Perkins 1300 EDi Series Instruction manual

i
Perkins
Peregrine EDi and 1300 Series EDi
Models WK to WS
WORKSHOP MANUAL
Peregrine 6 cylinder turbocharged diesel engines
with electronic management system for
automotive applications
1300 Series 6 cylinder turbocharged diesel engines
with electronic management system for
agricultural and industrial applications
Publication TPD 1353E, Issue 3
© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in April 2001 by Technical Publications,
Perkins Engines Company Limited, Peterborough PE1 5NA, England
This document has been printed from SPI². Not for Resale

ii
Perkins Approved Clear English
This publication is written in
Chapters
1 General information
2 Specifications
3 Cylinder head assembly
4 Piston and connecting rod assemblies
5 Crankshaft assembly
6 Timing case and drive assembly
7 Cylinder block assembly
8 Engine timing
9 Turbocharger
10 Lubrication system
11 Fuel system
12 Cooling system
13 Flywheel and housing
14 Electrical equipment
15 Auxiliary equipment
16 Special tools
17 Fault diagnosis
The following pages contain a detailed table of contents
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Workshop Manual, TPD 1353E, Issue 3 iii
Peregrine EDi and 1300 Series EDi
Contents
1 General information
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...1
Engine views . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...2
Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...3
Safety precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...4
Engine lift equipment .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...6
POWERPART recommended consumable products . ... ... ... ... ... ... ... ... ... ... ... ... ...7
2 Specifications
Basic engine data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...9
Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .10
Recommended torque settings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .19
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iv Workshop Manual, TPD 1353E, Issue 3
Peregrine EDi and 1300 Series EDi
3 Cylinder head assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 21
Rocker cover
Operation 3-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22
Operation 3-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23
Engine breather elements
Operation 3-3 To renew . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24
Rocker assembly
Operation 3-4 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25
Operation 3-5 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 26
Operation 3-6 To dismantle and inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27
Operation 3-7 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28
Cylinder head assembly
Operation 3-8 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29
Operation 3-9 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30
Valves and valve springs
Operation 3-10 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33
Operation 3-11 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34
Operation 3-12 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35
Operation 3-13 To inspect a valve rotator .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
Valve guides
Operation 3-14 To inspect a valve guide ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38
Operation 3-15 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39
Operation 3-16 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 40
Cylinder head
Operation 3-17 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41
Operation 3-18 To correct a valve seat with a valve seat cutter ... ... ... ... ... ... ... ... ... 43
Operation 3-19 To fit valve seat inserts . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44
Operation 3-20 To renew injector unit sleeves .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45
Operation 3-21 To set the valve tip clearance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 48
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Workshop Manual, TPD 1353E, Issue 3 v
Peregrine EDi and 1300 Series EDi
4 Piston and connecting rod assemblies
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .51
Big end bearing
Operation 4-1 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .52
Operation 4-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .53
Operation 4-3 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .54
Piston and connecting rod assembly
Operation 4-4 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .55
Operation 4-5 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .56
Operation 4-6 To dismantle and assemble (one-piece pistons) ... ... ... ... ... ... ... ... ... .58
Operation 4-7 To dismantle and assemble (two-piece pistons) ... ... ... ... ... ... ... ... ... .59
Operation 4-8 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .60
Connecting rod
Operation 4-9 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .61
Small end bush
Operation 4-10 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .61
Piston rings
Operation 4-11 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .62
Operation 4-12 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .63
5 Crankshaft assembly
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .65
Crankshaft pulley / damper assembly
Operation 5-1 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .66
Operation 5-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .67
Operation 5-3 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .68
Rear oil seal housing assembly
Operation 5-4 To remove the oil seal housing .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .69
Operation 5-5 To fit the oil seal housing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .70
Operation 5-6 To renew the rear oil seal and wear sleeve assembly ... ... ... ... ... ... ... .72
Crankshaft
Operation 5-7 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .75
Operation 5-8 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .77
Operation 5-9 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .79
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vi Workshop Manual, TPD 1353E, Issue 3
Peregrine EDi and 1300 Series EDi
Crankshaft gear
Operation 5-10 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 80
Thrust bearing
Operation 5-11 To check crankshaft end-float ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 81
