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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.

Summary of Contents for New 1000 Series

Page 1: ...K 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 reser...

Page 2: ...shaft 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 Elec...

Page 3: ...duction 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 sea...

Page 4: ...es 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 remov...

Page 5: ...iston 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...

Page 6: ...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 Cr...

Page 7: ...5 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 Cams...

Page 8: ...C 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 1...

Page 9: ...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...

Page 10: ...d 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 2...

Page 11: ...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 an...

Page 12: ...move 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...

Page 13: ...d 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 com...

Page 14: ...mpressors 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 an...

Page 15: ...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 l...

Page 16: ...10 16 Workshop Manual TPD 1350 issue 3 New 1000 Series L A0378N A0379...

Page 17: ...ged 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...

Page 18: ...us 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 o...

Page 19: ...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 Ch...

Page 20: ...h 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 an...

Page 21: ...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 num...

Page 22: ...te 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 a...

Page 23: ...inal bore AJ AK AM AP AQ YG YH YK 100 mm 3 937 in AR AS 103 mm 4 055 in Stroke 127 mm 5 00 in Compression ratio AJ AK AM AP AQ YG YH YK 17 25 1 AR AS 18 5 1 Cubic capacity AJ AK AM AP AQ 4 litres 243...

Page 24: ...fasteners are fitted in through holes into oil or coolant passages The identification of these fasteners as supplied is by a red blue or other colour sealant around the fastener threads With M E A S s...

Page 25: ...lightly with clean engine oil before they are fitted Standard torques for setscrews and nuts Standard torques for studs metal end Standard torques for pipe unions plugs and adaptors Torque Thread Siz...

Page 26: ...cting rod assemblies Nuts connecting rods 1 2 UNF 125 92 12 7 Setscrews connecting rods 1 2UNF 152 114 15 8 Banjo bolts piston cooling jets 3 8 UNF 27 21 2 7 Crankshaft assembly Setscrews main bearing...

Page 27: ...8 20 2 8 Torxscrew for the gear of the fuel injection pump M10 22 16 2 2 Setscrews fuel lift pump M8 22 16 2 2 Nuts for flange of fuel injection pump M8 22 16 2 2 Locking screw of Bosch VE fuel inject...

Page 28: ...7 1 Aspiration system Nuts turbocharger to manifold M10 44 33 4 5 Electrical equipment Nut alternator pulley CAV AC5RA and AC5RS 5 8 UNF 55 40 5 6 Thin nut A127 and motorola pulley 22 mm A F M17 60 4...

Page 29: ...n 350 kPa 50 lbf in2 3 5 kgf cm2 then those cylinders may be faulty Compression tests should not be the only method used to show the condition of an engine but they should be used together with other...

Page 30: ...30 This page is intentionally blank...

Page 31: ...cylinder each fitted with single valve springs The ports for the inlet and exhaust are on the right side of the cylinder head The face angle of the valves is either 45 or 30 The angle of the valve sea...

Page 32: ...me the cover is removed To fit 1 Check the seal of the oil filler cap B1 and the sealing washers B3 for the cap nuts B2 Warning The rocker cover joint may be made from viton read the safety precaution...

Page 33: ...head 2 Check that the push rods fit correctly in the sockets of the tappets Fit the rocker assembly ensure that the oil supply connection is fitted correctly into the oil seal Check that the ends of...

Page 34: ...in the position shown Ensure that the location screw A1 for the oil supply connection is fitted correctly in the rocker shaft Fit the clips to the ends of the rocker shaft To inspect and to correct 12...

Page 35: ...ion until the inlet valve B7 of number 4 cylinder has just opened and the exhaust valve B8 of the same cylinder has not closed completely Check the clearances of the valves B1 and B2 of number 1 cylin...

Page 36: ...valves A9 and A10 of number 5 cylinder 3 Set the valves A7 and A8 of number 4 cylinder Then check adjust the clearances of the valves A5 and A6 of number 3 cylinder 4 Set the valves A1 and A2 of numb...

Page 37: ...ker assembly see operation 12 2 4 Fit the valve spring compressor A1 and the relevant adaptor A2 or A3 5 Compress the valve spring and remove the collets Ensure that the valve spring is compressed squ...

Page 38: ...tion 12 1 Note If other or all of the valve springs are to be changed they can be changed two cylinders at a time The sets of cylinders are For 4 cylinder engines 1 and 4 2 and 3 For 6 cylinder engine...

Page 39: ...fasteners A3 fitted inside the manifold These fasteners retain the bottom half of the manifold to the cylinder head 8 For engines fitted with turbochargers Disconnect all connections to the turbochar...

Page 40: ...the rocker cover see operation 12 1 19 Remove the rocker assembly see operation 12 2 20 Remove the push rods 21 Release the cylinder head setscrews evenly and gradually in the reverse sequence to that...

Page 41: ...er head gasket must be fitted without jointing compound 2 Put the cylinder head gasket in position It is stamped FRONT TOP A2 for correct assembly 3 To ensure the cylinder head is fitted into the corr...

Page 42: ...h of the setscrew Tighten each setscrew in the correct sequence until the marks on the flange are next to and in line with the marks on the cylinder head 8 Put the push rods in position Ensure that th...

Page 43: ...upplied as one piece Caution Damage to the exhaust manifold can occur if it is not aligned and tightened correctly Some exhaust manifolds have large clearance holes for the fasteners if these manifold...

Page 44: ...he induction manifold and the top of the fuel injection pump 24 Fit the electrical connection to the coolant temperature sender unit 25 Connect the coolant outlet and the hoses for the cab heater Tigh...

Page 45: ...nder head is fitted into the correct position fit two suitable M10 guide studs A1 in positions 16 and 21 B Put the cylinder head in position Ensure that the two location pins are fully engaged in the...

Page 46: ...ording to the length of the setscrew Tighten each setscrew in the correct sequence until the marks on the flange are next to and in line with the marks on the cylinder head 10 Put the push rods in pos...

Page 47: ...anifolds have large clearance holes for the fasteners if these manifolds are renewed it is important that the two alignment bushes B2 supplied with the new manifold are in position New alignment bushe...

Page 48: ...let manifold A paper joint A5 is used in service instead of a liquid joint The liquid joint must be removed and the flange faces thoroughly cleaned with a suitable nylon scraper or solvent before the...

Page 49: ...A1 valve spring and valve stem seal A4 6 Repeat items 4 and 5 for the other valves To fit Warning Wear eye protection during this operation Note The components of the valve assembly are shown in A 1...

Page 50: ...lve is below the depth limit check the valve depth with a new valve in position If the valve depth is still below the limit and a valve seat insert is fitted the insert must be renewed 6 Check the val...

Page 51: ...f the valve head A3 move the valve radially away from the gauge With the valve held in this position set the gauge to zero 4 Move the valve radially across the axis of the cylinder head towards the ga...

Page 52: ...l ensure a good seal between the guide and its seat New valves and new valve seat inserts must be fitted each time a new valve guide is fitted Valves must not be lapped see operation 12 13 If all or m...

