Perkins 1000 Engine Series Manual

Full download: http://manualplace.com/download/perkins-1000-engine-series-manual/

SEBEI 006600

Shop
Manual

Perkins

Series
Diesel Engine

This material is proprietary to Komatsu Dresser Company and is not to be reproduced, used, or disclosed except
in accordance wtth wriien authorization from Komatsu Dresser Company.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.

Aug 1995 Copyright 1995 Komatsu Dresser Company

This is the cut pages sample. Download all 170 page(s) at: ManualPlace.com
Contents
General information . .. .. . . .. .. . ... ... ... ... ... 10
Specifications . .. ... . .. ... . .. ... ... ... ... *.. ... 11
SERVICE OPERATIONS

Cylinder head assembly . .. ... .. . ... ... ... ... ... 12

Pistons and connecting rod assemblies ... ... ... ... ... 13
Crankshaft assembly .. . ..i ... ... ... ... ... ... 14
Timing case and drive assembly ... ... ... ... ... ... 15
Cylinder block assembly ... ... ... ... ... ... ... ..a 16
Engine timing . .. ... ... ... ... ... ... ... ... . . . 17
Aspiration system . .. ... ... ... ... ... ... ... ... . . . 18
Lubrication system ... ... ... ... ... ... ... ... . . . 19
Fuel system . .. . .. ... ... ... ... ... ... ... ... . . . 20
Cooling system . .. ... ... ... ... ... ... ... ... . . . 21
Flywheel and housing ... ... ... ... ... ... ... ... . . . 22
Electrical equipment ... ... ... ... ... ... ... ... . . . 23
Auxiliary equipment ... ... ... ... ... ... ... . . . 24
List of special tools ... ... ... ... ... ... ... ... . . . 25
Fault finging guide ... *.. ... ... ... ... ... ... . . . 26

00.03
General information 10

Introduction ... ... ... ... ... . .. . .. __. ... ... ... ... _.. . .. ... ... ... ... . .. 10.02
Engine identification . .. ... ... ... _.. ... ... ._. ... ... ... . .. ... ... _.. ... _.. 10.03
Safety precautions . .. ... ... ... _.. .. . ... ... ... ... ... ... ... ... ... ... . .. 10.04
Asbestos joints . .. . .. ... ... ... _.. . .. ... ... ... ... ... ... ... _.. ... ... ... 10.05

10.01
 10
Introduction 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.
This workshop manual has been designed to provide assistance in
the service and overhaul of Perkins Phaser and 1000 Series
engines. Read and remember the “Safety precautions”. They are given
for your protection and must be used at all times.
Most of the general infomlation which is included in the relevant
User’s Handbook (sections 1 to 9) has not been repeated in this A hazard symbol in the text indicates that there is a
workshop manual and the two publications should be used 1 danger of personal injury if certain operations are
.
together. A not done correctly.

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

type of fuel injection pump which is fitted. The pump type can be
found by reference to the manufacturer’s identification plate on
the pump but, generally, the type of pump fitted is as shown
below.

Bosch EPVE Vehicle and truck applications

CAV DPA Naturally aspirated engines in industrial and

agricultural applications

CAV DPS Turbocharged engines in industrial and

agricuftural applications

When reference is made to the “left” or “right” side of the engine,

this is as seen from the flywheel end of the engine.

Phaser 11 OT
 10
Engine identification

The Perkins Phaser and 1000 Series engines have been designed
for specitic applications, as shown below.

Phaser for vehicle and truck applications

1000 Series for agricultural and industrial applications

Each series consists of both four and six cylinder engines, each of
which will have four basic engine types - naturally aspirated,
compensated, turbocharged and turbochargedAntercooled.

There are different models in each series.

Phaser engines are named according to their approximate power

output, for example:
Phaser 90 -four cylinder engine rated at 87 bhp

Phaser 180X - six cylinder engine rated at 180 bhp

1000 Series engines are identified by a system of numbers and
letters, for example:

1006-6TW - six cylinder engine of six litres

Further information about the engine number system can be found

in the relevant user’s handbook.

In this workshop manual, the diierent engine types are indicated

by their code letters. These are the first two letters of the engine
number as indicated below:

Code letters Enginetype

AA Four cylinder, naturally aspirated
AB Four cylinder, turbocharged
AC Four cylinder, compensated
AD Four cylinder, turbochargedAntercooled.
YA Six cylinder, naturally aspirated
YB Six cylinder, turbocharged
YC Six cylinder, compensated
YD Six cylinder, turbochargedAntercooled.

