Perkins Engine 1000 Service Manual

TPD1329E, Issue 3
July 2000

User’s
Handbook

Perkins 1000 Series

AA to AH
YA to YD

Chapters

1 General information

Th ispu blicationis w ritt en in
Perkins A ppr ovedClearEnglish

2 Engine view s

3 Operation instructions

4 Preventive maintenance

5 Engine fluids

6 Fault diagno sis

7 Engine preservation

8 Parts and service

9 General data

The following pages contain a detailed table of contents

2

Contents

1 General Information

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

How to care for your engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Engine identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Perkins companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

General safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Engine views

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Location of engine parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3 Operation instructions

How to start the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

How to stop the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Adjustment of the engine speed range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Running-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Turbocharged engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 Preventive maintenance

Preventive maintenance periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

How to drain the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

How to check the specific gravity of the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

How to check the drive belt(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

How to clean the gauze strainer of the fuel lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Fuel pre-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

How to renew the element(s) of the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

How to renew the element(s) of the separate element type . . . . . . . . . . . . . . . . . . . . . . 25

How to renew the filter canister of the canister fuel filter . . . . . . . . . . . . . . . . . . . . . . . . 26

How to renew the canister of the quick release fuel filter . . . . . . . . . . . . . . . . . . . . . . . . 27

Atomiser fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3

How to renew an atomiser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

How to eliminate air from the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

How to renew the lubricating oil of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

How to renew the canister of the lubricating oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

How to clean the closed breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

How to clean the integral closed breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

The open breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Restriction indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

How to check the valve tip clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5 Engine fluids

Fuel specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Lubricating oil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Coolant specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6 Fault diagnos is

Problems and possible causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

List of possible causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

7 Engine preservation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

8 Parts and service

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Service literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

POWERPART recommended consumable products . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

9 General data

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4

1

General Information 1

Introduction

The Perkins 1000 Series industrial and agricultural
engines are the latest developments from Perkins
Engines Limited a world leader in the design and
manufacture of high performance diesel engines.

More than sixty years of diesel production experience,
together with the latest technology, have been
applied to the manufacture of your engine to give you
reliable and economic power.

To ensure that you use the relevant information for
your specific engine type, refer to "Engine
identification" on page 7.

Danger is indicated in the text by two methods:

Warning! This indicates that there is a possible
danger to the person.

Caution: This indicates that there is a possibl e
danger to the engine.

Note: Is used where the information is important, but
there is not a danger.

A

A0314

5

1

How to care for your engine

Warning! Read the "Safety precautions" and
remember them. They are given for your protection
and must be applied at all times.

Caution: Do not clean an engine while it runs. If cold
cleaning fluids are applied to a hot engine, certain
components on the engine may be damaged.

This handbook has been written to assist you to
maintain and operate your engine correctly.

To obtain the best performance and the longest life
from your engine, you must ensure that the
maintenance operations are done at the intervals
indicated in "Preventive maintenance". If the engine
works in a very dusty environment or other adverse
conditions, certain maintenance intervals will have to
be reduced. Renew the filter canisters and lubricating
oil regularly in order to ensure that the inside of your
engine remains clean.

Ensure that all adjustments and repairs are done by
personnel who have had the correct training. Perkins
distributors have this type of personnel available. You
can also obtain parts and service from your Perkins
distributor. If you do not know the address of your
nearest distributor, enquire at one of the Perkins
companies listed on page 8.

The terms "left side" and "right side" apply when the
engine is seen from the flywheel end.

6

Engine identification

1

The 1000 Series consists of a range of both four and
six cylinder engines. Each range has four basic
engine types, naturally aspirated, compensated,
turbocharged and turbocharged with an intercooler.

There are different model variations within each
range. Identification of the various models is by a
system of numbers and letters, for example:

1006-60TW

1006 6 cylinder engine

-60 6 litre engine
T Turbocharged

TW Turbocharged, but with an air

to water intercooler to cool
the induction air between the
turbocharger and the
cylinders.

Engines used for generator sets have a similar
system of model identification, for example:

1006-60TWG1

1006 6 cylinder engine

-60 6 litre engine
T Turbocharged

1

A

2

A0043

The correct identification of the engine is by the full
engine number.

The engine number is stamped on a label (A1) which
is fastened to the left side of the cylinder block. Some
engines also have the engine number stamped on the
rear of the cylinder block (A2). An example of the
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. If there is a number in the
area of the label marked TPL N

o

, then this number

must also be given to your Perkins distributor.

