Jcb diesel 1000 series engine model yg service repair manual
- 1. Workshop Manual, TPD 1350, issue 3 1 New 1000 Series Perkins New 1000 Series Models AJ to AS and YG to YK WORKSHOP MANUAL 4 and 6 cylinder diesel engines for industrial and agricultural applications Publication TPD 1350E issue 3 © Proprietary information of Perkins Engines Company Limited, all rights reserved. The information is correct at the time of print. Published in March 2000 by Technical Publications.
- 2. 2 Workshop Manual, TPD 1350, issue 3 New 1000 Series Chapters 10 General information 11 Specifications 12 Cylinder head assembly 13 Piston and connecting rod assemblies 14 Crankshaft assembly 15 Timing case and drive assembly 16 Cylinder block assembly 17 Engine timing 18 Aspiration system 19 Lubrication system 20 Fuel system 21 Cooling system 22 Flywheel and housing 23 Electrical equipment 24 Auxiliary equipment 25 Special tools The following pages contain a detailed table of contents. Perkins Approved Clear English This publication is written in
- 3. Workshop Manual, TPD 1350, issue 3 3 New 1000 Series Contents 10 General information Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 15 Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 17 General safety precautions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 18 Engine lift equipment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 19 Viton seals . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 20 POWERPART recommended consumable products . ... ... ... ... ... ... ... ... ... ... ... ... . 21 11 Specifications Basic engine data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 23 Thread sealant ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 24 Standard torque tensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 25 Specific torque tensions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 26 Compression test data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 29
- 4. 4 Workshop Manual, TPD 1350, issue 3 New 1000 Series 12 Cylinder head assembly General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31 Rocker cover 12-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 32 Rocker assembly 12-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33 12-3 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34 12-4 To inspect and to correct ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34 Valve tip clearances 12-5 To check and to adjust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35 Valve springs 12-6 To change the valve springs (with cylinder head fitted) . ... ... ... ... ... ... ... ... ... ... 37 Cylinder head assembly 12-7 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39 Valves and valve springs 12-8 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49 12-9 To inspect and to correct ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50 Valve guides 12-10 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 51 12-11To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 52 Cylinder head 12-12 To inspect and to correct . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 54 12-13 To correct a valve seat with a valve seat cutter ... ... ... ... ... ... ... ... ... ... ... ... ... 55 12-14 To fit valve seat inserts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 56 Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 57
- 5. Workshop Manual, TPD 1350, issue 3 5 New 1000 Series 13 Piston and connecting rod assemblies General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 63 Big end bearing 13-1 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 65 13-2 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 66 Piston and connecting rod 13-3 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 67 13-4 To check the piston height above the cylinder block . ... ... ... ... ... ... ... ... ... ... ... . 70 Piston rings 13-5 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 71 Piston and connecting rod assembly 13-6 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 72 13-7 To check the length of a connecting rod ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 73 Piston and piston rings 13-8 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 74 Connecting rod 13-9 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 75 Partially finished small end bush 13-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 75 Piston cooling jets 13-11 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 76 13-12 To check the jet alignment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 76 Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 77
- 6. 6 Workshop Manual, TPD 1350, issue 3 New 1000 Series 14 Crankshaft assembly General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79 Crankshaft pulley 14-1 To remove and to fit - four cylinder engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 80 Crankshaft pulley and damper 14-2 To remove and to fit - six cylinder engines ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 81 14-3 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 83 Rear oil seal assembly 14-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 84 14-5 To renew the rear oil seal .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 85 Thrust washers 14-6 To check crankshaft end-float ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 86 14-7 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 87 Main bearings 14-8 To remove and to fit (with the crankshaft in position) ... ... ... ... ... ... ... ... ... ... ... 89 14-9 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 90 Crankshaft 14-10 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 91 14-11 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 94 Balancer unit 14-12 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 95 14-13 To dismantle and to assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 96 14-14 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 101 14-15 To remove and to fit the needle roller bearings for the drive shaft .. ... ... ... ... .. 102 14-16 To remove and to fit the bushes for the balance weights ... ... ... ... ... ... ... ... .. 103 Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 104
