the engine the push rods fit inside the baffle plates.
Page 168 New 1000 Series To fit a new type ‘D’ plug Caution: The baffle plates on the new type ‘D’ plug must be fitted horizontally and vertically to within ± 5°. This will ensure the maximum performance of the baffle plates.
Page 169: Cylinder Liner
Refer to the Data and dimensions for a "Partially finished liner" on page 26. Specialist training and equipment is needed to machine a partially finished liner. For further information contact your nearest Perkins Distributor. Workshop Manual, TPD 1350E, Issue 4...
Page 170: Operation 7-6 To Remove
New 1000 Series To remove Operation 7-6 Special requirements Special tools Description Part number Description Part number Remover/replacer for cylinder liner 21825543 Adaptors for use with 21825543 21825563 (main tool) Where several liners are to be removed or a very tight production liner is fitted, a press should be used. Where a single liner is to be removed or the crankshaft is to remain in position, a tool for hand operation is available.
Page 171 New 1000 Series 7 Put the bearing (B3) in the recess in the top of the tool with the flat face of the bearing to the bottom of the recess. 8 Fit the threaded rod (B2) through the bearing and the top of the tool until the handle (B1) is in the recess in the top of the bearing.
Page 172: Operation 7-7 To Fit A Service Liner
New 1000 Series To fit a service liner Operation 7-7 Special requirements Special tools Consumable products: Description Part number Description Part number Remover/replacer for cylinder liner 21825543 POWERPART Retainer (oil tolerant) 21820603 (main tool) Adaptors for use with 21825543 21825563...
Page 173 New 1000 Series 4 Engage the cylinder liner (B5) into the parent bore; ensure that the liner is vertical. Put the adaptor (B4) onto the top of the liner with the shoulder of the adaptor on the liner flange. Put the bearing (B3) into position in the recess in the top of the adaptor with the flat face of the bearing to the bottom of the recess.
Page 174 New 1000 Series 10 Use tool 21825496 to check that the liner flange is between 0,10 mm (0.004 in) above to 0,10 mm (0.004 in) below the top face of the cylinder block (C). This measurement must be from the flange (C2) of the cylinder liner, not the top of the flame ring (C1).
Page 175: Operation 7-8 To Fit A Partially Finished Liner
New 1000 Series To fit a partially finished liner Operation 7-8 Special requirements Special tools Consumable products: Description Part number Description Part number Remover/replacer for cylinder liner 21825543 POWERPART Safety cleaner 21820128 (main tool) Adaptors for use with 21825543 21825563...
Page 176 New 1000 Series 4 Apply a small amount of engine oil around the top of the parent bore to assist the entry of the liner. 5 Engage the cylinder liner (B5) into the parent bore; ensure that the liner is vertical. Put the adaptor (B4) onto the top of the liner with the flame ring in the groove of the adaptor.
Page 177 Refer to the Data and dimensions for "Partially finished liner" on page 26. Specialist training and equipment is needed to machine a partially finished liner. For further information contact your nearest Perkins Distributor. 11 Fit new piston rings, see Operation 4-8.
Page 178: Cylinder Bore, Engine Types Ar And As
Refer to the Data and dimensions for "Cylinder bore specifications (engine types AR and AS)" on page 27. Specialist training and equipment is needed to machine a cylinder bore. For further information contact your nearest Perkins distributor. Workshop Manual, TPD 1350E, Issue 4...
Page 179: Engine Timing
New 1000 Series Engine timing General description To reach the accurate fuel injection needed for engines to conform to emissions legislation, the latest fuel injection pumps operate at a static timing very close to TDC. The timing gears are stamped with timing marks to ensure that they are assembled correctly (A). The marked teeth of the crankshaft, the camshaft and the fuel pump gears will be in mesh with the idler gear when number 1 piston is close to top dead centre (TDC) on the compression stroke.
Page 180 Note: On the latest engines with belt driven coolant pumps, four tamper proof fasteners retain the fuel pump gear. Special tools are needed to remove these fasteners, refer to your Perkins distributor. To remove the fuel injection pump from the engine it is only necessary to remove the four setscrews (D1) which...
Page 181: Operation 8-1 To Set Number 1 Piston To Tdc On The Compression Stroke
New 1000 Series Engine timing To set number 1 piston to TDC on the compression stroke Operation 8-1 Special requirements Special tools Description Part number Description Part number Valve spring compressor 21825666 Setscrew adaptor for use with 21825932 21825666 Stud adaptor for use with 21825666...
Page 182: Operation 8-2 Another Method To Set Number 1 Piston To Tdc
New 1000 Series Another method to set number 1 piston to TDC on the compression stroke Operation 8-2 1 Fasten a temporary pointer to the timing case cover (or other suitable position) with its tip near to the outer edge of the crankshaft damper or pulley.
Page 183: Operation 8-3 To Check The Valve Timing
New 1000 Series To check the valve timing Operation 8-3 1 Set the piston of number 1 cylinder to TDC on the compression stroke, see Operation 8-1 or Operation 8-2. 2 Rotate the crankshaft, clockwise from the front, until the inlet valve of the rear cylinder is fully open.
Page 184: Operation 8-4 To Check The Timing Of The Fuel Injection Pump
If the hub is moved, it will be necessary for a fuel injection pump specialist to correctly position the hub on the shaft with special test equipment available to Perkins distributors. 1 Set the piston of number 1 cylinder to TDC on the compression stroke, see Operation 8-1 or Operation 8-2.
Page 185: Aspiration System
New 1000 Series Aspiration system General description Warning! Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and debris away from the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces. A turbocharger (A), is fitted between the exhaust and intake manifolds. The turbocharger is driven by exhaust gases and passes air to the engine at more than atmospheric pressure.
Page 186 New 1000 Series Some turbochargers are fitted with a waste-gate unit (B). This unit, which is controlled by boost pressure, allows some of the exhaust gases to bypass the turbine rotor at higher engine speeds. With this arrangement, the turbocharger can be designed to be more effective at lower engine speeds. A waste-gate guard, page 171 (A1) is fitted to protect the actuator rod, page 171 (A2) of some engines.
Page 187: Turbocharger
New 1000 Series Turbocharger To remove Operation 9-1 1 Thoroughly clean the turbocharger. 2 Remove the air cleaner hose at the compressor inlet. 3 Remove or disconnect the support bracket for the turbocharger. If necessary, remove the heat shield for the fuel lift pump.
Page 188: Operation 9-2 To Fit
New 1000 Series To fit Operation 9-2 Special requirements Consumable products Description Part number POWERPART Pipe sealant 21820122 Note: Reflective heat shields must be kept clean and free from dust, oil or paint. If the surface of the heat shield is not shiny, the part that is protected by the heat shield could be damaged.
Page 189 New 1000 Series 7 Where the exhaust elbow (B2) has a sleeve (B1), check that the sleeve protrusion from the end of the elbow is 23 mm (0.90in) (A9). 8 Fit the elbow in the correct position to the support bracket (B5) and tighten the setscrews (B4) finger tight.
Page 190: Operation 9-3 To Clean The Impeller And The Compressor Casing
New 1000 Series To clean the impeller and the compressor casing Operation 9-3 Generally, it is not necessary to remove the turbocharger to remove the compressor casing, except on some engines where the compressor casing is held by a circlip and access to the circlip is not always possible. This type of turbocharger is usually fitted to engines used in vehicle applications.
Page 191: Operation 9-4 To Remove And To Fit The Actuator Assembly Of The Waste-Gate Unit
New 1000 Series To remove and to fit the actuator assembly of the waste-gate unit Operation 9-4 It is important that the waste-gate actuator setting is not altered. Do not remove the actuator or mounting bracket unless it is necessary to renew the actuator assembly.
Page 192: Operation 9-5 To Check And Adjust The Operation Of The Waste-Gate
New 1000 Series To check and adjust the operation of the waste-gate Operation 9-5 If the waste-gate valve does not operate at the correct pressure, it can affect the engine performance. If the valve opens at a low pressure, this can cause black exhaust smoke and loss of power at lower engine speeds.
Page 193: Turbocharger Faults
New 1000 Series Turbocharger faults The chart below is given to assist in the correct diagnosis of turbocharger faults. If the inside of the intake manifold is wet, check that there is not a fuel leak from the fuelled starting aid, if there is one fitted, see Operation 14-11.
