Perkins 3000 Series Instruction Manual

1
Perkins 3000 Series
USER’S HANDBOOK
3012/CV12 12 cylinder diesel engines for industrial
applications
The contents of this handbook are applicable to both
CV12 and 3000 Series - 3012 engines.
Publication TSD 3138 (issue 13)
©Proprietary information of Perkins Group Limited, all rights reserved
The information is correct at the time of print.
Published in May 2001 by Technical Publications,
Perkins Engines Company Limited, Lancaster Road,
Shrewsbury, Shropshire SY1 3NX, England
This document has been printed from SPI². Not for Resale

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Contents
1 General information
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
How to care for your engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Perkins companies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Engine views
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Location of engine parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Operation instructions
Preparations for a new or an overhauled engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
How to start a new or overhauled engine or an engine which has been in storage . . . . 12
Normal start procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
How to start the engine in low ambient temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
How to stop the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Preventive maintenance
Preventive maintenance periods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Schedule for engines in normal use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Schedule for engines in intermittent use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Lubricating oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Restriction indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
How to renew the elements of the air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
How to drain the primary fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
How to check the drive belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to renew the fan belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to renew the alternator belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
How to check the specific gravity of the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
How to check the pH value of the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
How to renew the engine lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
How to renew the canisters of the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Continued
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How to clean the primary fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
How to renew the canister of the main fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
How to check/adjust the timing of the fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . 24
Fuel injector fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
How to remove the fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
How to correct the fuel injector sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
How to fit the fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
How to eliminate air from the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
How to check the tappet clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
How to drain the coolant system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
How to clean the coolant system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
How to fill the coolant system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5 Engine fluids
Diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Recommended oils for Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Recommended oils for remainder of the world . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6 Fault diagnosis
Problems and possible causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Code list of possible causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7 Engine preservation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Short period storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Long period storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal from storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Approved products for engine preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8 Parts and Service
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Service literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Service Bulletins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9 Engine data
3012 diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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1
General information 1
Introduction
The 3012 heavy duty diesel engine is the latest
development from Perkins Engines Company
Limited, a world leader in the design and manufacture
of high performance diesel engines.
More than fifty years of diesel production experience,
together with the use of the latest technology, have
been used in the manufacture of your engine to give
you reliable and economic power.
To ensure that you use the correct 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.
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
shown in ‘Preventive maintenance’. If the engine is
operated in a very dusty environment or other
adverseconditions,certainmaintenanceintervalswill
haveto be reduced.Renewthe filter elements and the
lubricating oil regularly 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 7.
The left and right sides of the engine are as seen from
the rear (flywheel) end. Where reference is made to
‘A’and ‘B’banks of cylinders: ‘A’bank is to the right
and ‘B’bank is to the left when viewed from the rear
end.
Read the ‘Safety precautions’and remember
them. They are given for yourprotection and must
be applied at all times.
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6
Engine identification
If you need parts, service or information for your
engine, you must give the complete engine number to
your Perkins distributor.
The engine number is stamped on the data plate
which is fastened to the left side of the crankcase.
For early engines, a typical engine number is:
6A27487U 59426U, which consists of these codes:
6A = Engine family
27487 = Engine number
U = Country of manufacture
59426 = Build line number
U = Year of manufacture
Engines made after August 1994, have a new engine
number system. For these engines, a typical number
is: SGJ 12 0029 U 3254 C, which consists of these
codes:
SG = Engine application
J = Engine type
12 = Number of engine cylinders
0029 = Engine specification number
U = Country of manufacture
3254 = Build line number
C = Year of manufacture
Units such as the fuel injection pump and
turbochargers have their own data plates.
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Perkins companies
Australia
Perkins Engines Australia Pty. Limited,
Suite 4, 13A Main Street,
Mornington, Victoria 3931, Australia.
Telephone: [phone]
Telex: Perkoil AA 30816
Fax: [phone]
China
Perkins Engines (Tianjin) Limited,
Jinwei Road,
Beichen District, Tianjin,
300402
China
Telephone: (86) (22) 2699 2288
Fax: (86) (22) 2699 3784
France
Perkins France SAS,
"Parc des reflets",
165 Avenue du Bois de la Pie,
95700 Roissy Charles de Gaulle, France.
Telephone: [phone]
Fax: [phone]
Germany
Perkins Motoren G.m.b.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]/564633
Fax: [phone]
Japan
Perkins Engines, Inc. Japan Branch,
8 Fl, 2-2-19 Akasaka, Minato-ku,
Tokyo 107-0052, Japan.
