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Workshop Manual, TPD 1353E, Issue 3

Peregrine EDi and 1300 Series EDi

Rocker shaft, rocker levers and bushes

Rocker shaft

Outside diameter:

WK to WN .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 21,567/21,593 mm (0.8491/0.8501 in)
WP to WS .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28,653/28,679 mm (1.1281/1.1291 in)

Rocker shaft springs

Quantity.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 5
Free length. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..103,1 mm (4.06 in)
Length under load of 31 N (7 lbf) 3,18 kgf . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 52,6 mm (2.07 in)

Diameter:

WK to WN .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25,9 mm (1.02 in)
WP to WS .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..33,629 mm (1.324 in)

Rocker levers and bushes

Internal diameter of bush ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 21,69 mm (0.854 in)

Clearance between rocker lever bush and rocker shaft:

WK to WN .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,048/0,124 mm (0.0019/0.0049 in)
WP to WS .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,076/0,127 mm (0.003/0.005 in)
Push rod length.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 273,685/274,447 mm (10.7750/10.8050 in)

Piston and connecting rod assemblies

Pistons

Type:

All engines up to and including 270 bhp (201 kW). ... ... One-piece, all aluminium. "Toroidal" combustion bowl
WM, WN, WR, and WS 
engines over 270bhp (201 kW).. ... ... ... ..Two-piece, high-pressure, steel crown. "Toroidal" combustion bowl
Diameter of the bore for the gudgeon pin .. ... ... ... ... ... ... ... ... ... ... ... 46,380/48,856 mm (1.9235/1.9255 in)
Cooling jets for each piston ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 2

Piston rings

Oil control ring groove clearance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,0508/0,102 mm (0.0020/0.0040 in)

Top ring groove width, measured over 2,921 mm (0.1150 in) gauge pins:

WK and WL ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .110 mm (4.3118 in)
WM and WN... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .114 mm (4.5015 in)
WP, WQ, WR, and WS .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 114,33/114,58 mm (4.501/4.511 in)

Second ring width, measured over 2,921 mm (0.1150 in) gauge pins:

WK and WL ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .110 mm (4.3118 in)
WM and WN... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .118 mm (4.6050 in)
WP, WQ, WR, and WS .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 116,84/116,92 mm (4.600/4.603 in)

Ring gap with new cylinder liner:

Top ring.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,040/0,066 mm (0.014/0.026 in)
Second ring ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1,65/1,91 mm (0.065/0.075 in)

Oil control ring:

WK and WL ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,024/0,054 mm (0.009/0.021 in)
WM and WN... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,028/0,055 mm (0.011/0.022 in)
WP, WQ, WR, and WS .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,028/0,055 mm (0.014/0.026 in)

This document has been printed from SPI². Not for Resale

Summary of Contents for 1300 EDi Series

Page 1: ...ed 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 res...

Page 2: ...ankshaft 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...

Page 3: ...mation 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 dime...

Page 4: ...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 gui...

Page 5: ...cting 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 Gener...

Page 6: ...n 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 Operatio...

Page 7: ...on 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 rem...

Page 8: ...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...

Page 9: ...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...

Page 10: ...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...

Page 11: ...on 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 descrip...

Page 12: ...xii This page is intentionally blank This document has been printed from SPI Not for Resale...

Page 13: ...d 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 thi...

Page 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 SPI Not for Resale...

Page 15: ...mp 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 seri...

Page 16: ...ny 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 electro...

Page 17: ...let 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 actuate...

Page 18: ...ded 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 l Check the engine lift bra...

Page 19: ...alants 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 wit...

Page 20: ...ccur 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...

Page 21: ...litres 466 4 in3 WM WN WR and WS 8 71 litres 531 0 in3 Firing order 1 5 3 6 2 4 Valve tip clearances cold Inlet and exhaust 0 64 mm 0 025 in Lubricating oil pressure Idle minimum 103 kPa 15 lbf in2 1...

Page 22: ...ble thickness after cylinder head face has been machined 128 02 mm 5 040 in Maximum permissible distortion of cylinder head 0 01 mm 0 004 in in any 228 6 mm 9 in Inlet and exhaust valves Inlet valves...

Page 23: ...th a load applied of 921 965 N 207 217 lbf 94 98 kgf WP to WS 37 5 mm 1 480 in with a load applied of 943 987 N 212 222 lbf 96 101 kgf Exhaust valve springs Colour White Free length WK to WN 62 18 mm...

Page 24: ...all aluminium Toroidal combustion bowl WM WN WR and WS engines over 270bhp 201 kW Two piece high pressure steel crown Toroidal combustion bowl Diameter of the bore for the gudgeon pin 46 380 48 856 mm...

Page 25: ...nkshaft 0 419 0 30 mm 0 0165 0 012 in Diameter of parent bore 85 000 85 131 mm 3 3516 3 3516 in Diameter of bearing fitted 80 000 80 100 mm 3 1524 3 1544 in Width of bearing WK WL WM and WN 34 7472 mm...

Page 26: ...5 0 0152 mm 3 525 0 0006 in 0 508 mm 0 020 in undersize 89 3 0 0152 mm 3 515 0 0006 in 0 762 mm 0 030 in undersize 89 0 0 0152 mm 3 505 0 0006 in Crank pins Width 35 2 mm 1 385 in Ovality maximum 0 0...

Page 27: ...58 115 mm 2 2845 2 2880 in Number 1 Outside diameter 63 6270 63 6651 mm 2 5050 2 5065 in Width 25 4 mm 1 00 in Parent bore diameter 63 5127 63 5508 mm 2 5005 2 5020 in Number 2 Outside diameter 63 157...

Page 28: ...mm 2 4805 2 4820 in Number 3 62 497 62 535 mm 2 4605 2 4620 in Number 4 61 988 62 026 mm 2 4405 2 4420 in Tappets Diameters Tappet body 28 435 28 448 mm 1 1195 1 1200 in Parent bore 28 511 28 549 mm...

Page 29: ...By pass valve Fitted inside the filter Operating pressure 193 kPa 28 lb in2 Oil temperature control valve Operating temperature range 54 4 148 9 C 65 300 F Valve closes at 104 4 115 6 C 235 240 F Valv...

Page 30: ...a radius of 165 1 mm 6 5 in Face run out clutch cover plate 0 19 mm 0 0075 in measured at a radius of 190 5 mm 7 5 in Face run out clutch applications flat 0 2 mm 0 008 in measured at clutch mounting...

Page 31: ...ng housing 13 9 6 1 3 Auxiliary equipment Nut air compressor drive gear 149 110 15 21 Setscrews air compressor mounting bracket to engine 115 85 11 9 Setscrews air compressor to engine 62 46 6 4 Setsc...