Operation 5-12 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 82
Operation 5-13 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 83
Main bearings
Operation 5-14 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 84
Operation 5-15 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 85
Operation 5-16 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 86
6 Timing case and drive assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 87
Components of the timing case ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 88
Timing case cover
Operation 6-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 89
Operation 6-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 90
Idler gears
Operation 6-3 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 91
Operation 6-4 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 92
Timing case backplate
Operation 6-5 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 93
Operation 6-6 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 94
Camshaft and tappets
Operation 6-7 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 95
Operation 6-8 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 97
Operation 6-9 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 98
Camshaft bushes
Operation 6-10 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 99
Camshaft motion sensor (CMS)
Operation 6-11 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 101
CMS verification of clearance
Operation 6-12 To check the air gap . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 102
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Peregrine EDi and 1300 Series EDi
7 Cylinder block assembly
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...103
Cylinder block
Operation 7-1 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...104
Operation 7-2 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...105
Cylinder liner
Operation 7-3 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...106
Operation 7-4 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...108
To inspect
Operation 7-5 Check the cylinder liners for damage and wear . ... ... ... ... ... ... ... ... ...109
8 Engine timing
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...111
Engine timing
Operation 8-1 To set number 1 cylinder to TDC on the compression stroke ... ... ... ...112
Operation 8-2 To check the valve timing (with a feeler gauge) . ... ... ... ... ... ... ... ... ...113
Operation 8-3 To check the valve timing (with a dial test indicator) .. ... ... ... ... ... ... ...114
9 Turbocharger
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...115
Turbocharger
Operation 9-1 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...116
Operation 9-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...117
Operation 9-3 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...118
Operation 9-4 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...120
Operation 9-5 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...121
Operation 9-6 To clean the impeller and compressor casing ... ... ... ... ... ... ... ... ... ...121
Operation 9-7 To remove and to fit the actuator assembly of the waste-gate unit ... ...122
Operation 9-8 To check the actuator assembly of the waste-gate unit . ... ... ... ... ... ...123
Operation 9-9 To adjust the actuator assembly of the waste-gate unit . ... ... ... ... ... ...124
Turbocharger faults .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...125
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viii Workshop Manual, TPD 1353E, Issue 3
Peregrine EDi and 1300 Series EDi
10 Lubrication system
General description (Low-pressure system) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 127
Filter canister
Operation 10-1 To renew the canister of the lubricating oil filter ... ... ... ... ... ... ... ... .. 129
Oil filter head and cooler assembly
Operation 10-2 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 131
Operation 10-3 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 132
Operation 10-4 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 133
Oil temperature control valve
Operation 10-5 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 134
Operation 10-6 To test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 134
Pressure regulating valve
Operation 10-7 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 135
Operation 10-8 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 135
Sump
Operation 10-9 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 136
Operation 10-10 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 137
Oil strainer and suction pipe
Operation 10-11 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 139
Lubricating oil pump
Operation 10-12 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 140
Operation 10-13 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 141
Operation 10-14 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 143
Front oil seal
Operation 10-15 To renew (oil pump removed) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 144
Operation 10-16 To renew (oil pump fitted) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 146
Pressure relief valve
Operation 10-17 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 148
Operation 10-18 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 148
Breather system
Operation 10-19 To clean .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 149
General description (High-pressure system) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 150
Sensor for injection control pressure
Operation 10-20 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 152
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Peregrine EDi and 1300 Series EDi
High-pressure pump
Operation 10-21 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...153
Operation 10-22 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...154
Regulator valve for injection control pressure
Operation 10-23 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...155
Supply manifold
Operation 10-24 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...156
Operation 10-25 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...157
11 Fuel system
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...159
Fuel injection cycle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...161
Fuel filter
Operation 11-1 To renew the fuel strainer and the canister of the fuel filter . ... ... ... ...165