- 7. Workshop Manual, TPD 1350, issue 3 7 New 1000 Series 15 Timing case and drive assembly General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 109 Timing case cover 15-1 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 110 Front oil seal 15-2 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 111 15-3 To fit wear sleeve .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 112 Idler gear and hub 15-4 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 113 Idler gear and hub for the Bendix compressor 15-5 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 116 Fuel pump gear 15-6 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 118 Camshaft gear 15-7 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 120 Crankshaft gear 15-8 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 121 Timing case 15-9 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 122 Camshaft and tappets 15-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 124 Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 125
- 8. 8 Workshop Manual, TPD 1350, issue 3 New 1000 Series 16 Cylinder block assembly General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 127 Cylinder block 16-1 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 128 16-2 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 129 Cylinder liner 16-3 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 130 16-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 131 Cylinder bore, engine types AR and AS 16-5 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 136 Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 137 17 Engine timing General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 141 Engine timing 17-1 To set number 1 piston to TDC on the compression stroke .. ... ... ... ... ... ... ... .. 143 17-2 Another method to set number 1 piston to TDC on the compression stroke . ... .. 144 17-3 To check the valve timing .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 144 17-4 To check the timing of the fuel injection pump ... ... ... ... ... ... ... ... ... ... ... ... ... .. 145 Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 146 18 Aspiration system General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 147 Turbocharger 18-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 149 18-2 To clean the impeller and the compressor casing . ... ... ... ... ... ... ... ... ... ... ... .. 151 18-3 To remove and to fit the actuator assembly of the waste-gate unit ... ... ... ... ... .. 152 18-4 To check and adjust the operation of the waste-gate ... ... ... ... ... ... ... ... ... ... .. 153 Turbocharger faults ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 154 Engine breather 18-5 To clean and to renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 156 18-6 To clean and to renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 157
- 9. Workshop Manual, TPD 1350, issue 3 9 New 1000 Series Data and dimensions. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 158 19 Lubrication system General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 159 Filter canister 19-1 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 163 Filter head 19-2 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 164 Sump 19-3 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 165 Oil strainer and suction pipe 19-4 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 165 16-5 To inspect and to correct ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 166 Lubricating oil pump 19-6 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 167 19-7 To renew the shaft for the idler gear . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 169 19-8 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 173 Relief valve 19-9 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 174 19-10 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 175 19-11 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 175 Flexible oil pipes 19-12 To remove, to fit and to inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 176 Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 178
- 10. 10 Workshop Manual, TPD 1350, issue 3 New 1000 Series Fuel system General description. .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 181 Cold start advance unit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 183 Typical fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 186 Fuel filters .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 187 Fuel filter element 20-1 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 188 Atomisers 20-2 Atomiser fault . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 191 20-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 191 Fuel lift pump 20-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 193 20-5 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 194 20-6 To test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 195 Bosch fuel injection pump 20-7 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 196 20-8 To adjust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 200 20-9 To eliminate air from the fuel system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 201 Lucas DP 200 Series fuel injection pump 20-10 To remove to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 203 20-11 To adjust .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 207 20-12 To eliminate air from the fuel system Lucas DP200 pump .. ... ... ... ... ... ... ... .. 208 Stanadyne fuel injection pump 20-13 To remove to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 210 20-14 To adjust .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 214 20-15 To eliminate air from the fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 215 Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 217