TW Turbocharged, but with an air

to water intercooler

G Generator set

1 Rating code number

In this handbook, the different engine types are
indicated by their code letters, which are the first two
letters of the engine number as indicated below:

Code Letters Engine type

AA Four cylinder, naturally aspirated.
AB Four cylinder, turbocharged.
AC Four cylinder, compensated.

AD

AG

AH

YA

Four cylinder, turbocharged
and intercooled.

Four cylinder, naturally aspirated,
belt driven coolant pump.

Four cylinder, turbocharged,
belt driven coolant pump.

Six cylinder,

naturally aspirated.
YB Six cylinder, turbocharged.
YC Six cylinder, compensated.

YD

Six cylinder, turbocharged

and intercooled

7

1

Perkins companies

Australia

Perkins Engines Australia Pty. Ltd,
Suite 4, 13A Main Street,
Mornington 3931, Victoria, Australia.
Telephone: [phone]
Telex: Perkoil AA30816
Fax: [phone]

France

Perkins France S.A.S,
“Parc des reflets”
165 Avenue Du Bois de la Pie
95700 Roissy Charles de Gaulle, France.
Telephone: [phone]
Fax: [phone]

United Kingdom

Perkins Engines Company Ltd,
Eastfield, Peterborough PE1 5NA,
England.
Telephone: [phone]
Telex: 32501 Perken G
Fax: [phone]

United States of America

Perkins International - North America,
26200 Town Center Drive,
Suite 280,
Novi, Michigan 48375
USA
Telephone: [phone]
Fax: [phone]

Germany

Perkins Motoren GmbH,
Saalaeckerstr asse 4,
63801 Kleinostheim,
Germany.
Telephone: [phone]
Fax: [phone]

Italy

Motori Perkins S.p.A.,
Via Socrate 8,
22070 Casnate con Bernate (Como), Italy.
Telephone: [phone]
Fax: [phone]

Japan

Perkins Engines, Inc.,
Address Building, 8th Floor,
2-2-19 Akasaka, Minato-ku,
Tokyo 107-0052, Japan.
Telephone: [phone]
Fax: [phone]

Singapore

Perkins Engines Latin America Inc,
Suite 200,
701, Waterford Way (NW 62nd Avenue),
Miami, FL 33134
U.S.A.
Telephone: [phone]
Telex: 32501 Perken G
Fax: [phone]

In addition to the above companies, there are
Perkins distributors in most countries. Perkins
Engines Company Limited., Peterborough or one
of the above companies can provide details.

Perkins Engines (Asia Pacific) pte Ltd
20 Harbour Drive
#07-06A, PSA Vista
Singapore 117612
Telephone: [phone]
Fax: [phone]

8

General safety precautions

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm. Battery
posts, terminals and related accessories contain
lead and lead compounds. Wash hands after
handling.

These safety precautions are important. You must
refer also to the local regulations in the country of use.
Some items only refer to specifi c appl ic ati on s.

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 care must be
used to prevent injury).

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 auxiliary equipment is in
operation.

l

Do not permit loose clothing or long hair near
moving parts.

l

Keep away from moving parts during engine
operation. Warning! Some moving parts 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 or any component 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 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.

l

Only one person must control the engine.

l

Ensure that the engine is operated only from the
control panel or from the operators position.

l

If your skin comes into contact with high-pressure
fuel, obtain medical assistance immediately.

l

Diesel fuel and lubricating oil (especially used
lubricating oil) can damage the skin of certain
persons. Protect your hands with gloves or a
special solution to protect the skin.

l

Do not wear clothing which is contaminated by
lubricating oil. Do not put material which is
contaminated with oil into the pockets of clothing.

l

Discard used lubricating oil and coolant in
accordance with local regulations to prevent
contamination.

l

Ensure that the control lever of the transmission
drive is in the "out-of-drive" position before the
engine is started.

l

Use extreme care if emergency repairs must be
made in adverse conditions.

l

The combustible material of some components of
the engine (for example certain seals) can
become extremely dangerous if it is burned. Never
allow this burnt material to come into contact with
the skin or with the eyes.

l

Always use a safety cage to protect the operator
when a component is to be pressure tested in a
container of water. Fit safety wires to secure the
plugs which seal the hose connections of a
component which is to be pressure tested.

l

Do not allow compressed air to contact your skin.
If compressed air enters your skin, obtain medical
help immediately.

l

Turbochargers operate at high speed and at high
temperatures. Keep fingers, tools and debris away
from the inlet and outlet ports of the turbocharger
and prevent contact with hot surfaces.

l

Fit only genuine Perkins parts.