Page 53: ...ut the valve guide in position on the adaptor and fit the distance piece A7 PD 1C 6 for inlet valve guides and PD 248 for exhaust valve guides Fit the attachment A8 to secure the valve guide to the ad...

Page 54: ...re deep scratches or for engines without valve seat inserts the valve depths are below the service limit 9 Use a straight edge and feeler gauges to check the cylinder head for distortion across and al...

Page 55: ...to the reamer and push the handle fully onto the reamer Ensure that the flat part of the reamer shank is towards the grub screw A1 and tighten the grub screw to secure the reamer to the handle The bla...

Page 56: ...ack of the insert has been ground ensure that the outer edge of the back face has a 0 9 1 3 mm 0 035 0 051 in chamfer at 30 to the vertical 5 With the bore of the new partially finished valve guide us...

Page 57: ...e has been machined 102 48 mm 4 035 in Inlet valves Diameter of valve stem 8 953 8 975 mm 0 3525 0 3533 in Clearance in valve guide 0 025 0 069 mm 0 001 0 0027 in Maximum permissible clearance in valv...

Page 58: ...and AS 41 88 42 12 mm 1 649 1 658 in Angle of valve face 45 or 30 Full length engine types AJ AK AM AP AQ YG YH YK 122 65 123 30 mm 4 829 4 854 in Full length engine types AR and AS 123 75 124 40 mm 4...

Page 59: ...10 715 mm 0 4167 0 4219 in B2 45 535 45 560 mm 1 7927 1 7937 in B3 Radius 0 38 mm 0 015 in maximum Exhaust B1 10 585 10 715 mm 0 4167 0 4219 in B2 43 535 43 560 mm 1 7139 1 7149 in B3 Radius 0 38 mm...

Page 60: ...354 1 361 in A6 42 75 43 00 mm 1 683 1 693 in A7 Radius 1 4 mm 0 055 in maximum A8 Radius 1 5 mm 0 06 in A9 1 5 mm 0 06 in A10 8 54 8 57 mm 0 336 0 337 in Inlet 45 valves engine types AR and AS A1 1 5...

Page 61: ...AS 136 3 153 7 N 30 6 34 5 lbf 13 9 15 7 kgf Number of active coils 3 3 Number of damper coils 0 Direction of coils Left hand Tappets Diameter of tappet stem 18 99 19 01 mm 0 7475 0 7485 in Diameter o...

Page 62: ...62 This page is intentionally blank...

Page 63: ...he pistons Note Engine types AR and AS have only one cooling jet fitted to spray the number one piston The correct piston height is important to ensure that the piston does not contact the cylinder he...

Page 64: ...cylinder bore Two oversize pistons and piston rings are available in service 0 5 mm 0 020 in and 1 00 mm 0 040 in Always use the engine identification number to order new parts The connecting rods ar...

Page 65: ...move the bearing cap B3 Remove the bolts from the connecting rod B2 If the bearing cap is retained by setscrews A4 the location of the bearing cap A3 will be by two dowels A2 To remove these bearing c...

Page 66: ...the lower half of the shell bearings into the cap ensure that the location tag is fitted correctly in its recess A1 Fit the connecting rod setscrews Fit the cap to the connecting rod Ensure that the a...

Page 67: ...matched to the relevant cylinder Note the position of each connecting rod and piston for correct assembly 6 Remove the big end caps and the big end bearings from the connecting rods see operation 13...

Page 68: ...piston rings when the piston and connecting rod assembly is fitted Ensure that the smaller end of the tapered bore is towards the face of the cylinder block 5 Put the piston ring gaps 120 apart Pass...

Page 69: ...on the same side Tighten the fasteners gradually and evenly to the recommended torque of 155 Nm 114 lbf ft 15 8 kgf m for setscrews or 125 Nm 92 lbf ft 12 7 kgf m for nuts 8 Check that the crankshaft...

Page 70: ...arefully put the tool over the top of the piston with the plunger of the gauge in contact with the piston above the axis of the gudgeon pin Rotate the crankshaft to ensure that the piston is at the hi...

Page 71: ...ng in the bottom groove with the latch pin A1 inside both ends of the spring A Fit the oil control ring over the spring B3 or C3 Ensure that the ring gap is at 180 to the latch pin 2 Fit the cast iron...

Page 72: ...eration 13 9 To assemble 1 Clean the bore of the small end bush and lubricate it with clean engine lubricating oil 2 Fit a new circlip in the circlip groove of one of the gudgeon pin bosses Ensure tha...

Page 73: ...that the piston height above the cylinder block is correct the engine may have up to six length grades F to L of connecting rods fitted Identification of the length grade is by a letter or colour whic...

Page 74: ...re the piston ring clearance in the groove to that given for new components in the data and dimensions and renew the piston if necessary Note The pistons have a tapered top groove and the piston ring...

Page 75: ...artially finished small end bush To remove and to fit 13 10 1 Press out the old bush with a suitable adaptor 2 Clean the parent bore of the connecting rod and remove any sharp edges 3 Press in the par...

Page 76: ...jet tube is not damaged Renew the valve assembly and or the body as necessary 2 Fit the piston cooling jet ensure that the assembly is fitted correctly on the dowel in the cylinder block Tighten the...

Page 77: ...ton rings Top compression ring Engine types AJ AK AM AP AQ YG YH YK Barrel face molybdenum insert wedge Engine types AR and AS Barrel face molybdenum insert rectangular Second compression ring Taper f...

Page 78: ...ged engines 31 55 31 88 mm 1 240 1 255 in Thickness at centre of bearings Naturally aspirated engines 1 835 1 842 mm 0 0723 0 0725 in Turbocharged engines 1 835 1 844 mm 0 0723 0 0726 in Bearing clear...

Page 79: ...s for Viton seals on page 18 The crankshaft pulley A3 of the four cylinder engine usually fitted without a damper is held in position by a plain thrust block A1 and three setscrews A2 The nose of the...

Page 80: ...the components and check for damage Renew damaged components To fit 1 Put the pulley in position on the crankshaft Lubricate lightly the threads of the setscrews with engine lubricating oil Lubricate...

Page 81: ...To remove 1 Remove the drive belts see operation 23 3 Warning The crankshaft pulley and damper assembly is heavy and must be given support before removal 2 Release the fasteners which secure the clamp...

Page 82: ...fitted with M12 setscrews tighten the fasteners to 75 Nm 55 lb ft 7 6 kgf m Caution Do not use a degreasing solution 2 Clean thoroughly the nose of the crankshaft the bore of the pulley and the taper...

Page 83: ...cover of the timing case Measure the alignment of the damper face at four locations 90 apart The maximum permissible difference between the maximum and minimum figures obtained is 0 18 mm 0 007 in 3 R...

Page 84: ...Check that the seal and the outer circumference of the crankshaft flange are not damaged Where a new seal has been fitted check that it is in the correct position in the housing 7 Ensure that the two...