- 11. Workshop Manual, TPD 1350, issue 3 11 New 1000 Series 21 Cooling system General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 219 Thermostats 21-1 To remove, to fit and to test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 220 Coolant pump - early gear driven pumps 21-2 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 221 Coolant pump - latest gear driven pumps 21-3 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 222 Coolant pump - belt driven 21-4 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 224 Coolant pump - belt driven high position 21- 5 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 226 Coolant pump - early gear driven pumps 21-6 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 229 Coolant pump - latest gear driven pumps 21-7 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 232 Coolant pump - belt driven 21-8 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 237 Fan 21-9 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 240 Fan drive (engines with gear driven coolant pumps) 21-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 240 Lubricating oil cooler 21-11 To remove and to fit - four cylinder turbocharged engines .. ... ... ... ... ... ... ... ... 241 21-12 To remove and to fit - six cylinder engines .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 242 21-13 To remove and to fit - pressed steel cover type .. ... ... ... ... ... ... ... ... ... ... ... ... 243 21-14 To remove and to fit - canister type.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 245 21-15 To dismantle and to assemble - four cylinder turbocharged engines .. ... ... ... ... 246 21-16 To dismantle and to assemble - six cylinder turbocharged engines ... ... ... ... ... 247 Cooler by-pass valve 21-17 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 247 21-18 To dismantle and to assemble pressed steel cooler type . ... ... ... ... ... ... ... ... ... 248
- 12. 12 Workshop Manual, TPD 1350, issue 3 New 1000 Series Intercooler 21-19 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 250 21-20 To clean and to inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 254 Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 255 22 Flywheel and housing General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 257 Flywheel 22-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 258 Ring gear 22-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 258 Flywheel housing 22-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 259 Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 260
- 13. Workshop Manual, TPD 1350, issue 3 13 New 1000 Series 23 Electrical equipment Alternators General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 261 Precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 261 Drive belts 23-1 To check ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 262 23-2 To adjust tension ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 262 23-3 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 262 Alternator 23-4 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 263 23-5 To maintain ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 263 Fault diagnosis Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 266 Starter motors General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 267 Starter motor 23-6 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 268 23-7 To maintain the brush gear and the commutator .. ... ... ... ... ... ... ... ... ... ... ... ... 269 23-8 To test on the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 269 Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 270 Starting aid General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 271 Starting aid ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 271 23-9 To remove and to fit a fuelled starting aid . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 271 23-10 To remove and to fit a port heater ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 273 Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 274
- 14. 14 Workshop Manual, TPD 1350, issue 3 New 1000 Series 24 Auxiliary equipment Compressors General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 275 Operation... ... ... ... ... .... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 275 Bendix Compressors 24-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 276 Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 279 Power steering pump 24-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 280 Adaptor for a hydraulic pump or a steering pump with a splined drive 24-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 281 24-4 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 281 Exhauster 24-5 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 283 25 Special tools List of special tools ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 286
- 15. Workshop Manual, TPD 1350, issue 3 15 10 New 1000 Series General information 10 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. Most of the general information which is included in the relevant User's Handbook (sections 1 to 9) has not been repeated in this workshop manual and the two publications should be used together. Where the information applies only to certain engine types, this is indicated in the text. The details of some operations will be different according to the of fuel injection pump which is fitted. The specific pump type used can be found by reference to the manufacturer's identification plate on the pump body. Generally, the type of pump fitted is as shown below. Lucas DP200 Series Bosch EPVE Stanadyne DB4 When reference is made to the "left" or "right" side of the engine, this is as seen from the flywheel end of the engine. Special tools have been made available and a list of these is given in section 25. Reference to the relevant special tools is also made at the beginning of each operation, where relevant. POWERPART recommended consumable products are listed on page 21. Reference to the relevant consumable products is also made at the beginning of each operation, where relevant. Data and dimensions are included at the end of each section. Read and remember the "Safety precautions". They are given for your protection and must be used at all times. Danger is indicated in the text by two methods: Warning! This indicates that there is a possible danger to the person. Caution: This indicates that there is a possible danger to the engine. Note: Is used where the information is important, but there is not a danger.
