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Perkins 3000 Series
USER'S HANDBOOK
3012/CV12
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
12 cylinder diesel engines for industrial
applications
1
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Table of Contents
Related Manuals for Perkins 3000 Series
Summary of Contents for Perkins 3000 Series
- Page 1 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,...
- Page 2 This document has been printed from SPI². Not for Resale...
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Page 3: Table Of Contents
Perkins companies ........ - Page 4 How to clean the primary fuel filter ......... 23 How to renew the canister of the main fuel filter .
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Page 5: General Information
Perkins distributors have this type of personnel available. You Caution: This indicates that there is a possible can also obtain parts and service from your Perkins danger to the engine. distributor. If you do not know the address of your... -
Page 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. -
Page 7: Perkins Companies
Telex: Perkoil AA 30816 Telephone: (822) 528 3377 Fax: 0061 (0)597 1305 Fax: (822) 528 3378 China Singapore Perkins Engines (Tianjin) Limited, Perkins Engines (Asia Pacific) Pte. Limited, Jinwei Road, 20 Harbour Drive, Beichen District, Tianjin, #07-06A, PSA Vista, 300402 Singapore 117612. -
Page 8: Safety Precautions
Do not permit loose clothing or long hair near Fit only genuine Perkins parts. moving parts. Keep away from moving parts during engine operation. -
Page 9: Engine Views
Engine views 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 5 Canisters of the lubricating oil filter 2 ‘B’... - Page 10 Rear and right side view of the 3012 engine 1 ‘A’ bank turbocharger 6 Starter motor 2 Alternator 7 Flywheel housing 3 Dipstick 8 Flywheel 4 Filler cap for lubricating oil 9 Canisters of the fuel filter 5 Lubricating oil sump 10 ‘A’...
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Page 11: Operation Instructions
Operation instructions 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. -
Page 12: How To Start A New Or Overhauled Engine Or An Engine Which Has Been In Storage
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. -
Page 13: Normal Start Procedures
Normal start procedures Precautions Service checks each day before first engine start The precautions that follow will help to ensure a long and fault-free life for the engine: 1 Check that the level of coolant is just at the bottom of the filler extension in the radiator. - Page 14 This document has been printed from SPI². Not for Resale...
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Page 15: Preventive Maintenance
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... -
Page 16: Schedule For Engines In Normal Use
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 Operation Check the amount of coolant Check the level of the lubricating oil... -
Page 17: Schedule For Engines In Intermittent Use
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... -
Page 18: Coolant Level
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 consist of the same original mixture as used to fill the system. -
Page 19: Restriction Indicator
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. -
Page 20: How To Check The Drive Belts
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. -
Page 21: How To Check The Specific Gravity Of The Coolant
How to check the specific gravity of the coolant Drain some coolant from the cooling system after the 40 45 50 55 60 engine has been stopped and before the formation of sediment. Proceed as follows: 1 For mixtures which contain inhibited ethylene glycol: (a) Put a hydrometer, and a reliable thermometer, into the antifreeze mixture and check the readings... -
Page 22: How To Renew The Engine Lubricating Oil
How to renew the engine lubricating oil 1 Operate the engine until it is warm. 2 Stop the engine, remove the sump drain plug and drain the lubricating oil from the sump. Fit the drain plug, complete with a new sealing washer, and tighten the plug to a torque of 47 Nm (35 lbf ft). -
Page 23: How To Clean The Primary Fuel Filter
How to clean the primary fuel filter 1 Remove the three bolts (A1) and remove the filter bowl (A2). 2 Clean all of the components with paraffin and dry them with a compressed air jet. 3 Fit the bowl to the filter head, together with a new sealing ring. -
Page 24: How To Check/Adjust The Timing Of The Fuel Injection Pump
How to check/adjust the timing of the fuel injection pump If it becomes necessary to check and adjust the timing of the fuel injection pump, the procedure which follows is recommended: 1 Ensure that the stop control is in the ‘STOP’ position. -
Page 25: Fuel Injector Fault
Fuel injector fault A fuel injector fault can cause an engine misfire. In order to find which injector is defective, operate the engine at a fast idle speed. Loosen and tighten the union nut of the high-pressure fuel pipe at each injector. - Page 26 6 Fit carefully each rocker box cover and fit the eight bolts, complete with plain and spring washers. Tighten the bolts to 27 Nm (20 lbf ft). For later engines, fit a new ‘O’ ring around the groove near the top of each fuel injector. Fit the pedestal rocker cover and tighten lightly all of the bolts.
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Page 27: How To Eliminate Air From The Fuel System
How to eliminate air from the fuel system If air enters the fuel system, the injection pump pressure may become insufficient to operate the injector valves and the engine may stop, misfire or fail to start. To eliminate air from the system, use the relevant procedure which follows: Low pressure system 1 Loosen the low pressure relief valves (A1) on the... -
Page 28: How To Check The Tappet Clearances
How to check the tappet clearances The tappet clearance is measured between the rocker levers and the top of the valve bridge pieces. See page 45 for the size of the clearances. Each valve bridge piece controls two valves. An adjustment screw and lock nut is fitted to each bridge piece to ensure that equal force is applied to both valves from the rocker arm. -
Page 29: Turbochargers
Turbochargers How to clean the coolant system At the periods given in the service schedule, The coolant system must be drained and flushed disconnect and remove the pipes from between the through with clean water until it flows clear from all of air filters and the turbochargers. - Page 30 This document has been printed from SPI². Not for Resale...