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]
Singapore
Perkins Engines (Asia Pacific) Pte. Limited,
20 Harbour Drive,
#07-06A, PSA Vista,
Singapore 117612.
Telephone: [phone]
Fax: [phone]
United Kingdom
Perkins Engines Company Limited,
Lancaster Road, Shrewsbury, SY1 3NX,
England.
Telephone: [phone]
Telex: 35171 PESL G
Fax: [phone]
United States of America
Perkins Engines - North America
12025, Tech Center Drive
Livonia
Michigan 48150
USA
Telephone: [phone]
Fax: [phone]
Perkins Engines Latin America Inc,
Suite 620,
999, Ponce de Leon Boulevard,
Coral Gables,
Florida 33134,
USA.
Telephone: [phone]
Telex: 32501 Perken G
Fax: [phone]
In addition to the above companies, there are
Perkins distributors in most countries. Perkins
Engines Company Limited, Shrewsbury or one of
the above companies can provide details.
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Safety precautions
These safety precautions are important.
Reference must also be made to the local regulations
in the country of operation.
l Only use these engines in the type of application
for which they have been designed.
l Do not change the specification of the engine.
l Do not smoke when you put fuel in the tank.
l Clean away fuel which has been spilt. Material
which has been contaminated by fuel must be
moved to a safe place.
l Do not put fuel in the tank while the engine runs
(unless it is absolutely necessary).
l Do not clean, add lubricating oil, or adjust the
engine while it runs (unless you have had the
correct training; even then extreme caution must
be used to prevent injury).
l Do not make adjustments that you do not
understand.
l Ensure that the engine does not run in a location
where it can cause a concentration of toxic
emissions.
l Other persons must be kept at a safe distance
while the engine or equipment is in operation.
l Do not permit loose clothing or long hair near
moving parts.
l Keep away from moving parts during engine
operation. Warning! Some moving parts cannot
be seen clearly while the engine runs.
l Do not operate the engine if a safety guard has
been removed.
l Do not remove the filler cap of the cooling system
while the engine is hot and while the coolant is
under pressure, because dangerous hot coolant
can be discharged.
l Do not use salt water or any other coolant which
can cause corrosion in the closed coolant circuit.
l Do not allow sparks or fire near the batteries
(especially when the batteries are on charge)
because the gases from the electrolyte are highly
flammable. The battery fluid is dangerous to the
skin and especially to the eyes.
l Disconnect the battery terminals before a repair is
made to the electrical system.
l Only one person must control the engine.
l Ensure that the engine is operated only from the
control panel or from the operator’s position.
l If your skin comes into contact with high-pressure
fuel, obtain medical assistance immediately.
l Diesel fuel and lubricating oil (especially used
lubricating oil) can damage the skin of certain
persons. Protect your hands with gloves or a
special solution to protect the skin.
l Do not wear clothing which is contaminated by
lubricating oil. Do not put material which is
contaminated with oil into the pockets.
l Discard used lubricating oil in a safe place to
prevent contamination.
l Ensure that the control lever of the transmission
drive is in the ‘out-of-drive’ position before the
engine is started.
l The combustible material of some components of
the engine (for example certain seals) can
become extremelydangerousifitis burned. Never
allow this burnt material to come into contact with
the skin or with the eyes.
l Fuel and oil pipes MUST be inspected for cracks
or damage before they are fitted to the engine.
l Fit only genuine Perkins parts.
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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 of the 3012 engine
1‘B’bank air cleaner
2‘B’bank turbocharger
3 Exhaust manifold
4 Coolant pump
5 Canisters of the lubricating oil filter
6 Crankcase breather
7 Fan
8 Thermostat housings
A
482
1
2
65
4
3
8
7
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Rear and right side view of the 3012 engine
B
483
1
6 5
4
3
9
8
7
10
2
1‘A’bank turbocharger
2 Alternator
3Dipstick
4 Filler cap for lubricating oil
5 Lubricating oil sump
6 Starter motor
7 Flywheel housing
8 Flywheel
9 Canisters of the fuel filter
10 ‘A’bank air cleaner
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3
Operation instructions 3
Preparations for a new or an overhauled
engine
Every new engine supplied by Perkins Engines
Company Limited, Shrewsbury, is run-in before it
leaves the factory.