Page 194: List Of Possible Causes
New 1000 Series List of possible causes 1 Element of the air filter dirty. 2 Restricted crankcase breather. 3 Element of the air filter not fitted, or not sealing correctly. Loose connection to turbocharger. 4 Internal distortion or restriction in pipe from air filter to turbocharger.
Page 195: Open Engine Breather
Introduction Open breathers fitted to New 1000 Series engines have a hose connected to the rocker cover which will allow any crankcase pressure to pass directly from the engine. An oil separator is fitted to the rocker cover to remove any oil mist and return it to the engine.
Page 196 New 1000 Series To renew (early and later types) Note: To remove the oil separator from the rocker cover, it will be necessary to make a tool (D) from 3,1 mm (0.125 in) mild steel plate, all dimensions are in millimetres.
Page 197: Operation 9-7 To Inspect
New 1000 Series To Inspect Operation 9-7 If excessive crankcase pressure is suspected, the following procedure must be used. Note: This procedure only refers to engines fitted with plastic rocker covers. 1 Remove the rocker cover and check if the end of the shroud (A4) has a skin of plastic.
Page 198: Closed Engine Breather
New 1000 Series Closed engine breather Closed breather systems fitted to New 1000 Series engines have an oil separator assembly which is fastened to the crankcase and a breather valve is fitted between the oil separator and the intake manifold. Crankcase gases pass through the oil separator where oil from the gases is returned to the sump.
Page 199: Operation 9-8 To Renew The Breather Valve Assembly
Ensure that the vent hole (A1) is not restricted during service. Note: The whole breather assembly must be renewed every complete overhaul of the engine or 8000 hours. The closed breather system used on the New 1000 Series engine consists of a body (A4) and a valve assembly (A5).
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Page 201: Lubrication System
New 1000 Series Lubrication system General description - four cylinder engine lubrication system Pressure lubrication is supplied by a rotor type pump which is driven through an idler gear from the crankshaft gear. The pump has an inner rotor and an outer rotor which are off-centre to each other. There is a key between the inner rotor and the drive shaft.
Page 202: General Description - Six Cylinder Engine Lubrication System
New 1000 Series General description - Six cylinder engine lubrication system The oil pump is similar to that used on four cylinder engines and is also driven through an idler gear from the crankshaft gear. The inner rotor has four lobes and the outer rotor has five lobes.
Page 203 New 1000 Series Lubrication system flow diagram A0289 Workshop Manual, TPD 1350E, Issue 4 This document has been printed from SPI². Not for Resale...
Page 204 New 1000 Series Lubrication system flow diagram for the relief valve and balancer A0290 Workshop Manual, TPD 1350E, Issue 4 This document has been printed from SPI². Not for Resale...
Page 205: Filter Canister
Caution: The canister contains a valve and special tube to ensure that lubricating oil does not drain from the filter. Therefore, ensure that the correct Perkins POWERPART canister is used. The filter can have one or two canisters (B4) or (A1) fitted. When two canisters are fitted, both must be renewed at the same time.
Page 206: Filter Head
New 1000 Series Filter head To remove and to fit Operation 10-2 Special requirements Consumable products Description Part number POWERPART Threadlock and 21820117 nutlock To remove 1 Put a tray under the filter head to contain spilt lubricating oil. 2 Remove the filter canister(s), see Operation 10-1.
Page 207: Sump
New 1000 Series Sump To remove and to fit Operation 10-3 Warning! Discard the used lubricating oil in a safe place and in accordance with local regulations. 1 Operate the engine until it is warm. 2 Stop the engine, remove the sump drain plug (A1) and its "O" ring and drain the oil. Where necessary, remove the dipstick and the dipstick tube.
Page 208: Oil Strainer And Suction Pipe
New 1000 Series Oil strainer and suction pipe To remove and to fit Operation 10-4 The oil strainer is an integral part of the suction pipe. No regular service is necessary but wash the strainer when it is removed. On four cylinder engines which have a balancer fitted, the suction pipe is normally a short pipe which is fastened to the balancer frame and a pipe bracket is not fitted.
Page 209: Operation 10-5 To Inspect And To Correct
New 1000 Series To remove 4 cylinder engines 1 Remove the sump, see Operation 10-3. 2 Release the setscrew which holds the bracket to the main bearing cap (B3). 3 Release the setscrews from the flange of the suction pipe (B1). Remove the suction pipe, strainer and bracket.
Page 210: Lubricating Oil Pump
New 1000 Series Lubricating oil pump The lubricating oil pump has a channel (B1) in the body of the pump. Lubricating oil from the front main bearing passes down the channel in the body of the pump to an oil hole in the idler shaft. The lubricating oil then passes through the hole in the idler shaft to the bush in the idler gear.
Page 211: Operation 10-7 To Fit
New 1000 Series To fit Operation 10-7 1 Fill the oil pump with clean engine lubricating oil. Fit the oil pump to the main bearing cap and tighten the setscrews to 22 Nm (16 lbf ft) 2,2 kgf m. 2 Check the idler gear and the bush for wear and other damage. If the gear and/or bush are damaged, they can be renewed as an assembly or the bush can be renewed as a single item.
Page 212: Operation 10-8 To Inspect
New 1000 Series To inspect Operation 10-8 Note: If any part is worn enough to have an effect on the performance of the oil pump, the complete oil pump must be renewed. 1 Release the setscrews and remove the cover of the oil pump. For pumps which are fitted to a balancer unit, remove the single setscrew and the cover.
Page 213: Lubricating Oil Pump Idler Gear Shaft
New 1000 Series Lubricating oil pump idler gear shaft The idler shaft for the lubricating oil pump fitted in the front main bearing cap of six cylinder engines is retained by a pin and POWERPART Retainer (oil tolerant). If it is necessary to renew the idler shaft on these engines, follow the procedure given below.
Page 214 New 1000 Series Alternative method to remove the idler shaft Caution: This method to remove the pin from the idler shaft must only be used if the pin cannot be removed by the earlier method. 1 Make a drill guide (C) to the dimensions given in the table below.
Page 215: Operation 10-10 To Fit (Six Cylinder Engines)
New 1000 Series To fit (six cylinder engines) Operation 10-10 Special requirements Consumable products Description Part number POWERPART Retainer (oil tolerant) 21820603 1 Check that the new idler shaft and the hole for the idler shaft in the bearing cap are clean and free from oil or grease.
Page 216: Operation 10-11 To Remove And To Fit (Four Cylinder Engines)
New 1000 Series To remove and to fit (four cylinder engines) Operation 10-11 Special requirements Consumable products Description Part number POWERPART Retainer (oil tolerant) 21820603 1 Support the front of the bearing cap. Put a suitable adaptor on the small diameter of the idler shaft and press the idler shaft out of the bearing cap.
Page 217: Relief Valve
New 1000 Series Relief valve To remove and to fit Operation 10-12 Four cylinder engines that have a balancer unit have a relief valve fitted inside the balancer frame. The relief valve of these engines cannot be removed as an assembly.
Page 218: Operation 10-13 To Dismantle And To Assemble
New 1000 Series To dismantle and to assemble Operation 10-13 If necessary, the relief valve can be dismantled and assembled while it is fitted to the engine. 1 Apply pressure to the end plate (A4 or B5) of the spring assembly; release the circlip (A5) or remove the pin (B1) and carefully release the pressure to remove the end plate and the spring (A3 or B4) from the valve body.
Page 219: Flexible Oil Pipes
New 1000 Series Flexible oil pipes The oil cooler pipes fitted to 6 cylinder engines do not have metal braid and are separate pipes. The part number of the pipes is stamped on a clip which is fastened to one end of each pipe. The pipes are not interchangeable and it is important that the correct pipes are fitted to the engine.
Page 220: Operation 10-16 To Fit
New 1000 Series To fit Operation 10-16 Arrangement 1 (A) 1 Put the three setscrews into position in the flange (A3) of the inner pipe (A5). Put a new joint (A2) in position on the setscrews. 2 Engage the setscrews by three or four threads in the flange of the oil cooler (A4). Engage the spigot (A1) of the outer pipe (A9), in the hole in the flange (A3) of the first pipe, ensure that it fits squarely in the flange.
Page 221: Operation 10-17 To Inspect
New 1000 Series Arrangement 2 (B) 1 Put a setscrew (B5) in position in the flange of the inner oil cooler pipe (B6). Put a new joint (B4) in position on the setscrew. Hold the flange and the joint in position and fit the centre setscrew (B8). Tighten the setscrews finger tight.
