JCB Engine New 1000 Series Service Manual (9806/2140)

JCB Engine New 1000 Series Service Manual (9806/2140)

This detailed workshop manual provides full service procedures for JCB New 1000 Series engines, including 4- and 6-cylinder diesel variants. It contains disassembly/reassembly guides, timing instructions, fuel and cooling system servicing, and component torque specifications, supporting complete engine overhaul and diagnostics.

Model Covers:

Perkins New 1000 Series Engine Model AJ to AS and YG to YK

4 and 6 cylinder diesel engines

File Format: PDF

Size: 12.25 MB

No. of pages: 290

Language: English

Delivery Method: Instant Download – Access your file immediately after purchase.

📑 Key Technical Sections:

General Information

Engine identification, safety instructions, service notes, and manual structure.

Specifications

Detailed measurements, tolerances, clearances, and torque settings for all engine components.

Cylinder Head Assembly

Removal and installation of cylinder head, valve mechanism, rocker gear, valve springs, and guides.

Piston and Connecting Rod Assemblies

Piston inspection, ring installation, connecting rod alignment, bearing fitting, and clearance checks.

Crankshaft Assembly

Main bearings, thrust washers, crankshaft removal, fitting, and end float measurement.

Timing Case and Drive Assembly

Gear train layout, timing gear alignment, oil seals, and timing case cover service.

Cylinder Block Assembly

Main structure inspection, liner installation, deck height checks, dowel and plug locations.

Engine Timing

Full timing procedures for camshaft and crankshaft synchronization, key indexing, and alignment tools.

Aspiration System

Inlet manifold, turbocharger setup, air intake cleaning, and EGR system overview.

Lubrication System

Oil pump service, filter replacement, pressure relief valves, flow diagram, and oil cooler routing.

Fuel System

Injector servicing, fuel lift pump, rotary and inline injection pumps, bleed procedures, fuel lines.

Cooling System

Thermostat, water pump, radiator hose connections, temperature sensors, and coolant routing.

Flywheel and Housing

Flywheel removal, ring gear replacement, torque settings, and housing alignment.

Electrical Equipment

Starter motor, alternator, temperature and pressure sensors, and basic wiring overview.

Auxiliary Equipment

Fan drives, belt tensioning, vibration dampers, brackets, and pulley alignment.

Special Tools

Lists all JCB-recommended tools for safe and accurate engine disassembly and testing.

This manual is essential for qualified technicians and mechanics performing professional overhauls and repairs on JCB New 1000 Series diesel engines.