Perkins New 1000 Series Manuals

Perkins New 1000 Series Manuals

Manuals and User Guides for Perkins New 1000 Series. We have 2 Perkins New 1000 Series manuals available for free PDF download: Workshop Manual

Perkins New 1000 Series Workshop Manual

Perkins New 1000 Series Workshop Manual (370 pages)

4 and 6 cylinder diesel engines for industrial and agricultural applications

Brand: Perkins | Category: Engine | Size: 18 MB

Table of Contents

Table of Contents
3
Special Tools
13
1 General Information

15
Introduction

15
Engine Views

16
Engine Identification

17
Safety Precautions

19
Viton Seals

20
Engine Lift Equipment

21
POWERPART Recommended Consumable Products

22
2 Specifications

25
Basic Engine Data

25
Data and Dimensions

26
Thread Sealant

49
Standard Torque Tensions

50
Specific Torque Tensions

51
Compression Test Data

54
3 Cylinder Head Assembly

55
General Description

55
Rocker Cover

56
- Operation 3-1 to Remove
  56
- Operation 3-2 to Fit
  57
Rocker Assembly

58
Valve Tip Clearances

60
- Operation 3-6 to Check and to Adjust (Four Cylinder Engines)
  60
- Operation 3-7 to Check and to Adjust (Six Cylinder Engines)
  61
Valve Springs

62
- Operation 3-8 to Change the Valve Springs (with Cylinder Head Fitted)
  62
Manifolds

64
Cylinder Head Assembly

70
Valves and Valve Springs

78
Valve Guides

81
4 Piston and Connecting Rod Assemblies

89
General Description

89
Big End Bearing

91
- Operation 4-1 to Remove
  91
- Operation 4-2 to Fit
  92
- Operation 4-3 to Inspect
  92
Piston and Connecting Rod

93
Piston Rings

97
- Operation 4-7 to Remove
  97
- Operation 4-8 to Fit
  98
Piston and Connecting Rod Assembly

99
Piston and Piston Rings

102
- Operation 4-12 to Inspect
  102
Connecting Rod

103
- Operation 4-13 to Inspect
  103
Partially Finished Small End Bush

104
- Operation 4-14 to Remove and to Fit
  104
Piston Cooling Jets

105
- Operation 4-15 to Remove and to Fit
  105
- Operation 4-16 to Check the Jet Alignment
  106
5 Crankshaft Assembly

107
General Description

107
Crankshaft Pulley

109
Crankshaft Pulley and Damper

110
- Operation 5-3 to Fit (Six Cylinder Engines)
  111
- Operation 5-4 to Inspect
  112
Rear Oil Seal Assembly

113
Thrust Washers

119
- Operation 5-9 to Check Crankshaft End-Float
  119
- Operation 5-10 to Remove
  120
- Operation 5-11 to Fit
  121
Main Bearings

122
Crankshaft

124
- Operation 5-15 to Remove
  124
- Operation 5-16 to Fit
  125
- Operation 5-17 to Inspect
  127
Balancer Unit

128
6 Timing Case and Drive Assembly

137
General Description

137
Timing Case Cover

138
- Operation 6-2 to Fit
  139
Front Oil Seal

141
- Operation 6-4 to Fit
  142
Idler Gear and Hub

145
- Operation 6-6 to Remove
  145
- Operation 6-7 to Fit
  147
Idler Gear and Hub for the Compressor

149
- Operation 6-9 to Fit
  150
Fuel Pump Gear

151
- Operation 6-10 to Remove
  151
- Operation 6-11 to Fit
  153
Camshaft Gear

155
- Operation 6-12 to Remove and to Fit
  155
Crankshaft Gear

156
- Operation 6-13 to Remove and to Fit
  156
Timing Case

157
- Operation 6-14 to Remove
  157
- Operation 6-15 to Fit
  158
Camshaft and Tappets

160
- Operation 6-16 to Remove
  160
- Operation 6-17 to Fit
  161
7 Cylinder Block Assembly

163
General Description

163
Cylinder Block

164
Cylinder Liner

169
Cylinder Bore, Engine Types AR and as

178
8 Engine Timing

179
General Description

179
9 Aspiration System

185
General Description

185
Turbocharger

187
Turbocharger Faults

193
List of Possible Causes

194
Open Engine Breather

195
- Operation 9-6 to Clean and to Renew
  195
- Operation 9-7 to Inspect
  197
Closed Engine Breather

198
- Operation 9-8 to Renew the Breather Valve Assembly
  199
10 Lubrication System