Page 222 This page is intentionally blank This document has been printed from SPI². Not for Resale...
Page 223: Fuel System
Caution: The fuel injection equipment must only be checked and adjusted by personnel who have had the correct training. New 1000 Series engines are used for industrial and agricultural applications and use various fuel injection pumps. Either Bosch (A), Lucas/Delphi (B) or Stanadyne (C) pumps may be fitted.
Page 224 New 1000 Series All of the fuel injection pumps have a pin timing hole (D1). Refer to Operation 8-4 for the correct method to time the pump. Turbocharged engines have pumps with a boost control. The boost control is a device which is affected by boost pressure (from the turbocharger) and reduces the maximum fuel delivery at lower engine speeds to match the reduced air supply to the cylinders.
Page 225 New 1000 Series Fuel injection pump types Bosch fuel injection pump The boost control fitted to the Bosch fuel pump is a diaphragm type (A1). A KSB type cold starting aid and a stop solenoid may also be fitted to these pumps.
Page 226: Cold Start Advance Unit
New 1000 Series Cold start advance unit Some Lucas/Delphi, Bosch and Stanadyne rotary fuel injection pumps have a cold start advance unit that holds the timing of the pump in an advanced position when the engine is cold. Caution: It is important that the electrical connections to the sender unit are connected correctly. Failure of the starting aid to operate correctly could result in damage to the engine as the timing will be fully advanced for normal operation.
Page 227 New 1000 Series Wiring diagrams for the cold start advance unit fitted to some Lucas/Delphi DP200 Series, Bosch and Stanadyne fuel injection pumps are shown in the illustrations (A), (B) and (C) respectively. For easy identification the cables are shown in circles on the illustrations.
Page 228 New 1000 Series Cold start advance unit (KSB) Bosch EPVE rotary fuel injection pump has a starting aid that holds the timing of the pump in an advanced position when cold. The device (A) is operated electrically and is connected by a shaft to the advance lever (A3) of the fuel injection pump.
Page 229: Typical Fuel System
New 1000 Series Typical fuel system Six cylinder engines Fuel systems vary from application to application, this information is provided for training purposes only. Fuel (A9) from the tank (A2) leaves the pre-filter (A4) and then passes to the diaphragm type lift pump (A1), which is driven by an eccentric on the camshaft.
Page 230: Fuel Filters
Fuel filters Cautions: l It is important that only the genuine Perkins parts are used. The use of a wrong canister or element can damage the fuel injection pump. l The pre-filter and main filter canisters must be renewed at the same time.
Page 231: Fuel Filter Element
Warning! Discard the used canister and fuel oil in a safe place and in accordance with local regulations. Cautions: l It is important that only the genuine Perkins parts are used. The use of a wrong canister or element can damage the fuel injection pump.
Page 232: Operation 11-2 To Renew - Canister Type
Warning! Discard the used canister and fuel oil in a safe place and in accordance with local regulations. Cautions: l It is important that only the genuine Perkins parts are used. The use of a wrong canister or element can damage the fuel injection pump.
Page 233: Operation 11-3 To Renew - Quick Release Canister Type
Warning! Discard the used canister and fuel oil in a safe place and in accordance with local regulations. Cautions: l It is important that only the genuine Perkins parts are used. The use of a wrong canister or element can damage the fuel injection pump.
Page 234: Atomisers
New 1000 Series Atomisers Regular maintenance of the atomisers is not necessary. The atomiser nozzles should be renewed and not cleaned, and renewed only if an atomiser fault occurs. The major problems that may indicate that new nozzles are needed are listed below:...
Page 235: Operation 11-4 To Remove
New 1000 Series To remove Operation 11-4 Caution: Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area around the connection. After a component has been disconnected, fit a suitable cover to all open connections.
Page 236: Operation 11-5 To Fit
New 1000 Series To fit Operation 11-5 Special requirements Consumable products Description Part number POWERPART Universal jointing 1861117 compound 1 Thoroughly clean the threads of the gland nut (A3) and the cylinder head. Caution: Do not allow any thread sealant to get below the gland nut threads.
Page 237 New 1000 Series Tighten the nut gradually and evenly to 40 Nm (30 lbf ft) 4,1 kgf m. As the nut is tightened the atomiser will rotate clockwise as the ball moves in the slot, this is acceptable. Remove any excess thread sealant.
Page 238: Fuel Lift Pump
New 1000 Series Fuel lift pump To remove and to fit Operation 11-6 Special requirements Consumable products Description Part number POWERPART Silicone rubber 1861108 sealant Notes: l A new fuel lift pump (B) is fitted to the latest four cylinder engines. The new fuel lift pump is a one-piece assembly and should not be dismantled.
Page 239: Operation 11-7 To Dismantle
New 1000 Series To dismantle Operation 11-7 Note: The new fuel lift pump is a one-piece assembly and should not be dismantled. 1 Clean the outside surfaces of the fuel lift pump. 2 Make a mark across the flanges of the two halves of the pump to ensure correct relationship when the pump is assembled.
Page 240: Operation 11-8 To Assemble
New 1000 Series To assemble Operation 11-8 1 Thoroughly clean the valve housings. Fit new seat washers (A3) and push the new valves (A4) into position. As the valves are the same, but one valve is fitted in reverse of the other, it is possible to fit the valves upside down.
Page 241: Operation 11-9 To Test
New 1000 Series To test Operation 11-9 1 Disconnect the fuel outlet pipe from the fuel lift pump. Fit a 0-70 kPa (0-10 lbf/in ) 0-0,7 kgf/cm pressure gauge to the outlet of the lift pump. Release the connection at the gauge and operate the priming lever of the lift pump to eliminate air from the pipe.
Page 242: Bosch Fuel Injection Pump
A special Torx socket part number 27610122 is needed to remove and to fit these tamper proof fasteners, refer to your Perkins distributor. All other engine models have four flanged setscrews to secure the gear.
Page 243 (D3) or on the rear mounting bracket (D2). The additional data plates are used by Perkins to identify fuel injection pumps after a minor modification to alter the pump and/or the engine performance.
Page 244: Operation 11-10 To Remove
New 1000 Series To remove Operation 11-10 Special requirements Special tools Description Part number Description Part number Spanner for flange nut of the Bosch 21825964 fuel injection pump Timing pin 27610032 Torx socket 27610122 1 Disconnect the battery before the fuel injection pump is removed from the engine.
Page 245 If the hub is moved, the hub will need to be accurately fitted to the pump by use of special equipment available to Perkins distributors. 6 Remove the four fasteners (D4) and release the fuel pump gear from the hub of the fuel injection pump.
Page 246: Operation 11-11 To Fit
If the hub is moved, the hub will need to be accurately fitted to the pump by use of special equipment available to Perkins distributors.
Page 247 A special Torx socket part number 27610122 is needed to remove and to fit these tamper proof fasteners, refer to your Perkins distributor. All other engine models have four flanged setscrews to secure the gear.
Page 248: Operation 11-12 To Adjust
The warranty of the engine can be affected if the seals on the fuel injection pump are broken during the warranty period by a person who is not approved by Perkins. 1 Remove any tamper-proof devices that are fitted to the adjustment screws.
Page 249: Lucas/Delphi Dp 200 Series Fuel Injection Pump
A special Torx socket part number 27610122 is needed to remove and to fit these tamper proof fasteners, refer to your Perkins distributor. All other engine models have four flanged setscrews to secure the gear.
Page 250 New 1000 Series Caution: A new fuel injection pump may be supplied with the pump shaft in the locked position. The drive shaft of the pump must not be turned without the spacer (D2) in position under the locking screw (D3).
Page 251: Operation 11-13 To Remove
New 1000 Series To remove Operation 11-13 Special requirements Special tools Description Part number Description Part number Timing pin Lucas/Delphi fuel 27610033 Torx socket 27610122 injection pumps 1 Disconnect the battery before the fuel injection pump is removed from the engine.
Page 252 If the hub is removed, the hub will need to be accurately fitted to the pump by use of special equipment available to Perkins distributors. 6 Remove the four fasteners (D6) and release the fuel pump gear from the hub of the fuel injection pump.
Page 253: Operation 11-14 To Fit