- 16. 10 16 Workshop Manual, TPD 1350, issue 3 New 1000 Series L A0378N A0379
- 17. Workshop Manual, TPD 1350, issue 3 17 10 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. In this workshop manual, the different engine types are indicated by their code letters. These are the first two letters of the engine number as indicated below: Code letters Engine type AJ Four cylinder, naturally aspirated. AK Four cylinder, turbocharged. AM Four cylinder, turbocharged and intercooled. AP Four cylinder, naturally aspirated, belt driven coolant pump. AQ Four cylinder, turbocharged, belt driven coolant pump. AR Four cylinder, naturally aspirated, 103 mm cylinder bore. AS Four cylinder, naturally aspirated, belt driven coolant pump, 103 mm cylinder bore. YG Six cylinder, naturally aspirated. YH Six cylinder, turbocharged. YK Six cylinder, turbocharged and intercooled. The correct identification of the engine is by the full engine number. The engine number is stamped on a label which is fastened to the left side (A2) of the cylinder block. An example of an engine number is: AK80920*U510256B* 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. Other identification labels fitted to the engine include: An emissions legislation label (A3) fitted to the side of the cylinder block. A label (A1) with the fuel injection pump part numbers. If a short engine has been fitted in service two engine serial numbers and a TPL number are stamped on the engine serial number pad (B3): Examples of the serial numbers are shown in (B). If parts for the short engine are needed in service, use the serial number (B4). If parts which were moved from the original engine to the short engine are needed, use the serial number (B1) and the TPL number (B2). 2 1 3 A A0043 4 1 2 3 B A0045 AK80920*U510256B* AJ39770 TPL No 212
- 18. 10 18 Workshop Manual, TPD 1350, issue 3 New 1000 Series General 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. ! Only use these engines in the type of application for which they have been designed. ! Do not change the specification of the engine. ! Do not smoke when you put fuel in the tank. ! Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a safe place. ! Do not put fuel in the tank while the engine runs (unless it is absolutely necessary). ! Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training; even then extreme care must be used to prevent injury). ! Do not make adjustments that you do not understand. ! Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions. ! Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation. ! Do not permit loose clothing or long hair near moving parts. ! Keep away from moving parts during engine operation. Warning! Some moving parts cannot be seen clearly while the engine runs. ! Do not operate the engine if a safety guard has been removed. ! Do not remove the filler cap or any component of the cooling system while the engine is hot and while the coolant is under pressure, because dangerous hot coolant can be discharged. ! Do not use salt water or any other coolant which can cause corrosion in the closed circuit of the cooling system. ! Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because the gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially to the eyes. ! Disconnect the battery terminals before a repair is made to the electrical system. ! Only one person must control the engine. ! Ensure that the engine is operated only from the control panel or from the operators position. ! If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately. ! Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons. Protect your hands with gloves or a special solution to protect the skin. ! Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated with oil into the pockets of clothing. ! Discard used lubricating oil in a safe place to prevent contamination. ! Ensure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is started. ! Use extreme care if emergency repairs must be made in adverse conditions. ! The combustible material of some components of the engine (for example certain seals) can become extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with the eyes, see page 20. ! Read and use the instructions relevant to lift equipment which are given on page 19. ! Always use a safety cage to protect the operator when a component is to be pressure tested in a container of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to be pressure tested. ! Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help immediately. ! Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and items away from the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces. ! 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. ! Fit only genuine Perkins parts.
- 19. Workshop Manual, TPD 1350, issue 3 19 10 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 . . . . . . . . . . 500 kg (1100 lbs) Six cylinder engines. . . . . . . . . . . . 600 kg (1320 lbs) Before the engine is lifted: ! Always use lift equipment of the approved type and of the correct capacity to lift the engine. It is recommended that lift equipment of the type shown in (A) is used, to provide a vertical lift directly above the engine lift brackets (A1). Never use a single lift bracket to raise an engine. ! Check the engine lift brackets for damage and that they are secure before the engine is lifted. The torque for the setscrews for the engine lift brackets is 44 Nm (33 lbf ft) 4,5 kgf m. ! To prevent damage to the rocker cover, ensure that there is clearance between the hooks and the rocker cover. ! Use lift equipment or obtain assistance to lift heavy engine components such as the cylinder block, cylinder head, balancer unit, flywheel housing, crankshaft and flywheel. . A A0044 1
- 20. 10 20 Workshop Manual, TPD 1350, issue 3 New 1000 Series Viton seals Some seals used in engines and in components fitted to engines are made of Viton. Viton is used by many manufacturers and is a safe material under normal conditions of operation. If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this burnt material to come into contact with the skin or with the eyes. If it is necessary to come into contact with components which have been burnt, ensure that the precautions which follow are used: ! Ensure that the components have cooled. ! Use neoprene gloves and discard the gloves safely after use. ! Wash the area with calcium hydroxide solution and then with clean water. ! Disposal of components and gloves which are contaminated must be in accordance with local regulations. If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention. .