Page 32: ...in the oil cooler 34 25 3 5 Lubrication system high pressure Drain plug supply manifold 81 60 8 3 End nut to secure the solenoid to the regulator valve 6 4 5 0 6 Regulator valve for injection control...

Page 33: ...an overhaul is necessary are how easily the engine starts and its general performance The cylinder head assembly has two valves fitted for each cylinder each fitted with a single valve spring a valve...

Page 34: ...the four tags B1 that secure the rocker cover electrical connector for the wiring loom to the rocker cover and push the connector into the rocker cover 5 Remove the 13 setscrews C that retain the rock...

Page 35: ...of the fuel injector units into its hole in the rocker cover Ensure that the four tags A1 engage on the rocker cover 6 Fit the rocker cover fit and tighten the 13 setscrews B to 18 Nm 13 lbf ft 1 8 kg...

Page 36: ...rocker cover see Operation 3 1 2 Remove and discard the breather elements A1 from their recesses A2 in the rocker cover 3 Clean the rocker cover Ensure that the recesses are clean 4 Fit a new breather...

Page 37: ...e lubricating oil cooler in order to drain the engine Open the tap or remove the drain plug at the bottom of the radiator in order to drain the radiator If the radiator does not have a tap or drain pl...

Page 38: ...Engage all the setscrews in their correct positions except the setscrews at each end of the shaft and tighten them finger tight 5 Ensure that the rocker shaft is in the correct position when the sets...

Page 39: ...e external diameter of the rocker shaft at two places 90 apart where it contacts the bushes of the rocker levers Record the readings 8 If the difference between the measurements is greater than 0 13mm...

Page 40: ...marked TOP at the centre of its length Ensure that this mark is at the top Slide the components onto the rocker shaft in the correct sequence ensure that the lubricating oil holes are aligned correct...

Page 41: ...Operation 3 4 6 Remove all the push rods and record their relative positions 7 Remove all the pipes and hoses from the turbocharger 8 Remove the exhaust manifold setscrews and remove the exhaust mani...

Page 42: ...inder head setscrews are dry and free from debris 2 Fit the thermostat if it was removed earlier 3 Check the cylinder liner protrusion see Operation 7 4 4 Fit the dowels into the cylinder block A 5 Fi...

Page 43: ...ust be renewed if the tool becomes tight on the setscrew thread This tightness indicates that the setscrew thread is extended and the setscrew must be discarded 12 The cylinder head setscrews must be...

Page 44: ...ply manifold 17 Fit the fuel pipe at the supply manifold 18 Fit the rocker cover see Operation 3 2 19 Fit the gasket for the exhaust manifold Fit the exhaust manifold and turbocharger assembly Fit and...

Page 45: ...damage its face 2 Use a valve spring compressor to compress the valve spring 3 Remove the collets A1 4 Release and remove the valve spring compressor 5 Remove the valve rotator A2 the valve rotator s...

Page 46: ...valve seal assembly is fitted fully into the valve spring recess in the cylinder head 4 Put the valve springs A4 in position on the valve seal assemblies Caution Ensure that the inlet valve springs a...

Page 47: ...ut the valve depth gauge in position over the head of each valve A and compare the measurement with the relevant Data and dimensions for the Inlet and exhaust valves on page 10 6 If a valve is below t...

Page 48: ...e guides 15 Check that the seat faces of the valves are not badly burnt or damaged Seat faces of valves that are damaged can be ground on a special machine Valves that have only a little damage can be...

Page 49: ...on 2 To test the operation of the rotator A4 put a valve spring A3 the valve rotator and a steel ball bearing A5 in a valve spring tester A1 3 Mark the rotator with a reference line A2 4 Compress the...

Page 50: ...4 Check the valve guides for wear The maximum clearance between the valve stem and the bore of the guide is 0 15 mm 0 006 in for the inlet valves and the exhaust valves If the clearance with new valve...

Page 51: ...linder head from the bottom face Fully fit the attachment A7 to secure the adapter in the valve guide A6 2 Turn the top handle A1 to take up the excess movement in the tool and turn the bottom handle...

Page 52: ...bottom face Fully fasten the valve guide with the large 15 chamfer at the bottom and the distance piece A7 21825935 onto the adapter with the attachment A8 4 Turn the top handle A1 to take up the exce...

Page 53: ...e connections of a component that is to be pressure tested 8 When the cylinder head is thoroughly clean check it for cracks Examine carefully the areas around the valve seats and around the holes for...

Page 54: ...here is little damage the valve and valve seat can be lapped When the valve seats are lapped keep the seat to the measurements given in the relevant Data and dimensions for the Cylinder head on page 1...

Page 55: ...e seat as this can damage the blades 4 Carefully rotate the cutter in a clockwise direction A Remove only the minimum material to ensure a good seat Keep the seat as narrow as possible 5 When the seat...

Page 56: ...nts then eye protection must also be worn 4 Put the valve seat inserts in a deep freeze unit for 30 minutes This will reduce the size of the valve seat inserts to allow them to fit more easily into th...

Page 57: ...cylinder 3 Put the special tap 27610091 A1 into the sleeve for the injector unit and cut a thread into the sleeve A Remove the tap 4 Fit and tighten the adaptor 27610092 B1 into the injector unit sle...

Page 58: ...inder or the tool used to fit the injector unit sleeve might hit the piston Do not allow debris to fall into the cylinder 1 Use a wire brush to clean the top and bottom of the bore for the injector un...

Page 59: ...e bore for the injector unit in the cylinder head G 5 Hit the tool with a hammer to drive the injector unit sleeve into position at the bottom of the bore H in the cylinder head 6 Remove the tool 7 Fi...

Page 60: ...ove the rocker cover see Operation 3 1 2 Rotate the crankshaft in the normal direction of rotation until valve A11 has just opened and valve A12 has not closed fully Check adjust the clearances of val...

Page 61: ...sed fully 3 Check the clearances of the valves C1 C2 C3 C6 C7 and C10 and adjust them if necessary 4 Rotate the crankshaft in the normal direction of rotation until the inlet valve C1 of number 1 cyli...

Page 62: ...This page is intentionally blank This document has been printed from SPI Not for Resale...

Page 63: ...their rings The top compression ring is marked TOP UP on its upper face the second compression ring is marked 2nd UP on its upper face The oil control ring is not marked and new rings may be fitted ei...

Page 64: ...to the relevant connecting rod setscrews is possible 5 Remove the setscrews from the connecting rod 6 Remove the bearing cap A together with the lower shell bearing 7 Carefully push the connecting rod...

Page 65: ...setscrews with clean engine lubricating oil 7 Hold the bearing cap in position on the connecting rod Ensure that the assembly number on the cap is the same as the number on the connecting rod and that...