1 Check that all protection covers and blanking plugs
have been removed.
2 Fit all components that were removed for storage
or for transport.
3 Ensure that drain plugs for coolant and for
lubricating oil are securely fitted.
4 Where necessary, connect the remote control
linkages, the pressure gauge pipes, the air inlet pipes
and the wiring loom.
5 Connect the fuel pipes.
6 Connect the exhaust pipes.
7 Fill the fuel tank(s) with the correct grade of fuel
(see page 31).
8 Fill the cooling system with the approved coolant
mixture (see page 31).
9 Fill the sump to the H mark on the dipstick with the
correct grade of lubricating oil (see page 32).
10 Clean the area around the plug (A1) on the
governor housing of the injection pump and remove
the plug. Add approximately 0,2 litres (1/3pint) of
clean engine oil of the correct grade (see page 32) to
the governor housing. Fit and tighten the plug
securely.
11 Add oil to the turbochargers as follows: Clean the
area around the blanking plug (B1) on the bearing
housing of eachturbocharger. Remove theplugs (B1)
and add 0,2 litre (1/3pint) of engine oil of the correct
grade to each turbocharger. Fit and tighten the plugs.
12 Eliminate air from the fuel system (see page 27).
13 Lubricate all of the control linkages and check the
linkages for free movement.
A57
1
2
B58
1
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How to start a new or overhauled engine
or an engine which has been in storage
Prepare to start the engine as given in paragraphs 1
to 13 on page 11.
If an engine has been in storage for a period of more
than one month, add clean lubricating oil to the fuel
injection pump and to the turbochargers. If the engine
has been in storage for less than one month, but the
fuel injection pump has been removed and fitted, add
lubricating oil to the fuel injection pump. The
procedure is described on page 11, paragraphs 10
and 11. Use clean engine oil of the same grade and
specification as that already in the system.
Start procedure
Ensure that the stop control is in the STOP position
and that the speed control lever is in the IDLE
position. Press the start button for 10 seconds and
then release it for 10 seconds, then press it for 20
seconds and release it for 20 seconds. Oil pressure
MUST be indicated on the gauge. Move the stop
control lever to the RUN position and proceed as for
a normal start.
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Normal start procedures
Service checks each day before first engine start
1 Check that the level of coolant is just at the bottom
of the filler extension in the radiator. Fill, if necessary,
to the required level with the approved coolant
mixture. If there is a large loss of coolant find the
reason.
2 Check the engine oil level. With the engine
stopped the oil level must be at the H mark on the
dipstick. If necessary, add oil of the same grade and
specification as that already in the system. Do NOT
add more oil than is necessary.
3 Ensure that the fuel tank is full.
4 Check the air restriction indicator.
Caution: If a fuel injection pump or turbocharger has
been removed from an engine, it must be primed with
clean engineoilofthe correctgrade beforetheengine
is first started. See page 11, paragraphs 10 and 11.
Variable speed engines
Perform the daily service checks then proceed as
follows:
Turn on the fuel supply.
Move the stop control to the RUN position.
Move the speed control lever to the maximum speed
position.
Press the start button and release it when the engine
starts.
Move the speed control lever to the idle position.
Constant speed engines
Perform daily service checks then proceed as follows:
Turn on the fuel supply.
Move the stop control to the RUN position.
Press the start button and release it when the engine
starts.
How to start the engine in low ambient
temperatures
An excess fuel device, within the fuel injection pump,
works as a starting aid when ambient temperatures
are below 0°C.
Before the engine is started, push fully in, the control
rod of the excess fuel device. Press the start button
and release it when the engine starts. The control rod
returns automatically to its original position when the
engine starts.
Caution: Theexcess fueldevice must notbe usedat
the same time as other cold starting aids as the extra
fuel will make the engine more difficult to start.
Precautions
The precautions that follow will help to ensure a long
and fault-free life for the engine:
Variable speed engines
1 Do not operate the engine at high speeds and loads
until the coolant has reached a minimum temperature
of 78°C.
2 Do not allow the engine to run at idle speed for
prolonged periods.
3 Do not exceed the maximum no load speed.
4 Never allow an engine to continue to run if the oil
pressure is below 170 kN/m²(25 lbf/in²) at rated
speed.
5 Fill the fuel tank(s) at the end of each day to prevent
condensation.
