Perkins Engine 1300EDi Service Manual
TPD1352E, Issue 4
November 2011
User’s
Handbook
1300 Series EDi
WK
WL
WM
WN
WP
WQ
WR
WS
Thispublication iswr ittenin
PerkinsApproved C learEngl ish
This publication is divided into six chapters:
1 General information
2 Engine views
3 Operation instructions
4 Preventive maintenance
5 Engine fluids
6 Fault diagnosis
The following pages contain a detailed table of contents
ii
1300 Series EDi Models WK to WS
Contents
1 General information
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 1
Safety precautions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 2
How to care for your engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 3
Engine preservation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 4
Parts and service ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 5
Training ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 5
Service literature . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 5
Engine identification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 6
Engine data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 8
2 Engine views
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 11
Location of engine parts .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 11
3 Operation instructions
How to start the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 13
How to start an engine with an ether start system .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15
How to stop the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16
Adjustment of engine speed range . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16
Engine operation at idle speed ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16
Running-in ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16
Altitude ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16
User’s Handbook, TPD 1352E, issue 3 iii
1300 Series EDi Models WK to WS
4 Preventive maintenance
Preventive maintenance periods . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 17
Schedules ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18
How to drain the cooling system .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19
How to fill the cooling system .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20
How to renew the canister of the coolant filter / inhibitor . ... ... ... ... ... ... ... ... ... ... ... ... 21
How to check the drive belt . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22
How to remove the drive belt ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22
Fuel pre-filter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23
How to renew the fuel strainer and the canister of the fuel filter .. ... ... ... ... ... ... ... ... ... 23
How to eliminate air from the fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24
How to renew the lubricating oil ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25
How to renew the canister of the lubricating oil filter ... ... ... ... ... ... ... ... ... ... ... ... ... ... 26
Air filter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27
Restriction indicator . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27
How to set the valve tip clearances . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28
5 Engine fluids
Fuel specification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29
Lubricating oil specification .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30
Coolant specification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31
6 Fault diagnosis
Problems and possible causes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33
List of possible causes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34
iv User’s Handbook, TPD 1352E, issue 3
1300 Series EDi Models WK to WS
1
General information 1
Introduction
The 1300 Series EDi is a family of engines which have an electronic management system. The engines are
designed for industrial and agricultural applications 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.
Note: To ensure that you use the relevant information for your specific engine type, refer to "Engine
identification" on page 6.
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.
A
User’s Handbook, TPD 1352E, issue 4 1
W251/1
1
1300 Series EDi Models WK to WS
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.
z Only use these engines in the type of application for which they have been designed.
z Do not change the specification of the engine.
z Do not smoke when you put fuel in the tank.
z Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
z Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
z 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).
z Do not make adjustments that you do not understand.
z Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
z Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation.
z Do not permit loose clothing or long hair near moving parts.
z Keep away from moving parts during engine operation.
Warning! Some moving parts cannot be seen clearly while the engine runs.
z Do not operate the engine if a safety guard has been removed.
z 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.
z Do not use salt water or any other coolant which can cause corrosion in the closed coolant circuit.
z 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.
z Disconnect the battery terminals before a repair is made to the electrical system.
z Only one person must control the engine.
z Ensure that the engine is operated only from the control panel or from the operator's position. Discard used
lubricating oil in a safe place to prevent contamination.
z Ensure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is
started.
z 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 materi al to come into contact with the skin or with
the eyes.
z 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.
z Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets of clothing.
z Discard used lubricating oil in accordance with local regulations to prevent contamination.
z Use extreme care if emergency repairs must be made in adverse conditions.
Continued
2 User’s Handbook, TPD 1352E, issue 4
1300 Series EDi Models WK to WS
z Always use a safety cage to protect the operator wh en a component is to be pressure te sted 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.
z Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
z Turbochargers operate at high speed and at high temperatures. Keep fingers, tools an d debris away from
the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.
z The fuel injector units of this engine are controlled electronically by a pulse of 110 volts.
z The fuel injector units are actuated by high-pressure e ngine lubricati ng oil. Do not remove any compone nt
of the high-pressure system while the engine oil is under pressure, because dangerous oil can be
discharged.
z Fit only genuine Perkins parts.
