Looking for the Perkins New 1000 shop manual PDF that dealers actually use? This 370-page factory shop manual (OEM #TPD 1350E) covers the New 1000 Series diesel engines, build codes AJ through AS and YG through YK. Inside: full rebuild procedures for the cylinder head, crankshaft, timing case, and cylinder block, plus a dedicated turbocharger fault section and alternator and starter motor wiring diagrams. You also get factory torque tension tables, compression test data, and service coverage for all three injection pumps: Bosch, Lucas/Delphi DP 200, and Stanadyne. Set inlet valve tip clearance at 0.20 mm and exhaust at 0.45 mm, then confirm your oil pressure holds a minimum of 280 kPa. A broken engine won't wait for the parts counter to open. Bookmarked PDF that opens on any device; carry it to the engine on your tablet and start wrenching.
What's Inside This Perkins New 1000, Perkins New 1000, AJ to AS, YG to YK Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-24 | Introduction, Engine Views, Engine Identification, Safety Precautions, Viton Seals, Engine Lift Equipment, Powerpart Recommended Consumable Products |
| Specifications | 25-54 | Basic Engine Data, Data and Dimensions, Thread Sealant, Standard Torque Tensions, Specific Torque Tensions, Compression Test Data |
| Cylinder Head Assembly | 55-88 | Rocker Cover, Rocker Assembly, Valve Tip Clearances |
| Piston and Connecting Rod Assemblies | 89-106 | Big End Bearing, Piston and Connecting Rod, Piston Rings, Piston and Connecting Rod Assembly, Piston and Piston Rings, Connecting Rod, Partially Finished Small End Bush |
| Crankshaft Assembly | 107-136 | Crankshaft Pulley, Crankshaft Pulley and Damper, Rear Oil Seal Assembly, Thrust Washers, Main Bearings, Crankshaft, Balancer Unit |
| Timing Case and Drive Assembly | 137-162 | Timing Case Cover, Front Oil Seal, Idler Gear and Hub, Idler Gear and Hub for the Compressor, Fuel Pump Gear, Camshaft Gear, Crankshaft Gear, Timing Case |
| Cylinder Block Assembly | 163-178 | Cylinder Block, Cylinder Liner, Cylinder Bore, Engine Types Ar and As |
| Engine Timing | 179-184 | Piston TDC Setting, Valve Timing, Fuel Injection Pump Timing, Timing Gears, Locking Screw |
| Aspiration System | 185-200 | Turbocharger, Turbocharger Faults, List of Possible Causes, Open Engine Breather, Closed Engine Breather |
| Lubrication System | 201-222 | Filter Canister, Filter Head, Sump, Oil Strainer and Suction Pipe, Lubricating Oil Pump, Lubricating Oil Pump Idler Gear Shaft, Relief Valve, Flexible Oil Pipes |
| Fuel System | 223-270 | Cold Start Advance Unit, Typical Fuel System, Fuel Filters, Fuel Filter Element, Atomisers, Fuel Lift Pump, Bosch Fuel Injection Pump |
| Cooling System | 271-324 | Thermostats, Coolant Pump - Early Gear Driven Pumps, Coolant Pump - Latest Gear Driven Pumps, Coolant Pump - Belt Driven, Fan, Fan Drive, Lubricating Oil Cooler, Intercoolers |
| Flywheel and Housing | 325-328 | Flywheel, Ring Gear, Flywheel Housing |
| Electrical Equipment | 329-342 | Alternators, Starter Motors, Starting Aids |
| Auxiliary Equipment | 343-362 | Bendix Compressor, Knorr-Bremse Compressor, Power Steering Pump, Adaptor for a Hydraulic Pump or a Steering Pump with a Splined Drive, Exhauster |
| Special Tools | 363-370 | List of Special Tools |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Bearing extension past the end of the pump body | 5 mm (0.2 in) | p. 38 |
| Valve tip clearance (Inlet) | 0,20 mm | p. 25 |
| Valve tip clearance (Exhaust) | 0,45 mm | p. 25 |
| Torque: Setscrews, fan drive housing to timing case | 44 Nm | p. 52 |
| AJ, AK, AM, AP, AQ, YG, YH, YJ, YK | ||
| Lubricating oil pressure (minimum) | 280 kPa | p. 25 |
| AR, AS | ||
| Lubricating oil pressure (minimum) | 207 kPa | p. 25 |
| AJ to AQ and YG to YK | ||
| Torque: Setscrews, cylinder head | 110 Nm | p. 72 |
Perkins New 1000, Perkins New 1000, AJ to AS, YG to YK Common Problems This Manual Covers
Perkins New 1000 runs rough and stalls minutes after fuel filter change, then won't restart
Check every low-pressure fuel connection for loose unions and cracked lines, then bleed the system using the air elimination procedure in the Fuel System section on page 223. Operate the lift pump priming lever until fuel flows free of bubbles at each vent point. If rough running persists, set valve tip clearances to 0.20 mm inlet and 0.45 mm exhaust.
