Diesel Engine, Truck, Heavy Equipment Service Manuals

Perkins Phaser, 1000 Series Engine Workshop Manual

$19.99

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Product Description

 High definition, searchable, printable PDF  Instant download

Covers: Perkins Phaser and 1000 Series (Models AA to AH and YA to YE)
Pages: 440
Format: PDF
Compatibility: Windows/Mac/Tablet

The Perkins Phaser, 1000 Series Workshop Manual contains all of the information needed to overhaul the engine to the manufacturer’s standards. In this downloadable PDF manual you will find detailed engine specifications, torques, illustrations and procedures to aid with engine service, repair and overhaul. View the manual on your computer or print off pages as needed.

Topics in the Perkins Phaser, 1000 Series Workshop Manual:

General information
Introduction
Engine views
Engine identification
Safety precautions
Asbestos joints
Viton seals
Engine lift equipment
POWERPART consumable products
Specifications
Data and dimensions
Thread sealant
Recommended torque settings
Compression test data
Cylinder head assembly
General description
Rocker cover
To remove Operation
To fit Operation
Rocker assembly
To remove and to fit Operation
To dismantle and to assemble Operation
To inspect and to correct Operation
Valve tip clearances
To check and to adjust (four cylinder engines) Operation
To check and to adjust (six cylinder engines) Operation
Valve springs
To change the valve springs (with cylinder head fitted) Operation
Cylinder head assembly
To remove Operation
To fit Operation
Valves and valve springs
To remove Operation
To fit Operation
To inspect and to correct Operation
Valve guides
To inspect Operation
To remove Operation
To fit Operation
Cylinder head
To inspect and to correct Operation
To correct a valve seat with a valve seat cutter Operation
To fit valve seat inserts Operation
Piston and connecting rod assemblies
General description
Big end bearing
To remove Operation
To fit Operation
To inspect Operation
Piston and connecting rod
To remove Operation
To fit Operation
To check the piston height above the cylinder block Operation
To check piston height grade of a “Fastram” piston Operation
Piston rings
To remove and to fit Operation
Piston and connecting rod assembly
To dismantle and to assemble Operation
Piston and piston rings
To inspect Operation
Connecting rod
To inspect Operation 4-11
Small end bush
To remove and to fit Operation 4-12
Piston cooling jets
To remove and to fit Operation 4-13
To check the jet alignment Operation 4-14
Crankshaft assembly
General description
Crankshaft pulley
To remove and to fit (four cylinder engines) Operation 5-1
Crankshaft pulley and damper
To remove (six cylinder engines) Operation 5-2
To fit (six cylinder engines) Operation 5-3
To inspect Operation 5-4
Rear oil seal assembly
To remove and to fit (one-piece assembly) Operation 5-5
To remove and to fit (two-piece assembly) Operation 5-6
To renew the rear end oil seal (two-piece assembly) Operation 5-7
To remove and to fit a wear sleeve Operation 5-8
Rear oil seal assembly (engines with a flywheel housing that is oil filled)
To remove Operation 5-9
To fit Operation 5-10
To renew the rear oil seals Operation 5-11
To fit and remove a “Wear-Sleeve” Operation 5-12
Thrust washers
To check crankshaft end-float Operation 5-13
To remove and to fit Operation 5-14
Main bearings
To remove (with the crankshaft in position) Operation 5-15
To fit (with the crankshaft in position) Operation 5-16
To inspect Operation 5-17
Crankshaft
To remove Operation 5-18
To fit Operation 5-19
To inspect Operation 5-20
Balancer unit
To remove Operation 5-21
To fit Operation 5-22
To dismantle Operation 5-23
To assemble Operation 5-24
To inspect Operation 5-25
To remove and to fit the needle roller bearings Operation 5-26
To remove and to fit the bushes for the balance weights Operation 5-27
Timing case and drive assembly
General description
Timing case cover
To remove Operation 6-1
To fit Operation 6-2
Front oil seal
To remove Operation 6-3
To fit Operation 6-4
To remove and to fit a wear sleeve Operation 6-5
Idler gear and hub
To remove Operation 6-6
To fit Operation 6-7
Idler gear and hub for the Bendix or Knorr-Bremse compressor
To remove Operation 6-8
To fit Operation 6-9
Fuel pump gear
To remove Operation 6-10
To fit Operation 6-11
Camshaft gear
To remove Operation 6-12
To fit Operation 6-13
Crankshaft gear
To remove and to fit Operation 6-14
Timing case
To remove Operation 6-15
To fit Operation 6-16
Camshaft and tappets
To remove Operation 6-17
To fit Operation 6-18
Cylinder block assembly
General description
Cylinder block
To dismantle Operation 7-1
To assemble Operation 7-2
To inspect Operation 7-3
To remove and to fit a new type ‘D’ plug to the tappet chamber Operation 7-4
Cylinder liner
To inspect Operation 7-5
To recover a glazed liner Operation 7-6
To remove Operation 7-7
