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Perkins Phaser and 1000 Series
WORKSHOP MANUAL
Phaser
1000 Series
Publication TPD 1312E, Issue 1.
(c) Perkins Group Limited 1995, all rights reserved.
Published 1 April 1995 by Technical Publications,
Perkins International Limited, Peterborough PE1 5NA, England
Perkins Phaser/1000 Series, April 1995
4 and 6 cylinder diesel engines for
automotive applications
4 and 6 cylinder diesel engines for
agricultural and industrial application
Contents
Contents
EXIT
EXIT
Contents
Contents
EXIT
EXIT
00.01
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Chapters
Table of Contents
Related Manuals for Perkins Phaser Series
Summarization of Contents
General information
Introduction
This workshop manual provides assistance in the service and overhaul of Perkins Phaser and 1000 Series engines.
Engine views
Provides visual representations of engine components and their arrangement for identification.
Engine identification
Explains the system for identifying Phaser and 1000 Series engines using code letters and numbers.
Safety precautions
Lists essential safety precautions for operating and servicing the engines.
Powerpart consumable products
Lists and describes Perkins Powerpart products recommended for engine maintenance.
Safety
Engine lift equipment
Details on recommended lift equipment capacity and procedures for safely lifting engines.
Asbestos joints
Precautions and procedures for handling engine joints containing asbestos.
Viton seals
Safety precautions regarding Viton seals, particularly if burned.
Specifications
Basic engine data
Provides fundamental technical data and specifications for the engines.
Recommended torque tensions
Lists recommended torque values for various engine components and fasteners.
CYLINDER HEAD ASSEMBLY 12
General description
Provides an overview of the cylinder head assembly and its function.
Rocker cover
Instructions for removing and fitting the rocker cover.
Rocker assembly
Procedures for removing, fitting, dismantling, and assembling the rocker assembly.
Valve tip clearances
Method for checking and adjusting valve tip clearances.
Valve springs
Instructions for changing valve springs with the cylinder head fitted.
Valves and valve springs
Procedures for removing, fitting, inspecting, and correcting valves and valve springs.
Valve guides
Instructions for inspecting valve guides for wear.
Cylinder head
Procedures for inspecting and correcting the cylinder head.
Data and dimensions
Provides detailed dimensions and data for cylinder head components.
PISTON AND CONNECTING ROD ASSEMBLIES 13
General description
Overview of pistons and connecting rods used in Phaser and 1000 Series engines.
Big end bearing
Instructions for removing, fitting, and inspecting big end bearings.
Piston and connecting rod assembly
Procedures for removing, fitting, dismantling, and assembling piston and connecting rod assemblies.
Piston rings
Instructions for removing, fitting, and inspecting piston rings.
Connecting rod
Procedures for inspecting connecting rods for distortion and wear.
Piston cooling jets
Instructions for removing, fitting, and checking the alignment of piston cooling jets.
Data and dimensions
Provides detailed dimensions and data for pistons and connecting rods.
CRANKSHAFT ASSEMBLY 14
General description
Describes the construction and function of the crankshaft and its components.
Crankshaft pulley
Instructions for removing and fitting the crankshaft pulley on four-cylinder engines.
Crankshaft pulley and damper
Procedures for removing and fitting the crankshaft pulley and damper on six-cylinder engines.
Rear oil seal assembly - engines which have the standard seal
Instructions for removing and fitting the rear oil seal assembly with a standard seal.
Rear oil seal assembly - engines which have a flywheel housing that is oil filled
Procedures for removing and fitting the rear oil seal assembly for engines with an oil-filled flywheel housing.
Thrust washers
Method for checking crankshaft end-float and fitting thrust washers.
Main bearings
Instructions for removing, fitting, and inspecting main bearings.
Crankshaft
Procedures for removing and fitting the crankshaft.
Balancer unit
Instructions for removing, fitting, dismantling, assembling, and inspecting the balancer unit.
Data and dimensions
Provides specifications and dimensions for crankshaft components.
TIMING CASE AND DRIVE ASSEMBLY 15
General description
Describes the construction and function of the timing case and drive components.
Timing case cover
Instructions for removing and fitting the timing case cover.
Front oil seal
Procedures for removing and fitting the front oil seal.
Idler gear and hub
Instructions for removing, fitting, and inspecting the idler gear and hub.
Compressor idler gear (Bendix)
Procedures for removing and fitting the compressor idler gear for Bendix compressors.
Fuel pump gear
Instructions for removing and fitting the fuel pump gear.
Camshaft gear
Procedures for removing and fitting the camshaft gear.
Crankshaft gear
Instructions for removing and fitting the crankshaft gear.
Timing case
Procedures for removing and fitting the timing case.
Camshaft and tappets
Instructions for removing and fitting the camshaft and tappets.