Page 85: ...e been used it is permissible to grind the crankshaft flange see section 11 1 Remove the seal and housing assembly see operation 14 4 2 Put the engine side of the housing on a suitable support and pre...

Page 86: ...en a thrust washer and the crankshaft B or with a dial test indicator on one end of the crankshaft to check the movement C If the end float is more than the tolerance given in data and dimensions thru...

Page 87: ...or to the rear to loosen a tight washer Use a suitable tool A1 made of a soft material to push the upper halves of the thrust washers from their recesses To fit 1 Lubricate the thrust washers with cle...

Page 88: ...ews gradually and evenly to 265 Nm 196 lbf ft 27 0 kgf m 7 Check the crankshaft end float see operation 14 6 8 If necessary fit the balancer unit see operation 14 12 9 If necessary fit the lubricating...

Page 89: ...nder engines it will be necessary to remove the suction pipe and strainer and the delivery pipe For four cylinder engines either the balancer unit or the suction pipe and strainer the delivery pipe an...

Page 90: ...e cap 5 Ensure that the location thimbles are fitted correctly to the cap or to the cylinder block Fit the bearing cap with the location tags of both bearings on the same side A1 6 Inspect the setscre...

Page 91: ...ster see section 24 8 Remove the timing case cover see operation 15 1 9 Remove the timing gears and the timing case see section 15 10 Remove the flywheel and the flywheel housing see section 22 11 Rem...

Page 92: ...ings Fit the bearings to the caps with the location tags fitted correctly in their recesses Lubricate the bearings with clean engine lubricating oil 6 Clean the lower halves of the thrust washers and...

Page 93: ...acturer When the setscrews are to be used again ensure that the threads of the setscrews and of the bridge piece are clean and a sealant is applied to the threads of the setscrews These instructions a...

Page 94: ...0016 in The main journals and the crank pins of standard size crank shafts can be machined to 0 25mm 0 010 in 0 50mm 0 020 in or 0 75 mm 0 030 in undersize on diameter see the data and dimensions Spec...

Page 95: ...down away from the cylinder block B2 The timing of the balance weights to the drive shaft is correct when the large hole and small hole in the front of the drive shaft gear are in the positions shown...

Page 96: ...e Continue to turn the nut with a suitable spanner until the Loctite seal on the splines of the drive shaft is broken and the gear is loose on the shaft Remove the nut and the drive gear and remove th...

Page 97: ...plug is fitted in the bottom of the balancer and the long plug is fitted in the side Caution Removal of these plugs can cause damage to the threads in the balancer frame and a new balancer frame will...

Page 98: ...y the splines A6 and the thread on the end of the drive shaft Apply a small amount of Loctite Nutlock to the splines and to the thread Fit the drive gear of the balance weights A1 with the flat face o...

Page 99: ...the cover onto the dowels Fit the cover setscrews and tighten them to 54 Nm 40 lbf ft 5 5 kgf m Check the end float of the balance weights with feeler gauges between the rear face of the balance weig...

Page 100: ...nt of the balancer unit with the idler gear in mesh with the gear of the drive shaft A11 Tighten the setscrew to 93 Nm 68 lbf ft 9 5 kgf m Check the end float of the idler gear with a feeler gauge bet...

Page 101: ...necessary 4 Check the drive gear for the balance weights for wear or other damage Renew the gear if necessary 5 Check the balance weights for wear or other damage If either balance weight is worn or...

Page 102: ...ainst the front face of the balancer frame In this position the front face of the bearing should be 130 0 131 0 mm 5 12 5 16 in from the front face of the balancer frame page 100 A 4 Make a suitable a...

Page 103: ...on the rear face of the bush should be 3 25 3 30 mm 0 128 0 130 in from the rear face of the balancer frame B Repeat this operation for the other bush 4 Fit a bush B1 onto the adaptor and put it into...

Page 104: ...n Six cylinder engines 51 97 51 99 mm 2 046 2 047 in Crankshaft end float 0 05 0 38 mm 0 002 0 015 in Maximum permissible end float 0 51 mm 0 020 in Fillet radii of journals and crank pins 3 68 3 96 m...

Page 105: ...0 76 mm 0 030 in 1 75 905 75 926 mm 2 9884 2 9892 in 75 651 75 672 mm 2 9784 2 9792 in 75 397 75 418 mm 2 9684 2 9692 in 2 63 216 63 236 mm 2 4888 2 4896 in 62 962 62 982 mm 2 4788 2 4796 in 62 708 6...

Page 106: ...s Steel back 20 tin aluminium bearing material Six cylinder engines Steel back 20 tin aluminium bearing material Bearing width Four cylinder engines Centre bearing 36 32 36 70 mm 1 430 1 445 in All ot...

Page 107: ...shaft 0 13 0 30 mm 0 005 0 012 in Diameter of bore for front bearing of drive shaft 34 912 34 937 mm 1 3745 1 3755 in Diameter of bore for rear bearing of drive shaft 29 972 29 993 mm 1 1800 1 1808 i...

Page 108: ...108 This page is intentionally blank...

Page 109: ...dle roller bearings The drive from the crankshaft gear passes through an idler gear to the camshaft gear and to the gear of the fuel injection pump The drive from the crankshaft gear also passes throu...

Page 110: ...pposite locations to hold the cover in position Fit the centralising tool in the oil seal housing B and use the special washer and the crankshaft pulley setscrews to put the cover in its correct posit...

Page 111: ...e seal do not fit the seal 2 Lubricate the outer circumference of the oil seal with clean engine lubricating oil and enter the seal into the housing Ensure that the spring loaded lip of the oil seal i...

Page 112: ...are in each service kit 2 Fit the wear sleeve in accordance with the manufacturer s instructions It is not necessary to remove the flange A3 of the wear sleeve after it has been fitted A new front oi...

Page 113: ...l be lost if the crankshaft is rotated when the idler gear is removed 5 Inspect the gear and the bushes B2 and B7 for wear and other damage and renew as necessary The gear and bushes are available as...

Page 114: ...gf m 3 For engines that use the idler gear assembly with needle roller bearings Inspect the components for wear and other damage and renew them as necessary Lightly lubricate the components with clean...

Page 115: ...e operation 15 1 6 Fit the coolant pump see operation 21 2 7 Fit the crankshaft pulley see operation 14 1 or operation 14 2 8 Where necessary fit the fan drive pulley see operation 21 10 9 Fit the dri...

Page 116: ...hub To remove and to fit 15 5 To remove 1 Set the piston of number 1 cylinder to TDC see operation 17 1 or operation 17 2 2 Remove the timing case cover A6 see operation 15 1 Caution Do not rotate the...

Page 117: ...ot rotate the engine crankshaft or the compressor crankshaft if the idler gear B5 is removed If either of the crankshafts are moved the compressor must be timed to the engine 2 Lightly lubricate the b...

Page 118: ...injection pump timing pin PD 246 1 Remove the timing case cover see operation 15 1 Caution Do not lock the shaft of the fuel injection pump see operation 20 7 or operation 20 10 2 Set the number one...