To fit a service liner Operation 7-8
To fit a partially finished liner Operation 7-9
Engine timing
Standard operations
To set number 1 piston to TDC on the compression stroke Operation 8-1
Another method to set number 1 piston to TDC Operation 8-2
To check the valve timing Operation 8-3
Engines fitted with Bosch EPVE fuel injection pumps
To check the timing of the fuel injection pump (10° or more, static) Operation 8-4
To check the timing of the fuel injection pump (9° or less, static) Operation 8-5
To check the timing mark of the fuel injection pump Operation 8-6
To check the engine timing mark Operation 8-7
To check the timing of the pin timed fuel injection pump Operation 8-8
Engines fitted with Bosch MW in-line fuel injection pumps
To check the timing of the fuel injection pump Operation 8-9
Engines fitted with Lucas/Delphi DPA and DPS fuel injection pumps
To check the timing of the fuel injection pump Operation 8-10
To check the timing mark of the fuel injection pump Operation 8-11
To check the engine timing mark Operation 8-12
To check the timing of the pin timed fuel injection pump Operation 8-13
Engines fitted with a Lucas/Delphi DP200 Series fuel injection pump
To check the timing of the fuel injection pump Operation 8-14
To check the timing of the pin timed fuel injection pump Operation 8-15
Engines fitted with Stanadyne fuel injection pumps
To check the timing of the fuel injection pump Operation 8-16
To check the timing mark of the fuel injection pump Operation 8-17
To check the engine timing mark Operation 8-18
To check the timing of the pin timed fuel injection pump Operation 8-19
Aspiration system
General description
Turbocharger
To remove Operation 9-1
To fit Operation 9-2
To clean the impeller and the compressor casing Operation 9-3
To remove and to fit the actuator assembly of the waste-gate unit Operation 9-4
To check and adjust the operation of the waste-gate Operation 9-5
Turbocharger faults
Open engine breather
To remove, to fit and to clean (early type) Operation 9-6
To clean and to renew (Later type) Operation 9-7
To renew (Latest type) Operation 9-8
To Inspect Operation 9-9
Closed breather system
To clean the early closed breather system Operation 9-10
To renew latest closed breather system Operation 9-11
To repair the connection for the latest breather outlet elbow Operation 9-12
Lubrication system
General description (four cylinder engine lubrication system)
General description (six cylinder engine lubrication system)
Lubrication system flow diagram
Lubrication system flow diagram for the relief valve and balancer
Filter canister
To renew Operation 10-1
Filter head
To remove and to fit Operation 10-2
Sump
To remove and to fit Operation 10-3
Oil strainer and suction pipe
To remove and to fit Operation 10-4
To inspect and to correct Operation 10-5
Lubricating oil pump
To remove Operation 10-6
To fit Operation 10-7
To inspect Operation 10-8
To remove the idler shaft Operation 10-9
Alternative method to remove the idler shaft Operation 10-10
To fit the idler shaft (Six cylinder engines) Operation 10-11
To remove and to fit the idler shaft (four cylinder engines) Operation 10-12
Relief valve
To remove and to fit Operation 10-13
To dismantle and to assemble Operation 10-14
To inspect Operation 10-15
Flexible oil pipes
To remove Operation 10-16
To fit Operation 10-17
To Inspect Operation 10-18
Fuel system
General description
Cold start advance unit
Fuel filter elements
Fuel filter element types Operation 11-1
To renew the filter element of the separate element type Operation 11-2
To renew the filter element of the canister type Operation 11-3
To renew the filter element of the quick release canister type Operation 11-4
Fuel filter canister (Bosch MW fuel injection pump)
To renew Operation 11-5
Atomisers
Atomiser fault Operation 11-6
To remove and to fit Operation 11-7
Fuel lift pump
To remove and to fit Operation 11-8
To dismantle Operation 11-9
To assemble Operation 11-10
To test Operation 11-11
Fuel lift pump (Bosch MW fuel injection pump)
To remove and to fit Operation 11-12
To dismantle and assemble Operation 11-13
Bosch EPVE fuel injection pump (without a locking screw)
To remove Operation 11-14
To fit Operation 11-15
Bosch EPVE fuel injection pump (with a locking screw)
To remove Operation 11-16
To fit Operation 11-17
To set Operation 11-18
Bosch EPVE fuel injection pump
To set the injection advance device (KSB) Operation 11-19
To adjust Operation 11-20
General description for pin timed fuel injection pump Operation 11-21
To remove pin timed fuel injection pump Operation 11-22
To fit pin timed fuel injection pump Operation 11-23
To adjust pin timed fuel injection pump Operation 11-24
To eliminate air from the fuel system Operation 11-25
To remove Operation 11-26
To fit Operation 11-27
To adjust the fuel injection pump Operation 11-28
To remove and fit the adaptor plate for the fuel injection pump Operation 11-29