The engine number is stamped on a label which is fastened to the

left side (Al), or rear (A2), of the cylinder block. An example of an
engine number is AB30126U510256N.

If you need parts, service or information for your engine, you must
give the complete engine number to your Perkins distributor.

10.03
 10
Safety precautions -

These safety precautions are important. You must refer also to

the local regulations in the country of use.
l Only use these engines in the type of application for which they

A
have been designed.
l

l
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. ..
1
0

l Do not put fuel in the tank while the engine runs (unless it is
absolutely necessary). _ _ .- ._
l Do not clean, add lubricating oil, or adjust the engine while it
runs (unless you have had the correct training; even then
extreme caution must be used to prevent injury). _ 1,.
l Do not make adjustments thatyou do not understand.
l Ensure that the engine does not run in a location where it can
cause a concentration of toxic emissions.
l Other persons must be kept at a safe distance while the engine
or equipment is in operation.
l Do not pem%t loose clothing or long hair near moving parts.
l Keep away from moving parts during engine operation.
Attention: The fan cannot be seen clearly while the engine runs.
l Do not operate the engine if a safety guard has been removed.
l Do not remove the filler cap of the cooling system while the
engine is hot and while the coolant is under pressure, because
dangerous hot coolant can be discharged.
l Do not use satt water or any other coolant which can cause
corrosion in the closed circuit of the cooling system.
l 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.

l Disconnect the battery terminals before a repair is made to the
electrical system.
.
0 Only one person must control the engine.
l Ensure that the engine is operated only from the control panel
or from the operator’s.position.
l If your skin comes into contact with high-pressure fuel, obtain
medical assistance immediately.
0 Diesel fuel can damage the skin of certain persons. Protect your
hands with gloves or a special solution to protect the skin.
l Do not move mobile equrpment if the brakes are not in good
condition.
0 Ensure that the control lever of the transmission drive is in the
“out-of-drive” position before the engine is started.
l Read and use the instructions relevant to asbestos joints which
are given on the next page.
l Fit only genuine Perkins parts,

10.04
 10
Asbestos joints

Some joints and gaskets contain’compressed asbestos fibres in a

rubber compound or in a metal outer cover. The “white” asbestos
(Chrysotile) which is used is a safer type of asbestos and the risk
of damage to health is extremely small.

The risk of asbestos from joints cccurs at their edges er if a joint is

damaged when a component is removed or if a joint is removed by
abrasion.

To ensure that the risk is kept to a minimum, the procedures given

below must be applied when an engine which has asbestos joints
is dismantled or assembled.
0 Work in an area with good ventilation.
l Do not smoke.
l Use a hand scraper to remove the joints - do not use a rotary
wire brush.
l Ensure that the joint to be removed is wet with oil or water to
contain loose particles.
l Spray all asbestos debris with water and put it in a closed
container which can be sealed for safe disposal.

10.05
 IlA
Basic engine data

Number of cylinders:
-AA,AB,AC,AD . . . . .. .. . ... ... .. . ... ._. . . . .._ ._. _.. 4
-YA,YB,YC,YD . . . .. .. . .. .. . .. . . .. ._. .. . . . . .._ ._. 6
Cylinder arrangement .. . ... .. . ... ._. .. . .. . ... . .. __. In-line

Cycle . .. .. .. . . .. .. . ... ... . .. .._ . .. ._. . . . ._. . .. Four stroke

Induction system:
-AA,YA .. . . . . .. ... .. . ... .. . .. . . .. .._ . .. ... .._ __. Naturally aspirated
-A& YB .. . . . .. . ... .. . ... .. . .. . ... _.. . .. ... . .. .._ Turbocharged
-AC,YC . . .. .. . .. ... ... ... .. . . .. ._. .. . ... .. . ._. Aitiiude compensated
-AD,YD .. .. . .. .. .. . ... .. . .. . . .. .. . .. . .. . ... .. . Turbocharged/intercoofed
Combustion system .. ._. _.. .. .__ . . . ._. .._ _.. .._ ._. Direct injection
Nominal bore ... . .. ... ._. . . . ... . .. .. .. . ... .. . . .. 100 mm (3.937 in)
Stroke . .. .. .. . .. .. . ... .. . ... ... ._. .. . ._. . . . . .. 127 mm (S.OOOin)
Compression ratio:
-AA,AG,YA,YC .. . ... .. ... . .. . .. . .. . .. .. . . . ... 16.51
-AB,AD,YB,YD ... .. .. . ... ... . .. ._. . .. .. . ___ . .. 1.. 16.0:1