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Page 31: Engine Fluids
150 mg/litre and a maximum total hardness of 250 life and could affect the warranty. Further details can mg/litre. be obtained from the Service Department at Perkins 1 If soft water is not used, the cooling system may be Engines Company Limited, Shrewsbury. -
Page 32: Lubricating Oil
Lubricating oil 1 Viscosity - Perkins Engines Company Limited recommend the use of SAE15W/40 for all engines that work in ambient temperatures above -15°C (5°F). Below -15°C (5°F) and down to -20°C (-4°F) the use of a 10W/30 oil is recommended. Down to - 30°C (-22°F) a 5W/40 fully synthetic oil is... -
Page 33: Recommended Oils For Europe
Below is a list of oils recommended by Perkins Engines Company Limited, Shrewsbury. The operator must ensure that the oil used conforms to the above requirements. Recommended oils for Europe Manufacturer of Preferred multi-grade oils which conform Acceptable multi-grade oils which... -
Page 34: Recommended Oils For Remainder Of The World
Recommended oils for remainder of the world Manufacturer of Mono-grade oils which Preferred multi-grade oils Acceptable multi-grade lubricating oil conform to ACEA E2 which conform to oils which conform to ACEA E3 ACEA E2 AGIP Sigma Turbo 15W/40 Universal Multifleet Blitum T 15W/40 15W/40 Master Super Turbo... -
Page 35: Fault Diagnosis
Fault diagnosis Continued This document has been printed from SPI². Not for Resale... -
Page 36: Problems And Possible Causes
Problems and possible causes Possible causes Problem Checks by service Checks by the user personnel The starter motor turns the engine too slowly 1, 2, 3, 4 The engine will not start 5, 6, 7, 8, 9, 10, 12, 13, 14, 34, 35, 36, 37, 38, 42, 43, 15, 17 The engine is difficult to start... -
Page 37: Code List Of Possible Causes
Code list of possible causes 34 A fault in the fuel injection pump. 35 A broken drive on the fuel injection pump. 1 The battery capacity is low. 36 The timing of the fuel injection pump is incorrect. 2 A bad electrical connection. 37 The valve timing is incorrect. - Page 38 This document has been printed from SPI². Not for Resale...
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Page 39: Engine Preservation
Engine preservation Introduction The recommendations indicated below are designed 6 Disconnect the supply of PX4 corrosion inhibitor to prevent damage to the engine when it is withdrawn from the fuel system and seal the end of the pipe. from service for a prolonged period. Use these Drain the fuel filters (see ‘Caution’... -
Page 40: Removal From Storage
18 Inject 2 grammes of VPI 260 powder into each paper element type air filter. Other types of air cleaners may be sprayed inside with PX4 corrosion inhibitor or with VPI 260 powder. Fit the air pipes. 19 Spray Crodafluid PM47 onto areas of the engine and auxiliary equipment which are not protected by paint. -
Page 41: Approved Products For Engine Preservation
Approved products for engine preservation Component Product Manufacturer Thermostat MS4 silicone grease Ambersil Limited Whitney Road Basingstoke Hampshire Lubrication system PX4 corrosion inhibitor Croda Chemicals Limited Churchill Road Doncaster Yorkshire Fuel system PX4 corrosion inhibitor Croda Chemicals Limited Valves and rocker assemblies PX4 corrosion inhibitor Croda Chemicals Limited Cooling system... - Page 42 This document has been printed from SPI². Not for Resale...
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Page 43: Parts And Service
Parts and Service Introduction If problems occur with your engine or with the components fitted to it, your Perkins distributor can make the necessary repairs. Your Perkins distributor will ensure that only the correct parts are fitted and that the work is done correctly. - Page 44 This document has been printed from SPI². Not for Resale...
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Page 45: Engine Data
Engine data 3012 diesel engine General Number of cylinders Cylinder arrangement 60 degree included angle ’V’ Cycle Four stroke Induction system Turbocharged and intercooled Combustion system Direct injection Nominal bore 135 mm (5.315 in) Stroke 152 mm (5.984 in) Compression ratio 14.5:1 Cubic capacity 26,11 litres (1593 in... - Page 46 Lift pump Mechanical, operated by camshaft Fuel supply pressure 140 to 210 kN/m² (20 to 30 lbf/in²) Fuel injectors Axial feed, low spring type. Six spray holes Injection pressure 250 bar (early engines 240 bar) Main fuel filter Two screw-on type canister Primary fuel filter/water separator Centrifugal type Lubrication system...
- Page 47 This document has been printed from SPI². Not for Resale...
- Page 48 Subject to any existing rights of third parties, the information given in this document is the property of Perkins Engines Company Limited and should not be copied (in whole or in part) or used for the manufacture or otherwise disclosed without the written consent of the Company.