Page 119: ...e slot Fit the small end of the pin B2 fully into the hole in the pump body Leave the pin B5 in position 3 Fit the fuel pump gear C1 over the pin C3 and into mesh with the idler gear C2 4 Loosely fit...

Page 120: ...the key in the camshaft is not lost 4 Inspect the gear for wear and any other damage and renew it if necessary To fit 1 Ensure that the key in the camshaft is fitted correctly 2 Remove the idler gear...

Page 121: ...is a transition fit on the crankshaft It may slide off easily or if it is a tight fit and the gear is to be renewed it may be necessary to remove the crankshaft see operation 14 10 to remove the gear...

Page 122: ...exhauster if fitted see section 24 8 Remove the timing case cover see operation 15 1 9 Rotate the crankshaft until the marked teeth of the crankshaft gear and the camshaft gear are in mesh with the i...

Page 123: ...t support plate in position and fit and tighten the remainder of the setscrews of the timing case If the front support plate has been separated from the alternator bracket ensure that the right side o...

Page 124: ...thrust washer Ensure that it is fitted correctly on the hollow dowel B2 5 Fit the timing case together with a new joint see operation 15 9 6 Check that the camshaft end float is within the limits sho...

Page 125: ...69 mm 0 2999 0 3029 in Inlet engine types AR and AS 8 58 mm 0 3378 in Exhaust engine types AJ AK AM AP AQ YG YH YK 7 71 7 79 mm 0 3036 0 3066 in Exhaust engine types AR and AS 8 80 mm 0 3464 in Maxim...

Page 126: ...8 50 80 mm 1 9999 2 000 in Outside diameter of hub 50 70 50 74 mm 1 9960 1 9975 in with needle roller bearing 54 987 55 000 mm 2 1648 2 1654 in Clearance of bushes on hub 0 04 0 10 mm 0 0016 0 0039 in...

Page 127: ...s been installed All liners are honed with silicon carbide tools to a controlled finish to ensure long life and low oil consumption The cylinder liners have a flame ring above the flange A bush is fit...

Page 128: ...lter the atomisers and the fuel injection pump see section 20 7 Remove the lubricating oil cooler where fitted see operation 21 11 8 Remove the lubricating oil filter assembly and the lubricating oil...

Page 129: ...ating oil sump see section 19 15 If necessary fit the lubricating oil cooler see operation 21 11 16 Fit the fuel filter the atomisers and the fuel injection pump see section 20 17 If necessary fit the...

Page 130: ...honed finish has been polished away Check especially the area around the top of the liner bore just below the carbon ring In this area thrust from the top piston ring is at its maximum Cautions Do not...

Page 131: ...on 13 11 5 Rotate the crankshaft to give access to the cylinder liner Protect the crank pin 6 Put the tool A4 on the top face of the cylinder block and over the centre of the liner A5 Ensure that the...

Page 132: ...top 50 mm 2 0 in 4 Engage the cylinder liner A5 into the parent bore ensure that the liner is vertical Put the adaptor PD 150B 17 2 A4 onto the top of the liner with the shoulder of the adaptor on th...

Page 133: ...checked The retainer will reach full strength after 6 hours The inside diameter of a service liner when fitted should be 100 00 100 06 mm 3 937 3 939 in 10 Use tool PD 41D to check that the liner fla...

Page 134: ...PD 150B 17A A4 onto the top of the liner with the flame ring in the groove of the adaptor Put the bearing A3 into position in the recess in the top of the adaptor with the flat face of the bearing to...

Page 135: ...ata and dimensions at the end of this section Specialist training and equipment is needed to machine the partially finished liner For further information contact your nearest Perkins distributor 11 Fi...

Page 136: ...he top of the liner bore just below the carbon ring In this area thrust from the top piston ring is at its maximum Cautions Do not use Flex hone to repair cylinder bores An engine can have high oil co...

Page 137: ...ore for main bearing 80 416 80 442 mm 3 1660 3 1670 in Camshaft bore diameter Four cylinder engines Number 1 for bush 55 56 55 59 mm 2 188 2 189 in Number 2 50 55 50 60 mm 1 990 1 992 in Number 3 50 0...

Page 138: ...liner before it is honed 99 873 99 924 mm 3 9320 3 9340 in Surface finish Ra 3 2 to 4 0 micrometers Maximum ovality and taper 0 02 mm 0 0008 in Diamond hone Hone angle cross hatch 35 Finish size diam...

Page 139: ...ond honed 103 449 103 461 mm 4 0727 4 0732 in Finish size of second oversize of bore diamond honed 103 949 103 961 mm 4 0924 4 0929 in Surface finish Ra 2 2 to 3 0 micrometers Maximum ovality and tape...

Page 140: ...140 This page is intentionally blank...

Page 141: ...sarily be in mesh in this position because of the different speeds at which the gears rotate The fuel injection pump is timed at TDC on the compression stroke of number 1 cylinder It is important that...

Page 142: ...e factory to ensure that the fuel pump is in the correct position for timing If the nut is removed and the hub moves the hub will need to be accurately fitted to the pump by use of specialist equipmen...

Page 143: ...ressor PD 6118B and the adaptor PD 6118 7 for pedestal studs or the adaptor PD 6118 8 for pedestal setscrews Caution Fit a suitable collar near the top of the valve to hold the valve if the crankshaft...

Page 144: ...ate the crankshaft clockwise until the mark on the damper or pulley aligns accurately with the tip of the pointer Number 1 piston is now at TDC on the compression stroke To check the valve timing 17 3...

Page 145: ...tools and personnel with the correct training are necessary to remove these fasteners refer to your nearest Perkins distributor 3 Insert the timing pin A1 through the hole A5 in the fuel pump gear an...

Page 146: ...to all engines unless an engine type code is shown Fuel system Bosch fuel injection pump Type EPVE pin timed with a locking screw Direction of rotation from drive end Clockwise from drive end Lucas fu...

Page 147: ...eries Aspiration system 18 General description Warning Turbochargers operate at high speed and at high temperatures Keep fingers tools and debris away from the inlet and outlet ports of the turbocharg...

Page 148: ...ows are included on the illustration to indicate the typical oil flow Some turbochargers are fitted with a waste gate unit B This unit which is controlled by boost pressure allows some of the exhaust...

Page 149: ...il supply pipe is flexible use a spanner to hold the flats on the pipe while the union connection is removed from the oil filter head adaptor plate This will prevent damage to the flexible section of...

Page 150: ...in position on the flange and fit the elbow Tighten the nuts to 22 Nm 16 lbf ft 2 2 kgf m plated or 25 Nm 18 lbf ft 2 5 kgf m non plated Fit or connect the support bracket between the elbow and the c...

Page 151: ...er A If the casing is tight lightly hit it with a soft faced hammer 5 Put the compressor casing in a suitable container that contains a non caustic solution Allow the dirt to become soft and then clea...