Fuel injector units
Operation 11-2 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...166
Operation 11-3 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...169
Operation 11-4 To renew the fuel injector unit seals . ... ... ... ... ... ... ... ... ... ... ... ... ...171
Fuel lift pump
Operation 11-5 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...173
Operation 11-6 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...174
Operation 11-7 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...175
Operation 11-8 To set the adjustment of the speed control .. ... ... ... ... ... ... ... ... ... ...176
Operation 11-9 To eliminate air from the fuel system ... ... ... ... ... ... ... ... ... ... ... ... ...177
12 Cooling system
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...179
Cooling system flow diagram .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...180
Coolant filter
Operation 12-1 To renew the canister of the coolant filter / inhibitor . ... ... ... ... ... ... ...181
Thermostat
Operation 12-2 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...182
Operation 12-3 To test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...182
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Coolant pump
Operation 12-4 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 183
Fan
Operation 12-5 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 184
Fan drive
Operation 12-6 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 184
Fan drive belt
Operation 12-7 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 185
13 Flywheel and housing
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 187
Flywheel
Operation 13-1 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 188
Operation 13-2 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 189
Starter ring
Operation 13-3 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 190
Flywheel housing
Operation 13-4 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 191
14 Electrical equipment
Alternator
Operation 14-1 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 194
Operation 14-2 To maintain ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 194
Alternator fault finding .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 195
Alternator wiring diagrams ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 197
Starter motor
Operation 14-3 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 199
Operation 14-4 To maintain ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 200
Operation 14-5 To test on the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 201
Starter motor wiring diagrams . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 202
Starting aid . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 203
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Peregrine EDi and 1300 Series EDi
Engine management system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...204
Sensors .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...206
Engine management system wiring diagrams ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...208
15 Auxiliary equipment
Compressors
Operation 15-1 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...216
Power steering pump
Operation 15-2 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...217
Power take-off adaptor
Operation 15-3 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...218
Operation 15-4 To tighten the drive gear nut ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...218
16 Special tools
List of special tools .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...219
17 Fault diagnosis
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...223
Basic diagnostics . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...224
The self-test system
Operation 17-1 How to check for faults codes .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...226
Operation 17-2 How to test for an open circuit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...226
The diagnostic tool
Operation 17-3 General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...227
Operation 17-4 The diagnostic program map ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...229
Operation 17-5 Code display options ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...232
Operation 17-6 The engine data list .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...233
Operation 17-7 How to connect the diagnostic tool ... ... ... ... ... ... ... ... ... ... ... ... ... ...236
Operation 17-8 How to check for faults codes .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...237
Operation 17-9 How to clear faults codes from the diagnostic tool ... ... ... ... ... ... ... ...239
Operation 17-10 How to do the “ENGINE OFF TEST” .. ... ... ... ... ... ... ... ... ... ... ... ...240
Operation 17-11 How to do the “ENGINE RUNNING TEST” ... ... ... ... ... ... ... ... ... ...244
Flash codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...246
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Workshop Manual, TPD 1353E, Issue 3 1
1
Peregrine EDi and 1300 Series EDi
General information 1
Introduction
The Peregrine EDi and the 1300 Series EDi are a family of turbocharged engines that have an electronic
management system. The Peregrine EDi engines are designed for automotive applications and the 1300
Series EDi engines are designed for industrial and agricultural applications. The Peregrine EDi and the 1300
Series EDi engines are from Perkins Engines Limited, a world leader in the design and manufacture of high-
performance diesel engines.
Perkins approved assembly and quality standards, together with the latest technology, have been applied to
the manufacture of your engine to give you reliable and economic power.
Most of the general information which is included in the relevant User’s Handbook (Chapters 1 to 6) has not
been repeated in this Workshop Manual and the two publications should be used together.
To ensure that you use the relevant information for your specific engine type, refer to "Engine identification"
on page 3.
Where the information applies only to certain engine types, this is indicated in the text by use of the engine
model code letters, refer to "Engine identification" on page 3.
When reference is made to the "left" or "right" side of the engine, this is as seen from the flywheel end of the
engine.