- 21. Thank you very much for your reading. Please Click Here Then Get More Information. NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
- 22. Workshop Manual, TPD 1350, issue 3 21 10 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. These products are available from your Perkins distributor. POWERPART Antifreeze Protects the cooling system against frost and corrosion. Part number 1 litre 21825166 or 5 litres 21825167, refer to the User's Handbook. POWERPART Easy Flush Cleans the cooling system. Part number 2182501 POWERPART Jointing compound Universal jointing compound which seals joints. Currently Hylomar. Part number 1861155 or 1861117. POWERPART Silicone rubber sealant Silicone rubber sealant which prevents leakage through gaps.Currently Hylosil. Part number 1861108. POWERPART Lay-Up 1 A diesel fuel additive for protection against corrosion. Part number 1772204, refer to the User's Handbook. POWERPART Lay-Up 2 Protects the inside of the engine and of other closed systems. Part number 1762811, refer to the User's Handbook. POWERPART Lay-Up 3 Protects outside metal parts. Part number 1734115, refer to the User's Handbook. POWERPART Chisel Allows easy removal of old gaskets and joints. Currently Loctite chisel. Part number 21825163. POWERPART Repel Dries damp equipment and gives protection against corrosion. Passes through dirt and corrosion to lubricate and to assist removal of components. Currently Loctite repel. Part number 21825164. POWERPART Threadlock To retain small fasteners where easy removal is necessary. Currently Loctite 222e. Part number 21820222. POWERPART Studlock To permanently retain large fasteners and studs. Currently Loctite 270. Part number 21820270. POWERPART Nutlock To retain and seal threaded fasteners and cup plugs where easy removal is necessary. Currently Loctite 242e. Part number 21820242 POWERPART Liquid gasket To seal flat faces of components where no joint is used. Especially suitable for aluminium components. Currently Loctite 518. Part number 21820518 POWERPART Threadlock (hydraulic/pnuematic) To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and pneumatic systems. Currently Loctite 542. Part number 21820542 POWERPART Threadlock (pipe) To retain and seal pipe connections with coarse threads. Pressure systems can be used immediately. Currently Loctite 575. Part number 21820575. POWERPART Retainer (oil tolerant) To retain components which have a transition fit. Currently Loctite 603. Part number 21820603. POWERPART Retainer (high strength) To retain components which have an interference fit. Currently Loctite 638. Part number 21820638. POWERPART Atomiser thread sealant To seal the threads of the atomiser into the cylinder head. Currently Hylomar Advance Formulation. Part number 21825474. Continued
- 23. 10 22 Workshop Manual, TPD 1350, issue 3 New 1000 Series POWERPART Compound To seal the outer diameter of seals. Currently Loctite Forma Gasket No 2. Part number 1861147. POWERPART Platelock For tight fitted metal surfaces. Suitable for metal plated surfaces and stainless steel, Currently Loctite 243. Part number 21826039. POWERPART Gasket eliminator Improves flange sealing when a gasket is not used. It provides a seal with temperature resistance that is flexible in positions where vibration and pressure occur. Currently Loctite 515. Part number 21826040. POWERPART Silicone adhesive An RTV silicone adhesive for application where low- pressure tests occur before the adhesive sets. Used to prevent leakage where movement of the joint occurs. Currently Loctite 5900. Part number 21826038.