Data and dimensions
Provides specifications and dimensions for timing case and drive assembly components.
CYLINDER BLOCK ASSEMBLY 16
General description
Describes the construction and function of the cylinder block.
Cylinder block
Procedures for dismantling and assembling the cylinder block.
Cylinder liner
Instructions for inspecting cylinder liners for wear and damage.
Data and dimensions
Provides specifications and dimensions for cylinder block components.
Engine timing 17
Bosch EPVE fuel injection pumps
Details on setting and checking engine timing for Bosch EPVE pumps.
Bosch MW in-line fuel injection pumps
Information regarding engine timing for Bosch MW in-line fuel injection pumps.
Lucas DPA and DPS fuel injection pumps
Procedures for setting and checking engine timing for Lucas DPA/DPS pumps.
Lucas DP200 Series fuel injection pump
Details on engine timing for Lucas DP200 Series fuel injection pumps.
Stanadyne fuel injection pump
Information on setting and checking engine timing for Stanadyne fuel injection pumps.
ASPIRATION SYSTEM 18
General description
Explains the function and operation of the turbocharger system.
Turbocharger
Instructions for removing and fitting the turbocharger.
Engine breather systems
Procedures for cleaning and maintaining open and closed engine breather systems.
Data and dimensions
Provides specifications and dimensions for turbocharger components and waste-gate pressure.
LUBRICATION SYSTEM 19
General description
Overview of the engine lubrication system, including oil flow and components.
Filter canister
Instructions for renewing the fuel filter canister.
Filter head
Procedures for removing and fitting the fuel filter head.
Sump
Instructions for removing and fitting the engine oil sump.
Oil strainer and suction pipe
Procedures for removing, fitting, inspecting, and correcting the oil strainer and suction pipe.
Lubricating oil pump
Instructions for removing, fitting, and inspecting the lubricating oil pump.
Relief valve
Procedures for removing, fitting, dismantling, assembling, and inspecting the relief valve.
Flexible oil pipes
Instructions for removing, fitting, and inspecting flexible oil pipes.
Data and dimensions
Provides specifications and dimensions for lubrication system components.
Fuel system 20
Bosch EPVE fuel injection pumps
Details on general description, fuel filter, atomisers, fuel lift pump, and fuel injection pump for Bosch EPVE.
Bosch MW in-line fuel injection pump
Information on general description, fuel filter, fuel lift pump, and fuel injection pump for Bosch MW.
Lucas DPA and DPS fuel injection pumps
Details on general description, fuel filter, atomisers, fuel lift pump, and fuel injection pump for Lucas DPA/DPS.
Lucas DP200 Series fuel injection pump
Information on general description, fuel filter, fuel lift pump, and fuel injection pump for Lucas DP200 Series.
Stanadyne fuel injection pump
Details on general description, fuel filter, atomisers, fuel lift pump, and fuel injection pump for Stanadyne.
COOLING SYSTEM 21
General description
Explains the engine cooling system operation and component flow.
Thermostats
Instructions for removing, fitting, testing, and data for thermostats.
Coolant pump
Procedures for removing, fitting, dismantling, and assembling coolant pumps (gear, belt, auxiliary).
Fan
Instructions for removing and fitting the fan.
Fan drive
Procedures for removing, fitting, checking, and adjusting fan drive belts.
Lubricating oil cooler
Instructions for removing, fitting, dismantling, and assembling lubricating oil coolers.
Cooler by-pass valve
Procedures for removing, fitting, and checking the cooler by-pass valve.
Intercooler
Instructions for removing, fitting, cleaning, and inspecting the intercooler.
Data and dimensions
Provides specifications and dimensions for cooling system components.
FLYWHEEL AND FLYWHEEL HOUSING 22
General description
Describes the construction and function of the flywheel, starter ring, and flywheel housing.
Flywheel
Instructions for removing, fitting, checking flywheel run-out, and alignment.
Ring gear
Procedures for removing and fitting the flywheel ring gear.
Flywheel housing
Instructions for removing, fitting, checking concentricity, and alignment of the flywheel housing.
Data and dimensions
Provides limits for flywheel housing run-out and alignment.
ELECTRICAL EQUIPMENT 23
Alternators
General description, precautions, drive belt procedures, and alternator fault diagnosis.
Starter motors
General description, removal/fitting, maintenance, and testing procedures for starter motors.
Starting aid
Information on fuelled starting aids and port heaters, including removal, fitting, and checks.
AUXILIARY EQUIPMENT 24
Compressors
General description, procedures for Wabco and Bendix compressors, and their drive assemblies.
Power steering pump
Instructions for removing, fitting, dismantling, and assembling the power steering pump.
Exhauster
Procedures for removing and fitting the exhauster.
LIST OF SPECIAL TOOLS 25
List of special tools
Lists special tools required for engine service with descriptions and part numbers.
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