Constant speed engines
1 Do not operate the engine with a full load until the
coolant has reached a minimum temperature of 78°C.
2 Do not allow the engine to run with no load for
prolonged periods.
3 Ensure that the fuel tank(s) are full to prevent
condensation.
How to stop the engine
Variable speed engines
1 Put the gear lever into the NEUTRAL position.
2 Operate the engine at approximately 800 rev/min
for 3 minutes to allow the turbochargers to reduce
speed and temperature.
3 Move the stop control to the STOP position.
Constant speed engines
1 Operate the engine for 3 minutes at idle speed with
no load to allow the turbochargers to reduce speed
and temperature.
2 Move the switches for the engine protection
devices to the OFF position.
3 Move the stop control to the STOP position.
4 Turn off the fuel supply.
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Preventive maintenance 4
Preventive maintenance periods
These preventive maintenance periods apply to
average conditions of operation. Check the periods
given by the manufacturer of the equipment in which
the engine is installed. If necessary, use the shorter
periods. When the operation of the engine must
conform to the local regulations, these periods and
proceduresmayneedto beadapted to ensurecorrect
operation of the engine.
The service intervals can be reduced for operation in
adverse conditions. The intervals must not be
extended unless Perkins Engines Company Limited
have approved the changes as indicated in the
Perkins Warranty. It is good preventive maintenance
to check for leakage and loose fasteners at each
service. These maintenance periods apply only to
engines that are operated with fuel and lubricating oil
which conform to the specifications given in this
handbook.
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Schedule for engines in normal use
The preventive maintenance operations must be applied at the interval (hours or months) which occurs first.
A- Every 10 hours or daily
B- Every 400 hours or 12 months
C- Every 1200 hours or 24 months
*By a person who has had the correct training.
In addition to the operations listed above, the operations listed below must be applied at 12 month
intervals:
l Drain and flush the coolant system and renew the coolant mixture
l Check the turbochargers, ensure that they are checked and corrected if necessary*
l Ensure that the alternator is checked and corrected if necessary*
A B C Operation
l
Check the amount of coolant
l
Check the level of the lubricating oil
l
Check the restriction indicators for the air filters and, when necessary, renew the filter
elements
l
Drain the water/sediment from the primary fuel filter
l
Check the condition and the tension of all drive belts
l
Check the specific gravity and the pH value of the coolant
l
Renew the lubricating oil
l
Renew the canisters of the lubricating oil filter
l
Renew the canister of the main fuel filter
l
Clean the primary fuel filter
l
Ensure that the mounting nuts for the turbochargers are tightened securely
l
Check that the air charge cooler and the radiator are clean and free from debris
l
Check the timing of the fuel injection pump
l
Check that the drive coupling bolts of the fuel injection pump are tightened to 120 Nm
(88 lbf ft)
l
Ensure that the fuel injectors are checked and corrected or renewed, if necessary*
l
Ensure that the tappet clearances are checked and adjusted, if necessary*
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4
17
Schedule for engines in intermittent use
For engines which are in use for a total of less than 400 hours in every twelve months, the schedule below
must be used:
The preventive maintenance operations must be applied at the interval (hours or months) which occurs first.
A- Monthly
B- Every 200 hours or 12 months
C- Every 1000 hours or 24 months
*By a person who has had the correct training.
In addition to the operations listed above, the operations listed below must be applied at 12 month
intervals:
l Drain and flush the coolant system and renew the coolant mixture
l Check the turbochargers, ensure that they are checked and corrected if necessary*
l Check that the air charge cooler and the radiator are clean and free from debris
l Ensure that the alternator is checked and corrected if necessary*
ABC Operation
l
Check the amount of coolant
l
Check the level of the lubricating oil
l
Check the restriction indicators for the air filters and, when necessary, renew the filter
elements
l
Start and run the engine with 30% load (minimum), until normal temperature of
operation is reached
l
Drain the water/sediment from the primary fuel filter
l
Check the condition and the tension of all drive belts
l
Check the specific gravity and the pH value of the coolant
l
Renew the lubricating oil
l
Renew the canisters of the lubricating oil filter
l
Renew the canister of the main fuel filter
l
Clean the primary fuel filter
l
Ensure that the mounting nuts for the turbochargers are tightened securely
l
Check the timing of the fuel injection pump
l
Check that the drive coupling bolts of the fuel injection pump are tightened to 120 Nm
(88 lbf ft)
l
Ensure that the fuel injectors are checked and corrected or renewed, if necessary*
l
Ensure that the tappet clearances are checked and adjusted, if necessary*
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4
18
Coolant level
Remove the filler cap from the radiator and check that
the level of the coolant mixture just touches the
bottom of the filler tube inside the radiator. If
necessary, add coolant until the level of the coolant
reaches the filler tube. Fit the filler cap.