Page 66: ...inspect Operation 4 3 Check the bearings and the crank pin for wear or other damage Measure the crank pins and compare the measurements with those given in the relevant Data and dimensions for the Cr...

Page 67: ...e lubricating oil strainer and suction pipe see Operation 10 11 7 Remove the setscrews C5 for the big end bearing cap and remove the big end bearing cap A 8 Push the piston and the connecting rod asse...

Page 68: ...tly in its recess 8 Put the piston ring gaps 120 apart and compress the rings with a suitable tool 9 Pass the connecting rod and piston assembly into the cylinder Ensure that the camside mark on the p...

Page 69: ...aft rotates freely 17 Check the side clearance of the connecting rod big end Refer to the relevant Data and dimensions for the Connecting rods on page 13 18 Fit the lubricating oil strainer and suctio...

Page 70: ...one of the gudgeon pin bosses Ensure that it fits correctly in the groove Caution If the original piston is used ensure that it is assembled to the correct connecting rod and that it is used in the o...

Page 71: ...piston crown B2 ensure that the marks made earlier are aligned 3 Fit a new circlip A in the circlip groove of one of the gudgeon pin bosses Ensure that it fits correctly in the groove Caution If the o...

Page 72: ...ll diameter of the piston and the gauge A 6 Fit the piston groove gauge 21825955 to the second compression ring groove measure and record the overall diameter of the piston and the gauge B 7 Fit a new...

Page 73: ...n pin for wear Refer to the relevant Data and dimensions for the Gudgeon pins on page 13 Small end bush To remove and to fit Operation 4 10 1 Press out the old bush with a suitable adaptor 2 Clean the...

Page 74: ...ton rings with a suitable ring expander A1 To fit 1 Use a suitable ring expander A1 to fit the piston rings Keep the rings with their relevant pistons for correct assembly 2 Fit the coil spring and la...

Page 75: ...il spring must be fitted to the oil control ring when the gap is measured 1 Clean all carbon from the top of the cylinder liners 2 Fit each piston ring A2 in the top part of the cylinder liner measure...

Page 76: ...This page is intentionally blank This document has been printed from SPI Not for Resale...

Page 77: ...s manual The area of the bearing surfaces of the seven main bearings is the same All the main bearings have location tags An integral damper with a rubber insert is built into the crankshaft pulley Th...

Page 78: ...drive belt see Operation 12 7 3 Release and remove the three setscrews A that hold the retainer plate of the pulley damper assembly 4 Remove the retainer plate A 5 Use the puller 21825965 to remove th...

Page 79: ...ealant from the retainer plate and from the pulley damper assembly 4 Put POWERPART Silicone RTV sealing and jointing compound on the inner face of the retainer plate and fit the retainer plate A 5 Lub...

Page 80: ...page 14 Measure and record damper alignment B at four places B1 90 apart on the damper face Ensure that the crankshaft is at the same end of its axial movement for each measurement This eliminates cra...

Page 81: ...gine 4 Remove the flywheel see Operation 13 1 5 Remove the rear oil seal see Operation 5 6 6 Remove the four setscrews that pass through the flange of the sump and into the bottom of the seal housing...

Page 82: ...he housing B2 into position on the engine fit and tighten the setscrews finger tight 5 Fit the plate from tool 21825963 to the guide adaptor Tighten the nut of the tool C until the plate comes into co...

Page 83: ...new rear oil seal wear sleeve and the POSE seal see Operation 5 6 11 Fit the lubricating oil sump see Operation 10 10 12 Fit the flywheel see Operation 13 2 13 Fit the drive components to the rear end...

Page 84: ...ne number N1194039 types WP WQ WR and WS a new rear oil seal assembly has been introduced that prevents the entry of debris from the environment The seal includes a Positive On Shaft Excluder P O S E...

Page 85: ...ed rod with the spanner to remove the wear sleeve 10 Discard the oil seal and wear sleeve 11 Clean the oil seal housing and the crankshaft palm 12 Fit the guide adaptor F from tool 21825963 to the end...

Page 86: ...from tool 21825963 comes into contact with the face of the seal housing the oil seal and the wear sleeve are in their correct positions 16 Fit the new POSE seal J1 to the wear sleeve on the crankshaft...

Page 87: ...the alternator and its mounting bracket see Operation 14 1 9 Remove the compressor and its drive assembly if one is fitted see Operation 15 1 10 Remove the timing case cover see Operation 6 1 11 Remov...

Page 88: ...with their relevant position number C 21 Remove the main bearing caps and the lower shell bearings Keep the bearings with their relevant bearing caps 22 Lift out the crankshaft D 23 Remove the upper s...

Page 89: ...correctly in their recesses 10 Lubricate the bearings with clean engine lubricating oil 11 Fit the bearing caps numbers 1 to 6 in their correct positions as shown by the position number stamped on th...

Page 90: ...Operation 4 5 21 Fit the lubricating oil suction pipe and strainer see Operation 10 11 22 Fit the rear oil seal housing see Operation 5 5 23 Fit the lubricating oil sump see Operation 10 10 24 Fit the...

Page 91: ...02 in The maximum permissible wear and ovality on the crank pins is 0 0075 mm 0 00025 in The main journals and the crank pins of standard size crankshafts can be machined to 0 25 mm 0 010 in 0 50 mm 0...

Page 92: ...a hammer and chisel to break the drive spline A2 for the oil pump and to break the crankshaft gear A1 4 Remove the drive spline for the oil pump and remove the crankshaft gear 5 Clean the crankshaft...

Page 93: ...ankshaft 1 Put a dial test indicator B2 against the face of the crankshaft flange B3 2 Use a lever B1 to move the crankshaft fully toward the front of the engine and set the indicator to zero 3 Use a...

Page 94: ...he setscrews of the rear main bearing and remove the main bearing cap A complete with the lower half of the thrust bearing A1 4 Push one end of the upper half of the thrust bearing with a suitable too...

Page 95: ...he specific torques shown below WK WL WM and WN engines 157 Nm 116 lbf ft 16 0 kgf m WK WL WM and WN engines from engine serial number 850000 176 Nm 130 lbf ft 18 0 kgf m Caution For WP WQ WR and WS e...

Page 96: ...cap and remove the bearing cap A 4 Remove the lower shell bearing from the cap 5 With a suitable tool push the upper shell bearing from the side opposite to the location tag to remove the bearing tag...

Page 97: ...WM and WN engines 157 Nm 116 lbf ft 16 0 kgf m WK WL WM and WN engines from engine serial number 850000 176 Nm 130 lbf ft 18 0 kgf m Caution For WP WQ WR and WS engines new setscrews must be fitted w...

Page 98: ...e bearings for wear and for other damage If a bearing is worn or damaged renew both shell bearings and check the condition of the other bearings If the thrust bearing number 7 has been removed and fit...

