Perkins 1000 Series Diesel Engines OEM Service & Repair Manual

Shop Manual Perkins SEBEI 006600 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

Contents General information ... ... ... ... Specifications ... ... ... ... ... ... SERVICE OPERATIONS Cylinder head assembly ... ... ... Pistons and connecting rod assemblies Crankshaft assembly ... ..i Timing case and drive assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder block assembly Engine timing ... Aspiration system ... Lubrication system Fuel system ... ... Cooling system ... Flywheel and housing Electrical equipment Auxiliary equipment List of special tools Fault finging guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 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 This workshop manual has been designed to provide assistance in the service and overhaul of Perkins Phaser and 1000 Series engines. Most of the general infomlation 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. 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. Read and remember the “Safety precautions”. They are given for your protection and must be used at all times. A 1 A hazard symbol in the text indicates that there is a danger of personal injury if certain operations are . 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 CAV DPA CAV DPS Vehicle and truck applications Naturally aspirated engines in industrial and agricultural applications 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 have been designed. l Do not change the specification of the engine. l Do not smoke when you put fuel in the tank. l Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a safe place. 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 that you 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, .. A 1 0 . . ,. _ ._ .,’ . 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 ... ... ... ... ... ... ... ._. ... .._ ._. _.. -YA,YB,YC,YD .. ... .. ... .. . ... ... ._. ... ... .._ ._. Cylinder arrangement ... ... ... ... ._. ... ... ... ... __. Cycle ... .. ... ... ... ... ... ... .._ ... ._. ... ._. ... Induction system: -AA,YA .. ... ... ... ... ... ... ... . .. .._ ... ... .._ __. -A& YB .. ... ... ... ... ... ... ... ... _.. ... ... ... .._ -AC,YC .. .. ... .. ... ... ... ... . .. ._. ... ... ... ._. -AD,YD .. .. ... .. ... ... .. . ... . .. ... ... .. . ... ... Combustion system .. ._. _.. .. .__ ... ._. .._ _.. .._ ._. Nominal bore ... ... ... ._. ... ... ... .. ... ... ... ... Stroke ... .. ... .. ... ... ... ... ... ._. ... ._. ... ... Compression ratio: -AA,AG,YA,YC ... ... . . ... . .. . .. ... ... ... .. ... -AB,AD,YB,YD ... .. ... ... ... ... ._. ... ... ___ ... 1.. Cubic capacity: -AA,AB.AC,AD ... . . ... ... ... ... ... ... ... .._ _.. ... -YA,YB.YC,YD ... .. . . ... ... .. ... ... ... ... __. ... Firing order -AA,AB,AC,AD .. ... ... ... ... ... ... _.. ... ... .._ _.. -YA,YB,YC,YD ... ... ... ... ... ... ... __. ... ... ._. ... Valve tip clearance (cold): - Inlet ... ... .. . .. . ._. ... ... . _.. ... ... _._ ... - Exhaust ... . ... ... ... ... ... ._. ... _.. ... ._. ... Lubricating oil pressure (minimum at maximum engine speed and normal engine temperature): -AA,AC,YA,YC . . ... ... ... ... ... .., ... ... ... ... ... -AB,AD,YB,YD . . ... ... ... ... ... ... ... ... ... ... ._. Direction of rotation . .. ... _.. .._ ... ... _.. _.. ... _._ __. 4 6 In-line Four stroke Naturally aspirated Turbocharged Aitiiude compensated Turbocharged/intercoofed Direct injection 100 mm (3.937 in) 127 mm (S.OOO in) 16.51 16.0:1 4 litres (243 ins) 6 litres (365 in3) 1,3,4,2 1,%3,6,2.4 0.20 mm (0.008 in) 0,45 mm (0.018 in) 207kN/m2 (3Olbf/n2) 2.1 kgf/cm2 280kN/m2 (40lbf/in2)2,8kgf/cm2 Clockwise from the front 11 A.02

IIA : .\ Weight table 1000 SERIES COMPONENT WEIGHTS Cylinder block assembly Rear end oil seal housing assembly Timing case Timing case cover Crankshaft Piston assembly Conecting rod assembly Cylinder head Gear, Idler Gear, camshaft Camshaft Lub oil pump assembly Gear, fuel pump Fuel pump injector Flywheel housing Flywheel Starter motor Fan drive housing Pulley, fan drive Sump Cylinder head cover Lub oil filter head Lub oil cooler assy Crank pulley Pulley extension/fan adapter Water pump assembly Alternator Induction manifold Turbocharger Induction elbow Exhaust manifold Fuel filter assembly Front mount adapters Unit: kg 64.00 0.40 4.15 1.63 47.00 1.85 2.11 59.00 2.76 1.88 5.00 2.89 1.86 6.00 0.27 30.00 48.00 19.75 4.03 3.64 49.00 3.03 1.10 1.91 10.16 4.94 6.75 5.10 3.31 8.04 0.78 6.35 0.85 3.16 llA.03

Recommended torque tensions Cylinder head assembly . .. ... . .. Pistons and connecting rod assemblies Crankshaft assembly . .. ... ... . .. Timing case and drive assembly ... ... Aspiration system ... ... !.. ... ... Lubrication system ... ... ... ... ... Fuel system . .. . .. ... ... ... ... Cooling system ... .. . .. . . .. ... ... Flywheel and housing .. . ... ... . .. Electrical equipment ... ... ... ... Auxiliary equipment ... ... ... ... IIB . .. . . . . .. . . . . . . _ .. . . . . . . . . . . . . .. . .. . 118.02 . .. . . . . . . . . . . . . _. . _. . . . . . . . .. . .. . . . . 118.02 . .. ... ... ... .-. . .. .. . .. . ... .. . ... ... 118.02 . . . . . . . . . . . . .. . . . . .. . .. . . . . .. . . . . . . . 118.02 . . . . . . . . . . . . .. . . .. . . . . . . .. . .. . . . . .. . 118.02 . . . . . . . .. . .. . . . . .. . . . . . . . .. .. . .. . . .. 118.02 . . . . .. . .. . . . . . . . . . . . . . . . . . . .. . .. . . . . 11 B.02 ... . .. . .. ... .. . _.. ._. ... ... ... .. . ... 11 B.02 . .. . . . . .. . . . . . . . . . . . . .. . . . . .. . . . . . . . 11 B.03 . .. . . . . .. . . . . . . . .. .. . . . . . . . . . . *.. . . . 11 B-03 . .. . . . . .. . . . .. . . .. _. . . . . . . . .. . . . . . . . 11 B-03 llB.01

Perkins 1000 Series Diesel Engines OEM Service & Repair Manual

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