1
How to care for your engine
This handbook has been written to assist you to maintain and operate your engine correctly.
To obtain the best performance and the longest life from your engine, you mu st ensur e that the m ainten ance
operations are done at the intervals indicated in Chap ter 4, Preventive maintenance. If the engine works in a
very dusty environment or other adverse conditions, certain maintenance intervals will have to be reduced.
Renew the filter canisters and lubricating oil regularly in order to ensure that the inside of your engine remains
clean.
Ensure that all adjustments and repairs are done by personnel who have had the correct training. Perkins
distributors have this type of personnel available. You can also obtain parts and service from your Perkins
distributor.
The terms "left side" and "right side" apply when the engine is seen from the flywheel end.
Warning! Read the "Safety precautions" on page 2 and remember them. They are given for your protection
and must be applied at all times.
User’s Handbook, TPD 1352E, issue 4 3
1
1300 Series EDi Models WK to WS
Engine preservation
Introduction
The recommendations indicated below are designed to prevent damage to the engine when it is withdrawn
from service for a prolonged period. Use these procedures after the engine is withdrawn fro m service.
Procedure
Caution: The procedure for this e ngine is different to th e procedure fo r other Perkins engines, because of the
design of the fuel injection units.
1 Completely clean the outside of the engine.
2 Operate the engine until it is warm. Stop the engine and drain the lubr icating oil from the sump. Ensure that
the oil gallery of the high-pressure lubrication system is drained.
Caution: If the gallery is not drained, the engine cylinders will be filled with engine lubricating oil when the fuel
injector units are removed.
3 Drain the fuel supply gallery, fitted to the cylinder head.
Caution: If the gallery is not drained, the engine cylinders will be filled with fuel when the fuel injector units are
removed.
4 Renew the canister of the lubricating oil filter, see "How to renew the canister of the lubricating oil filter" on
page 26.
5 Fill the sump to the full mark on the dipstick with new and clean lubricating oil. Use a correct preservative
fluid instead of the lubricating oil. If a preservative fluid is used, this must be drained and the lubricating oil
sump must be filled to the correct level with normal lubricating oil at the end of the storage period.
6 Drain the coolant circuit, see "How to drain the cooling system" on page 19. In order to protect the cooling
system against corrosion, fill it with an approved antifreeze mixture because this gives protection against
corrosion.
Caution: If protection against frost is not ne cessary and a corrosion in hibitor is to be used, it is recommended
that you consult the Technical Service Department, Perkins Engines Company Limited, Peterb or o ug h.
7 Connect the battery, eliminate air from the fuel system. Operate the engine for a short period in order to
circulate the lubricating oil and the coolant in the engine. Then correct leakages of fuel, lubricating oil or air.
8 Disconnect the battery. Then put the battery into safe storage in a fully charged condition . Before the battery
is put into storage, protect its terminals against corrosion.
9 Remove the air filter. Then, if necessary, remove the pipe(s) installed between the air filter and the
turbocharger. Seal the air inlet to the turbocharger with waterproof tape.
Continued
4 User’s Handbook, TPD 1352E, issue 4
1300 Series EDi Models WK to WS
10 Remove the exhaust pipe. Seal the manifold or the turbocharger with waterproof tape.
11 Clean the engine breather pipe and seal the end of the pipe.
12 When a preservative fuel is to be used, drain the fuel system and fill it with the preservative fuel. If
preservative fuel is not used, the system can be completely filled with normal fuel but the fuel must be drained
and discarded at the end of the storage perio d togeth e r w ith the fu el filte r can ist er .
13 Remove the drive belts and put them into storage.
14 Seal the vent pipe of the fuel tank or the fuel filler cap with waterproof tape.
Every month, the crankshaft must be rotated in order to change the spring loading on the valve train. Rotate
the crankshaft more than 180 degrees. Visibly check for damage or corrosion to the engine.
If the engine protection is done correctly according to the above recommendations, no corrosion damage will
normally occur. Perkins are not responsible for damage which may occur when an engi ne is in storage after a
period in service.