Page 99: ...essure pump All of the gears have timing marks except the gear for the high pressure pump There is a spline on the crankshaft nose to drive the lubricating oil pump A power take off can be fitted to t...

Page 100: ...1300 Series EDi Components of the timing case 1 Timing case cover 2 Pressure relief valve 3 Dowels 4 Timing case backplate 5 Joint 6 O ring 7 Joints 8 O rings 9 Timing indicator 1 A W231 2 4 5 3 6 7 8...

Page 101: ...ssembly see Operation 5 1 10 Remove the coolant pump pulley and the coolant pump see Operation 12 4 11 Disconnect the electrical cable A2 at the sensor A1 for engine oil temperature 12 Disconnect the...

Page 102: ...ction control pressure regulator A3 7 Fit the coolant pump and the coolant pump pulley see Operation 12 4 8 Fit the lubricating oil pump see Operation 10 13 9 Fit the pulley damper assembly see Operat...

Page 103: ...the upper idler gear A Measure and record the backlash of the lower idler gear B Compare the results with the relevant Data and dimensions for the Timing gears on page 15 Renew any gear that is out of...

Page 104: ...the upper idler gear A2 is supplied with a sealant on its thread Do not add more sealant to the thread of the setscrew Do not apply lubricating oil to the thread of this setscrew 7 Put the upper idler...

Page 105: ...filter 5 Remove the idler gears see Operation 6 3 6 Remove the oil pressure relief valve A2 from the crankcase 7 Remove the rocker assembly see Operation 3 4 Remove all the push rods and note their r...

Page 106: ...6 Fit the camshaft see Operation 6 8 7 Fit the tappets into their original bores 8 Fit the cylinder head see Operation 3 9 9 Fit the oil pressure relief valve together with its O ring A6 10 Fit the id...

Page 107: ...o the camshaft gear 1 Set number 1 cylinder to TDC on the compression stroke see Operation 8 1 2 Drain the engine lubricating oil 3 Drain the cooling system 4 Remove the timing case cover see Operatio...

Page 108: ...timing plate C3 9 Remove the timing plate from its dowels C1 10 Remove the setscrews from the camshaft thrust plate access to the setscrews is through the two holes in the gear face D 11 Carefully rem...

Page 109: ...A 3 Engage the timing plate dowels B1 and push the timing plate B3 onto the camshaft gear B4 fit and tighten the cap screws B2 to 7 Nm 5 lbf ft 0 7 kgf m 4 Fit the tappets C into their original bores...

Page 110: ...the camshaft lobes at line AA and at line BB in figure A and record the readings Measure the tappets the thrust plate and the camshaft bushes Compare all the readings with the relevant Data and dimens...

Page 111: ...7 Note Use Tool 21825995 to remove and to fit the bushes 2 To remove number 4 bush A4 pull it toward the rear of the engine 3 To remove the other three bushes pull them toward the front of the engine...

Page 112: ...er three bushes C in the sequence number 3 bush number 2 bush then the number 1 bush Put each bush into position from the front of the engine and then pull it toward the rear of the engine 8 Fit the c...

Page 113: ...ate and pull the sensor from the timing cover 3 Retain the shims A4 for when the sensor is fitted To fit 1 Clean the surfaces and apply a small amount of engine lubricating oil to the O ring A3 on the...

Page 114: ...te the reading 6 Rotate the crankshaft a further 1 2 turn clockwise and repeat step 3 note the reading 7 Add the measurements from steps 3 4 5 and 6 8 Divide the total by 4 to obtain an average readin...

Page 115: ...lock assembly 7 General description The cylinder block is made of cast iron and provides support for the wet cylinder liners which are also made of cast iron Four bushes are fitted to the cylinder blo...

Page 116: ...e 1 Clean thoroughly the cylinder block Ensure that all the oil passages are clean and free of debris 2 Fit the crankshaft see Operation 5 8 3 Fit the rear oil seal housing assembly see Operation 5 5...

Page 117: ...nd for the engine lubricating oil 2 Check the cylinder block for cracks and for other damage 3 The top face of the cylinder block must not be machined as this will affect the protrusion of the liner f...

Page 118: ...access to the cylinder liner and to protect the crank pin 7 Put the tool A4 on the top face of the cylinder block and over the centre of the cylinder liner A5 Ensure that the base of the tool is not...

Page 119: ...t the adaptor 21825956 B6 onto the threaded rod and against the bottom of the cylinder liner 11 Ensure that the two lugs on the top of the adaptor engage with the flats on the threaded rod 12 Fit the...

Page 120: ...kgf m Further tighten the three setscrews gradually and evenly to 110 Nm 80 lbf ft 11 06 kgf m 6 Measure the inside diameter of the cylinder liner see Operation 7 5 Note If the bore is too small this...

Page 121: ...ect Check the cylinder liners for damage and wear Operation 7 5 To check the wear of the cylinder liner see A and B and compare the results with the relevant Data and dimensions for the Cylinder liner...

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Page 123: ...r 1 piston is at TDC on the compression stroke The marked teeth of the idler gears may not necessarily be in mesh in this position because of the different speeds at which the gears rotate With all of...

Page 124: ...the front until the timing mark on the pulley damper assembly aligns with the pointer on the timing case 3 Check that the push rods of number 1 cylinder are free to rotate Number 1 piston is now at T...

Page 125: ...Slowly rotate the crankshaft clockwise from the front until the feeler gauge is tight This is the point where the inlet valve of number one cylinder will begin to open The timing mark on the pulley da...

Page 126: ...crankshaft clockwise from the front one full turn The reading on the dial indicator should be 3 93 5 59 mm 0 155 0 220 in If the reading is correct set the valve tip clearance of number one inlet valv...

Page 127: ...ed by oil from the oil filter head The oil passes through the bearing housing of the turbocharger and returns to the lubricating oil sump Some turbochargers are fitted with a waste gate unit This unit...

Page 128: ...ion A6 at the other end of the pipe on the oil filter head Use a spanner to hold the union A5 on the filter head when the union nut is released 6 Remove the pipe and discard the flange joint A3 7 Remo...

Page 129: ...hreads of the union connection A5 and A6 and apply a thread sealant to the union connection A5 9 Put the oil supply pipe A4 in position fit but do not tighten the flange setscrews A1 10 Use a spanner...

Page 130: ...rks A on the compressor casing on the backplate and on the turbine housing to ensure correct assembly later 3 Hold the turbocharger in a vice that is fitted with soft jaws to protect the turbocharger...

Page 131: ...he casing while it is fitted to the turbocharger because the compressor housing seal will be damaged 9 Remove the six setscrews D3 that hold the waste gate housing D4 to the turbine casing D2 and remo...