Manual Section: Fuel System p. 223Oil in the coolant and coolant in the sump but head gasket checks out fine
Inspect the timing case cover before condemning the head gasket; these covers corrode from the coolant side and cross-contaminate oil and coolant internally. Remove the cover following the Timing Case and Drive Assembly procedures beginning on page 137, and replace it if pitted. When refitting, torque the idler gear hub setscrews to 93 Nm (68 lbf ft).
Manual Section: Timing Case and Drive Assembly p. 137Oil pressure warning light flickers at hot idle on a high-hour engine
Fit a test gauge and check actual pressure at rated speed against page 25 specifications: minimum 280 kPa for AJ, AK, AM, AP, AQ and YG to YK engines; 207 kPa for AR and AS. If low, drop the sump and inspect the strainer, suction pipe, relief valve, and oil pump, Lubrication System section, page 201.
Manual Section: Lubrication System p. 25Engine overheats under load and loses coolant with no visible external leak
Test the cooling system under pressure and check the radiator for blockage first. Verify thermostat operation, then inspect the coolant pump for seal leakage and bearing play. When rebuilding the pump, press the bearing until it extends 5 mm (0.2 in) past the end of the pump body, per page 38, and follow the Cooling System procedures from page 271.
Manual Section: Cooling System p. 271Frequently Asked Questions
How do I change the fuel injection pump timing on a Perkins 1000 Series?
To time the fuel injection pump, set the number 1 piston to TDC on the compression stroke. Insert the correct timing pin (part number 27610032 for Bosch or 27610033 for Lucas/Delphi/Stanadyne) through the fuel pump gear and into the pump body. If the pin cannot be inserted, the pump timing is incorrect and must be adjusted by a specialist. p. 184
What is the tappet adjustment procedure for a four-cylinder Perkins 1000 Series engine?
Rotate the crankshaft until the inlet valve of number 4 cylinder has just opened and the exhaust valve of the same cylinder has not closed completely. Then, adjust the valve tip clearances for the valves of number 1 cylinder to 0,20 mm (0.008 in) for inlet and 0,45 mm (0.018 in) for exhaust. Repeat this sequence for the remaining cylinders as specified in the manual. p. 60
What is the torque specification for cylinder head setscrews on a Perkins 1000 Series engine?
For engine types AJ to AQ and YG to YK, tighten the cylinder head setscrews to 110 Nm (80 lbf ft). For engine types AR and AS, the tightening procedure involves an initial torque of 45 Nm (33 lbf ft) followed by a specific angular rotation based on the length of the setscrew. p. 72
What are the replacement specifications for fuel atomiser nozzles?
Atomiser nozzles should be renewed if faults occur, such as difficult starting, black smoke, or loss of power. The set and reset pressure for atomisers varies by code; for example, code KB requires 300 atm (4410 lbf/in²), while code RZ requires 250 atm (3675 lbf/in²). p. 45
What is the correct lubricating oil pressure for a Perkins 1000 Series engine?
For engine types AJ, AK, AM, AP, AQ, YG, YH, YJ, and YK, the minimum lubricating oil pressure at maximum engine speed and normal operating temperature is 280 kPa (40 lbf/in²). For engine types AR and AS, the minimum pressure is 207 kPa (30 lbf/in²). p. 25
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