Cubic capacity:
-AA,AB.AC,AD . .. .. ... .. . ... .. . . .. . .. .. . .._ _.. . .. 4 litres (243 ins)
-YA,YB.YC,YD .. . .. .. .. . .. . .. .. . . .. .. . .. . __. . . . 6 litres (365 in3)
Firing order
-AA,AB,AC,AD .. .. . ... ... .. . .. . . .. _.. .. . . .. .._ _.. 1,3,4,2
-YA,YB,YC,YD . .. ... .. . ... ... .. . ... __. .. . .. . ._. . . . 1,%3,6,2.4
Valve tip clearance (cold):
- Inlet .. . . . . . . . .. . ._. . .. .. . . _.. .. . . .. _._ . . . 0.20 mm (0.008 in)
- Exhaust ... . . . . . .. . . . .. . .. . ._. .. . _.. . . . ._. . . . 0,45 mm (0.018 in)
Lubricating oil pressure (minimum at maximum engine speed
and normal engine temperature):
-AA,AC,YA,YC . . .. . . .. . . . .. . . . . .., . .. . . . . . . .. . ... 207kN/m2 (3Olbf/n2) 2.1 kgf/cm2
-AB,AD,YB,YD . . . .. .. . . . . .. . . .. . . . . .. . . . . . . . .. ._. 280kN/m2 (40lbf/in2) 2,8kgf/cm2
Direction of rotation . .. . .. _.. .._ . .. ... _.. _.. . . . _._ __. Clockwise from the front

11 A.02
 IIA
: .\ Weight table

1000 SERIES COMPONENT WEIGHTS

Unit: kg

Cylinder block assembly 64.00

Rear end oil seal housing assembly 0.40
Timing case 4.15
Timing case cover 1.63
Crankshaft 47.00
Piston assembly 1.85
Conecting rod assembly 2.11
Cylinder head 59.00
Gear, Idler 2.76
Gear, camshaft 1.88
Camshaft 5.00
Lub oil pump assembly 2.89
Gear, fuel pump 1.86
Fuel pump 6.00
injector 0.27
Flywheel housing 30.00
Flywheel 48.00
Starter motor 19.75
Fan drive housing 4.03
Pulley, fan drive 3.64
Sump 49.00
Cylinder head cover 3.03
Lub oil filter head 1.10
Lub oil cooler assy 1.91
Crank pulley 10.16
Pulley extension/fan adapter 4.94
Water pump assembly 6.75
Alternator 5.10
Induction manifold 3.31
Turbocharger 8.04
Induction elbow 0.78
Exhaust manifold 6.35
Fuel filter assembly 0.85
Front mount adapters 3.16

llA.03
Perkins 1000 Engine Series Manual
Full download: http://manualplace.com/download/perkins-1000-engine-series-manual/

Recommended torque tensions IIB

Cylinder head assembly . .. ... . .. . .. ... . .. ... ... _.. ... ... ... ... .. . .. . 118.02
Pistons and connecting rod assemblies . .. ... ... ... ... _.. _.. .. . ... .. . .. . ... 118.02
Crankshaft assembly . .. ... ... . .. . .. ... ... ... .-. . .. .. . .. . ... .. . ... ... 118.02
Timing case and drive assembly ... ... ... ... ... ... .. . ... .. . .. . ... .. . ... ... 118.02
Aspiration system ... ... !.. ... ... ... ... ... ... .. . . .. ... ... .. . .. . ... .. . 118.02
Lubrication system ... ... ... ... ... ... . .. . .. . .. ... . .. ... ... . .. .. . .. . . .. 118.02
Fuel system . .. . .. ... ... ... ... ... . .. . .. ... ... ... ... ... ... .. . .. . ... 11 B.02
Cooling system ... .. . .. . . .. ... ... ... . .. . .. ... .. . _.. ._. ... ... ... .. . ... 11 B.02
Flywheel and housing .. . ... ... . .. . .. ... . .. ... ... ... .. . .. . ... .. . ... ... 11 B.03
Electrical equipment ... ... ... ... . .. ... . .. ... .. . . .. .. . ... ... .. . *.. ... 11 B-03
Auxiliary equipment . .. ... ... ... . .. ... . .. ... .. . . .. _.. ... ... .. . ... ... 11 B-03

llB.01

This is the cut pages sample. Download all 170 page(s) at: ManualPlace.com