1
Parts and service
If problems occur with your engine or with the components fitted onto it, your Perkins distr ibutor can make the
necessary repairs and will ensure that only the correct parts are fitted and that the work is done correctly.
Training
Local training for the correct operation, service and overhaul of engines is available at certain Perkins
distributors. If special training is necessary, your Perkins distributor can advise you how to obtain it at the
Perkins Customer Training Department, Peterborough, or other main centres.
Service literature
Workshop manuals, installation drawings and other service publications are available from your Perkins
distributor at a nominal cost.
User’s Handbook, TPD 1352E, issue 4 5
1
1300 Series EDi Models WK to WS
Engine identification
The 1300 Series EDi engines consist of a range of six cylinder in-line engines which are turbocharged or
turbocharged/intercooled. The engines have an electronic management system.
In this handbook, the different engine types are in dicated by their code letters, which are the first two letters of
the engine number as indicated in table 1.
Table 1
Code letters
WK 7,6 466 Turbocharged
WL 7,6 466 Turbocharged / intercooled
WM 8,6 531 Turbocharged
WN 8,6 531 Turbocharged / intercooled
WP 7,6 466 Turbocharged
WQ 7,6 466 Turbocharged / intercooled
WR 8,6 531 Turbocharged
WS 8,6 531 Turbocharged / intercooled
The engine number is stamped on the left side of the cylinder block (A1) on the earliest engines, behind the
high pressure pump. On later engines, the engine number is located at position (B1). On the current engine,
the identification plate is located on the top cover of the engine (C1).
Capacity
Litre in
3
Aspiration system
An example of an engine number is WP1296N1234567.
The components of the engine number are as follows:
WP = Type code letters
1296 = Build list number
N = Built in the USA
1234567 = Engine serial number
Certain engines built after 4th January 2010 use a different engine numb er format. An exampl e of the engin e
number in the different engine format is WGBF1296N12345U.
The components of the engine number are as follows:
W = Engine series
G = Application
B = Engine type
F = Number of cylinders
1296 = Build list number
N = Built in the USA
123456U = Engine serial number
If you need parts, service or information for your engine, you must give the complete engine number to your
Perkins distributor.
6 User’s Handbook, TPD 1352E, issue 4
1300 Series EDi Models WK to WS
1
1
A
C
W002
1
B
PW250/1
User’s Handbook, TPD 1352E, issue 4 7
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1300 Series EDi Models WK to WS
Engine data
Number of cylinders... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..6
Cylinder arrangement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. In line
Cycle.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..Four stroke
Induction system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Turbocharged or Turbocharged/intercooled
Combustion system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Direct injection
Nominal bore:
- WK and WL.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 109,2 mm (4.301 in)
- WM, WN, WP, WQ, WR and WS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 116,6 mm (4.590 in)
Stroke:
- WK, WL , WP and WQ ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 118,9 mm (4.681 in)
- WM, WN, WR and WS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 135,9 mm (5.350 in)
Compression ratio.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..16.5:1
Cubic capacity:
- WK, WL , WP and WQ. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 7,64 litres (466.4 in
- WM, WN, WR and WS. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 8,71 litres (531 .0 in
Firing order. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1, 5, 3, 6, 2, 4
Valve tip clearances (cold):
- Inlet and exhaust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,64 mm (0.025 in)
Lubricating oil pressure (minimum):
- Idle... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..137 kPa (20 lbf in
- maximum engine speed and normal engine temperature... ... ... ... ... ... ... ..276 kPa (40 lbf/in2) 2,8 kgf/cm
Capacity of a typical lubricating oil sump
(1)
:
2
) 1,4 kgf/cm
3
)
3
)
2
2
- Without filter canister... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 22,7 litres (40.0 UK pints) 24 US quarts
- With filter canister ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 28,3 litres (49.9 UK pints) 28 US quarts
Typical coolant capacity (engine only)... ... ... ... ... ... ... ... ... ... ... .. 12,8 litres (22.5 UK pints) 13,5 US quarts
Direction of rotation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Clockwise from the front
(1) The capacity of the sump may vary according to the application. Fill to the "Full" mark on the dipstick. Do not exceed the "Full" mark.
8 User’s Handbook, TPD 1352E, issue 4
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