Perkins peregrine edi and 1300 series edi ws diesel engine service repair manual
- 1. 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
- 2. 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 This document has been printed from SPI². Not for Resale
- 3. 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 This document has been printed from SPI². Not for Resale
- 4. 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 This document has been printed from SPI². Not for Resale
- 5. 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 This document has been printed from SPI². Not for Resale
- 6. 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 This document has been printed from SPI². Not for Resale
- 7. Workshop Manual, TPD 1353E, Issue 3 vii 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 This document has been printed from SPI². Not for Resale
- 8. 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 This document has been printed from SPI². Not for Resale
- 9. Workshop Manual, TPD 1353E, Issue 3 ix 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 This document has been printed from SPI². Not for Resale
- 10. x Workshop Manual, TPD 1353E, Issue 3 Peregrine EDi and 1300 Series EDi 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 This document has been printed from SPI². Not for Resale
- 11. Workshop Manual, TPD 1353E, Issue 3 xi 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 This document has been printed from SPI². Not for Resale
- 12. 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. This document has been printed from SPI². Not for Resale
- 13. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
- 14. 1 2 Workshop Manual, TPD 1353E, Issue 3 Peregrine EDi and 1300 Series EDi Engine views W250/1 B A PW251/1 This document has been printed from SPI². Not for Resale
- 15. 1 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 This document has been printed from SPI². Not for Resale
- 16. 1 4 Workshop 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. l Only use these engines in the type of application for which they have been designed. l Do not change the specification of the engine. l Do not smoke when you put fuel in the tank. l Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a safe place. l Do not put fuel in the tank while the engine runs (unless it is absolutely necessary). l Do 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). l Do not make adjustments that you do not understand. l Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions. l Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation. l Do not permit loose clothing or long hair near moving parts. l Keep away from moving parts during engine operation. Warning! Some moving parts cannot be seen clearly while the engine runs. l Do not operate the engine if a safety guard has been removed. l Do 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. l Do not use salt water or any other coolant which can cause corrosion in the closed coolant circuit. l Do 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. l Disconnect the battery terminals before a repair is made to the electrical system. l Only one person must control the engine. l Ensure that the engine is operated only from the control panel or from the operator’s position. l Discard used lubricating oil in a safe place to prevent contamination. l Ensure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is started. l The 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. l Diesel 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. l Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated with oil into the pockets of clothing. l Discard used lubricating oil in accordance with local regulations to prevent contamination. l Use extreme care if emergency repairs must be made in adverse conditions. l Always 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 This document has been printed from SPI². Not for Resale
- 17. 1 Workshop Manual, TPD 1353E, Issue 3 5 Peregrine EDi and 1300 Series EDi l Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help immediately. l Turbochargers 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. l The fuel injector units of this engine are controlled electronically by a pulse of 110 volts. l The 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. l Fit only genuine Perkins parts. Asbestos joints The engines are asbestos free. This document has been printed from SPI². Not for Resale