New 1000 Series To fit Operation 11-14 Special requirements Special tools Description Part number Description Part number Timing pin Lucas/Delphi fuel 27610033 Torx socket 27610122 injection pumps Cautions: l The engine must be set to TDC number 1 cylinder, compression stroke before the pump is fitted. If the crankshaft needs to be rotated, the pump must be fitted temporarily, or the loose gear could damage the timing case.
Page 254 If the hub is removed, it will need to be accurately fitted to the pump by use of special equipment available to Perkins distributors.
Page 255 New 1000 Series Caution: Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension. If there is a leakage from the union nut, ensure that the pipe is correctly aligned with the atomiser inlet.
Page 256: Operation 11-15 To Adjust
The warranty of the engine can be affected if the seals on the fuel injection pump are broken during the warranty period by a person who is not approved by Perkins. 1 Remove any tamper-proof devices that are fitted to the adjustment screws.
Page 257: Operation 11-16 Electrical Shut Off Solenoid (Esos)
New 1000 Series Electrical shut off solenoid (ESOS) Operation 11-16 General description A new Junior Power Timer (JPT) ESOS was introduced to all new engines fitted with Lucas/Delphi fuel injection pumps. A conversion kit is available to enable the new (JPT) ESOS male connector (A1) to be connected to the Twin Lucar terminals (A4) on the wiring loom.
Page 258 New 1000 Series To fit the adaptor kit 1 With a suitable tool, cut the cables near to the Lucar terminals and remove them from the wiring loom. 2 Remove 4,0 mm (0.17 in) of insulation from the ends of the two cables (D2) and put the cable seals (D4) on to each cable, the narrow end (D3) towards the 4 mm strip.
Page 259: Stanadyne Fuel Injection Pump
A requirement of emissions legislation is that access to adjustments that affect the engine’s exhaust emissions is limited to personnel approved by Perkins. The adjustment screw for the high idle speed, is sealed by the manufacturer. The setting must not be changed, unless approved, as it could affect the warranty of the engine.
Page 260 Perkins fastens a data plate (C1) to all “Range Pump” models, even if no change has been made to the original Stanadyne calibration, since the engines on which they are installed do not have a single specific speed rating.
Page 261 Perkins can change the voltage of operation from 12V to 24V or from 24V to 12V DC or from “Energised - Run” (ETR) to “Energised - Shut off” (ETOS). A new Perkins customer part number for the pump must be etched on the modification data plate shown in (E1).
Page 262: Operation 11-17 To Remove
If the hub is removed, the hub will need to be accurately fitted to the pump by use of special equipment available to Perkins distributors. 6 Remove the four fasteners (A6) and release the fuel pump gear from the hub of the fuel injection pump.
Page 263: Operation 11-18 To Fit
If the hub is removed, the hub will need to be accurately fitted to the pump by use of special equipment available to Perkins distributors.
Page 264 A special Torx socket part number 27610122 is needed to remove and to fit these tamper proof fasteners, refer to your Perkins distributor. All other engine models have four flanged setscrews to secure the gear.
Page 265: Operation 11-19 To Adjust
(B3), these are for the adjustment of the idle speed and the maximum no-load speed. Special tools (B1) and (B2) available at your Perkins distributor, are needed to adjust the idle or maximum speed settings on later engines.
Page 266 Normally the correct speed will be given in the manufacturer’s handbook for the application. If it is not given, refer to your nearest Perkins distributor. Caution: The setting for the maximum no load speed can change for different applications. For the correct maximum no-load speed, check the emissions data plate fitted to the left side of the cylinder block before any adjustment is made to the maximum no load speed.
Page 267 The setting of the idle speed can change for different applications. Normally the correct speed will be given in the manufacturer’s handbook for the application. If it is not given, refer to your nearest Perkins distributor. Caution: The setting for the maximum no load speed can change for different applications. For the correct maximum no-load speed, check the emissions data plate fitted to the left side of the cylinder block before any adjustment is made to the maximum no load speed.
Page 268: Air In The Fuel System
New 1000 Series Air in the fuel system If air enters the fuel system, it must be removed before the engine can be started. Air can enter the system if: l The fuel tank is drained during normal operation l The low-pressure fuel pipes are disconnected l A part of the low-pressure fuel system leaks during engine operation.
Page 269 New 1000 Series Note: If the drive cam of the fuel lift pump is at the point of maximum lift, it will not be possible to operate the priming lever. In this situation, the crankshaft must be rotated one revolution.
Page 270 New 1000 Series 6 Put the electrical system switch to the "ON" position. Ensure that the manual stop control, if one is fitted, is in the "RUN" position. Operate the starter motor until fuel, free from air, comes from the pipe connections.
Page 271: Cooling System
New 1000 Series Cooling system General description Coolant from the bottom of the radiator passes through the centrifugal coolant pump, which is fitted onto the front of the timing case to assist the flow of the coolant through the system.
Page 272: Thermostats Operation 12-1 To Remove
New 1000 Series Thermostats To remove Operation 12-1 Most engines are fitted with a single thermostat (A), some engines have twin thermostats fitted (B) Identification of the thermostat is by the nominal temperature which is stamped on the by-pass valve (A6) of the thermostat.
Page 273: Operation 12-2 To Fit
New 1000 Series To fit Operation 12-2 1 Clean the thermostat housing. Ensure that the groove (A2) for the clip retainers and the seat for the "O" ring are free of debris. 2 Ensure that the joint faces of the thermostat housing and the lower body are clean and that the jiggle pin (B1) in the thermostat is free to move.
Page 274: Operation 12-3 To Test
New 1000 Series To test Operation 12-3 1 Hang the thermostat in a suitable container filled with coolant. 2 Heat the coolant gradually. Use a thermometer to check the temperature at which the valve starts to open and at which it is fully open. For the correct operating temperatures, refer to the Data and dimensions for "Thermostat"...
Page 275: Coolant Pump - Early Gear Driven Pumps
New 1000 Series Coolant pump - early gear driven pumps Identification of the coolant pump is by the last four digits of the part number, for example 4131E011, stamped on the front of the pump body. Early gear driven coolant pumps have either a cover and a joint secured by four setscrews or a pressed steel cover that is pressed into the pump housing, for details on how to remove the pressed steel cover, see "To...
Page 276: Operation 12-5 To Fit
New 1000 Series To fit Operation 12-5 Special requirements Consumable products Description Part number POWERPART Silicone rubber 1861108 sealant 1 Check the "O" rings on the pump body (A2) and on the cover of the timing case (A1) for damage. If either of the "O"...
Page 277: Operation 12-6 To Dismantle
New 1000 Series To dismantle Operation 12-6 The coolant pump has a bearing assembly which has an integral oil seal. Identification of the coolant pump is by the last four digits of the part numbers, (4131E011) stamped on the front of the coolant pump body and by the bearing which extends approximately 5 mm (0.2 in) past the end of the pump body.
Page 278: Operation 12-7 To Assemble
New 1000 Series To assemble Operation 12-7 Special requirements Consumable products Description Part number Description Part number POWERPART Retainer POWERPART Threadlock and 21820638 21820117 (high strength) nutlock Caution: It is important that all of the components in the coolant pump kit are used during the overhaul of the pump.
Page 279 New 1000 Series 5 A tool (B) can be made to press the coolant seal into position. The tool should be made of a suitable material to the dimensions listed below: 44,0 mm (1.73 in) 40,0 mm (1.57 in) 11,6 mm (0.46 in) 35,8 mm (1.41 in)
Page 280 New 1000 Series Turn the pump over and support the drive end of the body. Do not lubricate the coolant seal (C4). It is important that the seal is not contaminated by oil or grease and if it is held in the hand, it should be held by the edge of the flange.
Page 281: Operation 12-8 To Remove And To Fit A Pressed Steel Cover (Early Coolant Pumps)
New 1000 Series To remove and to fit a pressed steel cover (early coolant pumps) Operation 12-8 Special requirements Consumable products Description Part number POWERPART Gasket and flange 21820518 sealant To remove Caution: Do not remove the pressed steel cover when the coolant pump is removed or fitted. It is only necessary to remove the cover when the pump is to be dismantled.