To eliminate air from the fuel system Operation 11-30
Lucas/Delphi DPA and DPS fuel injection pumps
To remove Operation 11-31
To fit Operation 11-32
To adjust Operation 11-33
Electrical shut off solenoid (ESOS) Operation 11-34
To eliminate air from the fuel system Operation 11-35
Standard method Operation 11-36
Self-vent method Operation 11-37
Lucas/Delphi DP 200 Series fuel injection pump
To remove Operation 11-38
To fit Operation 11-39
To adjust Operation 11-40
General description for pin timed fuel injection pump Operation 11-41
To remove pin timed fuel injection pump Operation 11-42
To fit pin timed fuel injection pump Operation 11-43
To adjust pin timed fuel injection pump Operation 11-44
Electrical shut off solenoid (ESOS) Operation 11-45
To eliminate air from the fuel system Operation 11-46
Stanadyne fuel injection pump
To remove Operation 11-47
To fit Operation 11-48
To adjust Operation 11-49
General description for pin timed fuel injection pump Operation 11-50
To remove pin timed fuel injection pump Operation 11-51
To fit pin timed fuel injection pump Operation 11-52
To adjust pin timed fuel injection pump Operation 11-53
To eliminate air from the fuel system Operation 11-54
Cooling system
General description
Thermostats
To remove Operation 12-1
To fit Operation 12-2
To test Operation 12-3
Coolant pump (gear driven)
To remove Operation 12-4
To fit Operation 12-5
To dismantle (early engines) Operation 12-6
To assemble (early engines) Operation 12-7
To dismantle (later engines) Operation 12-8
To assemble (later engines) Operation 12-9
To remove and fit pressed steel covers (latest engines) Operation 12-10
Coolant pump (belt driven)
To remove Operation 12-11
To fit Operation 12-12
To dismantle Operation 12-13
To assemble Operation 12-14
Coolant pump (auxiliary)
To remove and to fit Operation 12-15
To dismantle Operation 12-16
To assemble Operation 12-17
Fan
To remove and to fit Operation 12-18
Fan drive
To remove and to fit the early pulley Operation 12-19
To remove and to fit the latest pulley Operation 12-20
Lubricating oil cooler
To remove and to fit (four cylinder turbocharged engines) Operation 12-21
To remove and to fit (six cylinder engines) Operation 12-22
To remove (six cylinder turbocharged engines) Operation 12-23
To fit (six cylinder turbocharged engines) Operation 12-24
To dismantle and to assemble – six cylinder engines Operation 12-25
To dismantle and to assemble (six cylinder turbocharged engines) Operation 12-26
To remove and to fit vertical canister type Operation 12-27
To remove and to fit horizontal canister type Operation 12-28
Cooler by-pass valve
To remove and to fit Operation 12-29
Intercooler
To remove Operation 12-30
To fit Operation 12-31
To clean and to inspect Operation 12-32
Flywheel and housing
General description
Flywheel
To remove and to fit Operation 13-1
Ring gear
To remove and to fit Operation 13-2
Flywheel housing
To remove and to fit Operation 13-3
Electrical equipment
To check the drive belts Operation 14-1
To adjust belt tension Operation 14-2
To remove and to fit the drive belts Operation 14-3
To remove and to fit the alternator Operation 14-4
To maintain the alternator Operation 14-5
Alternator fault diagnosis
To remove and to fit Operation 14-6
To maintain the brush gear and the commutator Operation 14-7
To test on the engine Operation 14-8
To remove and to fit a fuelled starting aid Operation 14-9
To remove and to fit a twin fuelled starting Operation 14-10
How to check the fuelled starting aid Operation 14-11
To remove and to fit a port heater Operation 14-12
Auxiliary equipment
Wabco compressors
To remove the earliest•compressor and drive assembly Operation 15-1
To fit the earliest compressor and drive assembly Operation 15-2
To fit the early compressor and drive assembly Operation 15-3
To fit the early compressor only Operation 15-4
Compressor drive for Wabco compressors
To remove and to fit Operation 15-5
To dismantle Operation 15-6
To assemble Operation 15-7
Bendix compressors
To remove Operation 15-8
To fit Operation 15-9
Knorr-Bremse compressors
To remove Operation 15-10
To fit Operation 15-11
To remove the reed valves Operation 15-12
To fit the reed valves Operation 15-13
To remove the top unloader valve Operation 15-14
To fit the top unloader valve Operation 15-15
To remove the crankshaft / connecting rod / piston / piston rings Operation 15-16
To fit the crankshaft / connecting rod / piston / piston rings Operation 15-17
Power steering pump
To remove and to fit Operation 15-18
Adaptor for a hydraulic pump or a steering pump with a splined drive
To remove and to fit Operation 15-19
To dismantle Operation 15-20
To assemble Operation 15-21
Exhauster
To remove and to fit Operation 15-22
Special tools
List of special tools

Contains Specifications, Illustrations and Procedures

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