2002 Perkins 1100 Series 4-Cylinder Diesel Engine Workshop Manual - RE, RF, RG, RH, RJ, RK (TPD 1487E)

This Perkins 1100 Series workshop manual covers service and overhaul of RE, RF, RG, RH, RJ, and RK four-cylinder diesel engines for industrial, agricultural, and construction applications. Publication TPD 1487E, Issue 1, published October 2002, contains 16 chapters covering mechanical assemblies, fuel systems, electrical equipment, and service specifications.

• Cylinder head: Head removal and installation, rocker assembly overhaul, valve-guide replacement, valve-seat correction, and valve-clearance adjustment.

• Pistons and crankshaft: Fastram pistons, fracture-split connecting rods, main bearings, thrust washers, balancer service, and piston cooling-jet alignment.

• Fuel and timing: Bosch VP30, Bosch EPVE, and Delphi DP210 pump procedures, lift-pump testing, injector fault identification, and fuel-system air removal.

• Aspiration system: Garrett GT25 waste-gate testing, turbocharger troubleshooting, exhaust-elbow replacement, and open-breather service.

• Lubrication and cooling: Oil-pump inspection, relief-valve service, filter replacement, thermostat testing, coolant-pump overhaul, and oil-cooler service.

• Electrical equipment: Alternator diagnosis, starter testing, glow-plug checks, ECM and VLPM replacement, ECM programming, and connector repair.

• Workshop references: Component dimensions, torque tables, cold-start wiring diagrams, lubrication and coolant flow diagrams, exploded views, and illustrated special-tool listings.

Suited to mechanics familiar with normal workshop practice and engine overhauls; many electrical operations require Perkins Level 2 electronic diagnostics training or higher.

Cylinder Head and Internal Engine Repair

Overhaul procedures assume the engine has been removed from its application. The manual is intended to be used alongside the separate User’s Handbook, which supplies operating and maintenance information not repeated here.

Cylinder-head work includes leak and distortion checks, valve-depth inspection, guide and seat replacement, and staged fastener tightening. Piston and connecting-rod sections explain length grades and matched assemblies; incorrect piston height can allow piston-to-head contact.

Crankshaft inspection covers journal wear, end float, thrust washers, and undersize bearings. The specifications distinguish induction-hardened and nitrocarburized crankshafts, including the requirement to harden nitrocarburized shafts again after machining.

Injection Pumps and Timing Differences

Pump-specific procedures distinguish electronic VP30 equipment from mechanical EPVE and DP210 systems, including gear locking and air-removal differences. EPVE timing adjustment is described on the engine; DP210 timing resetting is referred to a Perkins dealer or distributor.

The VP30 hub-nut warning matters during pump removal: loosening that nut loses the factory timing and requires specialist resetting. Injector coverage includes fault identification and replacement; the factory-set injector assemblies are specified as non-serviceable.

Turbocharger, Lubrication and Cooling

The turbocharger fault chart connects low power, smoke, and oil consumption with possible intake, exhaust, lubrication, and waste-gate faults. This helps narrow the checks before replacing a suspected turbocharger.

Lubrication procedures distinguish canister and replaceable-element filters, separate and balancer-mounted oil pumps, and their relief valves. Open and naturally aspirated breather replacement is described; closed-breather servicing is referred to a Perkins dealer or distributor.

Cooling coverage includes thermostat operating-temperature checks, gear-driven coolant-pump disassembly and assembly, and oil-cooler inspection. Follow the manual’s precautions for high-pressure fuel, heavy-component lifting, and burned Viton seals.

Electrical Testing and Electronic Service Limits

Denso alternator diagnosis, on-engine starter tests, and glow-plug continuity and current checks are included. Internal alternator and starter repairs are referred to specialists.

The electronic section covers the Engine Control Module (ECM), Voltage Load Protection Module (VLPM), speed and timing sensor, and pressure and temperature sensors. ECM replacement programming uses TIPSS-EST and application-specific software; engine electronic fault finding is referred to the separate 1100 Series Diagnostic Manual.

Harness repair procedures cover sensor, diagnostic, ECM, and Machine Interface Connector (MIC) connections. Harness repairs are to follow direction from the Diagnostic Manual.

Assembly Views, Auxiliary Equipment and Tools

Illustrations include Delphi and Bosch cold-start advance unit (KSB) wiring, the basic charging circuit, lubrication and coolant flow diagrams, and an exploded hydraulic/steering pump-adapter assembly.

Flywheel runout and housing alignment checks accompany power-steering pump removal, PTO-adapter overhaul, and exhauster removal and installation. Special-tool references include crankshaft timing pin 27610211, camshaft timing pin 27610212, and wiring harness repair kit UKMK0662. POWERPART consumable listings identify thread sealants, gasket removers, and assembly adhesives by part number.

A Preview of Valve and Piston Measurements

These examples represent a small selection of the manual’s adjustment and assembly data. Cold valve-tip clearances are 0.20 mm (0.008 in) for intake valves and 0.45 mm (0.018 in) for exhaust valves.

The piston-height inspection specifies 0.21–0.35 mm above the cylinder-block face at top dead center. That measurement is linked to connecting-rod grade selection when major engine components are replaced.

Searchable Text, Circuit Detail and PDF Contents

Text search and circuit detail: The PDF has searchable text but no embedded bookmarks. Labels in the cold-start wiring diagrams and basic charging circuit are legible, with zoom useful for the smallest markings.

Supplied as one printable, English-language, 274-page PDF: 12 pages of front matter, 261 pages in the main numbered sequence, and one final blank page. The original cover, contents pages, and all internal blank or divider pages are already included in that total.