Page 282: Coolant Pump - Latest Gear Driven Pumps
New 1000 Series Coolant pump - latest gear driven pumps Note: A small amount of leakage of coolant across the surface of the face seal in the coolant pump is normal. It’s purpose is to provide lubrication for the seal. There is a hole in the coolant pump body to allow coolant to drain.
Page 283: Operation 12-10 To Fit
New 1000 Series To fit Operation 12-10 Special requirements Consumable products Description Part number Description Part number POWERPART Threadlock and POWERPART Silicon sealing and 21820117 1861108 nutlock jointing compound 1 Ensure that the joint faces on the pump body (A3) and on the cover of the timing case (A1) are clean. Check the joint faces for damage.
Page 284: Operation 12-11 To Dismantle
New 1000 Series To dismantle Operation 12-11 Special requirements Special tools Description Part number Basic puller 21825565 1 Remove the two studs from the pump body. 2 Use a lever under the edge of the pressed steel cover (A1) and remove the cover, there are three recesses (B1) around the edge of the pump body to give access for a lever.
Page 285 New 1000 Series Later coolant pumps have an impeller that has two 8 mm tapped holes. The impeller can be removed by using the basic puller attached to the impeller by two 8 mm setscrews (D1). Tighten the centre setscrew (D2) of the puller until the impeller is removed.
Page 286 New 1000 Series Caution: Do not damage the sealing face of the oil seal housing during removal of the seal. 5 Drill a 3.175 mm (0.125 in) hole through the top of the oil seal and fit a 25.4 mm (1.00 in) self-tapping screw.
Page 287: Operation 12-12 To Assemble
New 1000 Series To assemble Operation 12-12 Special requirements Special tools Consumable products Description Part number Description Part number POWERPART Retainer 21820638 (high strength) Coolant pump, oil seal replacer tool 27610031 POWERPART Gasket and flange 21820518 sealant Caution: It is important that all of the components in the kit for the coolant pump are used. The kit includes the latest components which may be of a different design to the original components fitted to the engine.
Page 288 New 1000 Series 4 Apply a thin layer of POWERPART Retainer (high strength) to the outer surface of the ball bearing (B2), but keep the retainer away from the ends of the bearing. Use a suitable spacer to support the drive gear end of the shaft.
Page 289 New 1000 Series 6 Lightly lubricate the oil seal (C2) with clean engine lubricating oil. Put the tapered tool 27610031 onto the drive shaft with the tapered end towards the bearing. The tapered tool ensures that the lip of the oil seal is correctly fitted when the seal is pressed into position.
Page 290 New 1000 Series Caution: Do not lubricate the coolant seal (E4). It is important that it is not contaminated with oil or grease and, if it is held in the hand, it should be held by the edge of the outside flange. Do not damage the ring of green sealant applied to the body of the coolant seal just behind the flange.
Page 291 New 1000 Series Coolant pump - belt driven Note: A small amount of leakage of coolant across the surface of the face seal in the coolant pump is normal. It’s purpose is to provide lubrication for the seal. There is a hole in the coolant pump body to allow coolant to drain.
Page 292 New 1000 Series 8 If it is necessary to remove the rear body (C1) of the pump from the cylinder block: Remove the setscrew for the alternator adjustment linkage and the spacer. Remove the four other setscrews and remove the rear body from the cylinder block.
Page 293 New 1000 Series To fit Operation 12-14 Note: The joints are fitted without jointing compound. 1 If the rear body of the pump (A1) was removed from the cylinder block: Thoroughly clean the joint faces of the cylinder block and pump rear body. Fit a new joint (A2) between the rear body of the pump and the cylinder block.
Page 294 New 1000 Series 5 Fit the key to the keyway and put the pulley onto the pump shaft. Put the plain washer and the spring washer in position onto the pulley. Fit the nut and tighten it to 77 Nm (57 lbf ft) 7,9 kgf m.
Page 295 New 1000 Series To remove high position pump Operation 12-15 Special requirements Special tools Description Part number Gear puller 21825565 Note: A small amount of leakage of coolant across the surface of the face seal in the coolant pump is normal.
Page 296 New 1000 Series 6 Remove the four setscrews "D", in illustration (C), which secure the coolant pump to the rear body of the pump (C1). 7 Remove the coolant pump (D5) and discard the joint. 8 If it is necessary to remove the rear body of the pump from the cylinder block: Remove the setscrew for the alternator adjustment linkage and the spacer.
Page 297 New 1000 Series To fit high position pump Operation 12-16 Note: The joints are fitted without jointing compound. 1 If the transfer plate (A4) was removed from the cylinder block: Thoroughly clean the joint faces of the cylinder block and transfer plate. Fit a new joint between the transfer plate and the cylinder block. Fit the transfer plate and tighten the five setscrews "C"...
Page 298 New 1000 Series 3 Tighten the five setscrews “C” in illustration (C) to 22 Nm (16 lbf ft) 2,2 kgf m 4 Fit the coolant pump (D2) and joint (D4) to the rear pump body (D1) and tighten the four M8 setscrews (D3) to 29 Nm (21 lbf ft) 2,9 kgf m.
Page 299 New 1000 Series To dismantle Operation 12-17 1 Remove the coolant pump (A) from the engine, see Operation 12-13 or Operation 12-15. 2 Remove the circlip (A4) for the bearing housing (A3). 3 Support the pulley end of the pump and press the shaft (A6) through the impeller (A1) and coolant seal (A2).
Page 300 New 1000 Series To assemble Operation 12-18 Special requirements Special tools Consumable products Description Part number Description Part number Standard bench press POWERPART Retainer (oil tolerant) 21820603 The service kit for the pump contains two bearings, the shaft, a circlip, a key, a joint and a coolant seal. Each bearing is filled with grease and sealed by the bearing manufacturer.
Page 301 New 1000 Series Caution: It is important that only the tool, shown in (B), is used to fit the new coolant seal. The coolant seal is an interference fit on the shaft and a tool will be necessary to fit the seal correctly.
Page 302 New 1000 Series 4 Support the pulley end of the shaft and press the new impeller (C1) onto the shaft until the clearance (C2) between the impeller blades and the pump body is 0,69/0,89 mm (0.027/0.035 in). For engine type AS the impeller blade clearance is 0,20/0,60 mm (0.008/0.024 in).
Page 303 New 1000 Series To remove and to fit Operation 12-19 To remove Release the setscrews and remove the fan. If necessary, fit the setscrews to retain the fan extension and the pulley to the hub. To fit Clean thoroughly the rear of the fan where it fits onto the fan extension. Also ensure that all paint is removed from this area.
Page 304 New 1000 Series Fan drive (engines with gear driven coolant pumps) To remove and to fit Operation 12-20 To remove 1 Loosen the pivot fasteners of the alternator and the fasteners of the adjustment link. Remove the drive belt(s). 2 Release the setscrews and remove the fan. Remove the fan extension, if fitted, and the pulley.
Page 305 New 1000 Series Lubricating oil cooler To remove (four cylinder turbocharged engines) Operation 12-21 1 Drain the cooling system. 2 Release the support bracket at the cooler (A3). 3 Release the setscrew and nut (A2) which fasten the low-pressure fuel pipes to the top of the cooler.
Page 306 New 1000 Series To fit (four cylinder turbocharged engines) Operation 12-22 1 Renew the "O" rings on the inlet connection for the coolant (A3) and the outlet flange for the coolant (A5). Ensure that the joint faces are clean. Renew the joint (A4) for the oil pipe flange.
Page 307 New 1000 Series To dismantle and to assemble (four cylinder engines) Operation 12-23 To dismantle 1 Remove the oil cooler from the cylinder block, see Operation 12-21. 2 Release the setscrews and remove the cover. 3 Release the self-locking nuts at the back of the oil cooler and remove the cooler element.
Page 308 New 1000 Series To remove (six cylinder turbocharged engines) Operation 12-24 Early lubricating oil coolers fitted to six cylinder engines have an aluminium cover, the cooler element may have a baffle (A3) to control coolant flow. The cooler element must be fitted with the baffle toward the front of the engine (A1).
Page 309 New 1000 Series To remove a later type lubricating oil cooler 1 Drain the cooling system. Warning! The engine oil may be hot, allow the engine temperature to cool down before the oil pipes are released. Caution: Do not remove both of the oil pipes at the same time.
Page 310 New 1000 Series To fit (six cylinder turbocharged engines) Operation 12-25 To fit an early type lubricating oil cooler or blanking plate Special requirements Consumable products Description Part number POWERPART Silicone rubber 1861108 sealant Early lubricating oil coolers fitted to six cylinder engines have an aluminium cover, the cooler element may have a baffle (A3) to control coolant flow.