201
General Description - Four Cylinder Engine Lubrication System

201
General Description - Six Cylinder Engine Lubrication System

202
Filter Canister

205
Filter Head

206
- Operation 10-2 to Remove and to Fit
  206
Sump

207
- Operation 10-3 to Remove and to Fit
  207
Oil Strainer and Suction Pipe

208
- Operation 10-4 to Remove and to Fit
  208
- Operation 10-5 to Inspect and to Correct
  209
Lubricating Oil Pump

210
- Operation 10-6 to Remove
  210
- Operation 10-7 to Fit
  211
- Operation 10-8 to Inspect
  212
Lubricating Oil Pump Idler Gear Shaft

213
Relief Valve

217
Flexible Oil Pipes

219
- Operation 10-15 to Remove
  219
- Operation 10-16 to Fit
  220
- Operation 10-17 to Inspect
  221
11 Fuel System

223
General Description

223
Cold Start Advance Unit

226
Typical Fuel System

229
Fuel Filters

230
Fuel Filter Element

231
Atomisers

234
- Operation 11-4 to Remove
  235
- Operation 11-5 to Fit
  236
Fuel Lift Pump

238
- Operation 11-6 to Remove and to Fit
  238
- Operation 11-7 to Dismantle
  239
- Operation 11-8 to Assemble
  240
- Operation 11-9 to Test
  241
Bosch Fuel Injection Pump

242
- Operation 11-10 to Remove
  244
- Operation 11-11 to Fit
  246
- Operation 11-12 to Adjust
  248
Lucas/Delphi DP 200 Series Fuel Injection Pump

249
- Operation 11-13 to Remove
  251
- Operation 11-14 to Fit
  253
- Operation 11-15 to Adjust
  256
- Operation 11-16 Electrical Shut off Solenoid (ESOS)
  257
Stanadyne Fuel Injection Pump

259
- Operation 11-17 to Remove
  262
- Operation 11-18 to Fit
  263
- Operation 11-19 to Adjust
  265
Air in the Fuel System

268
- Operation 11-20 to Eliminate Air from the Fuel System
  268
12 Cooling System

271
General Description

271
Thermostats Operation 12-1 to Remove

272
- Operation 12-2 to Fit
  273
- Operation 12-3 to Test
  274
Coolant Pump - Early Gear Driven Pumps

275
Coolant Pump - Latest Gear Driven Pumps

282
- Operation 12-9 to Remove
  282
- Operation 12-10 to Fit
  283
- Operation 12-11 to Dismantle
  284
- Operation 12-12 to Assemble
  287
  - Flywheel and Housing
    325
  - Electrical Equipment
    329
  - Auxiliary Equipment
    343
  - Special Tools
    363
  - Fuel Pump Gear
    369

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Perkins New 1000 Series Workshop Manual

Perkins New 1000 Series Workshop Manual (290 pages)

Models AJ to AS and YG to YK

Brand: Perkins | Category: Engine | Size: 77 MB

Table of Contents

Table of Contents
3
General Information
15
Introduction

15
Engine Identification

17
General Safety Precautions

18
- Specifications
  18
Engine Lift Equipment

19
Viton Seals

20
20 Fuel System

21
Cooling System

21
- Specifications
  23
POWERPART Recommended Consumable Products

21
Basic Engine Data

23
Thread Sealant

24
Standard Torque Tensions

25
Specific Torque Tensions

26
- Cylinder Head Assembly
  26
- Timing Case and Drive Assembly
  27
- Flywheel and Housing
  28
Compression Test Data

29
- Cylinder Head Assembly
  31
General Description

31
Rocker Cover

32
- To Remove and to Fit
  32
Rocker Assembly

33
- To Remove and to Fit
  33
- To Dismantle and to Assemble
  34
- To Inspect and to Correct
  34
Valve Tip Clearances

35
- To Check and to Adjust
  35
Valve Springs

37
- To Change the Valve Springs (with Cylinder Head Fitted)
  37
- Special Tools
  37
Cylinder Head Assembly

39
- To Remove and to Fit
  39
Valves and Valve Springs

49
- To Remove and to Fit
  49
- To Inspect and to Correct
  50
Valve Guides

51
- To Inspect
  51
- 12-11To Remove and to Fit
  52
Cylinder Head

54
Data and Dimensions

57
- Piston and Connecting Rod Assemblies
  63
General Description

63
Big End Bearing

65
- To Remove and to Fit
  65
- To Inspect
  66
Piston and Connecting Rod

67
- To Remove and to Fit
  67
- To Check the Piston Height above the Cylinder Block
  70
Piston Rings

71
- To Remove and to Fit
  71
Piston and Connecting Rod Assembly

72
- To Dismantle and to Assemble
  72
- To Check the Length of a Connecting Rod
  73
Piston and Piston Rings