Special tools have been made available and a list of these is given in Chapter 16, Special tools. Reference to
the relevant special tools is also made at the beginning of each operation.
Data and dimensions are included in Chapter 2, Specifications.
Read and remember the "Safety precautions" on page 4. They are given for your protection and must be used
at all times.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: This indicates that there is a possible danger to the engine.
Note: Is used where the information is important, but there is not a danger.
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2Workshop Manual, TPD 1353E, Issue 3
Peregrine EDi and 1300 Series EDi
Engine views
W250/1
B
A
PW251/1
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Workshop Manual, TPD 1353E, Issue 3 3
Peregrine EDi and 1300 Series EDi
Engine identification
The engines consist of a range of six cylinder in-line engines, which are turbocharged or turbocharged /
intercooled. These engines have an electronic management system.
In this publication, the different engine types are indicated by their code letters, which are the first two letters
of the engine number as indicated below:
The engine number is stamped on the left side of the cylinder block (A1), behind the high pressure pump.
An example of an engine number is WK1296N123456B.
The components of the engine number are as follows:
WK1296N123456B
WK = Model code letters
1296 = Build list number
N = Built in the USA
123456 = Engine serial number
B = Year of manufacture
If you need parts, service or information for your engine, you must give the complete engine number to your
Perkins distributor.
Code letters Capacity Aspiration system
Litre in3
WK 7,6 466 Turbocharged
WL 7,6 466 Turbocharged / intercooled
WM 8,7 531 Turbocharged
WN 8,7 531 Turbocharged / intercooled
WP 7,6 466 Turbocharged
WQ 7,6 466 Turbocharged / intercooled
WR 8,7 531 Turbocharged
WS 8,7 531 Turbocharged / intercooled
PW002
A
1
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4Workshop Manual, TPD 1353E, Issue 3
Peregrine EDi and 1300 Series EDi
Safety precautions
These safety precautions are important. You must refer also to the local regulations in the country of use.
Some items only apply to specific applications.
lOnly use these engines in the type of application for which they have been designed.
lDo not change the specification of the engine.
lDo not smoke when you put fuel in the tank.
lClean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
lDo not put fuel in the tank while the engine runs (unless it is absolutely necessary).
lDo not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training;
even then extreme caution must be used to prevent injury).
lDo not make adjustments that you do not understand.
lEnsure that the engine does not run in a location where it can cause a concentration of toxic emissions.
lOther persons must be kept at a safe distance while the engine or auxiliary equipment is in operation.
lDo not permit loose clothing or long hair near moving parts.
lKeep away from moving parts during engine operation.
Warning! Some moving parts cannot be seen clearly while the engine runs.
lDo not operate the engine if a safety guard has been removed.
lDo not remove the filler cap or any component of the cooling system while the engine is hot and while the
coolant is under pressure, because dangerous hot coolant can be discharged.
lDo not use salt water or any other coolant which can cause corrosion in the closed coolant circuit.
lDo not allow sparks or fire near the batteries (especially when the batteries are on charge) because the
gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially
to the eyes.
lDisconnect the battery terminals before a repair is made to the electrical system.
lOnly one person must control the engine.
lEnsure that the engine is operated only from the control panel or from the operator’s position.
lDiscard used lubricating oil in a safe place to prevent contamination.
lEnsure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is
started.
lThe combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes.
lDiesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons.
Protect your hands with gloves or a special solution to protect the skin.
lDo not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets of clothing.
lDiscard used lubricating oil in accordance with local regulations to prevent contamination.
lUse extreme care if emergency repairs must be made in adverse conditions.
lAlways use a safety cage to protect the operator when a component is to be pressure tested in a container
of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to
be pressure tested. Continued
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Workshop Manual, TPD 1353E, Issue 3 5
Peregrine EDi and 1300 Series EDi
lDo not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
lTurbochargers operate at high speed and at high temperatures. Keep fingers, tools and debris away from
the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.
lThe fuel injector units of this engine are controlled electronically by a pulse of 110 volts.
lThe fuel injector units are actuated by high-pressure engine lubricating oil. Do not remove any component
of the high-pressure system while the engine oil is under pressure, because dangerous oil can be
discharged.
lFit only genuine Perkins parts.