Page 311 New 1000 Series To fit a later type lubricating oil cooler or blanking plate Later lubricating oil coolers fitted to six cylinder engines have a pressed steel cover. 1 Thoroughly clean the joint faces of the lubricating oil cooler housing and the cylinder block. Thoroughly clean the seating area around the holes for the setscrews on the front face of the lubricating oil cooler.
Page 312 New 1000 Series To dismantle and to assemble (six cylinder engines) Operation 12-26 To dismantle an early type lubricating oil cooler 1 Remove the lubricating oil cooler, see Operation 12-24. 2 Release the nuts on the front of the cover and remove the element of the oil cooler (A).
Page 313 New 1000 Series To dismantle a later type lubricating oil cooler 1 Remove the oil cooler from the cylinder block, see Operation 12-25. 2 Put the oil cooler assembly on a clean work surface. Release the four nuts that retain the flanges for the lubricating oil pipes.
Page 314 New 1000 Series To remove and to fit (canister type) Operation 12-27 To remove 1 Drain the cooling system. 2 Release the hose clips of the coolant pipes at the oil cooler (A3). Release the threaded adaptor (A5) from the lubricating oil cooler and pull the oil cooler (A6) from the hose connections and the filter head (A1).
Page 315 New 1000 Series Intercoolers A water-to-air intercooler assembly is fitted to the induction manifold of some four and six cylinder high-rated engines to cool the air between the turbocharger and the combustion chamber. Hot air from the turbocharger passes through the casing of the intercooler and over the fins on the integral tube stack (A1) or (B1) before it enters the combustion chamber.
Page 316 New 1000 Series Horizontally mounted intercooler To remove Operation 12-29 1 Release the hose clips (A9) which fasten the air hose from the turbocharger to the intercooler. Slide the hose away from the intercooler air inlet pipe. Warning! Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged.
Page 317 New 1000 Series 5 Remove the four setscrews (B2); six cylinder engines have six setscrews, that secure the tubestack to the induction manifold. 6 Carefully lift the tubestack from the induction manifold, Do not use force. It may be necessary to push the inlet and outlet connections from the outside of the manifold to fully release the tubestack.
Page 318 New 1000 Series To fit Operation 12-30 Special requirements Consumable products Description Part number Description Part number POWERPART Silicone rubber POWERPART Threadlock and 1861108 21820117 sealant nutlock Adhesive sealing strips are fitted to the intercooler top cover and the induction manifold to seal the external surfaces of the tubestack.
Page 319 New 1000 Series 3 Fit the setscrews which retain the tubestack to the induction manifold and tighten them gradually and evenly to 22 Nm (16 lb ft) 2,2 kgf m. 4 Renew the joint between the flange face of the intercooler top cover and induction manifold. The joint is fitted without sealant.
Page 320 New 1000 Series Vertically mounted intercooler To remove Operation 12-31 1 Release the hose clips (A7) which fasten the air hose from the turbocharger to the intercooler. Slide the hose away from the intercooler air inlet pipe. Warning! Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged.
Page 321 New 1000 Series To fit Operation 12-32 Special requirements Consumable products Description Part number Description Part number POWERPART Silicone rubber POWERPART Threadlock and 1861108 21820117 sealant nutlock Adhesive sealing strips are fitted to the top cover and the induction manifold to seal the external surfaces of the tubestack.
Page 322 New 1000 Series 3 Fit the setscrews which retain the tubestack to the induction manifold and tighten them gradually and evenly to 22 Nm (16 lb ft) 2,2 kgf m. 4 Renew the joint between the flange face of the intercooler top cover and induction manifold. The joint is fitted without sealant.
Page 323 New 1000 Series To clean and to inspect Operation 12-33 To clean 1 Thoroughly clean the flange face of the intercooler top cover and the induction manifold with an approved detergent solution. Warning! Do not allow compressed air to contact your skin, if compressed air enters your skin obtain medical help immediately.
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Page 325: Flywheel And Housing
New 1000 Series Flywheel and housing General description The steel flywheel is fitted with a hardened starter ring. Generally the starter rings have 126 or 115 teeth. The flywheel housing is normally made of cast iron, but certain flywheel housings are made of aluminium alloy.
Page 326 New 1000 Series Ring gear To remove and to fit Operation 13-2 To remove Warning! Wear eye protection during this operation. Before the ring gear is removed, check the position of the chamfer on the teeth.To remove the ring gear use a hammer and a chisel to break the ring.
Page 327 New 1000 Series Flywheel housing To remove and to fit Operation 13-3 Warning! The flywheel housing is heavy, use lift equipment or get help to assist with the lift operation before removal of the flywheel housing fasteners. To remove 1 Remove the starter, see Operation 14-7, and the flywheel, see Operation 13-1.
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Page 329: Electrical Equipment
New 1000 Series Electrical equipment Alternators General description The alternator is driven from the crankshaft pulley by single or double belt(s). The Lucas/Delphi AC5RS, Magneti Marelli A127 and the Bosch KI 12 volt and NI 24 volt alternators have solid state regulators fitted at the rear.
Page 330 New 1000 Series To check the drive belts Operation 14-1 1 Check the belt(s) for wear and damage and renew the belt(s), if necessary. If twin belts are fitted, they should both be renewed. 2 Check the belt tension. If twin belts are fitted, check/adjust the tension on the tighter belt. To ensure maximum belt life, it is recommended that a belt tension gauge is used.
Page 331 New 1000 Series To adjust drive belt tension Operation 14-2 1 Loosen the pivot fasteners (A1) of the alternator and the fasteners of the adjustment link (A2). 2 Change the position of the alternator to give the correct tension. Tighten the adjustment link fasteners, refer to the Data and dimensions for "Special torques for setscrews and nuts"...
Page 332 New 1000 Series To remove and to fit the drive belts Operation 14-3 Where twin belts are fitted, they are supplied as a set and must be renewed as a set. 1 Loosen the pivot fasteners (A1) of the alternator and the adjustment link fasteners (A2).
Page 333 New 1000 Series To remove and to fit the alternator Operation 14-4 To remove 1 Disconnect the electrical connection. 2 Loosen the pivot fasteners of the alternator and the fasteners of the adjustment link. 3 Release all the belt tension and remove the belt(s).
Page 334 New 1000 Series Fault diagnosis Operation 14-6 The alternator is designed in such a way that a flow of current (indicated by no light at the warning light or a reading shown on an ammeter) shows that the system is in correct operation. If the system is in correct operation, no open circuit, voltage or current output checks need to be done on the installation unless: l The warning light does not show when the alternator is stationary and the switch is in the "ON"...
Page 335 New 1000 Series If the warning light continues to show and the ammeter shows no output when the alternator is in operation: Check all the connections at the regulator, alternator and battery. If no fault: Turn the switch to the "OFF" position. Disconnect the wire from the "F" terminal on the alternator and connect a wire between the "F"...
Page 336 New 1000 Series Starter motors General description The Magneti Marelli M127 starter motor is operated by a solenoid and has a six roller clutch. The solenoid engages the starter drive in two operations to ensure that the motor gets its maximum torque only when the starter motor is engaged fully with the flywheel.
Page 337 New 1000 Series To remove and to fit Operation 14-7 Special requirements Consumable products Description Part number POWERPART Silicone rubber 1861108 sealant Warning! Always disconnect the battery terminals before the removal of any component of the electrical system. To remove If the engine has a flywheel housing which is oil filled, drain the flywheel housing before the starter motor is removed.
Page 338 New 1000 Series To maintain the brush gear and the commutator Operation 14-8 S115 starter motors Inspect the brushes at intervals to ensure that they are free in their guides and that the wire connections are free to move. To check this, lift the spring from the brush and pull carefully on the flexible connections. If the brush does not move freely, remove it from its holder and clean the sides with a material which is damp with gasolene.
