Perkins Engine 1300EDi Service Manual

Perkins 1300 Series EDi

Models WK to WN

USER’S HANDBOOK

Contents

Contents

EXIT

EXIT

Six cylinder, turbocharged, diesel engines with an
electronic management system
for industrial and agricultural applications

Publication TPD. 1352E, Issue 2.
© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in May 1998 by Techni ca l Publ ic ati on s,
Perkins Engines Compan y Limited, Peterborough PE1 5NA, Englan d

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Th is p u b lic a t io n is writte n in
Perkins Approved Clear English

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Contents

1 General information

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

How to care for your engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Engine identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Perkins companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

How to stop the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Adjustment of engine speed range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Engine operation at idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Running-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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 renew 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

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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 diagnos is

Problems and possible causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

List of possible causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

7 Engine preservation

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8 Parts and service

POWERPART recommended consumable products . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

9 General data

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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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 high­performance 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 8.

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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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 must ensure that the
maintenance operations are done at the intervals
indicated in "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. If you do not know the address of your
nearest distributor, enquire at one of the Perkins
companies listed on page 9.

The terms "left side" and "right side" apply when the
engine is seen from the flywheel end.

Warning! Read the "Safety precautions" and
remember them. They are given for your protection
and must be applied at all times.

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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 material 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.

z 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.

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 and 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 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.

z Fit only genuine Perkins parts.

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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
indicated by their code letters, which are the first two
letters of the engine number as indicated below:

Code

letters

WK 7,6 466 Turbocharged

WL 7,6 466 Turbocharged / intercooled
WM 8,6 531 Turbocharged
WN 8,6 531 Turbocharged / intercooled

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
WL1296N123456.

The components of the engine number are as follows:
WL1296N123456
WL Type code letters

1296 Build list number

If you need parts, service or information for your
engine, you must give the complete engine number to
your Perkins distributor.

Capacity

Aspiration system

Litre

N Built in the USA

123456 Engine serial number

in

3

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Perkins companies

Australia

Perkins Engines Australia Pty. Ltd,
Suite 2, 364 Main Street,
Mornington 3931, Victoria, Australia.
Telephone: [phone]
Telex: Perkoil AA30816
Fax: [phone]

China

Perkins Engin es (Tianj in) Ltd,
Jinwei Road,
Beichen District,
Tianjin,
300402
China
Telephone: (86) (22) 2699 2288
Fax: (86) (22) 2699 3784

France

Moteurs Perkins S.A.,
"Parc des reflets",
165 Avenue du Bois de la Pie,
95700 Roissy Charles de Gaulle, France.
Telephone: [phone]
Fax: [phone]

Korea

Perkins Engines (Korea)
Textile Center 12F
Daechi 3 dong 944-31
Kangnam-Ku
Seoul, 135-283
Korea
Telephone: [phone]
Fax: [phone]

United Kingdom

Perkins Engines Company Ltd,
Eastfield, Peterborough PE1 5NA,
England.
Telephone: [phone]
Telex: 32501 Perken G
Fax: [phone]

United States of America

Perkins Engines - North America
12025 Tech Center Drive
Livonia
Michigan 48150
USA
Telephone: [phone]
Fax: [phone]

Germany

Perkins Motoren Gmb H,
Saalaeckerstrasse 4,
63801 Kleinostheim,
Germany.
Telephone: [phone]
Fax: [phone]

Italy

Motori Perkins S.p.A.,
Via Socrate 8,
22070 Casnate con Bernate (Como), Italy.
Telephone: [phone]/564625
Fax: [phone]

Japan

Perkins Engines (Japan) K.K.,
Reinanzaka Building, 5th Floor,
14-2 Akasaka, 1-chome, Minato-ku,
Tokyo 107, Japan.
Telephone: [phone]
Telex: Perkoil J2424823
Fax: [phone]

Perkins Engines Latin America Inc,
Suite 620,
999, Ponce de Leon Boulevard,
Coral Gables,
Florida 33134, U.S.A.
Telephone: [phone]
Telex: 32501 Perken G
Fax: [phone]

Singapore

Perkins Engines (Far East) Pte Ltd,
39 Tuas Avenue 13
Singapore 638999
Telephone: [phone]
Fax: [phone]

In addition to the above companies, there are
Perkins distributors in most countries. Perkins
Engines Company Limited., Peterborough or one
of the above companies can provide details.

9

2

Engine views 2

Introduction

Perkins engines are built for specific applications and the views which follow do not necessarily match your
engine specification.

Location of engine parts

Front and left side view (A)

1Fan
2 Wiring harness to the sensor for injection control

pressure
3 Sensor for engine oil temperature
4 Camshaft position sensor
5 Sensor for engine oil pressure
6 Crankshaft damper
7 Sump for the engine lubricating oil

1
2

8 Sensor for the inlet manifold air temperature

9 electrical connector for the injector units
10 Supply manifold
11 Lubricating oil filler and dipstick
12 Engine control module
13 Fuel strainer
14 Canis ter for the fuel filte r
15 Starter motor

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9

10
11

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12

4

13
14

5

15

6

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2

Rear and right side view (A)

16 Rear lift bracket
17 Engine breather pipe
18 Turbocharger
19 Wastegate
20 Flywheel
21 Flywheel housing
22 Canister for the lubricating oil filte
23 Air inlet connectionr

24 Front lift bracket
25 Coolant temperature sensor
26 Alternator
27 Tensioner for the drive belt
28 Canister for the coolant filter / inhibitor
29 Coolant pump
30 Coolant inlet connection
31 Lubricating oil cooler

12

A

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