Page 152: ...uator bracket to the turbocharger and remove the actuator and bracket assembly To fit 1 Put the actuator and bracket assembly in position on the turbocharger and tighten the setscrews 2 Connect to the...

Page 153: ...ft hammer during the test operation 4 If the operation of the waste gate is not correct the actuator rod can be adjusted 5 Remove the dial gauge from the end of the actuator rod 6 With the air pressur...

Page 154: ...at turbine end 2 7 8 17 19 20 22 28 30 31 32 Too much lubricating oil at compressor end 1 2 4 5 6 8 19 20 21 28 31 32 Not enough lubrication 8 12 14 15 16 23 24 29 32 33 37 38 Lubricating oil in the e...

Page 155: ...icating oil 16 Restricted lubricating oil supply pipe 17 Restricted lubricating oil drain pipe 18 Turbine housing damaged or restricted 19 Leakage from turbocharger seals 20 Worn turbocharger bearings...

Page 156: ...ning 4 If necessary renew the O ring seal A3 5 Check that the inside of the breather pipe is clean If the pipe is not clean release the setscrews and remove the pipe Wash the pipe with kerosene and dr...

Page 157: ...e crankcase and a breather valve is fitted between the oil separator and the induction manifold Crankcase gases pass through the oil separator where oil from the gases is returned to the sump The cran...

Page 158: ...ett T20 6 Cylinder engines Garrett T32 Waste gate test pressure for rod movement of 1 00 mm 0 039 in The turbocharger part number is on the turbocharger identification plate which is fitted to the bod...

Page 159: ...ted to the right side 19A 04 A of the engine the oil passes through a pipe connected between the relief valve and the right side of the cylinder block The oil passes from the pipe through a passage in...

Page 160: ...19 160 Workshop Manual TPD 1350 issue 3 New 1000 Series 1 2 3 4 A A0289...

Page 161: ...Workshop Manual TPD 1350 issue 3 161 19 New 1000 Series A A0290 1 2 3...

Page 162: ...s through a pipe connected between the relief valve and the right side of the cylinder block to the oil filter The lubricating oil passes from the filter to the pressure rail which is drilled the full...

Page 163: ...lar tool and then discard the canister Note If the adaptor is to be renewed insert the end of the adaptor which has the thread sealant applied during manufacture into the filter head 3 Clean the seal...

Page 164: ...the filter head A4 and the cylinder block 7 Fit the new joint to the filter head the joint is fitted dry Note Some engines have an adaptor A1 between the cylinder block and the filter head If an adap...

Page 165: ...s to 22 Nm 16 lbf ft 2 2 kgf m Fit the drain plug together with a new O ring and tighten the plug to 34 Nm 25 lbf ft 3 5 kgf m Where necessary fit the dipstick tube and the dipstick Fill the sump to t...

Page 166: ...d ensure that the clamp the bracket and the pipe are correctly aligned before the setscrews are tightened Ensure that there is no stress on the suction pipe 5 Fit the sump see operation 19 3 To inspec...

Page 167: ...ting oil sump see operation 19 3 2 Remove the suction pipe and strainer see operation 19 4 3 For four cylinder engines Remove the oil pressure relief valve see operation 19 9 and the delivery pipe For...

Page 168: ...lash between the oil pump gear and the idler gear B 3 If number 1 main bearing cap was removed lubricate the bearing with clean engine lubricating oil and fit the bearing cap Tighten the setscrews to...

Page 169: ...then passes through the hole in the idler shaft to the bush in the idler gear To remove the idler shaft Caution The pin is very hard if the tap is broken or the pin cannot be removed then the other m...

Page 170: ...in A3 1 0 mm 0 039 in A4 16 1 16 4 mm 0 633 0 646 in A5 6 9 x 22 mm 0 272 x 0 866 in diameter hole for 5 16 24 UNF x 18 mm thread A6 36 0 mm 1 42 in A7 6 5 6 6 mm 0 256 0 260 in diameter hole counters...

Page 171: ...en the shaft is pressed into position Enter the chamfer of the idler shaft into the hole If the idler shaft A3 has an oil hole ensure that the hole A2 in the idler shaft is at the top and that the fla...

Page 172: ...remove and to fit the idler shaft For four cylinder engines 1 Support the front of the bearing cap Put a suitable adaptor on the small diameter of the idler shaft and press the idler shaft out of the...

Page 173: ...he parts Check for cracks and any other damage 3 Fit the outer rotor and check the outer rotor to body clearance A 4 Check the inner rotor to outer rotor clearance B 5 Check the rotor end float with a...

Page 174: ...engine lubricating oil and push the delivery pipe into the oil pump Push the relief valve onto the delivery pipe and fit the relief valve to the cylinder block ensure that the thimble is correctly fit...

Page 175: ...low end to the inside Fit the spring and the end cap into the bore with the ends of the spring fitted around the bosses of the plunger and the end plate Apply pressure to the end plate and fit the cir...

Page 176: ...Discard the joint To fit the pipes arrangement 1 1 Put the three setscrews into position in the flange A3 of the inner pipe A5 part number 2483A005 Put a new joint A2 in position on the setscrews 2 En...

Page 177: ...crew Hold the flange and the joint in position and fit the centre setscrew A2 Tighten the setscrew finger tight 4 Put the flange of the outer pipe in position and fit the third setscrew A1 tighten it...

Page 178: ...ly 0 03 0 10 mm 0 001 0 004 in Lubricating oil pump six cylinder engines Type Differential rotor gear driven Number of lobes Inner rotor 4 Outer rotor 5 Clearance of outer rotor to body 0 15 0 34 mm 0...

Page 179: ...ton cooling jets 340 395 kPa 49 57 lbf in2 3 4 4 0 kgf cm2 With piston cooling jets 415 470 kPa 60 68 lbf in2 4 2 4 8 kgf cm2 Six cylinder engines 345 414 kPa 50 60 lbf in2 3 5 4 2 kgf cm2 Oil pressur...

Page 180: ...180 This page is intentionally blank...

Page 181: ...uel injection pumps have locking screws A2 and B1 which lock the shaft It is important that the lock screw is released and the pump shaft is free to turn when the pump is fitted to the engine Stanadyn...

Page 182: ...have a Stanadyne fuel injection pump C fitted The electrical stop solenoid on these fuel pumps is fitted inside the governor housing The earth connection C1 and the electrical supply connection C2 are...

Page 183: ...ith gear driven coolant pumps is on the rear of the timing case on the left side of the engine As the engine warms the sender unit energises to retard the pump timing to the correct timing for normal...

Page 184: ...ification numbers for the electrical components on the wiring diagram are shown in triangles Refer to the component identification list for the relevant wiring diagram to find a component Cable identi...

Page 185: ...ender unit in the coolant passage at the rear of the timing case energises to apply 24V to the wax filled element A1 As the wax expands it causes a rod connected to a lever to retard the pump timing t...

Page 186: ...remove air from the fuel system back into the fuel tank The fuel in the injection pump also lubricates and cools the pump A fuel heater or cooler may be fitted between the filter head and filter cani...