Page 132: ...ng to the backplate A6 and align the marks B Fit the three lock plates and the six setscrews C2 Tighten the setscrews to 21 24 Nm 15 5 17 7 lbf ft 2 14 2 44 kgf m Caution To change the angle of the co...

Page 133: ...bine shaft Push the shaft fully in one direction and set the gauge to zero Push the shaft fully in the other direction and record the reading on the gauge The correct end float tolerance is 0 02 0 10...

Page 134: ...ause the calibration of the actuator will be affected This may cause damage to the engine 1 Fit the actuator and bracket assembly A5 to the turbocharger and tighten the three setscrews A6 Note Do not...

Page 135: ...r will be affected and this may cause damage to the engine 1 Disconnect the boost sensor pipe at the actuator 2 Connect the actuator to an air supply that has a pressure regulator A5 and is fitted wit...

Page 136: ...high turn the end of the actuator rod to increase its overall length Note Turn the end of the actuator rod in half turn increments Caution Use only the end of the threaded rod to make adjustments To p...

Page 137: ...6 8 19 20 21 28 31 32 Not enough lubrication 8 12 14 15 16 23 24 29 32 33 37 38 Lubricating oil in the exhaust manifold 2 7 17 18 19 20 22 28 31 32 Inside of the induction manifold wet 1 2 3 4 5 6 8...

Page 138: ...Restricted lubricating oil supply pipe 17 Restricted lubricating oil drain pipe 18 Turbine housing damaged or restricted 19 Leakage from turbocharger seals 20 Worn turbocharger bearings 21 Excessive...

Page 139: ...ousing opens Oil that by passes the filter passes directly to the regulator valve The regulator valve either by passes oil to the sump or allows oil to pass to the main pressure rail and then through...

Page 140: ...Workshop Manual TPD 1353E Issue 3 Peregrine EDi and 1300 Series EDi Low pressure system flow diagram A1 Filtered oil A2 Hot oil A3 Cold oil 1 A W201 2 3 This document has been printed from SPI Not for...

Page 141: ...g oil 3 Clean thoroughly the outer surfaces of the filter assembly 4 Use a strap wrench or similar tool to loosen the filter canister remove and discard the canister Ensure that the adaptor A1 is secu...

Page 142: ...ained Oil pressure is indicated when the warning light is extinguished or by a reading on the gauge Caution Do not fill the sump past the FULL mark on the dipstick 10 When the engine starts check for...

Page 143: ...system 3 Remove the lubricating oil canister A8 see Operation 10 1 4 Disconnect the oil supply pipe A10 for the turbocharger 5 Remove the setscrew from the clamp A3 for the coolant inlet pipe A1 6 Rel...

Page 144: ...s for the filter head oil cooler assembly 4 Fit and tighten the setscrew for the clamp A3 of the coolant inlet pipe 5 Clean the threads of the union connection A9 for the turbocharger pipe A10 Apply P...

Page 145: ...il If there is a leakage from the oil cooler it must be renewed 2 Inspect the joint and seal faces for damage 3 Remove the oil temperature control valve A11 see Operation 10 5 and inspect it for damag...

Page 146: ...the valve 2 Fit the oil temperature control valve and tighten it to 34 Nm 25 lbf ft 3 5 kgf m 3 Fill the sump to the correct level with an approved lubricating oil see Chapter 5 in the User s Handboo...

Page 147: ...e to pull the valve from the crankcase To fit 1 Clean the oil filter head and cooler assembly the joint face on the cylinder block and the coolant inlet and outlet pipes 2 Fit the pressure regulating...

Page 148: ...p drain plug A4 and discard its sealing washer A3 Drain the lubricating oil from the sump 4 Remove the dipstick and dipstick tube 5 Provide a support for the sump A2 6 Remove the 22 setscrews that fas...

Page 149: ...lant more than five minutes before the sump is to be fitted to the engine 4 Put the joint A1 onto the sump with the bead of sealant toward the cylinder block 5 Put the sump and the joint in position o...

Page 150: ...inger tight 11 Tighten the 22 setscrews to 23 Nm 17 lbf ft 2 35 kgf m 12 Fit the drain plug C4 together with a new sealing washer C3 and tighten the plug to 68 Nm 50 lbf ft 7 0 kgf m 13 Fit the dipsti...

Page 151: ...e and strainer assembly 6 Discard the joint To fit 1 Clean the flange face of the suction pipe and the joint face of the crankcase 2 Put the oil strainer and suction pipe and its new joint in position...

Page 152: ...l see Operation 10 15 4 Remove the six setscrews of the oil pump Note There are short setscrews at the 2 o clock and the 3 o clock positions 5 Remove the oil pump body A1 and discard the O ring A2 6 R...

Page 153: ...n engine lubricating oil Put the backplate into position on the timing case cover 5 Lightly lubricate the inner rotor A1 with clean engine lubricating oil Fit the inner rotor 6 Lightly lubricate the o...

Page 154: ...N WR and WS 8 7 litre engines may reduce the life of the seal and affect its performance Seals are not interchangeable between 7 6 litre and 8 7 litre engines due to seal thickness and material 11 Fit...

Page 155: ...rotor are damaged or worn they must both be renewed as an assembly 4 Put the outer rotor and the inner rotor into the pump body 5 Check the outer rotor to body clearance A Refer to the relevant Data a...

Page 156: ...der 2 Using a suitable hand tool remove the wear sleeve and also the POSE if fitted from the pulley damper assembly A Caution Care must be taken not to damage the pulley flange 3 Remove the oil seal f...

Page 157: ...mpound to the inside diameter of the wear sleeve and using the same press fit the new wear sleeve together with the POSE seal onto the pulley damper assembly Remove excess compound Caution The wear sl...

Page 158: ...crankshaft nose with three locally obtained hexagon head M12 x 1 25 x 40 long setscrews B2 the heads must be small enough not to obstruct the thread of the replacer tool B5 5 Fit a new oil seal B3 ont...

Page 159: ...lip of the front oil seal with clean engine lubricating oil WM WN WR and WS 8 7 litre engines do NOT lubricate the seal Caution Lubrication of the front seal used on WM WN WR and WS 8 7 litre engines...

Page 160: ...o the valve Use the copper wire to pull the valve from the crankcase A To fit 1 Clean the joint faces of the timing case cover 2 Fit the pressure relief valve into position in the crankcase 3 Fit the...

Page 161: ...ough the breather element into an open breather pipe To renew the breather elements see Operation 3 3 Warning Do not direct compressed air at your skin 1 Remove the rocker cover see Operation 3 1 2 Re...

Page 162: ...the fuel injector units The value of the oil pressure can be altered by the engine management system this pressure is known as injection control pressure Three components work in a cycle to alter the...