Page 339 0°C (32° F) or less and uses fuel with a cetane number of 40 or less, the engine could be difficult to start and produce white smoke and misfire after the initial start. Perkins recommends that fuel with a minimum cetane number of 45 is used.
Page 340 New 1000 Series Starting aids General description There are two types of electrical starting aid in use: The fuelled starting aid and the port heater. The fuelled starting aid (B1) is a device which is operated electrically and ignites a controlled amount of diesel fuel in the induction manifold to heat the induction air.
Page 341 New 1000 Series To remove and to fit a twin-fuelled starting aid Operation 14-12 Some engines which have water-to-air intercoolers are fitted with twin fuelled starting aids (A3). These starting aids are in a recess on top of the induction manifold. In this situation, access to the electrical terminals (A2) can be restricted if the starting aids are not fitted correctly.
Page 342 New 1000 Series To check the fuelled starting aid Operation 14-13 If the inside of the induction manifold is wet, check that there is not a fuel leak from the fuelled starting aid. 1 Disconnect the fuel pipe and the electrical connection at the starting aid. Remove the starting aid from the manifold and fit a suitable plug in the manifold.
Page 343: Auxiliary Equipment
New 1000 Series Auxiliary equipment Compressors General description The engines can be fitted with either a Bendix or a Knorr-Bremse compressor. The compressor is fitted on the left side of the engine directly onto the rear face of the timing case. The compressor is driven from the main idler gear through an idler gear for the compressor.
Page 344 New 1000 Series Bendix Compressor To remove Operation 15-1 1 Drain the engine cooling system. 2 Release the air pressure in the air system. Disconnect the air pipes and the coolant pipes (A1) to and from the cylinder head of the compressor.
Page 345 New 1000 Series To fit Operation 15-2 1 Set the piston of number 1 cylinder to TDC, see Operation 8-1 or Operation 8-2. 2 Fit a new "O" ring (A5) in its recess in the drive housing. Lubricate the "O" ring with clean engine lubricating oil.
Page 346 New 1000 Series Caution: If the support bracket is mounted on the oil filter head, check that the nuts for the filter head are tightened correctly before the compressor support bracket is fitted. 8 Put the support bracket (E4) in position between the cylinder block or the filter head and the compressor.
Page 347 New 1000 Series Knorr-Bremse compressor To remove Operation 15-3 Note: Illustration (A) shows a compressor with a top unloader valve, and DIN drive. Illustration (B) shows a compressor that has a line unloader valve (line unloader valve not illustrated) and SAE drive.
Page 348 New 1000 Series To fit Operation 15-4 1 Set the piston of number 1 cylinder to TDC, see Operation 8-1 or Operation 8-2. 2 Fit a new "O" ring (A5) in its recess in the drive housing. Lubricate the "O" ring with clean engine lubricating oil.
Page 349 New 1000 Series 7 If the alignment is not correct, pull the compressor out of engagement and move the crankshaft of the compressor in the relevant direction to mesh with the next gear tooth. Carefully push the compressor assembly into position. Check that the mark on the rear of the crankshaft is in the correct position. Fit the nuts to the stud (E4) which passes through the timing case and to the stud (E3) at the bottom of the flange.
Page 350 New 1000 Series To remove the reed valves Operation 15-5 Note: To renew compressor cylinder head related components it may not be necessary to remove the compressor from the engine. 1 Drain the engine cooling system. 2 Release the air pressure in the air system.
Page 351 New 1000 Series To fit the reed valves Operation 15-6 1 Ensure all contact surfaces are clean. 2 Fit and align the new delivery reed (A5) to the delivery reed plate (A4), and secure with the delivery bridge (A6), setscrews (A3) and nuts (A7) tighten to 8,25 Nm (6.08 lbf ft) 8,41 kgf m.
Page 352 New 1000 Series To remove the top unloader valve Operation 15-7 1 Release the air pressure in the air system. Warnings! l Never apply compressed air to any part of the body or clothing, severe injury can occur. l Wear safety goggles/mask, and use correct shielding to protect others.
Page 353 New 1000 Series To fit the top unloader valve Operation 15-8 Note: Ensure all components are clean. 1 Fit a new ‘O’ ring (A4) to the balance piston (A6). 2 Fit a new ‘O’ ring (A5) to the balance piston (A6).
Page 354 New 1000 Series To remove the crankshaft / connecting rod / piston / piston rings Operation 15-9 1 Remove the compressor from the engine, see Operation 15-3. 2 Remove the compressor drive gear and drive key. 3 Remove the cylinder head, the cylinder head gasket, delivery reed plate, and the inlet reed.
Page 355 New 1000 Series To fit the crankshaft / connecting rod / piston / piston rings Operation 15-10 1 Fit a new crankshaft (A5) into the compressor through the rear opening. 2 Ensure all components are clean. Fit a new ‘O’ ring (A6) in its recess in the end plate (A7). Lubricate the ‘O’...
Page 356 New 1000 Series 7 Fit the connecting rod to the crankpin. 8 Lubricate the bearing cap (B12) with clean engine lubricating oil and fit and hold the bearing cap in position to the connecting rod. 9 Fit the two bearing cap retaining setscrews (B13) by hand. If they do not fit freely by hand, fit new setscrews.
Page 357 New 1000 Series Power steering pump To remove and to fit Operation 15-11 To remove 1 Disconnect the pipe connections at the power steering pump and fit covers to the open ends of the pipes. 2 Release the setscrews and remove the pump. If the pump is fitted to the rear of the compressor, ensure that the drive coupling is not lost.
Page 358 New 1000 Series Adaptor for a hydraulic pump or a steering pump with a splined drive To remove and to fit Operation 15-12 To remove 1 Release the cap screws and remove the adaptor assembly from the rear of the timing case.
Page 359 New 1000 Series To dismantle Operation 15-13 1 Remove the hydraulic pump or steering pump. 2 Remove the adaptor assembly, see Operation 15-12. 3 Remove the circlip (A4). Provide a support for the flange face of the housing (A5). Use a suitable adaptor on the front bearing (A7) to press the gear and bearings out of the housing.
Page 360 New 1000 Series To assemble Operation 15-14 Special requirements Consumable products Description Part number POWERPART Retainer (oil tolerant) 21820603 1 Apply a narrow ring of POWERPART Retainer (oil tolerant) to the outer face of the front bearing (A7) in the position shown (A1).
Page 361 New 1000 Series Exhauster To remove and to fit Operation 15-15 To remove 1 Disconnect the lubricating oil and vacuum pipes from the exhauster and fit covers to the open ends of the pipes. 2 Release the setscrews and remove the exhauster.
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Page 363: Special Tools
New 1000 Series Special tools These tools are available through your local Perkins Distributor. If you cannot obtain the correct tool locally contact: The Perkins Service Department, Peterborough, PE1 5NA, England, UK. Tel 01733 583000, Fax 01733 582240, Telex 32501 PERKEN G.
Page 364 New 1000 Series List of special tools Part number Description Illustration Remover / replacer for valve guides (main tool). 21825478 Reference number PD.1D. Adaptor for use with 21825478. 27610019 Reference number PD.1D-13. Inlet valve guide adaptor for use with 21825478.
Page 365 New 1000 Series Part number Description Illustration Replacer tool for crankshaft rear seal. 21825540 Reference number PD.145D. Remover / replacer for cylinder liner (main tool). 21825543 Reference number PD.150B. Adaptors for use with 21825543. 21825563 Reference number PD.150B-17A. Basic puller for camshaft gear.
Page 366 New 1000 Series Part number Description Illustration Centralising tool for timing case cover 21825574 (Six cylinder engines). Reference number PD.163A. Crankshaft rotation adaptor for use with a 21825576 12,7 mm (0.5 in) square drive. Reference number PD.165B. Replacer tool for seal of timing case cover (main tool).
Page 367 New 1000 Series Part number Description Illustration Adaptor for water immersion seal for use with 21825577. 21825583 Reference number PD.170-8. Spanner for flange nuts of the Bosch fuel injection pump. 21825964 Reference number PD.239. Replacer tool for pistons. 21825615 Reference number PD.206.
Page 368 New 1000 Series Part number Description Illustration Setscrew adaptor for use with 21825666. 21825932 Reference number PD.6118-8. Angle gauge to tighten cylinder head setscrews. 21825607 Reference number PD.198. (MS.1531). Combined reamer/cutters and handle for 27610030 valve guides and 31°/ 46° valve seat inserts.
Page 369: Fuel Pump Gear
New 1000 Series Part number Description Illustration Torx drive socket (fuel pump gear models AP, AQ and 27610122 Workshop Manual, TPD 1350E, Issue 4 This document has been printed from SPI². Not for Resale...
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Perkins New 1000 Series Workshop Manual