Page 187: ...three types of fuel filter element in use The separate element type A2 where the filter element is held between the filter head A1 and the bottom cover A3 The filter can have two elements A The canist...

Page 188: ...assembly If a drain tap is fitted to the bottom of the filter bowl drain the fuel from the filter 2 Hold the bottom cover of the filter element and release the setscrew A3 which is fitted through the...

Page 189: ...fit a suitable cover to all open connections 1 Thoroughly clean the outside surfaces of the fuel filter assembly 2 Loosen the drain device at the bottom of the filter A1 and allow the water fuel to dr...

Page 190: ...l of the fuel in the filter canister This will prevent fuel spill when the gland ring A7 is released 3 Support the filter canister s and rotate the gland ring to the left and remove the gland ring 4 R...

Page 191: ...engine at a fast idle speed Loosen and tighten the union nut of the high pressure fuel pipe at each atomiser Do not loosen the union nut more than half a turn When the union nut of the defective atomi...

Page 192: ...hreads in the cylinder head Caution Do not move the thread after it has been tightened the seal that is made when torque has been applied will be broken and leakage past the atomiser seat may occur Ti...

Page 193: ...amshaft eccentric is in the minimum lift position before the lift pump is fitted Clean the joint face of the lift pump A2 and the cylinder block and fit the lift pump together with a new joint A1 Appl...

Page 194: ...y Remove the rocker lever the pin A9 the link arm and the return spring Check the components for wear and other damage To assemble 1 Thoroughly clean the valve housings Fit new seat washers A3 and pus...

Page 195: ...Fit a 0 70 kPa 0 10 lbf in2 0 0 7 kgf cm2 pressure gauge to the outlet of the lift pump Release the connection at the gauge and operate the priming lever of the lift pump to eliminate air from the pi...

Page 196: ...e engine timing by rotation of the fuel pump the mounting flange A5 has holes instead of slots Accurate timing of the pump to the engine is by a pin A1 used to align the fuel pump gear and the hub A2...

Page 197: ...spanner to prevent movement of the high pressure outlet when the union nut for each high pressure pipe is released 5 Remove the pipes Remove the cables and the connections for the cold start device an...

Page 198: ...itted 5 Tighten the flange nuts of the fuel pump to 28 Nm 20 lbf ft 2 8 kgf m Caution Do not release the nut B6 from the fuel injection pump The fuel pump hub is fitted to the shaft in the factory to...

Page 199: ...ge from the union nut ensure that the pipe is correctly aligned with the atomiser inlet Do not tighten the atomiser union nut more as this can cause a restriction at the end of the pipe This can affec...

Page 200: ...rease the speed When the speed is correct tighten the lock nut The setting of the idle speed can change for different applications Normally the correct speed will be given in the manufacturer s handbo...

Page 201: ...s fitted loosen the vent plug instead 2 Operate the priming lever of the fuel lift pump B until fuel free from air comes from the banjo bolt Tighten the banjo bolt If the drive cam of the fuel lift pu...

Page 202: ...nd of the pipe This can affect the fuel delivery 6 Put the electrical system switch to the ON position Ensure that the manual stop control if one is fitted is in the run position Operate the starter m...

Page 203: ...be set accurately when the engine is in service To prevent incorrect adjustments to the engine timing by rotation of the fuel pump the mounting flange B1 has holes instead of slots Accurate timing of...

Page 204: ...re outlet when the union nut for each high pressure pipe is released 5 Remove the pipes the cables and the connections for the cold start device and the electrical stop solenoid from the fuel pump Cau...

Page 205: ...en the flange nuts of the fuel pump to 28 Nm 20 lbf ft 2 8 kgf m Caution Do not remove the nut C2 from the shaft of the fuel injection pump The fuel pump hub is fitted to the shaft in the factory to e...

Page 206: ...s a leakage from the union nut ensure that the pipe is correctly aligned with the atomiser inlet Do not tighten the atomiser union nut more as this can cause a restriction at the end of the pipe This...

Page 207: ...rease the speed When the speed is correct tighten the lock nut The setting of the idle speed can change for different applications Normally the correct speed will be given in the manufacturer s handbo...

Page 208: ...crankshaft must be rotated one revolution Caution Use a spanner to prevent movement of the fuelled starting aid C1 when the union nut C2 is loosened or tightened 3 Loosen the union nut C2 at the fuel...

Page 209: ...ions Tighten the high pressure pipe connections to 22 Nm 16 lbf ft 2 2 kgf m Return the switch to the OFF position 7 The engine is now ready to start Caution Operate the engine at low idle speed for a...

Page 210: ...shaft of the pump The hub B3 is permanently mounted onto drive shaft by the pump manufacturer to allow the pump timing to be set accurately when the engine is in service To prevent incorrect adjustmen...

Page 211: ...ipe is released 5 Remove the pipes the cables and the connections for the cold start device B2 and the electrical stop solenoid B1 from the fuel pump Cautions Do not rotate the crankshaft when the pum...

Page 212: ...ut B2 from the shaft of the fuel injection pump The fuel pump hub is fitted to the shaft in the factory to ensure that the fuel pump is in the correct position for timing If the hub is removed the hub...

Page 213: ...s a leakage from the union nut ensure that the pipe is correctly aligned with the atomiser inlet Do not tighten the atomiser union nut more as this can cause a restriction at the end of the pipe This...

Page 214: ...rease the speed When the speed is correct tighten the lock nut The setting of the idle speed can change for different applications Normally the correct speed will be given in the manufacturer s handbo...

Page 215: ...If the fuel system is empty or if the canister s of the fuel filter have been renewed it will be necessary to eliminate air from the fuel system especially the fuel injection pump 1 Loosen the vent p...

Page 216: ...Damage to the fuel injection pump battery and starter motor can occur if the starter motor is used excessively to eliminate air from the fuel system 5 Put the electrical system switch to the ON posit...

Page 217: ...of rotation Clockwise from drive end Stanadyne fuel injection pump Type Stanadyne DB2 or DB4 pin timed Direction of rotation from drive end Clockwise from drive end Fuel lift pump four cylinder engine...

Page 218: ...300 4410 30 4 KL 2645A312 2645A633 300 4410 30 4 KM 2645A313 2645A634 300 4410 30 4 KN 2645A315 2645A635 290 4263 29 4 KP 2645A311 2645A636 290 4410 30 4 KR 2645A311 2645A608 290 4263 29 4 KT 2645A311...

Page 219: ...ar of the cylinder block Some four cylinder engines have a cassette type oil cooler fitted between the oil filter canister and the oil filter head If the cassette oil cooler is fitted on the left side...

Page 220: ...stat housing ensure that the groove A2 for the clip retainers and the seat for the O ring are free of debris 2 Ensure that the joint faces of the thermostat housing and the lower body are clean and th...

Page 221: ...k the drive gear of the coolant pump for wear or other damage If the gear is damaged it must be renewed 3 Lightly lubricate the O ring on the pump body with clean engine lubricating oil Fit the pump t...