74
- To Inspect
  74
Connecting Rod

75
- To Inspect
  75
Partially Finished Small End Bush

75
- To Remove and to Fit
  75
Piston Cooling Jets

76
- To Remove and to Fit
  76
- To Check the Jet Alignment
  76
Data and Dimensions

77
- Crankshaft Assembly
  79
General Description

79
Crankshaft Pulley

80
- To Remove and to Fit - Four Cylinder Engines
  80
Crankshaft Pulley and Damper

81
- To Remove and to Fit - Six Cylinder Engines
  81
- To Inspect
  83
Rear Oil Seal Assembly

84
- To Remove and to Fit
  84
- To Renew the Rear Oil Seal
  85
Thrust Washers

86
- To Check Crankshaft End-Float
  86
- To Remove and to Fit
  87
Main Bearings

89
- To Remove and to Fit (with the Crankshaft in Position)
  89
- To Inspect
  90
Crankshaft

91
- To Remove and to Fit
  91
- To Inspect
  94
Balancer Unit

95
Data and Dimensions

104
- Timing Case and Drive Assembly
  109
General Description

109
Coolant Pump - Early Gear Driven Pumps

110
Timing Case Cover

110
- To Remove and to Fit
  110
Coolant Pump - Belt Driven

111
Front Oil Seal

111
- To Remove and to Fit
  111
- To Fit Wear Sleeve
  112
Coolant Pump - Belt Driven High Position

113
Idler Gear and Hub

113
- To Remove and to Fit
  113
Idler Gear and Hub for the Bendix Compressor

116
- To Remove and to Fit
  116
Fuel Pump Gear

118
- To Remove and to Fit
  118
Camshaft Gear

120
- To Remove and to Fit
  120
Crankshaft Gear

121
- To Remove and to Fit
  121
Timing Case

122
- To Remove and to Fit
  122
Camshaft and Tappets

124
- To Remove and to Fit
  124
Data and Dimensions

125
- Cylinder Block Assembly
  127
Coolant Pump - Early Gear Driven Pumps

128
- To Dismantle and to Assemble
  128
- To Inspect
  129
Cylinder Liner

130
Lubricating Oil Cooler

131
- To Remove and to Fit
  131
- Data and Dimensions
  137
- Engine Timing
  141
Engine Timing

144
- Aspiration System
  147
  - To Clean the Impeller and the Compressor Casing
    151
  - To Check and Adjust the Operation of the Waste-Gate
    153
Turbocharger Faults

154
Engine Breather

156
- To Clean and to Renew
  157
- Data and Dimensions
  158
- Lubrication System
  159
Fan Drive (Engines with Gear Driven Coolant Pumps)

165
- To Remove and to Fit
  165
- To Inspect and to Correct
  166
- To Renew the Shaft for the Idler Gear
  169
- To Inspect
  173
- To Dismantle and to Assemble
  175
- Data and Dimensions
  178
Lubricating Oil Pump

169
Coolant Pump - Belt Driven

175
- Fuel System
  181
General Description

183
Cold Start Advance Unit

183
Typical Fuel System

186
Fuel Filters

187
Data and Dimensions

191
- To Remove and to Fit
  191
Fuel Lift Pump

193
- To Dismantle and to Assemble
  194
- To Test
  195
Stanadyne Fuel Injection Pump

200
- To Adjust
  200
- To Eliminate Air from the Fuel System
  201
Lucas DP 200 Series Fuel Injection Pump

207
- To Adjust
  207
- To Eliminate Air from the Fuel System Lucas DP200 Pump
  208
Bosch Fuel Injection Pump

214
- To Adjust
  214
- To Eliminate Air from the Fuel System
  215
- Data and Dimensions
  217
General Description

219
Adaptor for a Hydraulic Pump or a Steering Pump with a Splined Drive

240
Cooler By-Pass Valve

250
- To Remove and to Fit
  250
Intercooler

254
- To Clean and to Inspect
  254
  - Data and Dimensions
    255
  - General Description
    257
Flywheel

258
Ring Gear

258
- Data and Dimensions
  260
- General Description
  261
Drive Belts

262
- To Adjust Tension
  262
Alternator

263
- To Maintain
  263
Fault Diagnosis

264
- Data and Dimensions
  266
- General Description
  267
- Starter Motor
  268
Starter Motor

269
- To Maintain the Brush Gear and the Commutator
  269
  - Data and Dimensions
    270
  - General Description
    271
Starting Aid

273
- To Remove and to Fit a Port Heater
  273
Data and Dimensions

274
General Description

275
Data and Dimensions

279
Bendix Compressors

280
Operation

280
- To Remove and to Fit
  280
  - To Dismantle and to Assemble
    281
  - To Remove and to Fit
    283
- 25 Special Tools
  285
List of Special Tools

286

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