1

9

This page is intentionally blank

2

Engine views 2

Introduction

Perkins engines are built for specific applications and the views which follow do not necessarily match your
engines specifica tio n.

Location of engine parts

Front and left side of the YB engine (A)

1 Filler cap for the lubricating oil
2 Fuel filter
3 Lubricating oil cooler
4 Fuel injection pump
5 Lubricating oil dipstick
6 Drain plug for the lubricating oil
7 Crankshaft pulley

13

12
11

10

8Drive belt

9 Coolant pump
10 Fan
11 Coolant outlet
12 Front lift bracket
13 Atomiser

1

2

3

A

9
8

7

4

5

6

A0314/1

11

2

Rear and right side of the YB engine (A)

14 Induction manifold
15 Alternator
16 Lubricating oil filter
17 Fuel lift pump
18 Lubricating oil sump
19 Starter motor

20 Flywheel housing
21 Flywheel
22 Turbocharger
23 Exhaust manifold
24 Rear lift bracket

12

24

23

22

21

20

19

A

14

15

16

17

18

A0315

3

Operation instructions 3

How to start the engine

Several factors affect engine start, for example:

l

The power of the batteries

l

The performance of the starter motor

l

The viscosity of the lubricating oil

l

The installation of a cold start system

Diesel engines need a cold starting aid if they are to
start in very cold cond itions. Nor mally, your vehicl e or
your machine will be fitted with the correct equipment
for your region of operation.

Perkins engines can be equipped with various cold
starting systems. For the 1000 Series engines these
systems are:

Fuelled starting aid

An electrically operated device which ignites a
specific amount of diesel fuel in the induction manifold
in order to heat the induction air.

Port heaters

These electrical devices are fitted in the induction
manifold and heat the induction air. They are
operated automatically when the starter motor is
engaged. When these devices are fitted, the start
procedure for a cold engine is the same as that given
for a cold engine start without starting aids.

Start Pilot

A hand pump is used to inject a cold start fluid into the
induction manifold through an atomiser. The cold start
fluid ignites at a lower temperature than diesel fuel.
The cold start fluid is contained in a separate
reservoir. Certain models use a push button to
actuate a solenoid which releases the cold start fluid
from an aerosol container.

KBi

This system uses an aerosol container filled with a
cold start fluid. The fluid is released by a solenoid,
which is operated by a push button. The cold start
fluid is sprayed into the induction manifold through a
nozzle. The cold start fluid ignites at a lower
temperature than diesel fuel.

Caution: If the engine is to be run after a period in
storage, see "Caution" on page 52.

13

3

0RH

H

S

0

R

S

How to start a warm engine
1 If the engine is equipped with a manual stop

control, ensure that it is in the "run" position.
2 Adjust the engine speed control to the quarter open

position.
3 Turn the start key to the "HS" or "S" position (A) or

(B) to engage the starter motor.
4 Allow the start key to return to the "R" position, as

soon as the engine starts.
Always ensure that the engine and starter motor are

stationary before the starter motor is engaged again.

How to start a cold engine without starting aids
1 If the engine is equipped with a manual stop

control, ensure that it is in the "run" position.
2 Adjust the engine speed control to the maximum

speed position.
3 Turn the start key to the "S" position (B) to engage

the starter motor. Allow the key to return to the "R"
position, when the engine starts. Then adjust the
engine speed control to get an even idle speed.

4 If the engine does not start in 30 seconds, allow the
start key to the "R" position for another 30 seconds.
Then engage the starter motor again for a maximum
period of 30 seconds.

How to start a cold engine with the fuelled starting
aid

Caution: Ether type fuels must not be used at the
same time as a fuelled starting aid.

1 If the engine is equipped with a manual stop
control, ensure that it is in the "run" position.

2 Turn the start key to the "H" position (A) and keep
it there for 15 seconds.

3 Adjust the engine speed control to the maximum
speed position.

4 Turn the start key to the "HS" position in order to
engage the starter motor. Allow the start key to return
to the "R" position, when the engine starts. Then
adjust the engine speed control to give an even idle
speed.

5 If the engine does not start in 15 seconds, turn the
start key to the "H" position and hold it there for 10
seconds. Then engage the starter motor again.

A

B

A1015

A1016

14

How to start a cold engine with manually operated
Start Pilot

3

How to start a cold engin e with K Bi or el ectr ical ly
operated Start Pilot

Caution: Start Pilot equipment must not be used with
heater type starting aids such as the fuelled starting
aid.

Do not use the hand pump until the starter motor is
engaged. The amount of fluid which is necessary for
an engine start will be found by experience.