Asbestos joints
The engines are asbestos free.
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6Workshop Manual, TPD 1353E, Issue 3
Peregrine EDi and 1300 Series EDi
Engine lift equipment
lThe maximum weight of the engine without coolant, lubricant or a gearbox fitted will vary for different
applications, it is recommended that lift equipment with a minimum capacity of 770 kg (1700 lbs) is used.
lAlways use engine lift equipment of the approved type and of the correct capacity to lift the engine. It is
recommended that lift equipment of the type shown in (A) is used, to provide a vertical lift directly above
the engine lift brackets. Never use a single lift bracket to raise an engine.
lCheck the engine lift brackets for damage and security before the engine is lifted.
lUse lift equipment or obtain assistance to lift heavy engine components such as the cylinder block, cylinder
head, flywheel housing, crankshaft and flywheel.
lTo avoid possible damage to the engine rocker cover by contact from the lift equipment, use the correct lift
equipment (A) to raise the engine.
A
W130
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Workshop Manual, TPD 1353E, Issue 3 7
Peregrine EDi and 1300 Series EDi
POWERPART recommended consumable products
Perkins have made available the products recommended below in order to assist in the correct operation,
service and maintenance of your engine and your machine. The instructions for the use of each product are
given on the outside of each container. These products are available from your Perkins distributor.
POWERPART Antifreeze
Protects the cooling system against frost and corrosion. Part number 21825166.
POWERPART Compound
To seal the outer diameter of seals. Part number 1861147.
POWERPART Easy Flush
Cleans the cooling system. Part number 21825001.
POWERPART Gasket and flange sealant
To seal flat faces of components where no joint is used. Especially suitable for aluminium components. Part
number 21820518.
POWERPART Gasket remover
An aerosol for the removal of sealants and adhesives. Part number 21820129.
POWERPART Griptite
To improve the grip of worn tools and fasteners. Part number 21820129.
POWERPART Hydraulic threadseal
To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and pneumatic systems.
Part number 21820121.
POWERPART Industrial grade super glue
Instant adhesive designed for metals, plastics and rubbers. Part number 21820125.
POWERPART Lay-Up 1
A diesel fuel additive for protection against corrosion. Part number 1772204.
POWERPART Lay-Up 2
Protects the inside of the engine and of other closed systems. Part number 1762811.
POWERPART Lay-Up 3
Protects outside metal parts. Part number 1734115.
POWERPART Metal repair putty
Designed for external repair of metal and plastic. Part number 21820126.
POWERPART Pipe sealant and sealant primer
To retain and seal connections with coarse threads. Pressure systems can be used immediately. Part number
21820122.
POWERPART Radiator stop leak
For the repair of radiator leaks. Part number 21820127.
Continued
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8Workshop Manual, TPD 1353E, Issue 3
Peregrine EDi and 1300 Series EDi
POWERPART Retainer (high strength)
To retain components that have an interference fit. Part number 21820638.
POWERPART Retainer (oil tolerant)
To retain components that have an interference fit, but is in contact with oil. Part number 21820603.
POWERPART Safety cleaner
General cleaner that is in an aerosol container. Part number 21820128.
POWERPART Silicone adhesive
An RTV silicone adhesive for application where low pressure tests occur before the adhesive sets. Used for
sealing flange where oil resistance is needed and movement of the joint occurs. Part number 21826038.
POWERPART Silicone RTV sealing and jointing compound
Silicone rubber sealant that prevents leakage through gaps. Part number 1861108.
POWERPART Stud and bearing lock
To provide a heavy duty seal to components that have a light interference fit. Part number 21820119 or
21820120.
POWERPART Threadlock and nutlock
To retain small fasteners where easy removal is necessary. Part number 21820117 or 21820118.
POWERPART Universal jointing compound
Universal jointing compound that seals joints. Part number 1861117.
This document has been printed from SPI². Not for Resale