Page 222: ...s by the last four digits of the part number for example 4131E011 stamped on the front of the pump body To remove and to fit 21 3 Consumable products POWERPART Threadlock To remove 1 Drain the cooling...

Page 223: ...he coolant pump 5 Fit the pump to the timing case cover with its gear in mesh with the gear of the fuel injection pump Note Three of the setscrews B3 have a sealant applied to the threads by the manuf...

Page 224: ...plain washer from the pump pulley It may be necessary to use extractor PD 155C to remove the pulley from the pump shaft A 6 If the pump is to be dismantled remove the key from the keyway of the pump s...

Page 225: ...pump rear body and coolant pump B2 Fit a new joint B4 to the coolant the pump 4 Fit the coolant pump and joint to the rear pump body and tighten the four M10 setscrews B3 to 44 Nm 33 lbf ft 4 5 kgf m...

Page 226: ...To remove and to fit 21 5 Special tool Gear puller PD 155C Consumable products POWERPART Retainer oil tolerant To remove 1 Remove the fan see operation 21 9 2 Remove the fan belt see operation 23 3 3...

Page 227: ...er block Remove the setscrew for the alternator adjustment linkage and the spacer Remove the four setscrews A and the other three setscrews B in illustration A and carefully remove the rear body from...

Page 228: ...Fit the three setscrews B in illustration A and remove the two guide studs Fit the other four setscrews A in illustration A Tighten the setscrews A to 44 Nm 33 lbf ft 4 5 kgf m and the setscrews B to...

Page 229: ...tion of the new coolant pump is by the last four digits of the part numbers 4131E011 stamped on the front of the coolant pump body and by the bearing which extends approximately 5 mm 0 2 in past the e...

Page 230: ...the outer surface of the bearing A3 but keep the retainer away from the ends of the bearing 3 Provide a suitable support under the impeller end of the pump body Put the bearing and shaft assembly in...

Page 231: ...al just behind the flange Put the seal into position on the end of the shaft Ensure that the ring of sealant is towards the bearing Use the tool to press the seal onto the shaft until the bottom of th...

Page 232: ...om the pump shaft Drill four 6 35 mm 0 25 in holes at equal distance around the end of the pump shaft between the shaft and the hub for the impeller These holes will break the interference fit between...

Page 233: ...il seal 6 Remove and discard the circlip A7 7 Put the impeller end of the pump body A1 face down on a suitable press Press the drive gear end of the shaft through the gear A4 and the pump body until t...

Page 234: ...ut the cover end of the pump body A1 face down on a suitable press Press the needle roller bearing A5 into the bearing housing until the end of the bearing is level with or 0 5 mm 0 020 in below the t...

Page 235: ...ss the new oil seal into position The tool should be made of steel to the dimensions shown below A 40 0 mm 1 57 in B 80 0 mm 3 15 in C 60 0 mm 2 36 in D 42 0 mm 1 65 in E 29 0 mm 1 14 in F 14 5 mm 0 5...

Page 236: ...material to the dimensions shown below A 44 0 mm 1 73 in B 40 0 mm 1 57 in C 12 2 mm 0 48 in D 35 8 mm 1 41 in E 16 1 mm 0 63 in F 1 00 mm 0 04 in at 45 G 2 00 mm 0 08 in at 45 The dimensions of the...

Page 237: ...oil tolerant To dismantle 1 Remove the coolant pump A from the engine see operation 21 4 2 Remove the circlip A4 for the bearing housing A3 3 Support the pulley end of the pump and press the shaft A6...

Page 238: ...race of the bearing Put the bearing A4 into position on the pump housing and shaft Use a suitable adaptor on the inner and outer race to ensure the pressure is applied evenly Press the bearing onto th...

Page 239: ...ngs Use the tool to press the seal onto the shaft until the bottom of the seal flange is in complete contact with the pump body Continue to apply force for approximately ten seconds to ensure that the...

Page 240: ...fan and tighten the setscrews to the torque shown in section 11 Fan drive engines with gear driven coolant pumps To remove and to fit 21 10 To remove 1 Loosen the pivot fasteners of the alternator and...

Page 241: ...nnection for the coolant B3 and the outlet flange for the coolant B5 Ensure that the joint faces are clean Renew the joint B4 for the oil pipe flange 2 Lightly lubricate the bore of the vent connectio...

Page 242: ...rews and nuts of the cover of the oil cooler and remove the cover together with the element A2 Thoroughly clean the flange face of the cover and the cylinder block To fit 1 If the studs A4 have been r...

Page 243: ...are released Caution Do not remove both of the oil pipes together 2 Put a drip tray under the oil cooler and remove the lubricating oil pipes from the oil cooler Do not remove both of the oil pipes to...

Page 244: ...to the cylinder block to prevent the leakage of coolant 2 Put a new paper joint into position on the studs the joint is fitted dry Fit the oil cooler assembly A3 to the cylinder block Gradually and e...

Page 245: ...joint face of the filter head A2 2 Check the washer A4 and the seals A7 and A8 for damage Renew the washer and the seals if they are damaged or worn Lightly lubricate the seals with clean lubricating...

Page 246: ...this does not enter the element Check that there is nothing to restrict the flow of lubricating oil through the element of the oil cooler If the inside of the element needs to be cleaned use a solven...

Page 247: ...be cleaned use a solvent which is suitable for copper Dry the element with low pressure air and then flush it with clean engine lubricating oil To assemble 1 Renew the O rings B1 on the flanges of the...

Page 248: ...t A3 4 Remove and discard the three piece O ring A4 from the element Warning Do not allow compressed air to contact your skin If compressed air enters your skin obtain medical help immediately 5 Clean...

Page 249: ...e flange face A1 for the three piece O rings on the inside of the cover 3 Fit the cover of the oil cooler to the element A2 4 Fit the two piece flanges A4 onto the studs A5 Tighten the nuts to retain...

Page 250: ...nd the system is under pressure because dangerous hot coolant can be discharged 2 Drain the coolant system and release the hose clips A5 which fasten the hoses to the coolant inlet and the outlet conn...

Page 251: ...they enter the holes in the manifold The tubestack will be in contact with the bottom of the manifold if the O rings are fitted correctly 3 Fit the setscrews which retain the tubestack to the inducti...

Page 252: ...a lever between the flange faces to separate the intercooler top cover from the induction manifold 4 Release the setscrews A2 which retain the intercooler cover to the induction manifold A6 work from...

Page 253: ...they enter the holes in the manifold The tubestack will be in contact with the bottom of the manifold if the O rings are fitted correctly 3 Fit the setscrews which retain the tubestack to the inducti...

Page 254: ...fluid to drain off and dry the fins with low pressure compressed air 3 Flush the tube stack through the outlet connection in the opposite direction of coolant flow with clean water 4 Thoroughly clean...