Caution: If coolant is added to the system during
service,it must consistofthe same originalmixtureas
used to fill the system.
Warning! On a hot engine release the filler cap
carefully as the system will be under pressure.
Lubricating oil level
At the periods given in the service schedule use the
dipstick to check the amount of lubricating oil in the
sump. While the engine runs, the oil level must be
above the L mark. With the engine stopped the oil
level must be at the H mark on the dipstick. If
necessary, put more oil into the sump. Use the same
grade and specification as that already in the system.
Do NOT overfill.
This document has been printed from SPI². Not for Resale

4
19
Restriction indicator
Each air filter is fitted with an indicator (A) which gives
a visual warning when the filter needs a service.
When the red warning indicator is seen through the
clear panel after the engine has stopped, the air filter
element must be renewed.
After a clean element has been fitted, press the reset
button on the restriction indicator.
How to renew the elements of the air
filters
The two air filters (B) contain paper elements. These
must not be washed. Renew the paper elements as
follows:
1 Loosen the clamp and remove the end cover (B1).
Remove the wing nut (B2), withdraw and discard the
filter element (B3).
2 Clean, thoroughly, the inside of the casing of the air
filter. Fit a new filter element and fit the end cover.
3 Reset the restriction indicator.
Repeat this procedure for the other air filter.
How to drain the primary fuel filter
1 Remove the drain plug from the base of the filter
bowl and allow any water or sediment to drain from
the unit.
2 Fit the drain plug and tighten it securely.
A37
B21
1
2
3
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4
20
How to check the drive belts
Check all drive belts and renew a belt if it is worn or
damaged. Where more than one belt is used between
two pulleys, all of the belts must be renewed together.
Maximum belt life will be obtained only if the belts are
kept at the correct tensions.
Check the belttensionat the centreofthelongestfree
length, for example, position (A5) to check the fan
drive belts.
Use a ‘Gates "Krikit" V-belt tension gauge’or similar
tool to check the tension of the belts.
The correct tension for all belts is 400 to 489 N (90 to
100 lbf). Where more than one belt is used between
two pulleys, check/adjust the tension on the tightest
belt.
Note: When new belts are fitted they must be
checked again after the engine has been run for 15
minutes and, if necessary, adjusted to the correct
tension.
How to adjust the tension of the fan belts
1 To adjust the tension of the fan belts, loosen the
nuts on the adjustment bolt. Loosen the large lock nut
(B1)onthebelttensionerandturntheadjustmentbolt
(B2) until the correct tension is obtained.
2 Tighten the lock nut and check the tension of the
belts again.
3 Run the engine for 15 minutes and then check the
belt tension again.
Check the tension of new belts every week for four
weeks and then at the intervals specified in the
service schedule
How to adjust the tension of the alternator belt
1 Loosen the alternator pivot bolt (A1), the
adjustment linkbolt(A3) and the adjustmentbolt (A2).
Move the alternator to obtain the correct belt tension
and tighten the bolts.
2 Run the engine for 15 minutes and then check the
belt tension again.
Check the tension of new belts every week for four
weeks and then at the intervals specified in the
service schedule.
How to renew the fan belts
1 To renew the fan belts, remove the six bolts which
fasten the fan to the pulley and push the fan forward
into the radiator cowl.
2 Release the tension on the belts and remove the
old belts. Ensure that the pulley grooves are free from
grease and dirt. Fit a new set of belts.
3 Fit the fan and tighten the bolts securely. Adjust the
fan belts to the correct tension.
How to renew the alternator belt
1 Remove the fan belts from the crankshaft pulley as
given on this page.
2 Loosen the adjustment bolts to release the tension
on the alternator belt and remove the old belt. Check
that the pulley grooves are clean and fit a new belt.
Adjust the belt to the correct tension. Fit the fan belts
as given on this page.
A59
5
3
4
2
1
B60
2
1
This document has been printed from SPI². Not for Resale