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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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
This document has been printed from SPI². Not for Resale