Page 163: ...is fitted to the high pressure pump and consists of a solenoid connected to a valve The solenoid receives a signal voltage from the engine control module the value of the signal affects the amount of...

Page 164: ...emove 1 Disconnect the electrical cable at the sensor for injection control pressure 2 Remove the sensor for the supply manifold and discard its O ring To fit 1 Fit a new O ring to the sensor 2 Apply...

Page 165: ...rom the fuel pipes of the lift pump remove and discard the copper washers 4 Disconnect the high pressure oil pipe B3 5 Remove the nut B6 that retains the solenoid B5 6 Remove the sensor for engine oil...

Page 166: ...Fit the sensor C1 for engine oil temperature and connect its electrical cable C2 4 Fit the solenoid B5 of the regulator valve Fit and tighten its nut B6 to 6 Nm 4 5 lbf ft 0 6 kgf m Connect its electr...

Page 167: ...se a suitable pump to drain the reservoir for the high pressure system Drain the reservoir through the hole for the sensor B1 5 Remove the nut B3 that retains the solenoid B2 6 Remove the regulator va...

Page 168: ...ipe 4 Remove the plug B2 and drain the lubricating oil from the gallery in the supply manifold B3 Remove and discard the O ring B1 5 Remove the container and discard the fluids safely in accordance wi...

Page 169: ...pipe A2 at the supply manifold A3 together with new copper washers 3 Fit the high pressure oil pipe A1 4 Fit the drain plug B2 together with a new O ring B1 5 Fit the valve C1 for the fuel return pipe...

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Page 171: ...o the fuel tank through a pipe Fuel from the supply manifold passes through galleries in the cylinder head to the fuel injector units A1 The injector unit increases the pressure of the fuel to 24 124...

Page 172: ...has two main chambers the oil chamber and the fuel chamber The oil chamber receives engine oil from the supply manifold at injection control pressure A valve which is connected to the armature of the...

Page 173: ...injection phase occurs during the down stroke of the piston l The end of injection phase and the fill phase occur during the up stroke of the piston Key to the colours in the illustrations Green Lubri...

Page 174: ...WM WN WR and WS engines An increase of pressure in the oil chamber causes an increase of pressure in the fuel chamber that is six or seven times greater As the piston moves down into the fuel chamber...

Page 175: ...l chamber the piston moves up into the oil chamber When the piston moves up the pressure of the fuel in the fuel chamber reduces rapidly This causes the flat valve to close As the piston continues to...

Page 176: ...ase the pressure in the fuel chamber E3 reduces When this pressure is less than supply pressure E2 the ball valve opens and fuel is allowed to fill the fuel chamber through holes in the side of the in...

Page 177: ...clean the outer surfaces of the fuel filter assembly 2 Use a strap wrench or similar tool to loosen the filter canister and remove the canister 3 Use a 29 mm 1 1 8 in socket spanner to remove the plas...

Page 178: ...engine lubricating oil The fuel injector units are controlled by the engine management system which cannot be adjusted by the operator 1 Put a container of approximately 2 litres 4 pints capacity unde...

Page 179: ...emove the screws that retain the plate for the electrical cables and remove the plate C 8 Remove the front setscrew D from the clamp that retains the injector unit Caution Do not remove the rear shoul...

Page 180: ...Di 10 Push the clamp toward the rear of the engine G 11 Use a lever H to carefully raise the injector unit 12 Remove the injector unit 13 Remove and discard the O rings and the washer see Operation 11...

Page 181: ...rear setscrew A2 to pass through it 3 Push the injector unit down A until it is on its seat 4 Tilt the clamp B until it is past the head of the rear setscrew 5 Push the clamp towards the front of the...

Page 182: ...lug F2 into the gallery in the supply manifold F3 10 Fit the valve G1 for the fuel return pipe and tighten it to 35 Nm 26 lb ft 3 6 kgf m 11 Fit new copper washers to the banjo union G3 of the fuel re...

Page 183: ...ector units have damaged O rings or seals then all injector units must be removed and checked l During removal of the O rings be careful to avoid damage to the body of the injector unit or the grooves...

Page 184: ...ver the injector body until it fits into its groove ensure that the ring is not damaged 3 Carefully slide the lubricated O ring B3 blue over the injector body until it fits into its groove 4 Carefully...

Page 185: ...he high pressure pump Note Ensure that the eccentric on the camshaft of the high pressure pump is in the minimum lift position If it is not rotate the crankshaft until it is 2 Fit a new joint to the l...

Page 186: ...card the O ring A9 from the end nut 6 Remove and discard the small O ring A11 from inside the end nut 7 Remove the plunger A8 the suction valve A7 the spring seat washer A6 the spring A5 and the secon...

Page 187: ...ion on top of the valve seat washer Ensure that the large diameter of the valve is toward the spring seat washer 6 Fit the plunger A8 in position in the pump body over the valve and spring 7 Renew the...

Page 188: ...nt of the speed control Operation 11 8 Special equipment is necessary to set the idle speed and the maximum no load speed If further information is required contact the Service Department of Perkins E...

Page 189: ...1 Loosen the vent plug A1 on the top of the fuel filter head 2 Operate the plunger of the fuel priming pump A2 until fuel free from air comes from the filter vent point Tighten the vent plug 3 Turn th...

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Page 191: ...leaves the cylinder head at the front and passes into the thermostat housing If the thermostat is closed the coolant goes directly through a by pass to the inlet side of the coolant pump if the therm...

Page 192: ...12 180 Workshop Manual TPD 1353E Issue 3 Peregrine EDi and 1300 Series EDi Cooling system flow diagram A PW137 This document has been printed from SPI Not for Resale...

Page 193: ...coolant when the filter canister is removed l From engine number N117199 a manual valve is fitted and is shown open A2 When the system pressure is released the valve lever must be turned counter clock...

Page 194: ...assembly and the outlet are clean 2 Fit a new O ring to the thermostat assembly and insert the thermostat assembly in position on the cylinder head Fit and tighten the setscrews 3 Connect the top hos...

Page 195: ...position B1 passes through the timing case to a nut on the rear of the timing case To fit 1 Ensure that the joint faces are clean 2 Fit a new O ring C2 to the coolant pump C1 and put the coolant pump...

Page 196: ...f the belt as the tension is set automatically Fan drive To remove and to fit Operation 12 6 To remove 1 Remove the fan see Operation 12 5 2 Release the setscrews and remove the fan spacer Remove the...

Page 197: ...sembly A1 2 Operate the lever to release the tension from the belt A4 and remove the belt The tensioner will return to its original position by spring pressure Remove the lever To fit 1 With the lever...

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Page 199: ...13 Peregrine EDi and 1300 Series EDi Flywheel and housing 13 General description The steel flywheel is fitted with a hardened starter ring The flywheel housing is made of cast iron This document has...

