Perkins 2000 Series Diesel Engine Workshop Repair Manual

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Covers: Perkins 2000 Series 6-Cylinder Diesel Engine

  • TG1, TG1A, TG2, TG2A
  • TAG, TAG2
  • TWG, TWG2
  • TTAG
  • 12TA1, 12TA2, 12TA3

Pages: 194
Format:
PDF
Compatibility: Windows/Mac/Tablet

This workshop manual has been designed to provide assistance in the service and the overhaul of Perkins 2000 Series engines.

The following is a list of topics contained in the Repair Manual:

10 General information
Introduction
New 2000 Series engines
Cylinder bore identification
Engine identification
General safety precautions
Safety
Engine lift equipment
Asbestos joints
Dangers from used engine oils
Environmental protection
Viton seals
Practical information
11 Specifications
Basic engine data
Recommended specific applied torques
Recommended nominal applied torques
12 Cylinder head assembly
Rocker cover
12-1 To remove and to fit Rocker assembly
12-2 To remove and to fit
Tappet clearances
12-3 To check and to adjust
Cylinder head
12-4 To remove and to fit
12-5 Procedure for retightening of the cylinder head bolts
12-6 To dismantle and to assemble
12-7 To clean and to inspect the cylinder head
12-8 To renew a valve spring with the cylinder head installed
12-9 To correct a valve seat
12-10 To remove a valve seat insert
12-11 To fit a valve seat insert
12-12 To inspect the valve guides
12-13 To renew a valve guide
Valves, valve springs and valve rotators
12-14 To remove and to fit
12-15 To clean and to inspect
Fuel injector sleeves
12-16 To remove and to fit
Push rods
12-17 To remove and to fit
12-18 To inspect
Fits and clearances – Rocker assemblies
Fits and clearances – Cylinder heads and valve assemblies
13 Piston and connecting rod assembly
General description
Piston and connecting rod assembly
13-1 To remove and to fit
13-2 To dismantle and to assemble
Piston and rings
13-3 To inspect
Connecting rod
13-4 To inspect
Small end bushes
13-5 To renew
Fits and clearances
14 Crankshaft assembly
General description
Damper and pulley – early engines
14-1 To remove and to fit
Damper and pulley – new engines
14-2 To remove and to fit
Crankshaft hub and front oil seal
14-3 To remove and to fit
14-4 To fit a new oil seal to a wheelcase removed from the engine
Rear oil seal
14-5 To remove and to fit
Crankshaft
14-6 To remove and to fit
14-7 To inspect
Fits and clearances
15 Wheelcase and drive assembly
General description
Wheelcase
15-1 To remove and to fit
Backplate
15-2 To remove and to fit
Camshaft gear – bolt-on type
15-3 To remove and to fit
Camshaft gear – integral type
15-4 To remove and to fit
15-5 To inspect
Idler gear
15-6 To remove and to fit
15-7 To set the gear backlash
Fits and clearances
16 Cylinder block assembly
General description
Crankcase
16-1 To fit to and to remove from a build stand
16-2 To dismantle and to assemble
16-3 To inspect
Cylinder liners
16-4 To remove and to fit
16-5 To clean and to inspect
Cam followers
16-6 To remove and to fit
Camshaft
16-7 To remove and to fit – bolt-on type
16-8 To remove and to fit – integral type
16-9 To inspect
Fits and clearances
17 Engine timing
Valve timing
17-1 To check
Fuel injection pump timing
17-2 To check and to adjust
18 Aspiration system
General description
Aspiration system maintenance
Turbocharger
18-1 To remove and to fit
18-2 How to check the waste-gate
Turbochargers: OE49342, OE50642, OE51140, and OE51430
18-3 To dismantle and to assemble
18-4 To clean and to inspect
Turbocharger: OE50674
18-5 To dismantle and to assemble
18-6 To clean and to inspect
Turbochargers: OE52534 and OE52535
18-7 To dismantle and to assemble
18-8 To clean and to inspect
Inlet manifold
18-9 To remove and to fit
Exhaust manifold
18-10 To remove and to fit
19 Lubrication system
General description
Lubricating oil filter
19-1 To renew the canister
By-pass filter/separator
19-2 To renew the canisters
Sump
19-3 To remove and to fit
Sump drain plugs
Lubricating oil pump
19-4 To remove and to fit
19-5 To dismantle and to assemble
19-6 To inspect
Oil pressure relief valve
19-7 To dismantle and to assemble
19-8 To inspect
20 Fuel system
General description
Overhaul instructions
Fuel injectors
20-1 To remove and to fit
20-2 To dismantle and to assemble
20-3 To clean and to inspect
20-4 To set and to test
Fuel lift pumps
Single acting type
20-5 To remove and to fit
20-6 To dismantle and to assemble
Double acting type
20-7 To remove and to fit
20-8 To dismantle and to assemble
20-9 To test
Fuel injection pump
20-10 To remove and to fit
20-11 How to eliminate air from the fuel system
Air stop cylinder
20-12 How to set the air-operated stop cylinder
21 Cooling system
General description
Radiator
21-1 To remove and to fit
Fan
21-2 To remove and to fit
Fan drive belts
21-3 How to check the fan belts
21-4 How to adjust the tension of the fan belts
Coolant pump
21-5 To remove and to fit
21-6 To dismantle and to assemble
21-7 To inspect
Thermostat
21-8 How to check the operating temperatures
21-9 How to check the operating speed
Oil cooler
21-10 To dismantle and to assemble
21-11 To inspect
22 Flywheel and flywheel housing
General description
Flywheel
22-1 To remove and to fit
22-2 To inspect
Flywheel housing
22-3 To remove and to fit
23 Electrical equipment
General description
Alternator drive belts
23-1 To check and to adjust the tension
Alternator
23-2 To remove and to fit
Starter motor
23-3 To remove and to fit
23-4 To dismantle and to assemble the solenoid switch
23-5 To dismantle and to assemble the starter motor
23-6 To clean
23-7 To inspect and to correct
23-8 To test
23-9 To fit the main starter cables
Engine stop solenoid
23-10 How to adjust the linkage
24 Auxiliary equipment
Compressor
24-1 To remove and to fit
24-2 Compressor gear alignment
25 Running-in and test
General description
Running-in and test
25-1 To run the engine
25-2 To check the consumption rate of the engine lubricating oil
26 List of special tools
Special tools

Contains  Perkins Specifications, Illustrations and Procedures

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