1 General Information

Introduction

Engine Views

Engine Identification

Safety Precautions

Viton Seals

Engine Lift Equipment

POWERPART Recommended Consumable Products

2 Specifications

Basic Engine Data

Data and Dimensions

Thread Sealant

Standard Torque Tensions

Specific Torque Tensions

Compression Test Data

3 Cylinder Head Assembly

General Description

Rocker Cover

Rocker Assembly

Valve Tip Clearances

Valve Springs

Manifolds

Cylinder Head Assembly

Valves and Valve Springs

Valve Guides

4 Piston and Connecting Rod Assemblies

General Description

Big End Bearing

Piston and Connecting Rod

Piston Rings

Piston and Connecting Rod Assembly

Piston and Piston Rings

Connecting Rod

Partially Finished Small End Bush

Piston Cooling Jets

5 Crankshaft Assembly

General Description

Crankshaft Pulley

Crankshaft Pulley and Damper

Rear Oil Seal Assembly

Thrust Washers

Main Bearings

Crankshaft

Balancer Unit

6 Timing Case and Drive Assembly

General Description

Timing Case Cover

Front Oil Seal

Idler Gear and Hub

Idler Gear and Hub for the Compressor

Fuel Pump Gear

Camshaft Gear

Crankshaft Gear

Timing Case

Camshaft and Tappets

7 Cylinder Block Assembly

General Description

Cylinder Block

Cylinder Liner

Cylinder Bore, Engine Types AR and as

8 Engine Timing

General Description

9 Aspiration System

General Description

Turbocharger

Turbocharger Faults

List of Possible Causes

Open Engine Breather

Closed Engine Breather

10 Lubrication System

General Description - Four Cylinder Engine Lubrication System

General Description - Six Cylinder Engine Lubrication System

Filter Canister

Filter Head

Sump

Oil Strainer and Suction Pipe

Lubricating Oil Pump

Lubricating Oil Pump Idler Gear Shaft

Relief Valve