Page 200: ...flywheel Caution When the flywheel is removed or fitted be careful not to damage the rear oil seal 1 Remove two opposite setscrews from the flywheel A2 and fit temporarily two guide studs A1 to ensur...

Page 201: ...to finger tight only Remove the two guide studs 4 Fit the remaining setscrews and tighten all the setscrews to 136 Nm 100 lbf ft 13 8 kgf m 5 Check the alignment of the flywheel B1 with a dial test in...

Page 202: ...teeth 2 To remove the starter ring use a hammer and a chisel to break the ring Ensure that the flywheel is not damaged during this operation To fit 1 It is necessary to heat the starter ring to not m...

Page 203: ...k the housing run out B with a dial test indicator B1 at the 3 o clock 6 o clock 9 o clock and 12 o clock positions The maximum tolerance is given in the relevant Data and dimensions for the Flywheel...

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Page 205: ...he battery while the engine is in operation This will cause a voltage surge in the alternator charge system which will immediately cause damage to the diodes or to the transistors l Do not disconnect...

Page 206: ...y the alternator bracket fasteners Ensure that the washers and the distance pieces are fitted in their correct positions and that the alternator pulley is aligned to the crankshaft pulley Tighten the...

Page 207: ...ter of good quality with a range of 0 100 ampere in the wire between the alternator and the positive terminal of the battery 3 Turn the warning lamp switch to the on position main switch on instrument...

Page 208: ...he switch to the on position and operate the engine at fast idle If there is no output there is a fault in the alternator If there is an output there is a fault in the regulator If the warning lamp co...

Page 209: ...estolite ACR5RS 60A A1 Alternator A2 Ammeter if fitted A3 Ignition switch A4 Alternator warning lamp 24v 24W B1 Alternator B2 Ammeter if fitted B3 Ignition switch B4 Alternator warning lamp 12v 2 2W A...

Page 210: ...until the pinion is completely engaged with the flywheel The Prestolite PE129 is a pre engaged starter motor and is actuated by a solenoid The solenoid is fitted to the starter motor outer casing When...

Page 211: ...er motor cables 3 Release the fasteners and remove the starter motor and if necessary the distance piece To fit 1 If necessary put the distance piece in position with its location lip to the flywheel...

Page 212: ...ect tension is 8 34 11 00 N 30 40 ozf 0 85 1 13 kgf 5 The new brushes must be the same grade as the original brushes To ensure that correct brushes are fitted use only parts from the approved manufact...

Page 213: ...power or there is no voltage drop across the battery check the switch all the connections and the wires 4 Slow action of the starter can be caused by faulty connections 5 Difficulty to engage smoothl...

Page 214: ...mmeter if fitted A7 Start inhibit relay 60 Amps A4 Ignition switch A8 Starter motor B1 2 x 12v batteries in parallel B5 Pin 46 on the engine control module B2 Fuse F12 30 Amps B6 33 RA relay B3 Ammete...

Page 215: ...s EDi Starting aid General description The engine electronics system provides cold start capability down to 20 C 4 F To start the engine below this temperature the customer must provide a suitable sta...

Page 216: ...on sensor A2 will send a digital signal The remainder temperature sensors A3 A6 and A9 will send an analogue signal The module uses the value of the return voltages to calculate pressures position of...

Page 217: ...l signal B1 is one that changes from one value directly to another value l An analogue signal is one that can show any value between two different values e g the signal from the engine oil temperature...

Page 218: ...ic pressure BARO A8 If the pressure decreases the return voltage will decrease If the pressure increases the value of the return voltage will increase Thermistors Thermistors are used to measure tempe...

Page 219: ...Hall effect sensors are used to measure the speed and position of a rotating mechanical device The camshaft motion sensor page 206 A2 is a Hall effect sensor The sensor contains a magnet When the mag...

Page 220: ...Air valve solenoid for the radiator shutter 1 Negative for the DC DC converter 2 Negative for the DC DC converter 16 Positive for the ATA data link 17 Negative for the ATA SAE J1708 21 Positive for th...

Page 221: ...A W256 1 2 B A E C 10 Am p 4 1 2 3 10 6 7 8 9 5 a b a b a b OFF ON START 5 Amp max 24 ECM 30 Amp 30 86 87 87 80 25 21 41 22 25 42 23 10 Amp 46 30 87 86 87 80 10 Amp 16 17 34 15 47 10 Amp 30 87 86 87...

Page 222: ...sensor Speed switch a reset accelerator b set coast Barometric absolute pressure sensor Speed switch remote a reset accelerator b set coast Ambient air temperature sensor Pre set speed switch a off b...

Page 223: ...b a 6 1 2 4 a 5 b a 3 9 4 3 2 C A B 3 5 6 7 8 9 b a b b a b a a a b b 10 Amp 10 Amp ECM 10 Amp 10 Amp 11 10 12 86 80 87 30 87 18 17 15 14 13 16 19 21 20 31 35 43 44 32 38 52 14 36 37 49 30 13 27 11 1...

Page 224: ...re sensor 30 Input from the remote speed control sensor 31 Input from the resume accelerate switch 32 Input from the cruise control set coast 35 Input from the cruise control on off 36 Input from the...

Page 225: ...b a 6 1 2 4 a 5 b a 3 9 4 3 2 C A B 3 5 6 7 8 9 b a b b a b a a a b b 10 Amp 10 Amp ECM 10 Amp 10 Amp 11 10 12 86 80 87 30 87 18 17 15 14 13 16 19 21 20 31 35 43 44 32 38 52 14 36 37 49 30 13 27 11 1...

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Page 227: ...compressor and also to the rear bush for the drive shaft Oil drains from the compressor crankcase into the drive housing and lubricates the drive gears and the bearing The oil returns to the engine su...

Page 228: ...bracket and its fasteners Note Spacers are used between the compressor bracket and the compressor body 10 Remove the compressor from the engine To fit 1 Fit the compressor to the timing case ensure t...

Page 229: ...ws and remove the pump Discard the O ring To fit 1 Fit a new O ring and lubricate it with clean engine lubricating oil 2 Fit the drive shaft into the end of the compressor output flange and push the p...

Page 230: ...p fully into position 3 Fit and tighten the setscrews 4 Fit the power steering pump see Operation 15 2 To tighten the drive gear nut Operation 15 4 1 Press the drive gear A1 of the PTO adaptor into th...

Page 231: ...number PD 1D 21825479 Adaptor for remover replacer for valve guide Tool number PD 1D 1A 21825496 Gauge for valve height for use with PD 208 Tool number PD 41D 21825543 Remover for cylinder liner main...