Page 255: ...g in pump body 0 01 0 04 mm 0 0004 0 0016 in Dimension of impeller boss to front face of pump body fitted 7 7 8 0 mm 0 303 0 315 in Dimension of gear from rear flat face of pump body fitted 21 0 21 5...

Page 256: ...8645 in Outside diameter of shaft 21 987 22 000 mm 0 8656 0 8661 in Interference fit of shaft in hub 0 029 0 062 mm 0 0011 0 0024 in Maximum permissible end float of shaft 0 200 mm 0 0079 in Part numb...

Page 257: ...ywheel and housing 22 General description The steel flywheel is fitted with a hardened starter ring Generally the starter rings have 126 or 115 teeth The flywheel housing is normally made of cast iron...

Page 258: ...Nm 77 lbf ft 10 7 kgf m 3 Check the flywheel run out with a dial test indicator A This must be less than 0 30 mm 0 012 in total indicator reading 4 Check the alignment of the flywheel face B The erro...

Page 259: ...ee from damage Ensure that the location dowels are fitted correctly If a felt seal is fitted to the rear flange of the sump renew the seal 2 Fit the housing onto the dowels and tighten lightly the set...

Page 260: ...used in the factory The information applies to all engines unless an engine type code is shown Flywheel and housing Limits for flywheel housing run out and alignment total indicator reading Diameter o...

Page 261: ...not disconnect the battery while the engine is in operation This will cause a voltage surge in the alternator charge system which will immediately cause damage to the diodes or to the transistors Do...

Page 262: ...eflection B With moderate thumb pressure 45 N 10 lbf 4 5 kgf the correct belt deflection is 10 mm 3 8 in To adjust tension 23 2 1 Loosen the pivot fasteners B1 of the alternator and the fasteners of t...

Page 263: ...t fasteners and the adjustment link and its fasteners Ensure that the washers and the distance pieces are fitted in their correct positions and that the alternator pulley is aligned to the crankshaft...

Page 264: ...een the alternator and the positive terminal of the battery 3 Turn the warning light switch to the on position main switch on instrument panel the warning light should be illuminated 4 Switch on a 10...

Page 265: ...l and the negative terminal on the alternator Turn the switch to the on position and operate the engine at fast idle If there is no output there is a fault in the alternator If there is an output ther...

Page 266: ...in the factory The information applies to all engines unless an engine type code is shown Electrical equipment The information which follows is general and can change with specific applications Alter...

Page 267: ...mature at high speed if the starter is held in the engaged position The Lucas S115 starter motor has a smooth surface with no protrusions This is because the solenoid and the main switch assemblies ar...

Page 268: ...nge face of the starter motor the distance piece if one is fitted and the face of the flywheel housing If the engine has a flywheel housing which is oil filled the starter motor must be sealed before...

Page 269: ...brushes are inserted in their holders it is advised that the holders are cleaned with compressed air or with a material which is damp with gasolene The commutator must be completely clean dirt or oil...

Page 270: ...The information applies to all engines unless an engine type code is shown Electrical equipment The information which follows is general and can change with specific applications Starter motors Make a...

Page 271: ...ove and to fit a fuelled starting aid 23 9 To remove 1 Disconnect the fuel pipe A2 and the electrical connection A3 2 Turn the spanner A1 counter clockwise and remove the starting aid To fit 1 Ensure...

Page 272: ...sure that the electrical connector s A2 are in the correct position It is not necessary to use POWERPART threadlock Caution To prevent electrical contact when the circuit is on and for easy removal du...

Page 273: ...er of the fuel lift pump until fuel free of air comes from the connection Tighten the connection 3 Start the engine and operate it at low speed Check that there is no fuel leakage from the valve of th...

Page 274: ...e those which are mainly used in the factory The information applies to all engines unless an engine type code is shown Electrical equipment The information which follows is general and can change wit...

Page 275: ...big end bearings of the compressor and also to the rear bush for the drive shaft Oil which drains from the compressor crankcase into the drive housing lubricates the drive gears and the bearing The o...

Page 276: ...ring pump from the rear of the compressor 5 Loosen the two setscrews A3 of the support bracket A4 at the rear end of the compressor Remove the two fasteners A5 which fasten the support bracket to the...

Page 277: ...he teeth of the drive gear are against the teeth of the idler gear A2 Slowly rotate the crankshaft of the compressor clockwise from the rear until the drive gear and the idler gear are in mesh 6 Caref...

Page 278: ...ners A5 Note Spacers A2 are used between the bracket and the body of the 1W150R compressor 9 Check that the O ring in the cover for the rear of the compressor is not damaged Fit the cover and tighten...

Page 279: ...personnel engaged on engine overhauls The dimensions which are shown are those which are mainly used in the factory The information applies to all engines unless an engine type code is shown Bendix c...

Page 280: ...of the compressor ensure that the drive coupling is not lost To fit 1 Renew the O ring and lubricate it with clean engine lubricating oil 2 Check the drive coupling or the gear for wear or for damage...

Page 281: ...ate it with clean engine lubricating oil Lubricate the bearings A2 and A7 with clean engine lubricating oil Fit the adaptor assembly to the timing case and tighten the cap screws To dismantle and to a...

Page 282: ...he bearing until the gear is onto its shoulder 7 Apply a narrow ring of POWERPART retainer oil tolerant to the outer face and to the inner face of the rear bearing A2 in the positions shown A1 Ensure...

Page 283: ...d fit covers to the open ends of the pipes 2 Release the setscrews and remove the exhauster To fit 1 Ensure that the joint faces of the exhauster and the timing case are clean and renew the joint Fit...

Page 284: ...284 This page is intentionally blank...

Page 285: ...Special tools 25 These tools are available through your local Perkins Distributor If you cannot obtain the correct tool locally contact The Perkins Service Department Peterborough PE1 5NA England UK...

Page 286: ...9 PD 1C 6 Inlet valve guide adaptor for use with PD 1D and PD 1D 1A Part number 21825482 PD 248 Exhaust valve guide adaptor for use with PD 1D and PD 1D 1A Part number 27610029 PD 245 Timing pin for B...

Page 287: ...linder liner main tool Part number 21825543 PD 150B 17A Adaptors for use with PD 150B Part number 21825563 PD 155C Basic puller for camshaft gear Part number 21825565 PD 155B 5 Adaptors for use with P...

Page 288: ...5 in square drive Part number 21825576 PD 170 Replacer tool for seal of timing case cover main tool Part number 21825577 PD 170 1 Pressure plate for use with PD 170 Part number 21825578 PD 170 2 Sleev...

Page 289: ...PD 206 Replacer tool for pistons Part number 21825615 PD 208 Dial gauge for use with PD 41D Part number 21825617 PD 6118B Valve spring compressor Part number 21825666 PD 6118 7 Stud adaptor for use w...

Page 290: ...tor PD 198 MS 1531 Angle gauge to tighten cylinder head setscrews Part number 21825607 PD 242 Combined reamer cutters and handle for valve guides and 31 46 valve seat inserts Part number 27610030 PD 2...

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