1 If necessary, fill the reservoir with fluid. Lift the
cover of the reservoir and press the can, head down,
onto the filler plug. Hold it squarely until the fluid fills
the bowl to the maximum mark.

2 If the engine is equipped with a manual stop
control, ensure that it is in the "run" position.

3 Adjust the engine speed control to the maximum
speed position.

4 Turn the start key to the "S" position (page 14/B) in
order to engage the starter motor. Hold the start key
in this position for a maximum of 30 seconds and
operate the hand pump during this period. When the
engine starts, release the start key to the "R" position
and adjust the engine speed control to get an even
idle speed.

5 If the engine does not start in 30 seconds, allow the
start key to return to the "R" position for another 30
seconds. Then engage the starter motor and operate
the hand pump again.

In certain conditions, it is necessary to inject a little
more fluid after the engine has started in order to
ensure that the engine continues to run.

Caution: KBi equipment must not be used with
heater type cold starting aids such as the fuelled
starting aid.

1 If necessary, renew the screw type canister. Ensure
that the sealing washer remains in position when the
new canister is fitted. Each container has a safety
valve.

2 If the engine is equipped with a manual stop
control, ensure that it is in the "run" position.

3 Adjust the engine speed control to the maximum
speed position.

4 Turn the start key to the "S" position (page 14/B) in
order to engage the starter motor.

5 When the engine turns, press the starting aid button
for a maximum period of 2 seconds. If the engine
does not start after the first 2 second application, keep
the starter motor engaged. After 5 seconds, press the
button again for 2 seconds.

6 Allow the start switch to return to the "R" position,
when the engine starts. Then adjust the engine speed
control to get an even idle speed. In certain conditions
it is necessary to inject a little more fluid after the
engine has started, in order to ensure that the engine
continues to run.

The air filter at the outer end of the pump must be
inspected from time to time. If necessary, it must be
washed in kerosene.

The inside surface of the cylinder can be lightly
lubricated with a thin lubricating oil.

The nozzle can be removed from the induction
manifold and washed in kerosene, if necessary. Use
the direction mark on the nozzle body to ensure that
the nozzle is fitted in its original posit ion .

15

3

Cautions:

How to stop the engine

Altitude

Caution: It is recommended that a turbocharged
engine is run at approximately 1000 rev/min at a
reduced load for 2-3 minutes before it is shut down.
This will allow the turbocharger to cool.

According to the equipment fitted, either turn the
engine start key to the "O" position (page 14/A or B)
or operate the manual stop control. If a manual stop
control is used, ensure that the control returns to the
"run" position after the engine has stopped. Also
ensure that the engine start key is turned to the "O"
position.

Adjustment of the engine speed range

The idle or the maximum speed settings must not be
changed by the engine operator, because this can
damage the engine or transmission. The warranty of
the engine can be affected if the seals on the fuel
injection pump are broken during the warranty period
by a person who is not approved by Perkins.

Running-in

If the naturally aspirated engine is to run at an altitude
above 600 m (2,000 ft), the fuel delivery can be
changed to reduce fuel consumption and smoke.
Perkins can give the percentage of fuel reduction
necessary if details of engine application and ambient
conditions are given. Changes to the settings of the
fuel injection pump must be made by a Perkins
distributor or by an approved distributor for the fuel
injection pump.

l

Do not operate the engine at high speeds without
a load.

l

Do not overload the engine.

A gradual running-in of a new engine or POWER
EXCHANGE engine is not necessary. Prolonged
operation at light loads during the early life of the
engine can cause lubricating oil to enter the exhaust
system. Maximum load can be applied to a new
engine as soon as the engne is put into service and
the coolant temperature has reached a minimum of

60 °C (140 °F).
The engine will benefit if the load is applied as soon

as possible after the engine is put into service.

Turbocharged engines

Because of the power characteristics of the
turbocharged engines it is necessary to maintain a
high engine speed when you climb a gradient. To
ensure that the engine is not overloaded at low engine
speeds engage a lower gear.

16

4

Preventive maintenance 4

Preventive maintenance periods

These preventive maintenance periods apply to average conditions of operation. Check the periods given by
the manufa ctur er of th e equ ipm ent in wh ich t he e ngi ne i s inst all ed. Use the p er iod s whi ch ar e sho rte st. When
the operation of the engine must conform to the local regulations these periods and procedures may need to
be adapted to ensure correct operation of the engine.

It is good preventive maintenance to check for leakage and loose fasteners at each service.
These maintenance periods apply only to engines that are operated with fuel and lubricating oil which conform

to the specifications given in this handbook.

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