Perkins New 1000 Series Diesel Engin Service Repair Manual
Table of Contents:
Perkins New 1000 Series Diesel Engines Workshop Service Repair Manual (Models AJ to AS and YG to YK)
0.0 INTRODUCTION
Manual Purpose, Scope, and How to Use This Guide
0.1 SAFETY AND YOU
Critical Safety Protocols, Hazard Recognition, and Workshop Warnings
1.0 GENERAL INFORMATION
1.1 Engine Identification Procedures
1.2 Build List Decoding
1.3 Engine Serial Number Locations
1.4 Service Precautions
1.5 Workshop Safety Procedures
1.6 Lubrication Requirements
1.7 Cooling Recommendations
1.8 Recommended Service Tools
2.0 ENGINE SPECIFICATIONS AND SERVICE LIMITS
2.1 Torque Specifications
2.2 Tightening Sequences
2.3 Wear Limits
2.4 Component Measurements
2.5 Service Tolerances
2.6 Valve Timing Specifications
2.7 Fuel Injection Timing
2.8 Compression Values
2.9 Crankshaft End Float
2.10 Connecting Rod Side Clearance
2.11 Camshaft Specifications
2.12 Piston Protrusion Measurements
3.0 CYLINDER HEAD REPAIR
3.1 Cylinder Head Removal
3.2 Pressure Testing
3.3 Surface Inspection
3.4 Crack Inspection
3.5 Valve Removal
3.6 Valve Guide Replacement
3.7 Valve Seat Machining
3.8 Valve Spring Inspection
3.9 Valve Seal Replacement
3.10 Rocker Shaft Inspection
3.11 Valve Clearance Adjustment
3.12 Reassembly Procedures
4.0 PISTONS AND CONNECTING ROD SERVICE
4.1 Piston Removal
4.2 Connecting Rod Inspection
4.3 Wrist Pin Replacement
4.4 Ring Installation
4.5 Ring Gap Inspection
4.6 Ring Orientation
4.7 Piston Measurement
4.8 Cylinder Inspection
4.9 Connecting Rod Alignment
4.10 Bearing Installation
4.11 Assembly Procedures
5.0 CRANKSHAFT AND MAIN BEARING OVERHAUL
5.1 Main Bearing Inspection
5.2 Crankshaft Removal
5.3 Journal Measurement
5.4 Oil Clearance Inspection
5.5 Bearing Replacement
5.6 Rear Oil Seal Installation
5.7 Front Seal Replacement
5.8 Crankshaft Gear Removal
5.9 End Float Adjustment
5.10 Flywheel Installation
6.0 TIMING GEAR TRAIN SERVICE
6.1 Timing Gear Removal
6.2 Timing Mark Alignment
6.3 Camshaft Replacement
6.4 Gear Inspection
6.5 Gear Backlash
6.6 Timing Cover Removal
6.7 Camshaft Bearing Replacement
6.8 Idler Gear Inspection
6.9 Reassembly Timing Procedures
7.0 LUBRICATION SYSTEM REPAIR
7.1 Oil Pump Service
7.2 Oil Pressure Relief Valve
7.3 Oil Cooler Service
7.4 Oil Filter Housing
7.5 Oil Passages
7.6 Pickup Tube
7.7 Oil Pan Service
7.8 Pressure Testing
7.9 Oil Pressure Diagnosis
8.0 FUEL INJECTION SYSTEM
8.1 Injection Pump Removal
8.2 Pump Timing
8.3 Injector Testing
8.4 Injector Replacement
8.5 Fuel Lift Pump
8.6 Fuel Filters
8.7 Bleeding Procedures
8.8 Air Removal
8.9 Fuel Line Inspection
8.10 Fuel Pressure Diagnosis
9.0 COOLING SYSTEM SERVICE
9.1 Water Pump Replacement
9.2 Thermostat Testing
9.3 Radiator Inspection
9.4 Coolant Recommendations
9.5 Cooling Passages
9.6 Temperature Diagnosis
9.7 Belt Inspection
9.8 Fan Installation
9.9 Leak Testing
10.0 TURBOCHARGER INSPECTION
10.1 Turbo Removal
10.2 Shaft Inspection
10.3 Bearing Inspection
10.4 Compressor Housing Service
10.5 Turbine Housing Service
10.6 Oil Supply Inspection
10.7 Boost Leak Diagnosis
10.8 Installation Procedures
11.0 FLYWHEEL HOUSING AND REAR COMPONENTS
11.1 Flywheel Removal
11.2 Ring Gear Replacement
11.3 Housing Alignment
11.4 Rear Crankshaft Seal
11.5 Starter Mounting Inspection
11.6 Housing Inspection
12.0 ELECTRICAL STARTING SYSTEM
12.1 Starter Motor Service
12.2 Charging System Service
12.3 Alternator Service
12.4 Wiring Inspection
12.5 Starting Circuit Diagnosis
12.6 Battery Testing
12.7 Ground Inspection
13.0 ENGINE DIAGNOSTICS AND TROUBLESHOOTING
13.1 Engine Will Not Start – Fuel Contamination
13.2 Engine Will Not Start – Air in Fuel System
13.3 Engine Will Not Start – Low Compression
13.4 Engine Will Not Start – Injection Timing
13.5 Engine Will Not Start – Battery Voltage
13.6 Engine Will Not Start – Starter Performance
13.7 Engine Will Not Start – Fuel Lift Pump
13.8 Engine Will Not Start – Injector Operation
13.9 Low Engine Power – Turbocharger Inspection
13.10 Low Engine Power – Air Restriction
13.11 Low Engine Power – Fuel Restriction
13.12 Low Engine Power – Compression Testing
13.13 Low Engine Power – Injection Timing
13.14 Low Engine Power – Valve Adjustment
13.15 Low Engine Power – Exhaust Restriction
13.16 Excessive Smoke – Black Smoke Diagnosis
13.17 Excessive Smoke – White Smoke Diagnosis
13.18 Excessive Smoke – Blue Smoke Diagnosis
13.19 Excessive Smoke – Injector Faults
13.20 Excessive Smoke – Turbocharger Wear
13.21 Excessive Smoke – Oil Consumption
13.22 Excessive Smoke – Incorrect Fuel Timing
13.23 Excessive Smoke – Air Restriction
13.24 Excessive Smoke – Compression Loss
13.25 High Engine Temperature – Thermostat Failure
13.26 High Engine Temperature – Water Pump Wear
13.27 High Engine Temperature – Coolant Circulation
13.28 High Engine Temperature – Radiator Blockage
13.29 High Engine Temperature – Fan Belt Tension
13.30 High Engine Temperature – Head Gasket Leakage
13.31 Low Oil Pressure – Worn Bearings
13.32 Low Oil Pressure – Oil Pump Wear
13.33 Low Oil Pressure – Pressure Relief Valve Failure
13.34 Low Oil Pressure – Oil Pickup Blockage
13.35 Low Oil Pressure – Oil Viscosity Problems
14.0 PREVENTIVE MAINTENANCE SCHEDULE
14.1 Engine Oil Intervals
14.2 Oil Filter Replacement
14.3 Fuel Filter Service
14.4 Air Cleaner Maintenance
14.5 Coolant Replacement
14.6 Belt Inspection
14.7 Valve Adjustment
14.8 Injector Inspection
14.9 Cooling System Service
