Description
Perkins New 1000 Series Workshop Manual for four- and six-cylinder diesel engines, covering engine models AJ to AS and YG to YK. This factory publication applies to New 1000 Series engines used in industrial and agricultural applications.
Prepared for professional technicians and engine repair workshops, the manual provides dismantling, inspection, adjustment, assembly and installation instructions. Technical data includes standard and specific tightening torques, compression test data, component dimensions and approved service information.
This is an engine workshop manual rather than a complete machine manual. Its coverage is confined to the Perkins engine and associated engine-mounted systems.
ENGINE GENERAL INFORMATION AND SPECIFICATIONS
The introductory chapters provide essential identification, safety and workshop reference information required before service work begins.
- Engine identification
- General safety precautions
- Engine lifting equipment
- Viton seal precautions
- Recommended consumable products
- Basic engine data
- Standard and specific tightening torques
- Compression test data
CYLINDER HEAD AND VALVE GEAR
Detailed procedures cover removal, dismantling, inspection, correction and installation of the cylinder head and valve gear assemblies.
- Rocker cover removal and installation
- Rocker assembly dismantling and inspection
- Valve tip clearance checking and adjustment
- Valve spring replacement with the cylinder head fitted
- Cylinder head removal and installation
- Valve and valve spring servicing
- Valve guide inspection and replacement
- Valve seat correction and insert installation
PISTONS, CONNECTING RODS AND CRANKSHAFT
The manual includes overhaul information for the principal rotating and reciprocating components, together with inspection limits and dimensional data.
- Big-end bearing removal, installation and inspection
- Piston and connecting rod removal and assembly
- Piston height measurement
- Piston ring removal, installation and inspection
- Connecting rod inspection and length checking
- Piston cooling jet servicing and alignment
- Main bearing and thrust washer procedures
- Crankshaft removal, installation and inspection
- Crankshaft end-float checking
- Balancer unit servicing
TIMING DRIVE AND CYLINDER BLOCK
Workshop procedures explain service operations for the timing case, gear train, camshaft, tappets, cylinder block and liners.
- Timing case cover and front oil seal
- Front seal wear-sleeve installation
- Idler gear and hub
- Fuel pump, camshaft and crankshaft gears
- Timing case removal and installation
- Camshaft and tappets
- Cylinder block dismantling and inspection
- Cylinder liner inspection and replacement
- Cylinder bore inspection for AR and AS engines
ENGINE TIMING AND ASPIRATION
Timing instructions cover the correct positioning and checking operations required during engine assembly and fuel-system work. Aspiration-system information includes turbocharger and breather service.
- Setting number one piston to TDC on compression
- Valve timing checks
- Fuel injection pump timing checks
- Turbocharger removal and installation
- Impeller and compressor casing cleaning
- Waste-gate actuator replacement
- Waste-gate operation checking and adjustment
- Turbocharger fault information
- Engine breather cleaning and renewal
LUBRICATION AND FUEL SYSTEMS
The Perkins New 1000 Series Workshop Manual provides practical service procedures for lubrication components and the fuel-system equipment fitted across the covered engine range.
- Oil filter canister and filter head
- Sump, oil strainer and suction pipe
- Lubricating oil pump inspection and service
- Oil-pressure relief valve
- Flexible oil pipe inspection
- Fuel filter element replacement
- Atomiser fault diagnosis and replacement
- Fuel lift pump overhaul and testing
- Bosch fuel injection pump removal and adjustment
- Lucas DP200 and Stanadyne injection pump procedures
- Fuel-system bleeding procedures
ADDITIONAL ENGINE SYSTEMS
The publication also contains dedicated chapters covering the cooling system, flywheel and housing, electrical equipment, auxiliary equipment and special tools. These sections support complete engine service without extending the manual to the host machine’s transmission, hydraulics or chassis.
TESTING, INSPECTION AND ADJUSTMENT
Inspection and adjustment data are integrated with the relevant procedures. Confirmed subjects include compression testing, valve clearance adjustment, piston height, crankshaft end-float, connecting-rod measurement, cooling-jet alignment, engine timing, waste-gate adjustment, oil-pump inspection and fuel lift-pump testing.
PERKINS NEW 1000 SERIES WORKSHOP MANUAL MODEL COVERAGE
Models covered: AJ, AK, AL, AM, AN, AP, AQ, AR, AS, YG, YH, YJ and YK.
Engine configuration: Four- and six-cylinder diesel engines.
Applications: Industrial and agricultural.
MANUAL DETAILS
- Manufacturer: Perkins Engines Company Limited
- Manual type: Factory workshop manual
- Series: New 1000 Series
- Publication number: TPD 1350E
- Issue: Issue 3
- Publication date: March 2000
- Page count: 290 pages
This Perkins New 1000 Series Workshop Manual is suitable for engine rebuilders, agricultural engineers, industrial maintenance departments and workshops responsible for servicing the specified engine models.
Model applicability should be confirmed from the engine identification details before work begins, particularly where different fuel-injection equipment or engine configurations are fitted.
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