Perkins 1000 Series Engine

Tools: standard screwdriver, wrench

1. Droop adjustment: rotate the set screw on the rear of the governor counter clockwise until it stops (do not use excess force).
2. If the required speed is between 1470 RPM and 1900 RPM turn the set screw clockwise one full turn; if between 2100 RPM and 3000 RPM turn it 4-1/2 times clockwise.
3. Speed adjustment: start and warm up the engine, then loosen the jam nut.
4. While observing the instrument panel tach, rotate the long adjustor clockwise to lower RPM and counter clockwise to raise RPM until the desired speed is obtained.
5. Hold the long adjustor securely with a wrench and tighten the jam nut, then stop the engine.

⚠ Lockout the starting switch of the prime mover and remove all external loads before installing or servicing couplings.

⚠ Make certain all lube plugs are installed before operating.

Tools: standard mechanics tools, wrench, straight edge, feeler gauges, spacer bar, soft mallet

1. Mount seals and hubs: clean all metal parts with non-flammable solvent, coat seals lightly with grease and place on shafts before mounting hubs; heat interference-fit hubs to max 275 F (135 C). Mount
2. Gap and angular alignment: use a spacer bar equal in thickness to the specified gap, insert at 90 degree intervals and measure clearance with feelers; difference must not exceed angular limits.
3. Offset alignment: align so a straight edge rests squarely on both hubs and also at 90 degree intervals; clearance must not exceed parallel offset limits.
4. Insert grid: pack gap and grooves with specified lubricant before inserting the grid; install segments so all cut ends extend in the same direction.
5. Pack with grease and assemble covers: position seals and gaskets, assemble covers with match marks on the same side, secure cover halves and tighten fasteners to the specified torque.

Tools: wrench, oil collector

1. Operate the engine until it is warm.
2. Stop the engine. Remove the sump drain plug and its O ring and drain the lubricating oil from the sump.
3. Fit the drain plug and its O ring and tighten to 34 Nm (25 lbf ft).
4. Fill the sump to the MAX mark on the dipstick with new and clean lubricating oil of an approved grade.
5. Return the unit to service by returning the AEC selector to automatic and close cooling system manual by-pass valve. Dispose of used oil properly.

⚠ Ensure that the correct Perkins POWERPART filter is used (contains a valve and special tube).

Tools: strap wrench, tray

1. Turn the engine off using the proper shutdown procedure.
2. Put a tray under the filter to retain spilt lubricating oil.
3. Remove the filter with a strap wrench or similar tool. Ensure the adaptor is secure in the filter head.
4. Clean the filter head.
5. Add clean engine lubricating oil to the new filter and allow it to pass through the element.
6. Lubricate the top of the filter seal with clean engine lubricating oil.
7. Fit the new filter and tighten it by hand only. Do not use a strap wrench.
8. Ensure there is oil in the sump; on turbocharged engines ensure the engine will not start and operate the starter until oil pressure is obtained.
9. Operate the engine and check for leakage; check oil level when cooled and top up if necessary.

Tools: hand priming pump, screwdriver

1. Make certain the condition that caused air to enter has been corrected. Do not attempt to loosen fuel injector lines to eliminate air.
2. Operate the hand priming pump located on the bottom of the fuel lift pump on the engine's right side.
3. Locate the air vent valve in the primary fuel filter base, slightly open it, and operate the hand primer until fuel is observed coming from the vent, then reclose.
4. Continue to operate the hand primer but loosen the cap nut on top of the secondary fuel filter until the filter is full and fuel is observed; re-tighten.
5. Start the engine by manual crank SW#1 or SW#2.
6. If the engine fails to start or runs erratic, recheck all fuel lines, connections and filters.

⚠ The turbocharger heat shield must be replaced when finished.

Tools: screwdriver, waste collector

1. Remove the cover and seal from the top of the lift pump. On 6T and 6TW engines remove the small turbocharger heat shield above the pump.
2. Remove the screen strainer.
3. Carefully wash the screen and lift pump body.
4. Reinstall the screen, being careful to align the hole.
5. Install the cover and seal, making sure it is seated properly. Do not over tighten the cover screw. Reinstall the heat shield on 6T and 6TW engines.
6. Operate the hand priming pump to aid in purging air from the system.

Tools: waste oil/fuel collector, hand priming pump

1. Using a waste oil or fuel collector, open the drain valve on the bottom of the transparent water separator bowl and drain until fuel can no longer be seen in the bowl.
2. Unscrew the bowl and bowl header from the filter element.
3. Turn the quick change ring of the filter element left until loose.
4. Grasp the filter element and pull straight down until dislodged from the filter base. Note the six embossments for alignment.
5. Fill the new element with fuel, making sure the grommet is lubricated. Align and install by pushing the element into place. Do not force.
6. Install the quick change ring by turning right approximately 1/3 turn until it clicks into position.
7. Screw the bowl and bowl header back onto the bottom of the new element and tighten the drain valve.
8. Prime the filter by operating the hand priming pump; open the air vent valve on the filter base until fuel is observed, then close.

⚠ Do not remove the pressure cap while coolant is at normal operating temperature.

⚠ Do not use 100% antifreeze; premix water and antifreeze.

1. Fill with a pre-mixed solution of 50% water and 50% permanent antifreeze up to the filler neck.
2. Install the pressure cap, start and run the engine until the temperature stabilizes at approximately 160-200 F (71-93 C).
3. When the overflow ceases, stop the engine.
4. Wait until the engine temperature drops to approximately 120 F (49 C) or lower before removing the pressure cap, then fill as necessary up to the bottom of the fill neck.

Tools: waste oil/fuel collector, hand priming pump

1. Using a waste oil or fuel collector, open the drain valve on the bottom of the filter element and drain until fuel stops running.
2. Follow steps 2 through 6 as described in the primary filter section.
3. Tighten the drain valve.
4. Operate the priming pump; loosen the cap ring on top of the filter base and operate the priming pump until fuel is observed around the cap, then re-tighten the cap ring.

⚠ Do not leave the mode selector switch in the MANUAL RUN position during automatic operation; the controller will be unable to stop the engine and damage may result.

1. Refer to Page 9 'Important' on AEC operation.
2. Position the mode selector to MANUAL RUN.
3. Lift and hold manual crank #1 until the engine starts, or release after 15 seconds. If the unit fails to start, wait 15 seconds, use manual crank #2 and repeat.
4. If cooling water is not flowing or engine temperature is too high, open the cooling system manual by-pass valve.
5. To stop: return the mode selector switch to AUTOMATIC and manual stop position; the engine will stop. Close the cooling system manual by-pass valve.