Perkins New 1000 Series Workshop Manual - 4 and 8 Cylinder Diesel Engines (P/N TPD 1350E)

• Covers Perkins New 1000 Series engine codes AJ, AK, AM, AP, AQ, AR, AS, YG, YH, and YK, including four- and six-cylinder naturally aspirated, turbocharged, and turbocharged/intercooled builds for industrial and agricultural applications.
• Documents cylinder-head and valve overhaul, piston and connecting-rod service, crankshaft and main-bearing repair, balancer overhaul, timing-gear and camshaft work, and cylinder-block and liner procedures.
• Provides fuel-system procedures for Bosch EPVE, Lucas DP200 Series, and Stanadyne DB2/DB4 rotary injection pumps, including pump removal and installation, timing checks, atomizer and lift-pump service, and system bleeding.
• Separates the major cooling and aspiration configurations: early and later gear-driven coolant pumps, standard and high-mounted belt-driven pumps, oil-cooler versions, water-to-air intercoolers, turbochargers, and waste-gate testing and adjustment.
• Includes alternator and starter diagnosis, cold-start advance wiring diagrams, starting-aid service, and auxiliary-equipment coverage for Bendix compressors, power-steering pumps, splined hydraulic-pump adaptors, and exhausters.
• Supplies component-specific torque tables, overhaul dimensions, clearances, wear limits, compression-test data, electrical test specifications, and an illustrated special-tool catalog in a 290-page PDF — Publication TPD 1350E, Issue 3, March 2000.

Exact Engine Coverage

The engine-identification section maps each code to a specific configuration. For four-cylinder engines, AJ is naturally aspirated, AK is turbocharged, and AM is turbocharged and intercooled. AP and AQ identify naturally aspirated and turbocharged versions with belt-driven coolant pumps. AR and AS are naturally aspirated 103 mm-bore engines, with AS also using the belt-driven pump. Six-cylinder coverage is YG naturally aspirated, YH turbocharged, and YK turbocharged/intercooled.

Perkins identifies this engine family as compliant with USA EPA/CARB Stage 1 and EEC Stage 1 for industrial and agricultural applications. The first two letters of the full engine number identify the build; the complete number and any TPL number are required when ordering parts or requesting service.

Most covered engines use a 100 mm bore with serviceable dry cylinder liners. The AR and AS builds use a 103 mm linerless block, so the manual gives them separate bore-inspection and oversize-machining data instead of the liner replacement procedure used on the other engines. It also distinguishes AR/AS piston, cooling-jet, cylinder-head, and tightening requirements. That separation is important when planning an overhaul or buying repair parts.

Repair Depth and Diagnostic Material

Factory procedures cover cylinder-head removal and installation, valve-spring replacement with the head installed, valve-guide and seat work, piston-height measurement, connecting-rod grading, crankshaft inspection and undersize repair, balancer timing, front and rear seal installation, timing-case service, and camshaft removal. Fuel and engine-timing sections show how to establish No. 1 cylinder at TDC, check valve and injection-pump timing, and use the correct timing pin for the pump fitted.

Representative technical views include the timing-gear alignment diagram, typical six-cylinder fuel-system layout, four- and six-cylinder lubrication schematics, manufacturer-specific cold-start advance wiring diagrams, the turbocharger symptom/cause chart, and alternator charging fault diagnosis. The special-tool section identifies tools by both tool number and Perkins order number, including Bosch timing pin PD.245 / 27610032, Lucas/Stanadyne timing pin PD.246 / 27610033, piston-height/valve-depth/liner-flange gauge PD.41D / 21825496, liner remover/replacer PD.150B / 21825543, and cylinder-head angle gauge PD.198 (MS.1531) / 21825607.

The injection-pump chapters warn against loosening the factory-set drive-hub nut; if the hub moves, accurate pump timing requires specialist test equipment. The later coolant-pump procedures require the seal to remain free of oil and grease because contamination can damage the new seal during assembly.

Scope and Workshop Requirements

This is an engine workshop manual for service and overhaul. It does not cover the host machine’s chassis or transmission and is not a parts catalog; hydraulic coverage is limited to the engine-mounted power-steering pump and splined pump-drive adaptor. Perkins states that overhaul procedures assume the engine has been removed from the application, while most general operating and routine maintenance material in User’s Handbook Sections 1–9 is not repeated. The two publications are intended to be used together.

The depth of the measuring, machining, lifting, and fuel-injection work makes this manual best suited to professional technicians and experienced engine rebuilders with appropriate workshop equipment. Some pump adjustments, liner finishing, and timing corrections explicitly require specialist training or test equipment. Follow the manual’s precautions for engine lifting, hot pressurized coolant, high-pressure fuel, rotating turbocharger parts, and electrical isolation during repair work.