Page 232: ...224 21825951 Socket for lower idler gear Tool number 1PD 225 21825953 Adaptor for installer for front oil seal Tool number PD 227 21825956 Adaptor for liner remover Tool number PD 231 21825959 Holdin...

Page 233: ...40 21825995 Remover replacer camshaft bush Tool number ZTSE 2893A 27610091 Special tap Tool number PD 250 27610092 Adaptor for injector unit sleeve remover Tool number PD 251 27610093 Adaptor for use...

Page 234: ...938 Adjustable valve seat cutters Tool number MS 73A 21825954 21825955 0 090 inch gauge for piston ring groove Tool number PD 229 0 115 inch gauge for piston ring groove Tool number PD 230 Part number...

Page 235: ...not been repaired When an active fault has been repaired it becomes an inactive fault after 15 seconds l An inactive fault is one that was an active fault at some time but is not present now This cou...

Page 236: ...onditions Coolant or lubricating oil in the fuel could be caused by leakage at the seals for the fuel injector unit 4 Check the air inlet and the exhaust system Check the air filter restriction indica...

Page 237: ...is not a blockage in the pipework and that there is no external damage to the pipes or hoses 9 Check the electrical systems Check all of the fuses Check that the engine wiring looms are in their corr...

Page 238: ...or the red lamp will flash once between codes l When the test is complete the red lamp will flash three times 3 Make a note of any codes that are shown 4 Set the start switch to the OFF position How...

Page 239: ...the illustration below The display can show a maximum of four lines of text It may also show some arrows Continued These arrows A10 indicate that more information is available press the scroll up key...

Page 240: ...There are keys marked 0 to 9 that are used to enter values There is also a button B8 in the side of the tool this is used to test all output circuits Scroll up key B2 Scroll left key B5 Scroll down k...

Page 241: ...st to test e g to move from ENGINE DATA LIST to ACTIVE FAULTS 1 Press DIAGNOSTIC CODES shows on the display 2 Press The first option that will show is ACTIVE CODES To return to ENGINE DATA LIST 1 Pres...

Page 242: ...ons shown on the display One of the options will have parentheses around it e g To select this option press To change to the other option press The parentheses will move then press CODE DESCRIPTION se...

Page 243: ...the box to the right Press to move to the item in the box to the left Press to move to the item in the box below Press to move to the item in the box above ENTER ENTER ENTER ENTER ENTER ENTER FUNC FUN...

Page 244: ...two options l Navistar l J1587 Navistar is the usual option needed J1587 is for use in the United States of America To change the CODE DESCRIPTION option 1 Move through the program until CODE DESCRIPT...

Page 245: ...it is an intermittent fault ENGINE HOURS is the total number of hours that the engine has operated TOTAL MILES is the total number of miles travelled by the application TOTAL FUEL USED GAL BATTERY is...

Page 246: ...W CC SET SW CC ON OFF COOLANT LEVEL ENG OIL PRES is the current pressure of the engine lubricating oil in lbf in2 ENG RTARD STAT CYLINDER 6 CYLINDER 4 CYLINDER 3 CYLINDER 2 PTO SPEED PTO CLUTCH SW PTO...

Page 247: ...HYDR PRES MODE RETARD ON OFF EXHAUST BACK PRESSURE EPR DUTY CYCLE IPR DUTY CYCLE FUELING PW EBP DESIRED PRESSURE ICP DESIRED VIN is the vehicle identification number MAKE MODEL is the model type of th...

Page 248: ...pplied with the tool then connect the other end of the wiring loom to the diagnostic connector on the application Note The display of the tool should be illuminated as soon as the tool is connected to...

Page 249: ...des EMPTY will show on the display l If there is a code it will show on the display with a short description 3 Record the fault l If there are no other codes go to step 6 l If there are other codes th...

Page 250: ...Record the fault l If there are no other codes see Operation 17 9 l If there are other codes the scroll up and scroll down symbols will show on the display e g 9 If the scroll symbols do show press to...

Page 251: ...s best to clear their codes from the memory of the ECM 1 Move through the program until CLEAR CODES shows on the display see Operation 17 4 2 Press 3 Press When the codes have been removed EMPTY will...

Page 252: ...ATE TEST Note These tests must be done in the sequence that follows STANDARD TEST 1 Move through the program until ENGINE OFF TESTS shows on the display Operation 17 4 2 Press When the test is complet...

Page 253: ...enoid When the test is complete l If there are no codes shown l If there are codes shown 9 Press e g 10 If the arrows show press to obtain the other codes 11 Record all the fault codes WIGGLE TEST 12...

Page 254: ...ssary press 15 Press OUTPUT STATE TEST 16 Move through the program until OUTPUT STATE TEST shows on the display see Operation 17 4 17 Press l If there are no faults l If there are faults 18 Press e g...

Page 255: ...on the left side of the tool to test for outputs HIGH Repeat the OUTPUTS STATE TEST steps 17 to step 21 23 When the test is complete record all the fault codes Press 24 Correct all the faults 25 Clear...

Page 256: ...ARD TEST 1 Start the engine and run it until the normal temperature of operation is obtained 2 Move through the program until ENGINE RUNNING TESTS shows in the display see Operation 17 4 3 Press 4 Pre...

Page 257: ...onnector up and down and from side to side to test for faulty connections l If a fault occurs a sound will be heard and the tool display will alter to show BEEP and NEW CODES 1 Press e g l When all th...

Page 258: ...4 897v Short circuit high Sensor failure 131 Speed control signal out of range low Signal voltage less than 0 152v Engine at low idle only Short circuit to grid or open in circuit Sensor failure 132 S...

Page 259: ...lectrical noise on circuit 216 Hydraulic pressure signal out of range low HPS signal voltage below 0 039v Circuit open short to ground defective sensor 221 Cruise PTO or remote PTO switch fault Signal...

Page 260: ...e warning lamp open circuit fault Engine warning lamp output circuit check engine off test only Open or short circuits 311 1 Engine oil temperature signal out of range low Signal voltage less greater...

Page 261: ...f Check for carboned signal line biased sensor 351 Change in exhaust back pressure unable to achieve commanded set point EBR below expected at 2300 rev min Check for carboned signal line biased biased...

Page 262: ...Left side short open and ground 513 1 Bank 1 open circuit low Injector units for cylinders 1 2 and 3 have an open circuit in the high voltage supply Open circuit Bank 1 514 1 Bank 2 open circuit low I...

Page 263: ...ot be read Fuel totals may be incorrect fit new VPM 635 Internal hour meter memory location in error VPM memory for hour meter cannot be read Hour totals may be incorrect fit new VPM 641 Internal odom...

Page 264: ...gramming fault Programming problem Programming problem Internal ECM problem 664 Calibration level incompatible Programming problem Programming problem 665 Programmable parameter memory content corrupt...

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